Canon iR1600, iR2000 Service Manual

0 (0)

iR1600/iR2000

REVISION 0

SEPT. 2001	FY8-13HJ-000
COPYRIGHT© 2001 CANON INC.	CANON iR1600/iR2000 REV.0 SEPT. 2001 PRINTED IN JAPAN (IMPRIME AU JAPON)

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Application

This manual has been issued by Canon Inc. for qualified persons to learn technical theory, installation, maintenance, and repair of products. This manual covers all localities where the products are sold. For this reason, there may be information in this manual that does not apply to your locality.

Corrections

This manual may contain technical inaccuracies or typographical errors due to improvements or changes in products. When changes occur in applicable products or in the contents of this manual, Canon will release technical information as the need arises. In the event of major changes in the contents of this manual over a long or short period, Canon will issue a new edition of this manual.

The following paragraph does not apply to any countries where such provisions are inconsistent with local law.

Trademarks

The product names and company names used in this manual are the registered trademarks of the individual companies.

This manual is copyrighted with all rights reserved. Under the copyright laws, this manual may not be copied, reproduced or translated into another language, in whole or in part, without the written consent of Canon Inc.

Printed in Japan

Imprimé au Japon

Caution

Use of this manual should be strictly supervised to avoid disclosure of confidential information.

CANON iR1600/iR2000 REV.0 SEPT. 2001 PRINTED IN JAPAN (IMPRIME AU JAPON)

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INTRODUCTION

1 Symbols Used

This documentation uses the following symbols to indicate special information:

Symbol Description

Memo

REF.

Indicates an item of a non-specific nature, possibly classified as Note, Caution, or Warning.

Indicates an item requiring care to avoid electric shocks.

Indicates an item requiring care to avoid combustion (fire).

Indicates an item prohibiting disassembly to avoid electric shocks or problems.

Indicates an item requiring disconnection of the power plug from the electric outlet.

Indicates an item intended to provide notes assisting the understanding of the topic in question.

Indicates an item of reference assisting the understanding of the topic in question.

Provides a description of a service mode.

Provides a description of the nature of an error indication.

Refers to the Copier Basics Series for a better understanding of the contents.

CANON iR1600/iR2000 REV.0 SEPT. 2001

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INTRODUCTION

2 Outline of the Manual

This Service Manual provides basic facts and figures needed to service the iR1600/ iR2000. Of the machine’s accessories, this manual covers the cassette unit and inner 2- way tray; for other accessories including the ADF, see its own Service Manual.

In this manual, the 1-Cassette Unit-F1, 2-Cassette Unit-G1 and 3-Cassette Unit-H1 are collectively called “cassette unit,” and the Inner 2-Way Tray-B1 is referred to as the inner 2-way tray.

This Service Manual consists of the following chapters:

Chapter 1	Introduction:	features, specifications, operation, system con-
		struction, routine maintenance by the user, safety,
		reproduction processes
Chapter 2	Basic Operation:	basic operation, outline of electrical circuitry, ba-
		sic sequence
Chapter 3	Image Reading/
	Processing System:	principles of operation of the exposure system,
		principles of operation of the image processing
		system, timing of operation; disassembly/assembly
		and adjustment
Chapter 4	Laser Exposure System:	principles of operation of the image formation sys-
		tem, timing of operation; disassembly/assembly
Chapter 5	Image formation system: standards, adjustments, troubleshooting tables
Chapter 6	Pickup/Feeding System:	principles of operation of the pickup/feeding sys-
		tem, timing of operation; disassembly/assembly
		and adjustment
Chapter 7	Fixing System:	principles of operation of the fixing system, timing
		of operation; disassembly/assembly and adjust-
		ment
Chapter 8 Externals and Auxiliary
	Control System:	principles of operation of the externals/auxiliary
		control system, timing of operation; disassembly/
		assembly and adjustment
Chapter 9	Cassette Unit:	principles of operation of the pickup system; disas-
		sembly/assembly and adjustments
Chapter 10 Inner 2-Way Tray:		principles of operation; disassembly/assembly and
		adjustment
Chapter 11 Installation:		site requirements and installation procedure
Chapter 12 Maintenance and
	Inspection:	table of periodically replaced parts, table of
		durables, scheduled servicing chart
Chapter 13 Troubleshooting:		maintenance and inspection, standards/adjustment,
		troubleshooting image faults/malfunctions; service
		mode, self diagnosis
Chapter 14 Version up:		version up
Appendix:		general timing chart, general circuit diagram
ii	COPYRIGHT © 2001 CANON INC.		CANON iR1600/iR2000 REV.0 SEPT. 2001

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INTRODUCTION

The descriptions are subject to change for product improvement, and major changes will be communicated in the form of Service Information bulletins.

All service persons are expected to go through the contents of this Service Manual and Service Information bulletins and have a good understanding of the machine, readying themselves to promptly respond to the needs of the field (i.e., identifying and correcting faults).

CANON iR1600/iR2000 REV.0 SEPT. 2001

iii

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INTRODUCTION

The descriptions in this Service Manual are based on he following rules:

1.In each chapter, the uses of the function in question and its relationship to electrical and mechanical systems are discussed and the timing of operation of its associated parts is explained by means of outlines and diagrams.

In the diagrams, the symbol represents a mechanical path, while the symbol with a name next to it indicates the flow of an electric signal.

The expression “turn on the power” means turning on the power switch, closing the front door, and closing the delivery door so that the machine will be supplied with power.

2.In circuit diagrams (digital), a signal whose level is High is expressed as being ‘1’, while a single whose level is Low is expressed as being ‘0’; the level of voltage, however, varies from circuit to circuit.

The machine uses CPUs, whose internal mechanisms cannot be checked in the field, and, therefore, are not explained. In addition, the machine’s PCBs are not intended for repairs at the user’s and, therefore, are explained by means of block diagrams: two types are used, i.e., between sensors and inputs of PCBs equipped with a control or drive function and between outputs equipped with a control or drive function and

loads; in addition, functional block diagrams are used at times.

Changes made to the machine for product improvement are communicated in the form of a Service Information bulletin as needed. All service persons are expected to go through all service documentation including the bulletins and be equipped to respond to the needs of the field (as by being able to identify possible causes of problems).

CANON iR1600/iR2000 REV.0 SEPT. 2001

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INTRODUCTION

System Configuration

1.The machine may be configured as follows with its accessories (except the original/ paper feed device and boards):

[1]

[3]

[2]

[6]

[4]

[7]

[5]

[1]ADF-J1

[2]Finisher-L1 (if PDL output, requires hard disk.)

[3]Inner 2-Way Tray-B1

[4]1-Cassette Unit-F1 (iR1600 only)

[5]2-Cassette Unit-G1 (iR2000 only)

[6]3-Cassette Unit-H1 (iR1600 only)

[7]Card Reader-E1

CANON iR1600/iR2000 REV.0 SEPT. 2001

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CONTENTS

2. The machine may be configured with the following accessory boards:

Hard

Centronics interface

Disk

Printer [3]

or USB interface

Board

[1]

Flash ROM	[2]
[4]	[2]	Ethernet	LAN interface
[4]		Ethernet	LAN interface
		Board

:Internal interface

:External interface

[1]Printer Board-N1*

[2]Ethernet Network Interface Adapter iN-E5*

[3]Hard Disk HD-65

[4]Flash ROM Module FR-65

* : standard if printer model

CANON ADF-J1 REV.0 SEPT. 2001

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INTRODUCTION

Be sure to turn off the power switch and disconnect the power plug before starting disassembly/assembly work; further, keep the following in mind:

1.If you turn off the main power switch while a printer function is in use, the data being processed can be lost. Check to be sure that the online LED in the control panel is OFF before operating the power switch.

2.Do not turn off the power switch while downloading is taking place; otherwise, the machine may fail to operate.

3.Remember that not all power will be removed in response to the opening of the front cover as long as the power switch remains ON.

4.Be sure to use SHUT DOWN MENU to shut down the printer if the Hard Disk HD-65 (accessory) has been installed.

[2]

[1]

[1]Power switch

[2]Online LED

CANON iR1600/iR2000 REV.0 SEPT. 2001

vii

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Contents

CHAPTER 1 INTRODUCTION


1	Features		..............................................	1-1	4	Control Panel ....................................		1-18
	1.1	Features ......................................		1-1		4.1	Control Panel ...........................	1-18
2	Specifications .....................................			1-1		4.2	Basic Operation .......................	1-21
	2.1	Copier ........................................		1-3		4.3	Extended Operation .................	1-21
	2.1.1		Type .....................................	1-3		4.4	User Mode ...............................	1-22
	2.1.2		System .................................	1-3	5	Cleaning by the User ........................		1-30
	2.1.3		Functions .............................	1-4		5.1	Cleaning by the User ...............	1-30
	2.1.4		Others ..................................	1-6		5.1.1 Cleaning the


2.2	Cassette Unit .............................		1-8		Fixing Roller .....................	1-30
2.3	Inner 2-Way Tray .......................		1-9	5.1.2 Cleaning the Copyboard Glass,
3 Names of Parts .................................			1-10		Reading Glass, and Copyboard
3.1	External View ..........................		1-10		Cover White Plate ............	1-32
3.1.1		Copier ................................	1-10	6 Safety and Warnings ........................		1-33
3.1.2		Cassette Unit .....................	1-12	6.1	Safety of Laser Light ..............	1-33
3.1.3		Inner 2-Way Tray ..............	1-13	6.2	CDRH Requirements ...............	1-33
3.2	Cross Section ...........................		1-14	6.3	Handling the Laser Unit ..........	1-34
3.2.1		Copier ................................	1-14	6.4	Safety of the Toner ..................	1-35
3.2.2		Cassette Unit .....................	1-16	7 Reproduction Processes ...................		1-36
3.2.3		Inner 2-Way Tray ..............	1-17	7.1	Outline .....................................	1-36

CHAPTER 2 BASIC OPERATION


1 Basic Operation ..................................			2-1	1.3.3 Wiring Diagram of Electrical
1.1	Functional Construction ............		2-1	Components (2/2) ................	2-8
1.2	Outline of Electrical Circuitry ..		2-2	1.4 Basic Sequence of Operation ....	2-9
1.2.1		Image Processor PCB .........	2-2	1.4.1 Outline .................................	2-9
1.2.2		DC Controller PCB .............	2-3	1.4.2 Basic Sequence of Operation
1.2.3		Power Supply PCB ..............	2-5	(power-on) .........................	2-10
1.2.4		Analog Processor PCB ........	2-5	1.4.3 Basic Sequence of Operation

1.3 Inputs to and Outputs from Electri-		(printing) ...........................	2-11
cal Components .........................	2-6	1.5 Controlling the Main Motor
1.3.1 Wiring Diagram of the Major		(M101) .....................................	2-13
PCBs ....................................	2-6	1.5.1 Outline ...............................	2-13

1.3.2Wiring Diagram of the Electri-

cal Components (1/2) ..........

2-7

viii

CANON iR1600/iR2000 REV.0 SEPT. 2001

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CONTENTS

CHAPTER 3 IMAGE READING/PROCESSING SYSTEM

1 Outline of Operation ..........................			3-1	4.9	Edge Emphasis ........................		3-17
1.1	Outline .......................................		3-1	4.10 Editing .....................................			3-17
2 Reader Drive System .........................			3-2	4.11 Density Conversion (LUT, i.e.,
2.1	Outline .......................................		3-2		look-up table processing) ........		3-17
2.2	Controlling the Reader Motor ...		3-3	4.11.1 Density Adjustment
2.2.1 Moving the Carriage in						(F-value conversion) .........	3-17
		Reverse After an		4.11.2 Density Correction
		Image Scan ..........................	3-3			(g correction) .....................	3-17
3 Detecting the Size of Originals .........			3-4	4.12 Binary Processing ....................			3-18
3.1	Outline .......................................		3-4	4.12.1		Error Diffusion ..................	3-18
3.2	Detection by the			4.13 Image Memory Control ...........			3-18
	Original Size Sensors ................		3-4	4.13.1		Compression/Expansion,
3.3	Detecting the Size of					Rotation, and Enlargement/
	Originals ....................................		3-6			Reduction ..........................	3-18
3.4	Detection by the ADF ...............		3-7	4.13.2		SDRAM .............................	3-18
4 Image Processing ...............................			3-8	4.14 Output Image Processing ........			3-19
4.1	Outline .......................................		3-8	4.14.1		Smoothing .........................	3-19
4.2	Contact Sensor ...........................		3-9	5 Disassembly and Assembly .............			3-20
4.2.1 Outline of the Contact				5.1	Copyboard Glass .....................		3-21
		Sensor ..................................	3-9	5.1.1		Removing the
4.2.2 Construction of the Contact						Copyboard Glass ...............	3-21
		Sensor (CS) .......................	3-10	5.1.2		After Replacing the
4.3	A/D Conversion .......................		3-11			Copyboard Glass ...............	3-23
4.4	Shading Correction ..................		3-11	5.2	CS Unit ....................................		3-23
4.4.1		Black Shading		5.2.1		Removing the CS Unit ......	3-23
		Correction ..........................	3-12	5.2.2		Points to Note When
4.4.2		White Shading				Mounting the CS Unit .......	3-26
		Correction ..........................	3-12	5.2.3		After Replacing the
4.5	Re-Ordering .............................		3-12			CS Unit ..............................	3-28
4.6	ABC (auto background control)			5.2.4		Points to Note When
	.................................................		3-13			Handling the CS Unit ........	3-29
4.7	LED Intensity Adjustment ......		3-14	5.3	Reader Motor ...........................		3-30
4.8	Enlargement/Reduction ...........		3-14	5.3.1		Removing the Reader
4.8.1		Enlargement/Reduction in				Motor .................................	3-30
		Main Scanning Direction ..	3-14	5.3.2		Points to Note When Mounting
4.8.2		Changing the Reproduction				the Reader Motor ..............	3-31
		Ratio in Sub Scanning
		Direction ............................	3-16

CANON iR1600/iR2000 REV.0 SEPT. 2001

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CONTENTS

CHAPTER 4 LASER EXPOSURE SYSTEM

1	Outline of Operation ..........................		4-1	4	Controlling the Scanner Motor		.......... 4-8
	1.1	Outline .......................................	4-1		4.1	Outline .......................................	4-8
	1.2	Basic Sequence of Operation			4.2	Controlling the Scanner
		(laser exposure system) .............	4-3			Motor .........................................	4-8
2	Generating the Horizontal Signal ......		4-4		4.3	Scanner Pre-Rotation ................	4-9
	2.1	Outline .......................................	4-4	5	Disassembly and Assembly .............		4-10
	2.2	Signals Used ..............................	4-4		5.1	Removing the Laser/
3	Laser Driver Circuit ...........................		4-6			Scanner Unit ............................	4-11
	3.1	Laser Control .............................	4-6

CHAPTER 5 IMAGE FORMATION SYSTEM

1 Outline of Processes ...........................			5-1	3.4	Controlling the Voltage Level of
1.2	Sequence of Operation				the Developing DC Bias ............	5-7
	(image formation system) .........		5-3	4 Controlling the Transfer
2 1 Controlling the Primary Charging				Charging Roller Bias ..........................		5-8
Roller Bias ..........................................			5-4	4.1	Outline .......................................	5-8
2.1	Outline .......................................		5-4	4.2	Turning On and Off the Bias .....	5-9
2.2	Turning On and Off the Bias .....		5-5	4.2.1 Turning On and Off the
2.2.1		DC Bias ...............................	5-5		Positive DC Bias .................	5-9
2.2.2		AC Bias ...............................	5-5	4.2.2 Turning On and Off the
2.3	Bias Constant Voltage/				Negative DC Bias ................	5-9
	Constant Current Control ..........		5-5	4.3	Controlling the Bias to a Constant
2.3.1		DC Bias Constant Voltage			Current /Voltage Level ..............	5-9
		Control .................................	5-5	4.3.1 Controlling the DC Bias to a
2.3.2 AC Bias Constant Current					Constant Current Level .......	5-9
		Control .................................	5-5	4.3.2 Controlling the DC Bias to a
3 Controlling the Developing Bias .......			5-6		Constant Level ....................	5-9
3.1	Outline .......................................		5-6	4.4	Correcting the Voltage Level
3.2	Turning On/Off the Bias ...........		5-7		(ATVC control) ........................	5-10
3.2.1		DC Bias ...............................	5-7	4.5	Controlling the Output According
3.2.2		AC Bias ...............................	5-7		to Operation Mode ..................	5-10
3.3	Controlling the Bias to a			4.5.1 Type of Mode ....................		5-10
	Constant Voltage Level ..............		5-7	5 Detecting the Presence/Absence of a
3.3.1		Controlling the Developing		Cartridge and the Level of Toner .....		5-11
		DC Bias to a Constant		5.1	Outline .....................................	5-11
		Level ....................................	5-7	5.2	Sequence of Detection
3.3.2		Controlling the Developing			(level of toner) .........................	5-12
		AC Bias to a Constant		6 Monitoring the Waste Toner Case ...		5-14
		Voltage Level .......................	5-7	6.1	Outline .....................................	5-14
x		COPYRIGHT © 2001 CANON INC.			CANON iR1600/iR2000 REV.0 SEPT. 2001

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CONTENTS

6.2	Sequence of Operation ............		5-15	7.2	Developing Assembly .............		5-18
7 Disassembly and Assembly .............			5-16	7.2.1		Removing the Developing
7.1	Photosensitive Drum ...............		5-17			Assembly ...........................	5-18
7.1.1		Removing the Drum		7.3	Transfer Roller ........................		5-20
		Unit ....................................	5-17	7.3.1		Removing the Transfer
7.1.2		Cleaning the				Roller .................................	5-20
		Photosensitive Drum .........	5-17

CHAPTER 6 PICKUP/FEEDING SYSTEM

1 Outline		................................................	6-1
1.1	Specifications and Constructions
	...................................................		6-1
1.2	Arrangement of Major Rollers and
	Sensors .......................................		6-2
2 Controlling ......the Pickup Assembly			6-3
2.1	Controlling the Pickup from the
	Cassette ......................................		6-3
2.1.1 .................................		Outline	6-3
2.1.2 ....Pickup form the Cassette			6-4
2.1.3 ........................		Pickup Retry	6-6

2.1.4Detecting the Size of Paper in

the Cassette .........................	6-7
2.2 Controlling the Pickup from the
Multifeeder Tray ........................	6-8
2.2.1 Outline .................................	6-8

2.2.2Pickup from the Multifeeder

Tray ......................................

6-9

2.2.3Multifeeder Retry Operation

........................................... 6-11

2.2.4Setting the Paper Size for the Multifeeder Tray (user mode)

		...........................................	6-11
3 Controlling the Registration Roller
..........................................................			6-12
3.1	Detecting the Leading Edge of
	Paper ........................................		6-12
4 Detecting Jams .................................			6-13
4.1	Outline .....................................		6-13
4.2	Sequence of Jam Detection .....		6-14
4.2.1		Delay Jam ..........................	6-14
4.2.2		Stationary Jams .................	6-16
4.2.3		Cover Open Jam ................	6-17

4.2.4 Jam History .......................	6-17
5 Disassembly and Assembly .............	6-18
5.1 Cassette Pickup Assembly ......	6-19

5.1.1Remove the Cassette Pickup

Assembly ...........................

6-19

5.1.2Removing the Cassette

Pickup Roller .....................

6-21

5.1.3Removing the Feeding/

Separation Roller ..............

6-22

5.1.4Removing the Cassette

Pickup Solenoid ................

6-22

5.1.5Removing the Paper Size

Detecting Switch ...............

6-22

5.1.6Removing the Cassette Paper

Sensor ................................

6-23

5.1.7Removing the Retry Sensor

........................................... 6-23

5.1.8Removing the Pickup Motor

(iR2000 only) ....................	6-23
5.2 Multifeeder Tray Assembly ....	6-24

5.2.1Removing the Multifeeder

Tray ....................................

6-24

5.2.2Removing the Manual feed

Pickup Roller .....................

6-25

5.2.3Removing the Separation Pad

........................................... 6-26

5.2.4Removing the Multifeeder

Paper Sensor ......................

6-26

5.2.5Removing the Multifeeder

Pickup Solenoid ................	6-27
5.3 Drive Assembly .......................	6-27

5.3.1Removing the Drive

Assembly ...........................

6-27

CANON iR1600/iR2000 REV.0 SEPT. 2001

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CONTENTS

5.4 Registration Roller Assembly		5.4.2	Removing the Registration
.................................................	6-31		Paper Sensor ......................	6-32
5.4.1 Removing the Registration		5.4.3	Removing the Registration
Roller .................................	6-31		Clutch ................................	6-33

CHAPTER 7 FIXING SYSTEM

1 Outline of Operation ..........................			7-1	2.3.3 Conditions for Error
1.1	Outline .......................................		7-1		Detection .............................	7-8
2 Controlling the Fixing Temperature ..			7-3	2.4	Protective Mechanism .............	7-10
2.1	Outline .......................................		7-3	3 Disassembly and Assembly .............		7-11
2.2	Controlling the Temperature .....		7-4	3.1	Removing the Fixing
2.2.1 Control at Time of Power-On					Assembly .................................	7-12
		.............................................	7-5	3.2	Cleaning the Inside of the
2.2.2		Control According to the			Fixing Assembly or Replacing
		Type of Paper ......................	7-6		Its Parts ....................................	7-15
2.2.3 Control at Time of Down				3.3	Removing the Delivery Sensor 7-15
		Sequence ..............................	7-6	3.4	Removing the Pressure Roller 7-16
2.2.4		Control in ESS		3.5	Removing the Fixing Roller/
		(energy save mode) .............	7-7		Fixing Heater/Separation
2.3	Detecting an Error .....................		7-8		Claw .........................................	7-22
2.3.1		Outline .................................	7-8	3.6	Mounting the Fixing Roller/
2.3.2 Control in Response to an					Fixing Heater/Separation
		Error .....................................	7-8		Claw .........................................	7-24

CHAPTER 8 EXTERNALS AND AUXILIARY CONTROL SYSTEM

1 Control Panel ......................................		8-1	3 Control at Time of Energy
1.1	The machine’s control panel has		Save Mode		..............................................	8-6
	the following construction ........	8-1	3.1	Outline .......................................		8-6
2 Power supply ......................................		8-2	3.2	Control .......................................		8-6
2.1	Power Supply .............................	8-2	3.3		Operation .............................	8-8
2.1.1 Outline .................................		8-2	4		Fan .......................................	8-9
2.1.2 Rated Outputs from the Power			4.1		Outline .................................	8-9
	Supply PCB .........................	8-4	4.2		Control ...............................	8-10
2.2	Protective Mechanisms .............	8-5	4.2.1		Controlling the Speed .......	8-10
2.3	High-Voltage Power Supply		4.2.2		Error Detection ..................	8-11
	Circuit ........................................	8-5	4.2.3		Sequence of Operation
					(fan drive) ..........................	8-11
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					CONTENTS

5 Back-Up Battery ...............................			8-12	6.1.1 Removing the Front Cover
5.1	Back-Up Mechanism ...............		8-12		...........................................	8-20
5.1.1		Outline ...............................	8-12	6.1.2 Removing the Control Panel
5.1.2		Lithium Battery (BAT1) ....	8-13		Lower Cover ......................	8-20
5.2	Back-Up Data ..........................		8-15	6.2	Control Panel ...........................	8-21
5.2.1		Types of Data ....................	8-15	6.2.1 Removing the Control Panel
5.2.2 Printing Out the Back-Up					...........................................	8-21
		Data List ............................	8-16	6.3	Main Motor ..............................	8-22
6 Disassembly and Assembly .............			8-17	6.3.1 Removing the Main Motor
6.1	External Covers .......................		8-18		8-22
				6.4	Fan ...........................................	8-23

CHAPTER 9 CASSETTE UNIT

1 Outline		................................................	9-1	4.2		Cassette Pickup Assembly
1.1	Outline .......................................		9-1			...........................................	9-12
1.2	Specifications and Construction			4.2.1		Removing the Cassette
	...................................................		9-1			Pickup Assembly ...............	9-12
1.3	Arrangement of Major Rollers			4.2.2		Removing the Cassette
	and ................................Sensors		9-2			Pickup Roller .....................	9-12
2 Pickup ................................Assembly			9-4	4.2.3		Removing the Cassette
2.1	Pickup .............Control System		9-4			Pickup Solenoid ................	9-12
2.2	Pickup ...........................Control		9-7	4.2.4		Removing the Paper Size
2.3	Cassette ........Pickup Operation		9-7			Switch ................................	9-12
2.4	Pickup ..........Re-Try Operation		9-7	4.2.5		Removing the Cassette
2.5	Cassette ..Paper Size Detection		9-7			Paper Sensor ......................	9-12
3 Detecting ...................................Jams			9-8	4.2.6		Removing the Re-Try
3.1	Outline .......................................		9-8			Sensor ................................	9-12
3.2	Sequence .......of Jam Detection		9-8	4.3	PCBs ........................................		9-13
3.1.1 ............................		Delay Jam	9-8	4.3.1		Removing the Cassette Unit
3.1.2 .....................		Stationary Jam	9-8			Controller PCB ..................	9-13
3.1.3 .........................		Jam History	9-8	4.4	Drive-Related Parts .................		9-13
4 Disassembly ...............and Assembly			9-9	4.4.1		Removing the Pickup Motor
4.1	Removing ...the Cassette Unit		9-10			...........................................	9-13

CANON iR1600/iR2000 REV.0 SEPT. 2001

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CONTENTS

CHAPTER 10 INNER 2-WAY TRAY

1	Specifications ...................................		10-1	3	Detecting Jams .................................			10-4
	1.1	System .....................................	10-1		3.1	Outline .....................................		10-4
	1.2	Arrangement of Rollers and			3.2	Sequence of Jam Detection .....		10-4
		Sensors .....................................	10-2		3.2.1		Delay Jam ..........................	10-4
2	Controlling Delivery Operation .......		10-3		3.2.2		Stationary Jam ...................	10-4
	2.1	Controlling Delivery Operation			3.2.3		Jam History .......................	10-4
		.................................................	10-3	4	Disassembly and Assembly .............			10-5
	2.2	Selecting a Delivery Slot			4.1	Removing the Inner 2-Way Unit
		(user mode) ..............................	10-3			.................................................		10-6

CHAPTER 11 INSTALLATION

1 Selecting the Site of Installation .....		11-1	2.10 Data Initialization through
2 Unpacking and Installing the				Service Operation ..................	11-21
Machine ............................................		11-3	2.11	Setting the Date/Time
2.1	Points to Note Before Starting			(user mode) ............................	11-22
	the Work ...................................	11-3	2.12	Storing the Specifications
2.2	Installing the Machine ............	11-4		Report ....................................	11-23
2.3	Unpacking and Removing the		2.13	Checking the Printer Functions
	Fixing Members ......................	11-5		(if equipped with printer
2.4	Removing the Dummy Drum			functions) ...............................	11-24
	.................................................	11-7	3 Relocating the Machine .................		11-25
2.5	Mounting the Drum Unit ........	11-9	4 Installing the Card Readere-E1
2.6	Mounting the Toner Cartridge		(accessory) ......................................		11-26
	...............................................	11-11	4.1	Points to Note for Installation
2.7	Putting Paper in the Cassette			...............................................	11-26
	...............................................	11-14	4.2	Installation .............................	11-27
2.8	Placing Paper in the		5 Installing the Image RAM
	Multifeeder Tray ....................	11-18	(accessory) ......................................		11-31
2.9	Checking the Copy Images ...	11-20	5.1	Installation .............................	11-31

xiv

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CONTENTS

CHAPTER 12 MAINTENANCE AND INSPECTION

1	Periodically Replaced Parts .............		12-1
	1.1	Copier ......................................	12-1
	1.2	Cassette Unit ...........................	12-1
	1.3	Inner 2-Way Tray .....................	12-1
2	Guide to Durables ............................		12-2
	2.1	Checking the Timing of Replace-
		ment .........................................	12-2
	2.2	Copier ......................................	12-2
	2.3	Cassette Unit ...........................	12-2
	2.4	Inner 2-Way Tray .....................	12-2
3	Basic Service Work ..........................		12-3

	3.1	Basic Service Work .................	12-3
4	Cleaning During a Visit ...................		12-4
5	Points to Note When Storing/Handling
	the Drum Unit ..................................		12-7
	5.1	Outline .....................................	12-7
	5.2	Storage and Handing After Remov-
		ing the Packaging Seal ............	12-7

5.2.1Storage After Removing the

Packaging Seal ..................

12-7

5.2.2Points to Note When Handling

the Drum Unit ...................

12-8

CHAPTER 13 TROUBLESHOOTING

1	Image Adjustment Basic Procedure
	..........................................................		13-1
	1.1	Image Adjustment Basic
		Procedure .................................	13-1
2	Standards and Adjustments ..............		13-3
	2.1	Image Adjustments ..................	13-3

2.1.1Standards for Image

Position ..............................

13-3

2.1.2Adjusting the Image

Position ..............................

13-4

2.1.3Adjusting the Leading Edge Margin for the Printer Unit

(if equipped printer
functions) ...........................	13-5
2.1.4 Adjusting the Image
Position for Copying .........	13-7
2.2 Fixing System ..........................	13-9

2.2.1Checking the Fixing Roller

Pressure (nip)	.................... 13-9
2.3 Electrical Parts ......................	13-10

2.3.1When Replacing the

	Major Parts ......................	13-10
2.3.2	Gain Auto Adjustment ....	13-10
2.3.3	When Replacing the
	Contact Sensor ................	13-10

2.3.4When Replacing the

Image Processor PCB ..... 13-11

2.3.5When Replacing the DC

Controller PCB ................

13-12

2.3.6When Replacing the Analog

		Processor PCB .................	13-12
2.4	Checking the Sensors ............		13-13
2.4.1		Checking the Sensors ......	13-13
3 Troubleshooting Image/Operation
Faults		..............................................	13-16
3.1	Making Initial Checks on Image
	Faults .....................................		13-16
3.1.1 ...........		Site of Installation	13-16
3.1.2 ...		Checking the Originals	13-16

3.1.3Copyboard Cover and Copyboard Glass (standard

white plate) ......................

13-16

3.1.4Checking the Transfer Charging Roller/Static Eliminator

......................................... 13-17

3.1.5Checking the Drum Unit . 13-17

3.1.6 Checking the Paper .........

13-17

3.1.7Image Adjustment Basic

	Procedure .........................	13-17
3.1.8 Others ..............................		13-17
3.2	Image Fault Samples .............	13-20
3.3	Troubleshooting Image Faults
	...............................................	13-21

CANON iR1600/iR2000 REV.0 SEPT. 2001

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CONTENTS

3.3.1The copy is too light.

(halftone only) .................

13-21

3.3.2The copy is too light.

(both halftone and solid black)

......................................... 13-21

3.3.3The copy is too light. (entire copy, appreciably)

......................................... 13-21

3.3.4The copy has uneven density.

(darker along front) .........

13-24

3.3.5The copy has uneven density.

	(lighter along front) ........	13-24
3.3.6	The copy is foggy.
	(entire copy) ....................	13-25
3.3.7	The copy is foggy.
	(feeding direction). .........	13-26

3.3.8The copy has black lines. (feeding direction, fuzzy, thick)

......................................... 13-26

3.3.9The copy has black lines. (feeding direction, fine) .. 13-26

3.3.10The copy has white strips.

(feeding direction) ..........	13-27
3.3.11 The copy has white lines.
(feeding direction) ..........	13-27

3.3.12The output has white strips. (cross-feeding direction)

......................................... 13-28 3.3.13 The back of the copy is soiled.

......................................... 13-29 3.3.14 The copy has a poor fixing.

......................................... 13-30

3.3.15The copy has displaced registration. (leading edge extremely excessive margin).

	.........................................	13-31
3.3.16	The copy has displaced
	registration. (leading edge,
	excessive margin) ............	13-31
3.3.17	The copy has displaced
	registration. (leading edge,
	no margin) .......................	13-31
3.3.18	The copy has blurred
	images. ............................	13-32
xvi	COPYRIGHT ©	2001 CANON INC.

3.3.19	The copy is foggy. (cross-feed-
	ing direction) ...................	13-33
3.3.20	The copy has poor sharpness.
	.........................................	13-34
3.3.21	The copy is blank. ...........	13-35
3.3.22	The copy is solid black. ..	13-36
3.4 Troubleshooting Malfunctions
...............................................		13-37
3.4.1	AC power is absent. ........	13-37
3.4.2	DC power is absent. ........	13-38

3.4.3Pickup operation fails.

(cassette) ..........................

13-39

3.4.4Pickup operation fails.

(multifeeder tray) ............

13-40

3.4.5Pickup operation fails. (cas-

sette unit) .........................

13-41

3.4.6The vertical path roller fails to

rotate. ...............................

13-42

3.4.7The registration roller fails to

rotate. ...............................

13-42

3.4.8The contact sensor fails to go

ON. ..................................

13-43

3.4.9The speaker fails to operate.

......................................... 13-43 3.4.10 The ‘Add Toner’ message fails

to go OFF. ........................

13-44

3.4.11The ‘Add Paper’ message fails to go OFF. (machine

and cassette unit) .............

13-45

3.4.12The ‘Add Paper’ message fails to go OFF. (multifeeder tray)

.........................................	13-46
3.4.13 The ‘Jam’ message fails to
go OFF. ............................	13-46

3.4.14The ‘Waste Toner Full’ message does not go OFF.

......................................... 13-47

3.4.15The ‘Controller Card Set’ message does not go ON.

......................................... 13-47

3.4.16The ‘Control Card Set’ message does not go OFF.

......................................... 13-47 3.5 Troubleshooting Feeding Faults

............................................... 13-48

CANON iR1600/iR2000 REV.0 SEPT. 2001

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CONTENTS

3.5.1	Outline .............................	13-48
3.5.2	Pickup Assembly .............	13-49

3.5.3Transfer/Feeding Assembly

......................................... 13-50

3.5.4Fixing/Delivery Assembly

......................................... 13-51

3.5.5Feeding Fault (double feeding)

......................................... 13-52

3.5.6Feeding Faults (wrinkling)

		.........................................	13-53
4 Arrangement and Functions
of Electrical Parts ...........................			13-54
4.1	Outline ...................................		13-54
4.1.1		Outline .............................	13-54
4.1.2		Checking the Sensors ......	13-54
4.2	Clutches, Solenoids, Motors,
	and Fans .................................		13-55
4.3	Sensors ...................................		13-56
4.4	PCBs ......................................		13-57
4.5	Switches, Others ....................		13-59
4.6	Cassette Unit .........................		13-61
4.7	Inner 2-Way Tray ...................		13-63
4.8	Variable Resistors (VR),
	Light-Emitting Diodes
	(LED), and Check Pins .........		13-64
4.8.1		Image Processor PCB .....	13-65
4.8.2		DC Controller PCB .........	13-66
4.8.3		Power Supply PCB ..........	13-67
4.8.4		Analog Processor PCB ....	13-68

4.8.51-Cassette Unit Controller

PCB ..................................

13-69

4.8.62/3-Cassette Unit Controller

	PCB ..................................	13-69
5 Service Mode .................................		13-70
5.1	Outline ...................................	13-70
5.2	Using the Mode .....................	13-72
5.3	Service Mode Menus ............	13-73
5.4	Setting the parameters ...........	13-77

5.4.1Registering the Bit Switch

(#1 SSSW) .......................

13-77

5.4.2Setting Numeric Parameters (#3 NUMERIC Param.) .. 13-79

5.4.3Selecting the Country/Region of Installation (#5 TYPE) 13-82

5.4.4Setting Original Read Func-

tions (#6 SCANNER) ...... 13-83

5.4.5Setting the Printer Parameters

(#7 PRINTER) .................	13-86
5.4.6 PDL (#8 PDL) .................	13-86

5.4.7Counters (#9 COUNTER)

......................................... 13-87

5.4.8Generating a Report

	(#10 REPORT) ................	13-90
5.4.9	Downloading
	(#11 DOWNLOAD) ........	13-91
5.4.10	Clear (#12 CLEAR) ........	13-92
5.4.11	ROM Indication (#13 ROM)
	.........................................	13-93
5.4.12	Resetting the CS Unit Position
	(#14 CS SET) ..................	13-93
5.5 Test Mode (TEST MODE) ....		13-94
5.5.1	Outline .............................	13-94
5.5.2	Test Mode Menu .............	13-95

5.5.3D-RAM Test (1: D-RAM)13-98

5.5.4CCD Test (2: CCD TEST)

....................................... 13-100

5.5.5PRINT Test (3: PRINT) 13-101

5.5.7Faculty Test (6: FACULTY

TEST) ............................

13-102

5.5.8Book Read Test (8: BOOK

		TEST) ............................	13-108
5.6	Report ..................................		13-109
5.6.1		User report .....................	13-109
5.6.2		Service Report ...............	13-110
6 Self Diagnosis ..............................			13-117
6.1	Outline .................................		13-117
6.2	Error Codes ..........................		13-118

6.2.1Error Codes Used for the

Machine .........................	13-118
6.2.2 Finisher Error Codes .....	13-123

CANON iR1600/iR2000 REV.0 SEPT. 2001

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CONTENTS

CHAPTER 14 VERSION UP

1	Upgrading .........................................		14-1	2.3	Installing the Firmware ...........		14-7
	1.1	Outline .....................................	14-1	2.4	Downloading the System
2	Upgrading by Downloading .............		14-3		Software .................................		14-10
	2.1	Before Starting the Work ........	14-3	2.5	Downloading for the Finisher-L1
	2.2	Installing the USB Driver			...............................................		14-17
		(only if Windows 98 or		2.5.1		Outline .............................	14-17
		Windows 98SE) .......................	14-4	2.5.2		Downloading ...................	14-18

APPENDIX

A General Timing Charts ......................	A-1
B General Circuit Diagram ..................	A-3
C 1-cassette unit ....................................	A-5
D 2/3-cassette unit ................................	A-6

E Inner 2-way tray ................................	A-7
F Special Tools .....................................	A-9
G Solvents and Oils ............................	A-11

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CHAPTER 1

INTRODUCTION

CANON iR1600/iR2000 REV.0 SEPT. 2001

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			CHAPTER 1 INTRODUCTION

1 Features

1.1 Features
1. High-Speed, High Image Quality
Copying speed	16 copies/min (iR1600 ; 1-to-N, from cassette)
	20 copies/min (iR2000 ; 1-to-No: from cassette)
Reading resolution		:	600 dpi x 600 dpi
Printing resolution
	Copying	:	1,200 (equivalent) x 600 dpi
	PDL output	:	2,400 (equivalent) x 600 dpi

2. Large Paper Source

With the addition of accessories, as many as 1,100 sheets (80 g/m2) may be accommodated.

Multifeeder : 100 sheets (A4R, A4, B5, B5R, A5, A5R; 80 g/m2)

•iR1600 Cassette Cassette 1 : 250 sheets

1-cassette unit (accessory) : 250 sheets 3-cassette unit (accessory) : 250 sheets x 3

•iR2000 Cassette Cassette 1 : 250 sheets Cassette 2 : 250 sheets

2-cassette unit (accessory) : 250 sheets x 2

3.Mixed Paper Sizes (of same configuration)

Installation of an ADF will enable mixing of different paper sizes (of the same configura-

tion).

4.Networking

Mounting of a printer board and network interface board will enable the use of the ma-

chine as a network printer in an Ethernet environment.

5.Hard Disk

Installation of a hard disk (accessory) will enable storage of image data on the hard disk. Since the images will be read from the hard disk, multiple sets of copies may be obtained faster (RIP-once function).

CANON iR1600/iR2000 REV.0 SEPT. 2001

1-1

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CHAPTER 1 INTRODUCTION

6.Selection of a Delivery Tray

Installation of an inner 2-way tray (accessory) will enable the selection of trays sepa-

rately for copier and printer output (in user mode).

7.Auto Start/Interrupt Copying

The existing models retains no more than one job. The machine, however, keeps jobs on queue, thus enabling auto-start/interrupt copying.

1-2

CANON iR1600/iR2000 REV.0 SEPT. 2001

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			CHAPTER 1 INTRODUCTION

2 Specifications

2.1 Copier
2.1.1 Type
	Item		Description

	Body		Desktop
	Copyboard		Fixed
	Light source		LED
	Lens		Rod lens array
	Photosensitive medium		OPC (30-mm dia.)
			T01-201-01
2.1.2 System
	Item		Description

	Copying		Indirect photoelectric reproduction
	Charging		Roller charging
	Exposure		Semiconductor laser
	Copy density adjustment		Auto or manual
	Development		Dry, 1-component toner projection
	Pickup	Auto	Cassette
		Manual	Manual feed tray
	Transfer		Roller charging
	Separation		Curvature + static (static eliminator)
	Cleaning		Rubber blade
	Fixing		Heat roller (800 W for 120/230V)
			T01-201-02

CANON iR1600/iR2000 REV.0 SEPT. 2001

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CHAPTER 1 INTRODUCTION

2.1.3 Functions

Item		Description
Original type	Sheet, book, 3-D (2 kg max.)
Maximum original size	A3/279.4 x 431.8mm (11" x 17")
Reproduction ratio	Direct (1:1)
4R4E	Reduce I (1:0.500), Reduce II (1:0.707)
	Reduce III (1:0.816), Reduce IV (1:0.865)
	Enlarge I (1:1.154), Enlarge II (1:1.224), Enlarge III (1:1.414)
	Enlarge IV (1:2.000)
4R3E	Reduce I (1:0.500), Reduce II (1:0.647), Reduce III (1:0.733)
	Reduce IV (1:0.786)
	Enlarge I (1:1.214), Enlarge II (1:1.294), Enlarge III (1:2.000)
4R2E	Reduce I (1:0.500), Reduce II (1:0.707)
	Enlarge I (1:1.414), Enlarge II (1:2.000)
	Zoom (1:0.500 to 2.00; 50% to 200%; 1%-increment)
Wait time	30 sec or less from power-on (at 20°C room temperature)
First copy time	Less than 8.2 sec (from copier cassette; Direct, A4/LTR, non-AE)
Continuous copying	99 copies max.
Copy size
Cassette
	AB :	A3 max.
		A5 (vertical) min.
	Inch : 11x17 (279.4 x 431.8 mm) max.
		STMT (vertical) min.
Multifeeder
pickup	AB :	A3 max.
		Postcard min.
	Inch	11x17 (279.4 x 431.8 mm) max.
		STMT (vertical) min.
		T01-201-03

1-4

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		CHAPTER 1 INTRODUCTION

Item		Description

Paper type
Cassette	Plain paper (60 to 90 g/m2), recycled paper (60 to 90 g/m2), colored paper, label sheet
Multifeeder	Plain paper (60 to 90 g/m2), thick paper (90 to 128 g/m2), recycled paper (64 to 90 g/
	m2), colored paper, transparency, postcard, double-postcard, envelope
Multifeeder	10 mm in height
Tray AB:	Plain paper, recycled paper, colored paper
	100 sheets if A4R, A4, B5, B5R, A5, A5R (80 g/m2)
	50 sheets if A3, B4 (80 g/m2)
	50 sheets if transparency, thick paper (90 to 128 g/m2)
	10 sheets if envelope
Inch:	Plain paper, recycled paper, colored paper
	100 sheets if LTR, LTRR, STMT, STMTR (80 g/m2)
	50 sheets if transparency, thick paper (90 to 128 g/m2)
	10 sheets if envelope
	50 sheets if 11x17 (279.4x431.8 mm), LGL
Cassette	25 mm in depth (250 sheets max. of 80 g/m2)
Delivery	Face-down (250 sheets max. of 80 g/m2)
Non-image width
Leading edge		3.0±2mm
Trailing edge		3.0±2mm
Left/right		3.0±2mm
Auto clear	Yes (2 min standard; may be changed between 0 and 9 min in 1-min increment)
Energy saver	Yes (15 min standard; may be changed between 3 and 30 min in 1-min increment)
Accessory	Cassette unit

Finisher

ADF

Inner 2-way tray

Card reader

Hard disk

Expansion RAM

Flash ROM

Network interface board *1

PCL printer board *1

*1 : Standard if printer model.

T01-210-04

CANON iR1600/iR2000 REV.0 SEPT. 2001

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CHAPTER 1 INTRODUCTION

2.1.4 Others

Item		Description
Operating environment
Temperature range		15 to 30°C; 59 to 86°F
Humidity range		10% to 80%
Atmospheric pressure range		810.6 to 1013.3 hPa (0.8 to 1.0 atm)
Power supply		120V (60Hz), 230V (50Hz)
Serial number		iR1600 : UHRxxxxx	iR2000 : UHSxxxxx
		UJJxxxxx	UJKxxxxx
		SDMxxxxx	SDPxxxxx
		SEDxxxxx	SEExxxxx
		TDWxxxxx	TDYxxxxx
		TENxxxxx	TEPxxxxx
		QSKxxxxx	QSMxxxxx
		RSMxxxxx	RSSxxxxx
		QENxxxxx	QEQxxxxx
		QFBxxxxx	QFCxxxxx
		QSLxxxxx	QSNxxxxx
		RSNxxxxx	REVxxxxx
		RENxxxxx	REPxxxxx
		RFJxxxxx	RFKxxxxx
		RSPxxxxx	RSTxxxxx
		RSQxxxxx	RSTxxxxx
Power consumption
Maximum		940W
Standby		30W (reference) *1
Continuous copying		900W (reference) *1
Energy saver	High	20W (reference) *1
	Low	4.8W (reference) *1
Noise
Copying		66 dB or less
Standby		40 dB or less
Dimensions		iR 1600 615 (W) x 631 (D) x 560 (H) mm/24.0 (W) x
		24.8 (D) x 22.0 (H) in.
		iR 2000 615 (W) x 631 (D) x 645 (H) mm/24.0 (W) x
		24.8 (D) x 25.1 (H) in.
Weight		iR 1600 38.0kg/83.8lb
		iR 2000 43.4kg/95.7lb
Consumables
Paper		Keep wrapped to avoid humidity.
Toner		Avoid direct sunshine, and keep at 40°C (104°F) 85% or
		less.

*1 : In copyboard cover model; for rated power supply voltage in the absence of printer board.

T01-210-05

1-6

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CHAPTER 1 INTRODUCTION

Reproduction ratio	Size	Paper size	Copies/min (1-to-N)
			iR1600	iR2000
Direct	A3 (297 x 420mm)	A3	9	9
	A4 (297 x 420mm)	A4	16	20
	B4 (297 x 420mm)	B4	10	10
	B5 (297 x 420mm)	B5	16	20
	A4R (297 x 420mm)	A4R	12	15
	B5R (297 x 420mm)	B5R	13	16
	A5 (297 x 420mm)	A5	16	20

Auto paper select ON, Auto density adjustment ON, Non-sort, Pickup from cassette

T01-201-06

The above specifications are subject to change for product improvement.

Reproduction ratio	Size	Paper size Copies/min (1-to-N)
			iR1600	iR2000

Direct	279.4 x 431.8mm	279.4 x 431.8mm	9	9
	(11" x 17")	(11" x 17")
	LTR	LTR	16	20
	LGL	LGL	10	10
	LTRR	LTRR	12	16
	STMT	STMT	16	20

Auto paper select ON, Auto density adjustment ON, Non-sort, Pickup from cassette

T01-201-07

The above specifications are subject to change for product improvement.

CANON iR1600/iR2000 REV.0 SEPT. 2001

1-7

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CHAPTER 1 INTRODUCTION

2.2 Cassette Unit

Item	Description
Pickup	Claw-less (retard) method
Paper type	Same as host.
Cassette	25 mm deep (250 sheets of 80 g/m2 paper max.)
Serial Number	1-cassette type : XGQxxxxx
	2-cassette type : XGRxxxxx
	3-cassette type : XGSxxxxx
Dimensions
1-cassette type	560 (W) x 564.3 (D) x 90.8 (H) mm
	22.0 (W) x 22.0 (D) x 3.54 (H) in.
2-cassette type	560 (W) x 564.3 (D) x 175.8 (H) mm
	22.0 (W) x 22.0 (D) x 6.79 (H) in.
3-cassette type	560 (W) x 564.3 (D) x 260.8 (H) mm
	22.0 (W) x 22.0 (D) x 10.2 (H) in.
Weight
1-cassette type	6.3 kg/13.9 lb (approx.; including cassette)
2-cassette type	12.7 kg/28.0 lb (approx.; including cassette)
3-cassette type	19.1 kg/42.1 lb (approx.; including cassette)
Power supply	DC power from host
Operating environment	Same as host
Temperature range
Humidity range
Atmospheric pressure
	T01-202-01

The above specifications are subject to change for product improvement.

1-8

CANON iR1600/iR2000 REV.0 SEPT. 2001

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Canon iR1600, iR2000 Service Manual

CONTENTS

CHAPTER 1

1 Features

2 Specifications