CANON iR1600 User Manual

iR1600/iR2000/ iR1610/iR2010 SERIES

REVISION 0

MAR. 2002

FY8-13HS-000

iR1600/iR2000/iR1610/iR2010 SERIES

REV.0 MAR. 2002 PRINTED IN JAPAN (IMPRIME AU JAPON)

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.

iR1600/iR2000/iR1610/iR2010 SERIES

REV.0 MAR. 2002 PRINTED IN JAPAN (IMPRIME AU JAPON)

INTRODUCTION

1 Symbols Used

This documentation uses the following symbols to indicate special information:

Symbol Description

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).

Memo

REF.

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.

2002 CANON INC. 2001 2001 CANON iR1600/iR2000/iR1610/iR2010 SERIES REV.0 MAR. 2002

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 2way 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

2002 CANON INC. 2001 2001 CANON iR1600/iR2000/iR1610/iR2010 SERIES REV.0 MAR. 2002

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).

2002 CANON INC. 2001 2001 CANON iR1600/iR2000/iR1610/iR2010 SERIES REV.0 MAR. 2002

iii

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).

2002 CANON INC. 2001 2001 CANON iR1600/iR2000/iR1610/iR2010 SERIES REV.0 MAR. 2002

INTRODUCTION

This service manual covers the models shown in the following table. Be sure to have a good understanding of the difference from model to model before referring to this manual.

Model

iR1600

iR2000

iR1610F

iR2010F

ADF

function

√ √

Fax

function

√ √

Printer

function

Cassette

Type

1-cassette

2-cassette

1-cassette

2-cassette

Copying speed (cpm) at Direct

16cpm/LTR

20cpm/LTR

16cpm/LTR

20cpm/LTR

The notation “ √” indicates that the item in question is available.

*1 : Fax function not supported.

2002 CANON INC. 2001 2001 CANON iR1600/iR2000/iR1610/iR2010 SERIES REV.0 MAR. 2002

INTRODUCTION

System Configuration

1. The machine may be configured as follows with its accessories (except the printer/fax device):

[1]

[3]

[2]

[6]

[4]

[5]

F1 F2

[1] ADF-J1 (iR1600/iR2000 only) [2] Finisher-L1 (if PDL output, requires hard disk.) [3] Inner 2-Way Tray-B1 [4] 1-Cassette Unit-F1 (16cpm model only) [5] 2-Cassette Unit-G1 (20cpm model only) [6] 3-Cassette Unit-H1 (16cpm model only) [7] Card Reader-E1

[7]

2002 CANON INC. 2001 2001 CANON iR1600/iR2000/iR1610/iR2010 SERIES REV.0 MAR. 2002

INTRODUCTION

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

• Printer accessories

Hard

Disk

Printer

Board

[1]

: Internal interface : External interface

[3]

Flash ROM

[4] [4]

PS Module

[5]

[1] Printer Board-N1 [2] Ethernet Network Interface Adapter iN-E5 [3] Hard Disk HD-65 [4] Flash ROM Module FR-65 [5] PS Module-B1

[2]

Ethernet

Board

Centronics interface

or USB interface

LAN interface

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vii

INTRODUCTION

• Fax accessories (iR1610F/iR2010F only)

[1] G3 FAX BOARD

NCU PCB

: Internal interface

: External interface

[1] G3 FAX BAORD*

Modular

PCB

[2] G3 FAX EXPANSION KIT-B1*

*1 : Standard (iR1610F/iR2010F) *2 : iR1610F/iR2010F 120V only

[2] G3 FAX EXPANSION KIT-B1

NCU PCB

G3 multiport PCB

2-line

Modular

PCB

PSTN

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INTRODUCTION

Be sure to turn off the power switch and disconnect the power plug before starting dis-

assembly/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 indicator 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] Power switch [2] Online indicator

[1]

2002 CANON INC. 2001 2001 CANON iR1600/iR2000/iR1610/iR2010 SERIES REV.0 MAR. 2002

Contents

CHAPTER 1 INTRODUCTION

1 Features .............................................. 1-1

1.1 Features...................................... 1-1

2 Specifications ..................................... 1-3

2.1 Copier ........................................ 1-3

2.1.1 Type ..................................... 1-3

2.1.2 System ................................. 1-3

2.1.3 Functions ............................. 1-4

2.1.4 Others .................................. 1-6

2.2 Cassette Unit ............................. 1-8

2.3 Inner 2-Way Tray ....................... 1-9

3 Names of Parts ................................. 1-10

3.1 External View .......................... 1-10

3.1.1 Copier ................................ 1-10

3.1.2 Cassette Unit ..................... 1-12

3.1.3 Inner 2-Way Tray .............. 1-13

3.2 Cross Section ........................... 1-14

3.2.1 Copier ................................ 1-14

3.2.2 Cassette Unit ..................... 1-16

3.2.3 Inner 2-Way Tray .............. 1-17

4 Control Panel .................................... 1-18

4.1 Control Panel ........................... 1-18

4.1.1 Control Panel for a

Non-Fax Model ................. 1-18

4.1.2 Control Panel for a

Fax Model ......................... 1-21

4.1.3 Master Password ............... 1-25

4.2 Basic Operation ....................... 1-26

4.2.1 Basic Operation for a

Non-Fax Model ................. 1-26

4.2.2 Basic Operation for

a Fax Model....................... 1-26

4.3 Extended Operation ................. 1-27

4.3.1 Extended Operation for a

Non-Fax Model ................. 1-27

4.3.2 Extended Operation for a

Fax Model .........................1-27

4.4 User Mode ............................... 1-28

4.4.1 User Mode for a

Non-Fax Model ................. 1-28

4.4.2 User Mode for a

Fax Model .........................1-36

5 Cleaning by the User ........................ 1-59

5.1 Cleaning by the User ............... 1-59

5.1.1 Cleaning the Fixing Roller 1-59

5.1.2 Cleaning the Copyboard Glass, Reading Glass, and Copyboard

Cover White Plate ............ 1-61

5.1.3 Cleaning the ADF Roller/

Guide Assembly ................ 1-62

6 Safety and Warnings ........................ 1-64

6.1 Safety of Laser Light .............. 1-64

6.2 CDRH Requirements ............... 1-64

6.3 Handling the Laser Unit .......... 1-65

6.4 Safety of the Toner .................. 1-66

7 Reproduction Processes ...................1-67

7.1 Outline ..................................... 1-67

CHAPTER 2 BASIC OPERATION

1 Basic Operation .................................. 2-1

1.1 Functional Construction ............ 2-1

1.2 Outline of Electrical Circuitry .. 2-2

1.2.1 Image Processor PCB ......... 2-2

1.2.2 DC Controller PCB ............. 2-3

1.2.3 Power Supply PCB.............. 2-5

2002 CANON INC. 2001 2001 CANON iR1600/iR2000/iR1610/iR2010 SERIES REV.0 MAR. 2002

1.2.4 Analog Processor PCB........ 2-5

1.3 Inputs to and Outputs from

Electrical Components ................ 2-6

1.3.1 Wiring Diagram of the Major

PCBs .................................... 2-6

CONTENTS

1.3.2 Wiring Diagram of the Electrical

Components (1/2) ................ 2-7

1.3.3 Wiring Diagram of Electrical

Components (2/2)................ 2-8

1.4 Basic Sequence of Operation .... 2-9

1.4.1 Outline ................................. 2-9

1.4.2 Basic Sequence of Operation

(power-on) ......................... 2-10

CHAPTER 3

1 Outline of Operation .......................... 3-1

1.1 Outline ....................................... 3-1

2 Reader Drive System ......................... 3-2

2.1 Outline ....................................... 3-2

2.2 Controlling the Reader Motor ... 3-3

2.2.1 Moving the Carriage in Reverse After an

Image Scan .......................... 3-3

3 Detecting the Size of Originals ......... 3-4

3.1 Outline ....................................... 3-4

3.2 Detection by the

Original Size Sensors ................ 3-4

3.3 Detecting the Size of

Originals .................................... 3-6

3.4 Detection by the ADF ............... 3-7

4 Image Processing ............................... 3-8

4.1 Outline ....................................... 3-8

4.2 Contact Sensor ........................... 3-9

4.2.1 Outline of the Contact

Sensor .................................. 3-9

4.2.2 Construction of the Contact

Sensor (CS) ....................... 3-10

4.3 A/D Conversion ....................... 3-11

4.4 Shading Correction .................. 3-11

4.4.1 Black Shading

Correction .......................... 3-12

4.4.2 White Shading

Correction .......................... 3-12

4.5 Re-Ordering ............................. 3-12

4.6 ABC

(auto background control) ....... 3-13

IMAGE READING/PROCESSING SYSTEM

1.4.3 Basic Sequence of Operation

(printing) ........................... 2-11

1.5 Controlling the Main Motor

(M101) ..................................... 2-13

1.5.1 Outline ............................... 2-13

4.7 LED Intensity Adjustment ...... 3-14

4.8 Enlargement/Reduction ........... 3-14

4.8.1 Enlargement/Reduction in Main Scanning Direction .. 3-14

4.8.2 Changing the Reproduction Ratio in Sub Scanning

Direction ............................ 3-16

4.9 Edge Emphasis ........................ 3-17

4.10 Editing ..................................... 3-17

4.11 Density Conversion (LUT, i.e.,

look-up table processing) ........ 3-17

4.11.1 Density Adjustment

(F-value conversion) ......... 3-17

4.11.2 Density Correction

(γ correction) ..................... 3-17

4.12 Binary Processing .................... 3-18

4.12.1 Error Diffusion .................. 3-18

4.13 Image Memory Control........... 3-18

4.13.1 Compression/Expansion, Rotation, and Enlargement/

Reduction .......................... 3-18

4.13.2 SDRAM ............................. 3-18

4.14 Output Image Processing ........ 3-19

4.14.1 Smoothing ......................... 3-19

5 Disassembly and Assembly ............. 3-20

5.1 Copyboard Glass ..................... 3-21

5.1.1 Removing the

Copyboard Glass ............... 3-21

5.1.2 After Replacing the

Copyboard Glass ............... 3-22

2002 CANON INC. 2001 2001 CANON iR1600/iR2000/iR1610/iR2010 SERIES REV.0 MAR. 2002

CONTENTS

5.2 CS Unit .................................... 3-23

5.2.1 Removing the CS Unit ...... 3-23

5.2.2 Points to Note When

Mounting the CS Unit ....... 3-26

5.2.3 After Replacing the

CS Unit .............................. 3-28

5.2.4 Points to Note When

Handling the CS Unit ........ 3-29

5.3 Reader Motor ........................... 3-30

5.3.1 Removing the Reader

Motor ................................. 3-30

5.3.2 Points to Note When Mounting

the Reader Motor .............. 3-31

CHAPTER 4 LASER EXPOSURE SYSTEM

1 Outline of Operation .......................... 4-1

1.1 Outline ....................................... 4-1

1.2 Basic Sequence of Operation

(laser exposure system) ............. 4-3

2 Generating the Horizontal Signal ...... 4-4

2.1 Outline ....................................... 4-4

2.2 Signals Used .............................. 4-4

3 Laser Driver Circuit ........................... 4-6

3.1 Laser Control ............................. 4-6

4 Controlling the Scanner Motor .......... 4-8

4.1 Outline ....................................... 4-8

4.2 Controlling the Scanner

Motor ......................................... 4-8

4.3 Scanner Pre-Rotation ................ 4-9

5 Disassembly and Assembly ............. 4-10

5.1 Removing the Laser/

Scanner Unit ............................ 4-11

CHAPTER 5 IMAGE FORMATION SYSTEM

1 Outline of Processes........................... 5-1

1.1 Sequence of Operation

(image formation system) ......... 5-3

2 1 Controlling the Primary Charging

Roller Bias .......................................... 5-4

2.1 Outline ....................................... 5-4

2.2 Turning On and Off the Bias..... 5-5

2.2.1 DC Bias ............................... 5-5

2.2.2 AC Bias ............................... 5-5

2.3 Bias Constant Voltage/

Constant Current Control .......... 5-5

2.3.1 DC Bias Constant Voltage

Control ................................. 5-5

2.3.2 AC Bias Constant Current

Control ................................. 5-5

3 Controlling the Developing Bias ....... 5-6

3.1 Outline ....................................... 5-6

3.2 Turning On/Off the Bias ........... 5-7

3.2.1 DC Bias ............................... 5-7

3.2.2 AC Bias ............................... 5-7

3.3 Controlling the Bias to a

Constant Voltage Level.............. 5-7

3.3.1 Controlling the Developing DC Bias to a Constant

Level .................................... 5-7

3.3.2 Controlling the Developing AC Bias to a Constant

Voltage Level ....................... 5-7

3.4 Controlling the Voltage Level of

the Developing DC Bias............ 5-7

4 Controlling the Transfer

Charging Roller Bias.......................... 5-8

4.1 Outline ....................................... 5-8

4.2 Turning On and Off the Bias..... 5-9

4.2.1 Turning On and Off the

Positive DC Bias ................. 5-9

4.2.2 Turning On and Off the

Negative DC Bias ................ 5-9

4.3 Controlling the Bias to a Constant

Current /Voltage Level .............. 5-9

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CONTENTS

4.3.1 Controlling the DC Bias to a

Constant Current Level ....... 5-9

4.3.2 Controlling the DC Bias to a

Constant Level .................... 5-9

4.4 Correcting the Voltage Level

(ATVC control) ........................ 5-10

4.5 Controlling the Output According

to Operation Mode ..................5-10

4.5.1 Type of Mode .................... 5-10

5 Detecting the Presence/Absence of a

Cartridge and the Level of Toner ..... 5-11

5.1 Outline ..................................... 5-11

5.2 Sequence of Detection

(level of toner) ......................... 5-12

6 Monitoring the Waste Toner Case ... 5-14

6.1 Outline ..................................... 5-14

6.2 Sequence of Operation ............ 5-15

7 Disassembly and Assembly ............. 5-16

7.1 Photosensitive Drum ............... 5-17

7.1.1 Removing the Drum

Unit .................................... 5-17

7.1.2 Cleaning the

Photosensitive Drum ......... 5-17

7.2 Developing Assembly ............. 5-18

7.2.1 Removing the Developing

Assembly ........................... 5-18

7.3 Transfer Roller ........................ 5-20

7.3.1 Removing the Transfer

Roller ................................. 5-20

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

2.1.4 Detecting 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

2.2.2 Pickup from the

Multifeeder Tray ................. 6-9

2.2.3 Multifeeder Retry

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

2.2.4 Setting 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

5.1.1 Remove the Cassette Pickup

Assembly ........................... 6-19

5.1.2 Removing the Cassette

Pickup Roller..................... 6-21

5.1.3 Removing the Feeding/

Separation Roller .............. 6-22

5.1.4 Removing the Cassette

Pickup Solenoid ................ 6-22

5.1.5 Removing the Paper Size

Detecting Switch ............... 6-22

5.1.6 Removing the Cassette Paper

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

5.1.7 Removing the Retry

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

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CONTENTS

5.1.8 Removing the Pickup Motor

(20 cpm model only) ......... 6-23

5.2 Multifeeder Tray Assembly .... 6-24

5.2.1 Removing the Multifeeder

Tray.................................... 6-24

5.2.2 Removing the Multifeeder

Pickup Roller..................... 6-25

5.2.3 Removing the Separation

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

5.2.4 Removing the Multifeeder

Paper Sensor ...................... 6-26

5.2.5 Removing the Multifeeder

Pickup Solenoid ................ 6-27

5.3 Drive Assembly .......................6-27

5.4 Registration Roller

CHAPTER 7 FIXING SYSTEM

1 Outline of Operation .......................... 7-1

1.1 Outline ....................................... 7-1

2 Controlling the Fixing Temperature .. 7-3

2.1 Outline ....................................... 7-3

2.2 Controlling the Temperature ..... 7-4

2.2.1 Control at Time of

Power-On ............................. 7-5

2.2.2 Control According to the

Type of Paper ...................... 7-6

2.2.3 Control at Time of Down

Sequence.............................. 7-6

2.2.4 Control in ESS

(energy save mode) ............. 7-7

2.3 Detecting an Error ..................... 7-8

2.3.1 Outline ................................. 7-8

2.3.2 Control in Response to an

Error..................................... 7-8

2.4 Protective Mechanism ............. 7-10

3 Disassembly and Assembly ............. 7-11

3.1 Removing the Fixing

3.2 Cleaning the Inside of the

3.3 Removing the Delivery Sensor 7-15

3.4 Removing the Pressure Roller 7-16

3.5 Removing the Fixing Roller/

3.6 Mounting the Fixing Roller/

5.3.1 Removing the Drive

Assembly ........................... 6-27

Assembly ................................. 6-31

5.4.1 Removing the Registration

Roller ................................. 6-31

5.4.2 Removing the Registration

Paper Sensor ...................... 6-32

5.4.3 Removing the Registration

Clutch ................................ 6-33

2.3.3 Conditions for Error

Detection ............................. 7-8

Assembly ................................. 7-12

Fixing Assembly or Replacing

Its Parts .................................... 7-15

Fixing Heater/Separation

Claw ......................................... 7-22

Fixing Heater/Separation

Claw ......................................... 7-24

CHAPTER 8 EXTERNALS AND AUXILIARY

CONTROL SYSTEM

1 Control Panel ...................................... 8-1

1.1 The machine’s control panel has

the following construction ........ 8-1

2 Power supply ...................................... 8-2

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2.1 Power Supply ............................. 8-2

2.1.1 Outline ................................. 8-2

2.1.2 Rated Outputs from the Power

Supply PCB ......................... 8-4

CONTENTS

2.2 Protective Mechanisms ............. 8-5

2.3 High-Voltage Power Supply

Circuit ........................................ 8-5

3 Control at Time of Energy

Save Mode .......................................... 8-6

3.1 Outline ....................................... 8-6

3.2 Control ....................................... 8-6

3.3 Operation ................................... 8-8

4 Fan ...................................................... 8-9

4.1 Outline ....................................... 8-9

4.2 Control ..................................... 8-10

4.2.1 Controlling the Speed ....... 8-10

4.2.2 Error Detection.................. 8-11

4.2.3 Sequence of Operation

(fan drive) .......................... 8-11

5 Back-Up Battery............................... 8-12

5.1 Back-Up Mechanism ............... 8-12

5.1.1 Outline ............................... 8-12

5.1.2 Vanadium Lithium Secondary

Battery (BAT2) .................. 8-12

5.1.3 Lithium Battery (BAT1) .... 8-13

5.2 Back-Up Data .......................... 8-16

5.2.1 Types of Data .................... 8-16

5.2.2 Printing Out the Back-Up

Data List ............................ 8-18

6 Disassembly and Assembly ............. 8-19

6.1 External Covers .......................8-20

6.1.1 Removing the Front

Cover ................................. 8-22

6.1.2 Removing the Control Panel

Lower Cover ...................... 8-22

6.2 Control Panel ........................... 8-23

6.2.1 Removing the Control

Panel .................................. 8-23

6.3 Main Motor .............................. 8-24

6.3.1 Removing the Main

Motor ................................. 8-24

6.4 Fan ........................................... 8-25

6.4.1 Removing the Heat

Discharge fan .................... 8-25

6.5 PCBs ........................................ 8-26

6.5.1 Removing the

DC Controller PCB ........... 8-26

6.5.2 After Replacing the

DC controller PCB ............ 8-26

6.5.3 Removing the

Image Processor PCB .......8-27

6.5.4 When Replacing the

Image Processor PCB .......8-27

6.5.5 Removing the

RAM DIMM ..................... 8-27

6.5.6 Removing the

ROM DIMM...................... 8-28

6.5.7 Removing the Analog

Processor PCB ................... 8-28

6.5.8 After Replacing the Analog

Processor PCB ................... 8-31

6.5.9 Removing the

Power Supply PCB............ 8-31

6.5.10 Removing the Original Detec-

tion/Reader Motor PCB .... 8-32

6.5.11 Removing the Printer Board Unit (if equipped with

printer functions) .............. 8-32

6.5.12 Removing the Cassette controller PCB

(20 cpm model only) ......... 8-32

CHAPTER 9 CASSETTE UNIT

1 Outline ................................................ 9-1

1.1 Outline ....................................... 9-1

1.2 Specifications and Construction

................................................... 9-1

1.3 Arrangement of Major Rollers

and Sensors ................................ 9-2

2002 CANON INC. 2001 2001 CANON iR1600/iR2000/iR1610/iR2010 SERIES REV.0 MAR. 2002

2 Pickup Assembly ................................ 9-4

2.1 Pickup Control System ............. 9-4

2.2 Pickup Control ........................... 9-7

2.3 Cassette Pickup Operation ........9-7

2.4 Pickup Re-Try Operation .......... 9-7

2.5 Cassette Paper Size Detection .. 9-7

CONTENTS

3 Detecting Jams ................................... 9-8

3.1 Outline ....................................... 9-8

3.2 Sequence of Jam Detection ....... 9-8

3.2.1 Delay Jam ............................ 9-8

3.2.2 Stationary Jam..................... 9-8

3.2.3 Jam History ......................... 9-8

4 Disassembly and Assembly ............... 9-9

4.1 Removing the Cassette Unit ... 9-10

4.2 Cassette Pickup Assembly ...... 9-12

4.2.1 Removing the Cassette

Pickup Assembly ............... 9-12

4.2.2 Removing the Cassette

Pickup Roller..................... 9-12

4.2.3 Removing the Cassette

4.2.4 Removing the Paper Size

4.2.5 Removing the Cassette

4.2.6 Removing the Re-Try

4.3 PCBs ........................................ 9-13

4.3.1 Removing the Cassette Unit

4.4 Drive-Related Parts ................. 9-13

4.4.1 Removing the Pickup

CHAPTER 10 INNER 2-WAY TRAY

1 Specifications ................................... 10-1

1.1 System ..................................... 10-1

1.2 Arrangement of Rollers and

Sensors ..................................... 10-2

2 Controlling Delivery Operation ....... 10-3

2.1 Controlling Delivery

Operation ................................. 10-3

2.2 Selecting a Delivery Slot

(user mode) .............................. 10-3

3 Detecting Jams ................................. 10-4

3.1 Outline ..................................... 10-4

3.2 Sequence of Jam Detection ..... 10-4

3.2.1 Delay Jam .......................... 10-4

3.2.2 Stationary Jam................... 10-4

3.2.3 Jam History ....................... 10-4

4 Disassembly and Assembly ............. 10-5

4.1 Removing the Inner 2-Way

Unit .......................................... 10-6

Pickup Solenoid ................ 9-12

Switch ................................ 9-12

Paper Sensor ...................... 9-12

Sensor ................................ 9-12

Controller PCB .................. 9-13

Motor ................................. 9-13

CHAPTER 11 INSTALLATION

1 Selecting the Site of Installation ..... 11-1

2 Unpacking and Installing the

Machine ............................................11-3

2.1 Points to Note Before

Starting the Work .................... 11-3

2.2 Installing the Machine ............ 11-4

2.3 Unpacking and Removing the

Fixing Members ...................... 11-5

2.4 Removing the Dummy Drum.. 11-7

2.5 Mounting the Drum Unit ........ 11-9

2.6 Mounting the Toner Cartridge

............................................... 11-11

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2.7 Putting Paper in the Cassette

2.8 Placing Paper in the

2.9 Checking the Copy Images ... 11-20

2.10 Selecting the Country/Region

2.11 Setting the Date/Time

2.12 Storing the Specifications

............................................... 11-14

Multifeeder Tray.................... 11-18

through Service Operation .... 11-21

(user mode) ............................ 11-22

Report .................................... 11-23

CONTENTS

2.13 Setting the Fax Functions (if equipped with fax

functions) ............................... 11-24

2.13.1 Connecting the Line ......... 11-24

2.13.2 Setting the Dialing

Method ............................. 11-24

2.13.3 Communications Test ....... 11-24

2.14 Checking the Printer Functions (if equipped with printer

functions) ............................... 11-25

3 Relocating the Machine ................... 11-26

4 Flow of accessory installation ......... 11-27

(if equipped with a fax function) ...... 11-27

5 Installing the Card Readere-E1

(accessory)...................................... 11-28

5.1 Points to Note for

Installation .............................. 11-28

5.2 Installation .............................. 11-29

5.3 Setting and Checking After

Installation ............................. 11-33

6 Installing the Image RAM

(accessory)...................................... 11-34

6.1 Non-Fax Model ..................... 11-34

6.1.1 Installation....................... 11-34

6.2 FAX Model ............................ 11-36

6.2.1 Before Starting the Work 11-36

6.2.2 Mounting the RAM ......... 11-36

7 Installing the Remote Diagnostic

Device II (accessory) ..................... 11-39

7.1 Parts to Procure ..................... 11-39

7.2 Unpacking .............................. 11-39

7.3 Installation to the Copier ...... 11-40

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

Replacement ............................. 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

5.2.1 Storage After Removing the

Packaging Seal .................. 12-7

5.2.2 Points 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

2.1.1 Standards for Image

Position .............................. 13-3

2.1.2 Adjusting the Image

Position .............................. 13-4

2.1.3 Adjusting 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

2002 CANON INC. 2001 2001 CANON iR1600/iR2000/iR1610/iR2010 SERIES REV.0 MAR. 2002

xvii

CONTENTS

2.1.5 Adjusting the Image Position

for ADF Copying............... 13-9

2.2 Fixing System ........................ 13-11

2.2.1 Checking the Fixing

Roller Pressure (nip) ....... 13-11

2.3 Electrical Parts ...................... 13-12

2.3.1 When Replacing the

Major Parts ...................... 13-12

2.3.2 Gain Auto Adjustment .... 13-12

2.3.3 When Replacing the

Contact Sensor ................ 13-12

2.3.4 When Replacing the

Image Processor PCB .....13-13

2.3.5 When Replacing the

DC Controller PCB ......... 13-15

2.3.6 When Replacing the

Analog Processor PCB .... 13-15

2.4 Checking the Sensors ............ 13-16

2.4.1 Checking the Sensors ...... 13-16

3 Troubleshooting Image/

Operation Faults ............................. 13-19

3.1 Making Initial Checks on

Image Faults .......................... 13-19

3.1.1 Site of Installation........... 13-19

3.1.2 Checking the Originals ... 13-19

3.1.3 Copyboard Cover and Copyboard Glass

(standard white plate) ..... 13-19

3.1.4 Checking the Transfer Charging Roller/

Static Eliminator ............. 13-20

3.1.5 Checking the Drum Unit .. 13-20

3.1.6 Checking the Paper ......... 13-20

3.1.7 Image Adjustment Basic

Procedure ......................... 13-20

3.1.8 Others .............................. 13-20

3.2 Image Fault Samples ............. 13-22

3.3 Troubleshooting Image

Faults ..................................... 13-23

3.3.1 The copy is too light.

(halftone only) ................. 13-23

3.3.2 The copy is too light. (both half-

tone and solid black) ........ 13-23

3.3.3 The copy is too light. (entire

copy, appreciably) ........... 13-23

3.3.4 The copy has uneven density.

(darker along front) ......... 13-26

3.3.5 The copy has uneven density.

(lighter along front) ........ 13-26

3.3.6 The copy is foggy.

(entire copy) .................... 13-27

3.3.7 The copy is foggy.

(feeding direction) ..........13-28

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

thick) ............................... 13-28

3.3.9 The copy has black lines. (feed-

ing direction, fine) ............ 13-28

3.3.10 The copy has white strips.

(feeding direction) ............ 13-29

3.3.11 The copy has white lines.

(feeding direction) ............ 13-29

3.3.12 The output has white strips. (cross-feeding direction) . 13-30

3.3.13 The back of the copy is

soiled ............................... 13-31

3.3.14 The copy has a poor

fixing ................................ 13-32

3.3.15 The copy has displaced registration. (leading edge extremely

excessive margin) ............. 13-33

3.3.16 The copy has displaced registration. (leading edge, excessive

margin)............................. 13-33

3.3.17 The copy has displaced registration. (leading edge, no

margin) ............................. 13-33

3.3.18 The copy has blurred

images .............................. 13-34

3.3.19 The copy is foggy. (cross-feeding direction) . 13-35

3.3.20 The copy has poor

sharpness. ........................ 13-36

3.3.21 The copy is blank. ............ 13-37

3.3.22 The copy is solid black. .... 13-38

3.3.23 The copy has a black line

(stream reading). ............. 13-39

3.4 Troubleshooting

Malfunctions .......................... 13-40

3.4.1 AC power is absent. ......... 13-40

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CONTENTS

3.4.2 DC power is absent. ......... 13-41

3.4.3 Pickup operation fails.

(cassette).......................... 13-42

3.4.4 Pickup operation fails.

(multifeeder tray) ............ 13-43

3.4.5 Pickup operation fails.

(cassette unit) .................. 13-44

3.4.6 The vertical path roller

fails to rotate. .................. 13-45

3.4.7 The registration roller

fails to rotate. .................. 13-45

3.4.8 The contact sensor

fails to go ON. ................. 13-46

3.4.9 The speaker fails to

operate. ............................ 13-46

3.4.10 The ‘Add Toner’ message

fails to go OFF. ................ 13-47

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

cassette unit) ................... 13-48

3.4.12 The ‘Add Paper’ message fails to go OFF.

(multifeeder tray) ............ 13-49

3.4.13 The ‘Jam’ message

fails to go OFF. ................ 13-49

3.4.14 The ‘Waste Toner Full’ message

does not go OFF. .............. 13-50

3.4.15 The ‘Controller Card Set’ mes-

sage does not go ON. .......13-50

3.4.16 The ‘Control Card Set’ mes-

sage does not go OFF. ..... 13-50

3.5 Troubleshooting Feeding

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

3.5.1 Outline ............................. 13-51

3.5.2 Pickup Assembly ............. 13-52

3.5.3 Transfer/

Feeding Assembly ........... 13-53

3.5.4 Fixing/

Delivery Assembly .......... 13-54

3.5.5 Feeding Fault

(double feeding) .............. 13-55

3.5.6 Feeding Faults

(wrinkling) ....................... 13-56

4 Arrangement and Functions of

Electrical Parts ...............................13-57

4.1 Outline ................................... 13-57

4.1.1 Outline ............................. 13-57

4.1.2 Checking the Sensors ...... 13-57

4.2 Clutches, Solenoids,

Motors, and Fans ................... 13-58

4.3 Sensors ................................... 13-59

4.4 PCBs ...................................... 13-60

4.5 Switches, Others .................... 13-62

4.6 Cassette Unit ......................... 13-64

4.7 Inner 2-Way Tray ................... 13-66

4.8 Variable Resistors (VR), Light-Emitting Diodes (LED),

and Check Pins ...................... 13-67

4.8.1 Image Processor PCB ..... 13-68

4.8.2 DC Controller PCB ......... 13-69

4.8.3 Power Supply PCB.......... 13-70

4.8.4 Analog Processor PCB.... 13-71

4.8.5 1-Cassette Unit

Controller PCB ................ 13-72

4.8.6 2/3-Cassette Unit

Controller PCB ................ 13-72

5 Service Mode ................................. 13-73

5.1 Outline ................................... 13-73

5.2 Using the Mode ..................... 13-75

5.3 Service Mode Menus ............ 13-76

5.4 Setting the parameters ........... 13-84

5.4.1 Registering the Bit Switch

(#1 SSSW) ....................... 13-84

5.4.2 Menu Switch Setting

(#2 MENU) ................... 13-111

5.4.3 Setting Numeric Parameters (#3 NUMERIC Param.) . 13-113

5.4.4 SPECIAL Setting

(#4A SPECIAL) ............ 13-120

5.4.5 NCU Setting

(#4B NCU) ....................13-120

5.4.6 ISDN Setting

(#4C ISDN) ...................13-120

5.4.7 Selecting the Country/ Region of Installation

(#5 TYPE) ..................... 13-121

2002 CANON INC. 2001 2001 CANON iR1600/iR2000/iR1610/iR2010 SERIES REV.0 MAR. 2002

xix

CONTENTS

5.4.8 Setting Original Read Functions

(#6 SCANNER) ............. 13-121

5.4.9 Setting the Printer Parameters

(#7 PRINTER)............... 13-126

5.4.10 PDL (#8 PDL) ...............13-129

5.4.11 Counters

(#9 COUNTER) ............ 13-130

5.4.12 Generating a Report

(#10 REPORT) .............. 13-133

5.4.13 Downloading

(#11 DOWNLOAD) ...... 13-134

5.4.14 Clear (#12 CLEAR) ......13-135

5.4.15 ROM Indication

(#13 ROM) .................... 13-136

5.4.16 Resetting the CS Unit Position (#14 CS SET) .. 13-136

5.5 Test Mode (TEST MODE) .. 13-137

5.5.1 Outline ........................... 13-137

5.5.2 Test Mode Menu ........... 13-138

5.5.3 D-RAM Test

(1: D-RAM) ................... 13-143

5.5.4 CCD Test

(2: CCD TEST) ............. 13-145

5.5.5 PRINT Test

(3: PRINT)..................... 13-146

5.5.6 MODEM NCU Test

(4: MODEM NCU) .......13-147

5.5.7 Faculty Test

(6: FACULTY TEST) ....13-150

5.5.8 Book Read Test

(8: BOOK TEST) .......... 13-160

5.6 Report .................................. 13-161

5.6.1 User Report ................... 13-161

5.6.2 Service Report............... 13-164

6 Self Diagnosis .............................. 13-176

6.1 Outline ................................. 13-176

6.2 Error Codes .......................... 13-177

6.2.1 Error Codes Used for

the Machine ................... 13-177

6.2.2 Finisher Error Codes ..... 13-183

6.3 Fax Error Code .................... 13-190

6.3.1 Service Error Code

Output ............................ 13-190

6.3.2 Error Codes ................... 13-190

6.3.3 Causes and Remedies for

User Error Codes........... 13-194

6.3.4 Causes and Remedies for

Service Error Codes ...... 13-201

CHAPTER 14 VERSION UP

1 Upgrading ......................................... 14-1

1.1 Outline ..................................... 14-1

2 Upgrading by Downloading ............. 14-3

2.1 Before Starting the Work ........ 14-3

2.2 Installing the USB Driver (only if Windows 98 or

Windows 98SE) ....................... 14-4

2.3 Installing the Firmware ......... 14-10

2.4 Downloading the System

Software ................................. 14-13

2.5 Downloading for G3 FAX ..... 14-20

2.6 Downloading for the

Finisher-L1 ............................ 14-21

2002 CANON INC. 2001 2001 CANON iR1600/iR2000/iR1610/iR2010 SERIES REV.0 MAR. 2002

2.6.1 Outline ............................. 14-21

2.6.2 Downloading ................... 14-22

3 Back Up Data ................................. 14-27

3.1 Outline ................................... 14-27

3.2 Backing Up Data ................... 14-27

3.2.1 Making Preparations ....... 14-27

3.2.2 Making Connections ....... 14-28

3.2.3 Backing Up Data ............. 14-29

3.2.4 Downloading Backup

Data .................................. 14-34

3.2.5 Managing Backup Data .... 14-38

APPENDIX

CONTENTS

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

2002 CANON INC. 2001 2001 CANON iR1600/iR2000/iR1610/iR2010 SERIES REV.0 MAR. 2002

xxi

CHAPTER 1

INTRODUCTION

2002 CANON INC. 2001 2001 CANON iR1600/iR2000/iR1610/iR2010 SERIES REV.0 MAR. 2002

CHAPTER 1 INTRODUCTION

1 Features

1.1 Features

1.High-Speed, High Image Quality

Copying speed 16 copies/min (iR1600/iR1610F ; 1-to-N, from cassette)

20 copies/min (iR2000/iR2010F ; 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/m

dated.

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

• 16cpm model Cassette Cassette 1 : 250 sheets 1-cassette unit (accessory) : 250 sheets 3-cassette unit (accessory) : 250 sheets x 3

• 20cpm model Cassette Cassette 1 : 250 sheets Cassette 2 : 250 sheets 2-cassette unit (accessory) : 250 sheets x 2

) may be accommo-

)

3. Mixed Paper Sizes (of same configuration)

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

ration).

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).

1-1

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

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.)

2.1.2 System

CHAPTER 1 INTRODUCTION

T01-201-01

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

1-3

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 min.

Inch : 11x17 (279.4 x 431.8 mm) max.

STMT min. Multifeeder pickup AB : A3 max.

Postcard min.

Inch 11x17 (279.4 x 431.8 mm) max.

STMT min.

1-4

T01-201-03

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