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NP7160
Service Manual
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Service Manual
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Canon NP7160 Service Manual

SERVICE MANUAL
REVISION 0
AUG. 1998
COPYRIGHT © 1998 CANON INC. CANON NP7161/NP7160 REV.0 AUG. 1998 PRINTED IN JAPAN (IMPRIME AU JAPON)
FY8-13FB-000
IMPORTANT
THIS DOCUMENTATION IS PUBLISHED BY CANON INC., JAPAN, TO SERVE AS A SOURCE OF REFERENCE FOR WORK IN THE FIELD.
SPECIFICATIONS AND OTHER INFORMATION CONTAINED HEREIN MAY VARY SLIGHTLY FROM ACTUAL MACHINE VALUES OR THOSE FOUND IN ADVERTISING AND OTHER PRINTED MATTER.
ANY QUESTIONS REGARDING INFORMATION CONTAINED HEREIN SHOULD BE DIRECTED TO THE COPIER SERVICE DEPARTMENT OF THE SALES COMPANY.
THIS DOCUMENTATION IS INTENDED FOR ALL SALES AREAS, AND MAY CONTAIN INFORMATION NOT APPLICABLE TO CERTAIN AREAS.
COPYRIGHT © 1998 CANON INC.
Printed in Japan
Imprimé au Japon
Use of this manual should be strictly supervised to avoid disclosure of confidential information.
Prepared by
OFFICE IMAGING PRODUCTS TECHNICAL SUPPORT DEPT. 1
OFFICE IMAGING PRODUCTS TECHNICAL SUPPORT DIV.
CANON INC.
5-1, Hakusan 7-chome, Toride-shi, Ibaraki 302-8501, Japan
COPYRIGHT © 1998 CANON INC. CANON NP7161/NP7160 REV.0 AUG. 1998 PRINTED IN JAPAN (IMPRIME AU JAPON)

INTRODUCTION

This Service Manual contains basic facts and figures on the NP7161/NP7160
needed to service the machine in the field.
This copier is designed to enable full automatic copying work, and comes with the
following systems accessories:
1. ADF-G1*
2. Staper Sorter-L1*
3. MS-C1*
4. Cassette Feeding Module-C1 * NP7161 only.
This Service Manual covers the copier only, and consists of the following chapters:
Chapter 1 General Description introduces the copier’s features and specifications,
shows how to operate the copier, and explains how copies are made.
Chapter 2 Basic Operation provides outlines of the copier's various mechanical
workings.
Chapter 3 Exposure System discusses the principles of operation used for the
copier's lens drive unit and scanner drive unit. It also explains the timing at which these drive units are operated, and shows how they may be disassembled/assembled and adjusted.
Chapter 4 Image Formation System discusses the principles of how images are
formed. It also explains the timing at which the various units involved in image formation are operated, and shows how they may be disassembled/ assembled and adjusted.
Chapter 5 Pick-Up/Feeding System explains the principles used from when copy
paper is picked up to when a copy is delivered in view of the functions of electrical and mechanical units and in relation to their timing of operation. It also shows how these units may be disassembled/assembled and adjusted.
Chapter 6 Fixing System explains the principles used to fuse toner images to transfer
media in view of the functions of electrical and mechanical units and in relation to their timing of operation. It also shows how these units may be disassembled/assembled and adjusted.
Chapter 7 Externals/Auxiliary Mechanisms shows the copier’s external parts, and
explains the principles used for the copier’s various control mechanisms in view of the functions of electrical and mechanical units and in relation to their timing of operation. It also shows how these units may be disassembled/assembled and adjusted.
Chapter 8 Installation introduces requirements for the site of installation, and shows
how the copier may be installed using step-by-step instructions.
Chapter 9 Maintenance and Servicing provides tables of periodically replaced parts
and consumables/durables and scheduled servicing charts.
Chapter 10 Troubleshooting provides tables of maintenance/inspection, standards/
adjustments, and problem identification (image fault/malfunction).
Appendix contains a general timing chart and general circuit diagrams.
COPYRIGHT © 1998 CANON INC. CANON NP7161/NP7160 REV.0 AUG. 1998 PRINTED IN JAPAN (IMPRIME AU JAPON)
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The following rules apply throughout this Service Manual:
1. Each chapter contains sections explaining the purpose of specific functions and the relationship between electrical and mechanical systems with reference to the timing of operation.
In the diagrams, represents the path of mechanical drive—where a signal name accompanies the symbol , the arrow indicates the direction of the electric signal.
The expression “turn on the power” means flipping on the power switch, closing the front door, and closing the delivery unit door, which results in supplying the machine with power.
2. In the digital circuits, ‘1’ is used to indicate that the voltage level of a given signal is “High,” while ‘0’ is used to indicate “Low.” (The voltage value, however, differs from circuit to circuit.)
In practically all cases, the internal mechanisms of a microprocessor cannot be checked in the field. Therefore, the operations of the microprocessors used in the machines are not discussed: they are explained in terms of from sensors to the input of the DC controller PCB and from the output of the DC controller PCB to the loads.
The descriptions in this Service Manual are subject to change without notice for product improvement or other purposes, and major changes will be communicated in the form of Service Information bulletins.
All service persons are expected to have a good understanding of the contents of this Service Manual and all relevant Service Information bulletins and be able to identify and isolate faults in the machine.
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COPYRIGHT © 1998 CANON INC. CANON NP7161/NP7160 REV.0 AUG. 1998 PRINTED IN JAPAN (IMPRIME AU JAPON)
System Configuration
The copier is designed to accommodate the following accessories: *NP7161 only.
MS-C1*
Sorts and groups up to 10 sets of pages automatically.
Stapler Sorter-L1*
In addition to the functions of a 10-bin sorter, staples sorted pages automatically.
ADF-G1*
Feeds a stack of original pages to the copyboard page by page.
Control Card IV N
Controls volumes of copying work.
Cassette Feeding Module-C1
Provides an additional cassette.
COPYRIGHT © 1998 CANON INC. CANON NP7161/NP7160 REV.0 AUG. 1998 PRINTED IN JAPAN (IMPRIME AU JAPON)
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COPYRIGHT © 1998 CANON INC. CANON NP7161/NP7160 REV.0 AUG. 1998 PRINTED IN JAPAN (IMPRIME AU JAPON)

CONTENTS

CHAPTER 1 GENERAL DESCRIPTION
I. FEATURES .............................................. 1-1
II. SPECIFICATIONS ................................... 1-2
A. Copier ................................................. 1-2
1. Type ............................................. 1-2
2. Mechanisms ................................. 1-2
3. Performance................................. 1-3
4. Others........................................... 1-5
III. NAMES OF PARTS.................................. 1-8
A. External View ..................................... 1-8
B. Cross Section ..................................... 1-9
1. Copier ........................................... 1-9
CHAPTER 2 BASIC OPERATION
I. BASIC MECHANISMS ............................. 2-1
A. Functional Construction ..................... 2-1
B. Outline of the Electrical Circuitry........ 2-2
C. Basic Sequence of Operations .......... 2-4
1. Basic Sequence of Operations at
Power-On ..................................... 2-4
2. Basic Sequence of Operations at
Copy Start .................................... 2-6
D. Main Motor (M1) Control Circuitry ...... 2-8
1. Outline .......................................... 2-8
2. Operation...................................... 2-8
3. Detecting an Error ........................ 2-8
E. Inputs to the DC Controller ................ 2-9
1. Inputs to the
DC Controller (1/3)....................... 2-9
IV. OPERATING THE MACHINE ................ 1-10
A. Control Panel.................................... 1-10
B. User Mode........................................ 1-12
1. Outline ........................................ 1-12
V. ROUTINE MAINTENANCE
(BY THE USER) .................................... 1-14
VI. PONITS TO NOTE (BY THE USER) ..... 1-15
VII.IMAGE FORMATION ............................. 1-16
A. Outline .............................................. 1-16
2. Inputs to the
DC Controller (2/3)..................... 2-10
3. Inputs to the
DC Controller (3/3)..................... 2-11
F. Outputs from the DC Controller ....... 2-12
1. Outputs from the
DC Controller (1/4)..................... 2-12
2. Outputs from the
DC Controller (2/4)..................... 2-13
3. Outputs from the
DC Controller (3/4)..................... 2-14
4. Outputs from the
DC Controller (4/4)..................... 2-15
G. Inputs to and Outputs from
Accessories (1/1) ............................. 2-16
COPYRIGHT © 1998 CANON INC. CANON NP7161/NP7160 REV.0 AUG. 1998 PRINTED IN JAPAN (IMPRIME AU JAPON)
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CHAPTER 3 EXPOSURE SYSTEM
I. OUTLINE OF OPERATION ..................... 3-1
A. Changing the Reproduction Ratio...... 3-1
II. LENS DRIVE SYSTEM ............................ 3-3
A. Driving the Lens ................................. 3-3
1. Outline .......................................... 3-3
2. Motor Control Circuit .................... 3-4
3. Moving the Lens........................... 3-5
III. SCANNER DRIVE SYSTEM.................... 3-6
A. Outline ................................................ 3-6
B. Scanner Motor Control Circuit ........... 3-7
C. Relationship between Scanner
Sensor and Signals ............................ 3-7
D. Basic Sequence of Operations
(scanner) ........................................... 3-8
E. Scanner Movement in
Page Separation Mode ...................... 3-9
IV. OTHERS................................................. 3-10
A. Detecting the Original Size .............. 3-10
CHAPTER 4 IMAGE FORMATION SYSTEM
1. Outline ........................................ 3-10
2. Detection of the Original Size
by the ADF ................................. 3-10
V. DISASSEMBLY/ASSEMBLY ................. 3-11
A. Scanner Drive Assembly.................. 3-12
1. Removing the Scanner Motor .... 3-12
2. Removing the Scanner Drive
Cable .......................................... 3-13
3. Routing the Scanner Drive
Cable .......................................... 3-15
4. Adjusting the Position
of the Mirror................................ 3-16
5. Adjusting the Tension
of the Scanner Drive Cable........ 3-17
B. Lens Drive Assembly ....................... 3-18
1. Removing the Lens Drive
Motor .......................................... 3-18
2. Removing the Mirror Motor ........ 3-19
I. OUTLINE OF THE PROCESSES............ 4-1
A. Outline ................................................ 4-1
B. Basic Sequence of Operations
(image formation system) .................. 4-2
C. Controlling the Intensity of the
Scanning Lamp .................................. 4-3
1. Outline .......................................... 4-3
2. Operation...................................... 4-4
3. Protection Mechanisms ............... 4-5
D. Controlling the Primary/Transfer Bias .. 4-6
1. Outline .......................................... 4-6
2. Turning On/Off the Primary/
Transfer Bias................................ 4-6
E. Controlling the Developing/Separation
Static Eliminator Bias ......................... 4-7
1. Outline .......................................... 4-7
2. Turning On/Off the Developing
DC Bias ........................................ 4-8
3. Turning On/Off the Developing AC Bias/Separation Eliminator
Bias .............................................. 4-9
4. Controlling the Developing DC Bias to a Specific Voltage
to Suit Copy Density .................. 4-10
F. Controlling the Blank Exposure Lamp ... 4-12
1. Outline ........................................ 4-12
2. Turning On the Blank Exposure
Lamp in Reduce Mode............... 4-13
3. Turning On the Blank Exposure
Lamp in Direct/Enlarge Mode .... 4-13
4. Turning On the Blank Exposure
Lamp in Multifeeder Mode ......... 4-13
II. DEVELOPING ASSEMBLY/DRUM
CLEANER ASSEMBLY.......................... 4-14
A. Outline .............................................. 4-14
B. Detecting and Controlling
the Level of Toner ............................ 4-16
C. Monitoring the Waste Toner
Feeding Screw ................................. 4-17
D. Monitoring the Waste Toner Box ..... 4-18
E. Control by the Cleaner Thermistor... 4-20
1. Copying Speed Down
Sequence ................................... 4-20
F. Auto Density Adjustment (AE) ......... 4-21
1. Outline ........................................ 4-21
2. Measuring the Density
of the Original............................. 4-21
III. DISASSEMBLY/ASSEMBLY ................. 4-23
A. Scanning Lamp Assembly ............... 4-24
1. Removing the Scanning Lamp .. 4-24
2. Mounting the Scanning Lamp .... 4-25
3. Removing the Thermal Fuse ..... 4-25
B. Exposure Assembly ......................... 4-26
1. Removing the Pre-Exposure/ Blank Exposure Lamp
Assembly.................................... 4-26
2. Removing the Dust-Proofing
Glass .......................................... 4-26
3. Cleaning the No. 6 Mirror........... 4-27
C. Drum Unit ......................................... 4-28
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COPYRIGHT © 1998 CANON INC. CANON NP7161/NP7160 REV.0 AUG. 1998 PRINTED IN JAPAN (IMPRIME AU JAPON)
1. Removing the Drum Unit ........... 4-28
2. Cleaning the Photosensitive
Drum........................................... 4-29
3. Removing the Cleaner
Thermistor .................................. 4-29
D. Primary Charging Assembly ............ 4-30
1. Removing the Primary
Charging Assembly.................... 4-30
E. Transfer Charging Assembly ........... 4-31
1. Removing the Transfer
Charging Assembly.................... 4-31
F. Charging Wire .................................. 4-32
CHAPTER 5 PICK-UP/FEEDING SYSTEM
1. Outline ........................................ 4-32
2. Stringing the Charging Wires..... 4-32
3. Adjusting the Height of the
Charging Wires .......................... 4-36
G. Developing Assembly....................... 4-37
1. Removing the Developing
Assembly.................................... 4-37
2. Removing the Developing
Blade .......................................... 4-37
3. Removing the Developing
Cylinder ...................................... 4-38
I. OUTLINE OF OPERATION ..................... 5-1
II. PICK-UP FROM THE CASSETTE .......... 5-2
A. Pick-Up Operation.............................. 5-2
B. Sequence of Operations
(pick-up/feeding) ................................ 5-3
C. Operation of the Cassette Lifter......... 5-4
D. Detecting the Size of the Cassette .... 5-6
1. Outline .......................................... 5-6
2. Detecting the Cassette Size ........ 5-7
III. PICK-UP FROM THE MULTIFEEDER .... 5-8
A. Pick-Up Operation.............................. 5-8
B. Detecting the Size of Paper
in the Multifeeder................................ 5-9
C. Sequence of Operations
(pick-up from multifeeder) ................ 5-10
IV. CONTROLLING THE REGISTRATION
CLUTCH ................................................. 5-11
V. DETECTING JAMS ................................ 5-12
A. Outline .............................................. 5-12
B. Sequence of Operations
(jam detection).................................. 5-13
1. Registration Delay Jam.............. 5-13
2. Registration Stationary Jam....... 5-13
3. Delivery Delay Jam .................... 5-14
4. Delivery Stationary Jam ............. 5-14
VI. DISASSEMBLY/ASSEMBLY ................. 5-15
A. Pick-Up Assembly ............................ 5-16
1. Removing the Pick-Up Roller..... 5-16
2. Mounting the Pick-Up Roller ...... 5-16
3. Removing the Pick-Up Drive
Assembly.................................... 5-17
4. Removing the Pick-Up
Assembly.................................... 5-17
5. Removing the Feed Roller ......... 5-18
6. Removing the Separation Roller .. 5-18
7. Mounting the Separation Roller ... 5-19
B. Multifeeder Assembly....................... 5-20
1. Removing the Multifeeder Tray.... 5-20
2. Removing the Multifeeder
Assembly .................................... 5-20
3. Removing the Multifeeder
Pick-Up Roller ............................ 5-21
4. Removing the Separation Pad..... 5-21
5. Adjusting the Pressure of the
Separation Pad .......................... 5-22
C. Registration Roller Assembly........... 5-23
1. Removing the Registration
Roller Assembly ......................... 5-23
D. Cassette Assembly .......................... 5-24
1. Removing the Cassette Size
Switch......................................... 5-24
2. Changing the Cassette Size
(AB/INCH) .................................. 5-25
3. Adjusting the Left/Right
Registration ................................ 5-26
COPYRIGHT © 1998 CANON INC. CANON NP7161/NP7160 REV.0 AUG. 1998 PRINTED IN JAPAN (IMPRIME AU JAPON)
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CHAPTER 6 FIXING SYSTEM
I. OUTLINE OF OPERATION ..................... 6-1
A. Outline ................................................ 6-1
B. Controlling the Fixing Temperature ... 6-2
C. Error Detection Circuit........................ 6-5
1. Outline .......................................... 6-5
2. Surface Temperature of the
Fixing Upper Roller ...................... 6-6
3. Activation of the
Fixing Heater (H1)........................ 6-6
II. DISASSEMBLY/ASSEMBLY ................... 6-7
A. Fixing Assembly ................................. 6-8
1. Construction ................................. 6-8
2. Locking Mechanism ..................... 6-8
3. Removing the Fixing Assembly ... 6-8
4. Removing the Fixing Heater ...... 6-10
5. Removing the Thermal Switch
Assembly.................................... 6-11
CHAPTER 7
I. FANS ........................................................ 7-1
II. POWER SUPPLY..................................... 7-4
A. Outline of Power Supply .................... 7-4
B. Power Supply Circuitry....................... 7-5
1. AC Power Supply ......................... 7-5
2. DC Power Supply......................... 7-5
3. Mirror Heater, Cassette/ Drum Heater, and Accessory
Cassette Heater ........................... 7-6
4. ADF and Sorter ............................ 7-6
C. Protection Mechanisms of the
Power Supply Circuitry....................... 7-7
III. DISASSEMBLY/ASSEMBLY ................... 7-8
A. External Covers.................................. 7-9
1. Removing the Right Door .......... 7-10
2. Removing the Upper
Right Cover ................................ 7-10
3. Removing the Upper
Left Cover................................... 7-11
4. Removing the Delivery
Lower Cover............................... 7-11
5. Removing the Delivery
Upper Cover............................... 7-11
6. Removing the Lower
Inside Cover ............................... 7-12
B. Control Panel.................................... 7-13
1. Removing the Control Panel...... 7-13
C. Copyboard Glass ............................. 7-14
EXTERNALS/AUXILIARY MECHANISMS
6. Removing the Main Thermistor ... 6-12
7. Removing the Sub Thermistor ... 6-12
8. Removing the Fixing Upper
Roller .......................................... 6-13
9. Removing the Fixing Lower
Roller .......................................... 6-14
10. Removing the Heat Discharge
Roller .......................................... 6-14
11. Adjusting the Height of the
Fixing Inlet Guide ....................... 6-14
12. Adjusting the Nip........................ 6-15
B. Delivery Assembly............................ 6-16
1. Removing the Upper
Separation Claw......................... 6-16
2. Removing the Lower
Separation Claw......................... 6-16
3. Removing the Delivery Roller .... 6-17
1. Removing the Copyboard
Glass .......................................... 7-14
D. Fans.................................................. 7-15
1. Removing the Scanner
Cooling Fan................................ 7-15
2. Removing the Exhaust Fan ....... 7-16
3. Remove the Ozone Filter ........... 7-17
E. Counter Assembly............................ 7-18
1. Removing the Counter
Assembly.................................... 7-18
F. Main Motor Assembly....................... 7-18
1. Removing the Main Motor
Assembly.................................... 7-18
G. DC Controller PCB ........................... 7-19
1. Removing the
DC Controller PCB..................... 7-19
2. Points to Note When Replacing
the DC Controller PCB............... 7-19
H. Removing the Power Supply PCB... 7-20
1. Removing the
Power Supply PCB .................... 7-20
I. Removing the High-Voltage
Power Supply PCB........................... 7-20
1. Removing the High-Voltage
Power Supply PCB .................... 7-20
J. Lamp Regulator PCB ....................... 7-21
1. Removing the Lamp
Regulator PCB ........................... 7-21
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COPYRIGHT © 1998 CANON INC. CANON NP7161/NP7160 REV.0 AUG. 1998 PRINTED IN JAPAN (IMPRIME AU JAPON)
CHAPTER 8 INSTALLATION
I. SELECTING THE SITE............................ 8-1
II. UNPACKING AND INSTALLATION ........ 8-2
A. Unpacking .......................................... 8-2
B. Removing the Metal Fixings............... 8-3
C. Mounting the Drum Unit..................... 8-4
D. Cleaning the Parts and Making Checks .. 8-6 E. Checking the Images/Operations and
User Mode.......................................... 8-8
F. Supplying Toner ............................... 8-10
III. RELOCATING THE MACHINE.............. 8-12
CHAPTER 9 MAINTENANCE AND SERVICING
I. PERIODICALLY REPLACED PARTS ..... 9-1
A. Copier ................................................. 9-1
II. CONSUMABLES AND DURABLES ........ 9-2
A. Copier ................................................. 9-2
CHAPTER 10 TROUBLESHOOTING
IV. INSTALLING THE CONTROL
CARD IV N ............................................. 8-13
V. INSTALLING THE REMOTE
DIAGNOSTIC DEVICE II .......................... 8-14
VI. INSTALLING THE ACCESSORY
COUNTER ................................................8-23
VII.INSTALLING THE ACCESSORY
HEATER ................................................. 8-25
A. Installing the Heater Switch ............. 8-25
B. Mounting the Cassette/Drum Heater 8-26
C. Installing the Mirror Heater ............... 8-27
III. SCHEDULED SERVICING CHART ........ 9-3
IV. SCHEDULED SERVICING TABLE ......... 9-5
A. Copier ................................................. 9-5
I. GUIDE TO TROUBLESHOOTING
TABLES.................................................. 10-1
A. Image Adjustment Basic Procedure 10-3 B. Points to Note for Scheduled Servicing . 10-4
II. STANDARDS AND ADJUSTMENTS .... 10-5
A. Mechanical ....................................... 10-5
1. Leading Edge Non-Image Width (blank exposure lamp
off timing).................................... 10-5
2. Image Leading Edge Margin
(registration on timing) ............... 10-5
3. Left/Right Registration
(cassette).................................... 10-6
B. Exposure System ............................. 10-7
1. Routing the Scanner Drive
Cable .......................................... 10-7
2. Adjusting the Position
of the Mirror................................ 10-8
3. Adjusting the Tension
of the Scanner Drive Cable........ 10-9
C. Image Formation System............... 10-10
1. Outline ...................................... 10-10
2. Stringing the Charging Wires... 10-10
3. Adjusting the Height of the
Charging Wires ........................ 10-13
D. Pick-Up/Feeding System ............... 10-14
1. Adjusting the Pressure
of the Separation Pad .............. 10-14
2. Changing the Cassette Size
(AB/INCH) ................................ 10-14
E. Fixing System................................. 10-16
1. Adjusting the Height of the
Fixing Assembly Inlet Guide .... 10-16
2. Adjusting the Pressure of
the Lower Roller (nip)............... 10-16
F. Electrical System............................ 10-18
1. Obtaining Optimum Exposure ... 10-18
2. AE Adjustment ......................... 10-19
3. After Replacing the
DC Controller PCB................... 10-22
4. Checking the Photointerrupters .... 10-23
III. IMAGE FAULTS ................................... 10-25
A. Initial Checks .................................. 10-25
1. Checking the Site Environment .... 10-25
2. Checking the Originals............. 10-25
3. Checking the Copyboard Cover and Copyboard Glass ... 10-25
4. Checking the Charging
Assembly.................................. 10-26
5. Checking the Developing
Assembly.................................. 10-26
6. Checking the Paper ................. 10-26
7. Checking the Periodically
Replaced Parts......................... 10-26
8. Others....................................... 10-26
COPYRIGHT © 1998 CANON INC. CANON NP7161/NP7160 REV.0 AUG. 1998 PRINTED IN JAPAN (IMPRIME AU JAPON)
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B. Image Fault Samples ..................... 10-28
C. Troubleshooting Image Faults ....... 10-29
1. The copy is too light.
(halftone area only) .................. 10-29
2. The copy is too light.
(including solid black area) ...... 10-30
3. The copy is too light.
(entirely, considerably)............. 10-30
4. The copy has uneven density.
(front side dark) ........................ 10-31
5. The copy has uneven density.
(front side light) ........................ 10-31
6. The copy is foggy. (overall)...... 10-32
7. The copy is foggy. (vertical)..... 10-33
8. The copy has black lines.
(vertical, fuzzy, thick) ............... 10-33
9. The copy has black lines.
(vertical, thin)............................ 10-33
10. The copy has white spots.
(vertical).................................... 10-34
11. The copy has white lines.
(vertical).................................... 10-34
12. The copy has white spots.
(vertical).................................... 10-35
13. The back of the copy is soiled. .. 10-36
14. The copy has faulty fixing. ....... 10-37
15. The copy has a displaced
leading edge............................. 10-38
16. The copy has a displaced
leading edge............................. 10-38
17. The copy has a displaced
leading edge............................. 10-38
18. The copy has a blurred image. .. 10-39
19. The copy is foggy.
(horizontally)............................. 10-39
20. The copy has poor sharpness. .. 10-40
21. The copy is blank. .................... 10-41
22. The copy is solid black............. 10-41
IV. TROUBLESHOOTING
MALFUNCTIONS ................................. 10-42
A. Copier ............................................. 10-42
1. E000 ......................................... 10-42
2. E001 ......................................... 10-43
3. E002/E003 ............................... 10-44
4. E004 ......................................... 10-45
5. E010 ......................................... 10-45
6. E013 ......................................... 10-46
7. E030 ......................................... 10-46
8. E031 ......................................... 10-47
9. E202 (The keys on the control
panel fail to operate.) ............... 10-47
10. E208 ......................................... 10-48
11. E210 ......................................... 10-48
12. E220 ......................................... 10-49
13. E261 ......................................... 10-49
14. E710/E711 ............................... 10-49
15. E712 ......................................... 10-50
16. E717 ......................................... 10-50
17. E800 ......................................... 10-51
18. E805 ......................................... 10-51
19. E821 ......................................... 10-51
20. AC power is absent.................. 10-52
21. DC power supply is absent...... 10-53
22. The scanner fails to move........ 10-54
23. The lens fails to move.............. 10-55
24. The mirror fails to move. .......... 10-55
25. The scanning lamp
fails to turn on........................... 10-56
26. The pre-exposure lamp
fails to turn on........................... 10-57
27. The blank exposure lamp
fails to turn on........................... 10-57
28. Pick-up fails. (cassette)............ 10-58
29. Pick-up operation fails.
(multifeeder) ............................. 10-59
30. The registration roller fails
to rotate. ................................... 10-59
31. The fixing heater fails to
turn on. ..................................... 10-60
32. The Add Toner indicator
does not flash/turn on. ............. 10-60
33. The Add Toner indicator fails
to turn off. ................................. 10-61
34. The Waste Toner Box Full i
ndicator fails to flash/turn on.... 10-61
35. The Waste Toner Box Full
indicator fails to turn off............ 10-62
36. The Add Paper indicator
fails to flash. ............................. 10-62
37. The Add Paper indicator
fails to turn off........................... 10-63
38. The Jam indicator fails to
flash.......................................... 10-63
39. The Jam indicator fails to
turn off. ..................................... 10-64
40. The Set Control Card indicator
fails to turn on........................... 10-64
41. The Set Control Card indicator
fails to turn off........................... 10-65
V. TROUBLESHOOTING FEEDING
PROBLEMS.......................................... 10-66
A. Copy Jams ..................................... 10-66
1. Pick-Up/Feeding Assembly...... 10-67
2. Fixing/Delivery Assembly......... 10-68
B. Faulty Feeding................................ 10-69
1. Double Feeding........................ 10-69
2. Wrinkles.................................... 10-69
VI. ARRANGEMENT AND FUNCTIONS
OF ELECTRICAL PARTS .................... 10-70
A. Sensors and Switches ................... 10-70
B. Motors, Fans, Clutches,
and Solenoids................................. 10-72
C. Heaters, Lamps, and Others.......... 10-74
D. PCBs .............................................. 10-76
E. Variable Resistors, Light-Emitting
Diodes, and Check Pins by PCB ... 10-77
x
COPYRIGHT © 1998 CANON INC. CANON NP7161/NP7160 REV.0 AUG. 1998 PRINTED IN JAPAN (IMPRIME AU JAPON)
1. DC Controller PCB................... 10-77
2. Power Supply PCB .................. 10-80
3. Lamp Regulator PCB ............... 10-80
4. High-Voltage Power Supply
PCB .......................................... 10-81
VII.SERVICE MODE .................................. 10-82
A. Outline ............................................ 10-82
B. Using Service Mode ....................... 10-82
1. Starting Service Mode.............. 10-82
2. Selecting Service Mode ........... 10-82
C. Using Adjust Mode and
Function Mode................................ 10-83
APPENDIX
D. Display Mode [1] ............................ 10-84
E. I/O Display Mode [2]....................... 10-88
F. Adjust Mode [3] .............................. 10-92
G. Function Mode [4] .......................... 10-94
H. Option Mode [5].............................. 10-95
I. Counter Mode [6] ........................... 10-97
J. Application Mode [7]....................... 10-98
VIII. SELF DIAGNOSIS .............................. 10-99
A. Copier ............................................. 10-99
B. ADF .............................................. 10-103
C. Sorter............................................ 10-104
D. Cassette Feeding Module............ 10-104
A. GENERAL TIMING CHART...............A-1
B. SIGNALS AND ABBREVIATIONS ....A-2
C. GENERAL CIRCUIT DIAGRAM ........ A-5
D. SPECIAL TOOLS LIST...................... A-7
E. SOLVENTS AND OILS ......................A-8
COPYRIGHT © 1998 CANON INC. CANON NP7161/NP7160 REV.0 AUG. 1998 PRINTED IN JAPAN (IMPRIME AU JAPON)
xi

CHAPTER 1

GENERAL DESCRIPTION
This chapter introduces the copier’s features and specifications, shows how to operate the copier, and explains how copies are made.
I. FEATURES .............................................. 1-1
II. SPECIFICATIONS ................................... 1-2
A. Copier ................................................. 1-2
III. NAMES OF PARTS.................................. 1-8
A. External View ..................................... 1-8
B. Cross Section ..................................... 1-9
IV. OPERATING THE MACHINE ................ 1-10
COPYRIGHT © 1998 CANON INC. CANON NP7161/NP7160 REV.0 AUG. 1998 PRINTED IN JAPAN (IMPRIME AU JAPON)
A. Control Panel.................................... 1-10
B. User Mode........................................ 1-12
V. ROUTINE MAINTENANCE
(BY THE USER) .................................... 1-14
VI. PONITS TO NOTE (BY THE USER) ..... 1-15
VII.IMAGE FORMATION ............................. 1-16
A. Outline .............................................. 1-16
CHAPTER 1 GENERAL DESCRIPTION

I. FEATURES

1. The copier is designed light in weight (about 42 kg), and compact in size (566 mm wide, 541mm deep).
2. The copier turns out as many as 16 copies each minute (A4/LTR).
3. The addition of the Cassette Feeding Module-C1 (accessory) enables a source of paper capable of holding a maximum of 1,050 sheets.
4. The density may be adjusted to 33 different shades, or in automatic mode (AE).
5. The use of a photo mode promises faithful reproduction of halftone.
6. The use of an auto power-off function promises power-saving operation.
COPYRIGHT © 1998 CANON INC. CANON NP7160/NP7161 REV.0 AUG. 1998 PRINTED IN JAPAN (IMPRIME AU JAPON)
1–1
CHAPTER 1 GENERAL DESCRIPTION

II. SPECIFICATIONS

A. Copier
1. Type
Body Copyboard Light source Lens Photosensitive material
2. Mechanisms
Copying Charging Exposure Copy density adjustment
Desktop Fixed Halogen lamp (120V:200W/230V:220W) Lens array OPC (30 dia.)
Indirect electrostatic Corona Slit (moving light source)
Auto or manual Development Auto
Pick-up
Manual Transfer Separation Cleaning Fixing
Dry (toner projection)
Front cassette (1 pc.)
2
Multifeeder (5 mm deep approx.; about 50 sheets of 80 g/m
Corona
Curvature + static eliminator
Blade
Heat roller (1000 W for 120V model; 1050 W for 230V model)
paper)
1–2
COPYRIGHT © 1998 CANON INC. CANON NP7160/NP7161 REV.0 AUG. 1998 PRINTED IN JAPAN (IMPRIME AU JAPON)
3. Performance
CHAPTER 1 GENERAL DESCRIPTION
Original type Maximum original size Direct Reduce I Reduce II Reduce III Reduce IV
Reproduction ratio
Enlarge I Enlarge II Enlarge III Enlarge IV Zoom Wait time
Sheet, book, 3-D object (2 kg max.) A3/279 × 432 mm (11"×17") 1:1.000 1:0.5000 1:0.707 1:0.0816 1:0.0865 1:1.154 1:1.224 1:1.414 1:2.000 1:0.500 to 2.000 (in 1% increments) 30 sec or less (at 20°C room temperature)
First copy Continuous copying Copy size Cassette
Copy paper type
Multifeeder
5.8 sec or less (A4, Direct, non-AE, cassette) 999 sheets max. A3/279×432 mm (11"×17") max. B5R/STMTR min.
2
• Plain paper (64 to 80 g/m
)
A3, B4, A4R, A4, B5R,B5, 279 × 432 mm (11"×17"), LTRR, LTR, LGL
• Colored paper (recommended by Canon) B4, A4
2
• Plain paper (64 to 80 g/m
) A3, B4, A4R, A4, B5R, B5, A5, 279X432 mm (11"×17"), LTRR, LTR,
LGL, STMTR
• Tracing paper (SM-1, GNT80) A3, B4, A4R, A4, B5R, B5, A5
• Transparency (recommended by Canon) A4/LTR
• Colored paper (recommended by Canon)* B4, A4
• Label paper (recommended by Canon) A4/LTR
2
• Heavy paper (up to 128 g/m
)
*May be used, but may not feed properly.
COPYRIGHT © 1998 CANON INC. CANON NP7160/NP7161 REV.0 AUG. 1998 PRINTED IN JAPAN (IMPRIME AU JAPON)
1–3
CHAPTER 1 GENERAL DESCRIPTION
Claws Cassette
Frame Copy tray
Leading edge Non-image width
Trailing edge Left/right Auto clear
Auto power-off
Auto pre-heat
Accessories
Used
2
55 mm deep (500 sheets of 80 g/m 100 sheets approx. (plain paper ; 64 to 80 g/m
paper; 250 sheets if B5)
2
)
Direct 2.0 ±1.0 mm Direct 2.5 ±1.5 mm Direct 2.5 ±2.0 mm Provided (2 min standard; may be changed between 1 and 9 min
in 1-min increments) Provided (30 min standard; may be changed between 10 and 90 min
in 10-min increments) Provided (15 min standard; may be changed between 15 and 90 min
in 15-min increments)
• ADF-G1*
• MS-C1*
• Control Card IV N
• Cassette Feeding Module-C1
• Stapler Sorter-L1*
• Remote Diagnostic Device II
*Applies to the NP7161 only.
1–4
COPYRIGHT © 1998 CANON INC. CANON NP7160/NP7161 REV.0 AUG. 1998 PRINTED IN JAPAN (IMPRIME AU JAPON)
4. Others
CHAPTER 1 GENERAL DESCRIPTION
Operating
Temperature Humidity
conditions
Atmospheric pressure
120V Power
120V (UL) source
127V 230V Maximum
Power Standby
consumption Continuous
Copying Noise
Standby
7.5° to 32.5°C/45.5° to 90.5°F 5% to 80% RH
810.6 to 1013.3 hPa (0.8 to 1.0 atm)
NP7160
NLB xxxxx
---­NLC xxxxx PHQ xxxxx
NP7161
----
NLD xxxxx
----
PHS xxxxx
1.5 kW or less
0.135 kWh (approx.; reference only)
0.645 kWh (approx.; reference only) 66 dB or less (sound power level by ISO method)
40 dB or less (sound power level by ISO method) Ozone (8-hr average) Width Dimensions
Depth Height
Weight
Copy paper Consumables
Toner
Specifications subject to change without notice.
0.05 ppm or less
566 mm/22.3 in
541 mm/21.3 in
389 mm/15.3 in
NP7160
42 kg/92.6 lb (approx.)
42 kg/92.6 lb (approx.)
NP7161
Keep wrapped, and avoid humidity.
Avoid direct sunlight, and store at 40°C, 85% or less.
COPYRIGHT © 1998 CANON INC. CANON NP7160/NP7161 REV.0 AUG. 1998 PRINTED IN JAPAN (IMPRIME AU JAPON)
1–5
CHAPTER 1 GENERAL DESCRIPTION
Reproduction mode Copy paper
A3 (297 × 420mm) A4 (210 × 297mm) B4 (257 × 364mm)
Direct
(100%)
B5 (182 × 257mm) A4R (297 × 210mm) B5R (257 × 182mm)
I
(70.7%)
Reduce
II
Size
A3 → A4R B4 → B5R B4 → A4R
A3 A4 B4
B5 A4R B5R A4R B5R A4R
(81.6%)
III
(86.5%)
I
A3 → B4 A4 → B5
A5R → A3
B4
B5
A3
(200%)
Copies/min
9 16 11 17 13 14 11 13 12
10 17
8
Enlarge
II
(141.4%)
III
(122.4%)
IV
(115.4%)
A4R → A3 B5R → B4 A4R → B4
B4 → A3 B5 → A4
A3 B4 B4
A3 A4
Specifications subject to change without notice.
8
9
9
8 11
1–6
COPYRIGHT © 1998 CANON INC. CANON NP7160/NP7161 REV.0 AUG. 1998 PRINTED IN JAPAN (IMPRIME AU JAPON)
CHAPTER 1 GENERAL DESCRIPTION
Reproduction mode Copy paper
11" × 17" (279 × 432mm)
LTR (297 × 216mm)
Direct
(100%)
LGL (216 × 356mm)
LTRR (216 × 297mm)
I
11" × 17" → LTRR
Size
11" × 17"
LTR
LGL LTRR LTRR
(64.7%)
Reduce
II
11" × 17" → LGL
LGL
(73.3%)
III
LGL → LTRR
LTRR
(78.6%)
I
STMTR → 11" × 17"
11" × 17"
(200%)
Enlarge
II
(129.4%)
LTRR → 11" × 17"
11" × 17"
Copies/min
9 16 11 13 12
11
12
8
8
III
(121.4%)
LGL → 11" × 17"
11" × 17"
Specifications subject to change without notice.
8
COPYRIGHT © 1998 CANON INC. CANON NP7160/NP7161 REV.0 AUG. 1998 PRINTED IN JAPAN (IMPRIME AU JAPON)
1–7
CHAPTER 1 GENERAL DESCRIPTION

III. NAMES OF PARTS

A. External View
[1] Control panel [2] Copyboard glass [3] Copyboard cover [4] Power switch
[1] [2]
[3]
[11]
[12]
[5] Upper right cover [6] Upper rear cover [7] Multifeeder [8] Waste toner box
[10]
[4]
[9]
[5]
[7]
[6]
[9] Right door [10] Right cover [11] Front door [12] Cassette
[8]
[1] Copy tray [2] Upper left cover [3] Upper delivery cover
Figure 1-301
[1] [2] [3] [4] [5]
[4] Lower delivery cover [5] Front fixing cover [6] Inside cover
[7] [8]
[6]
[9]
[7] Open/close lever [8] Lower inside cover [9] Static eliminator
Figure 1-302
1–8
COPYRIGHT © 1998 CANON INC. CANON NP7160/NP7161 REV.0 AUG. 1998 PRINTED IN JAPAN (IMPRIME AU JAPON)
CHAPTER 1 GENERAL DESCRIPTION
B. Cross Section
1. Copier
[1] [2] [3] [4] [5] [6] [10] [11] [13][7] [8] [9] [14][12] [15]
[1] No. 3 mirror [2] No. 2 mirror [3] Scanning lamp [4] No. 1 mirror [5] Copyboard glass [6] Lens [7] Pre-exposure lamp [8] Primary charging assembly [9] Blank exposure lamp [10] No. 6 mirror
[11] Dust-proofing glass [12] Developing cylinder [13] No. 4 mirror [14] No. 5 mirror [15] Multifeeder pick-up roller [16] Feed roller [17] Separation roller [18] Vertical path roller [19] Pick-up roller [20] Registration roller
Figure 1-303
[16][17][19][24][25][26] [20][21][22][23] [18]
[21] Transfer charging assembly [22] Separation static eliminator [23] Heat discharging roller [24] Lower fixing roller [25] Upper fixing roller [26] Delivery roller
COPYRIGHT © 1998 CANON INC. CANON NP7160/NP7161 REV.0 AUG. 1998 PRINTED IN JAPAN (IMPRIME AU JAPON)
1–9
CHAPTER 1 GENERAL DESCRIPTION

IV . OPERA TING THE MACHINE

A. Control Panel
[1]
[2] [3]
[4]
[5]
[6]
[7]
[9][8]
[1 1][10]
[12]
[15]
[16]
[17]
[18]
1[9]
[20]
[21]
[14][13]
Image Combination
Sort
Two-page Separation
Staple-
Sort
Group
[22]
Ref. Name
Sorter key*
[1]
Sorter indicator*
[2]
2-on-1*/Page
[3]
Separate key Fit Page key
[4]
Photo
Max. 200% A4/LTR A3 B5 B4 A4/LTR B4 B4 A3 B5 A4/LTR
A3 B4 A4/LTR B5 B4 A4/LTR A3 B5A4/LTR B4 Min. 50%
Reduce
123
1 : 1
1 : 1
Enlarge
Auto Paper A3/1117 A4/LTR A4/LTR B4/LGL B5 U1
R
B5 U2
Paper Select
Auto Zoom
R
Zoom
Fit Image
A
Reset
%
Additional Functions
Interrupt
2 31 5 64 8 97
ID
0 C
[23] [24][25] [26][27] [28]
Figure 1-401
Description Remarks
Press it to select or deselect Sort, Staple Sort, or Group Sort mode.
Indicates the selected delivery mode. It remains off in non-sort mode.
Press it to select or deselect 2-on-1 or Page Separate mode.
Press to select or deselect Fit Page mode. Use the mode to make a copy covering all image area of the original.
Energy Saver
Stop
Start
Clear
*Requires a sorter or stapler sorter.
*Requires an ADF.
ON/OFF
[5]
Photo key Reduce/Direct/
[6]
Enlarge key Default Ratio indicator
[7]
Control Card indicator
Jam indicator
[8]
Toner indicator
Paper indicator
Paper Source/Jam
[9]
* Applies to the NP7161 only
Press it to select or deselect Photo mode. Press it to select Reduce/Enlarge (default ratio) or
reset any ratio to Direct. Indicates the selected default reproduction ratio. Flashes when the control card is not set properly.
Flashes when a jam occurs. Flashes when toner is running out. It stops
flashing and remains on when toner runs out completely.
Flashes if paper runs out in the selected cassette or the manual feed tray (or, when the cassette is not set properly).
Indicates the selected cassette or the manual tray; flashes the location of a jam, if any. (It also flashes when a jam occurs in the ADF or when the sorter or the right door needs to be checked.)
Table 1-401
Requires a Control Card Unit.
1–10
COPYRIGHT © 1998 CANON INC. CANON NP7160/NP7161 REV.0 AUG. 1998 PRINTED IN JAPAN (IMPRIME AU JAPON)
CHAPTER 1 GENERAL DESCRIPTION
Ref. Name
Location indicator
[10]
Paper Size indicator
[11]
Paper Select key
[12]
Copy Count/Ratio
[13]
indicator Auto Ratio key*
[14]
[15]
% key
[16]
Reset key
[17]
Keypad
[18]
Start key
Description Remarks
Flashes when the waste toner box needs to be replaced. When the case becomes full, it stops flashing and remains on.
Indicates the size of the paper in the cassette selected by the Paper Select key.
Press it to select Auto Paper Select*, Cassette, or Manual Feed Tray mode.
Indicates the copy count/ratio and the selected user mode.
Use it to select or deselect Auto Ratio mode, in which the best reproduction ratio is automatically selected to suit the original and the selected paper.
Press it to indicate the selected reproduction ratio. Use it to reset the current copy mode to default. Use it to set a copy count or to enter a numeric value. Press it to start copying.
*Requires an ADF.
*Requires an ADF.
[19]
Stop key
[20]
Power Save key
[21]
Power switch Copy Density
[22]
lever AE key
[23]
Zoom key
[24]
[25]
User Mode key Interrupt key
[26]
ID key
[27]
Clear key
[28]
Press it to stop continuous copying. Press it to select or deselect power save mode. Press it to turn on or off the power. Slide it to adjust the copy density manually.
Press it to select or deselect AE (auto density adjustment) mode.
Press it to select a reproduction ratio (50% to 200%) in 1% increments. Hold it down to increase/decrease the ratio continuously.
Press it to set or change user mode settings. Press it to stop an ongoing copying run to make a
copy of a different original. Press it after entering an appropriate ID number.
Press it also after entering a number for ID registration.
Press it to reset the copy count to 1 or to clear any wrong input when making settings.
* Applies to the NP7161 only
Table 1-402
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1–11
CHAPTER 1 GENERAL DESCRIPTION
B. User Mode
1. Outline
The copier provides user modes, which may be changed freely by the user. These modes
provide the functions shown in the following table.
Notation
U00
U01
U02
U03
U04
U05
Resetting user mode
Changing auto clear time
Changing auto power-save time
Changing auto power-off time
Fine-adjusting Zoom
Turning on/off auto cassette change
DescriptionItem
Use it to reset new settings made in user mode to default settings.
Use it to set the auto clear time length between 1 an 9 min in 1-min increments. Setting it to 0 disables the auto-clear function.
Use it to select an appropriate auto power­save time length: 10, 15, 20, 30, 40, 50, 60, or 90 min (8 lengths).
Use it to select an appropriate auto power­off time length: 10, 15, 20, 30, 40, 50, 60, 90 (8 lengths).
Use it to adjust vertical and horizontal reproduction ratios over ±5 grades in 0.2% increments. Rang: -1.0% to +1.0% in units of 0.2%
Use it to turn on/off the auto cassette change function, in which copying is continued by switching cassettes when the selected cassette runs out of paper. O N : Enable auto cassette change. OFF : Disable auto cassette change.
Factory settings
(default)
–
2 min
15 min
30 min
±0.0%
ON
U06
U07
U08
1–12
Turning on/off auto sort
Turning on/off ADF jam recovery
Cleaning feeder
COPYRIGHT © 1998 CANON INC. CANON NP7160/NP7161 REV.0 AUG. 1998 PRINTED IN JAPAN (IMPRIME AU JAPON)
Use it to turn on/off the auto sort function, in which sorting takes place when making multiple copies of multiple originals using an ADF. O N : Enable auto sort. OFF : Disable auto sort.
Use it to turn on/off auto counting of originals in ADF jam recovery. O N : Enable auto count. OFF : Disable auto count.
Use it to clean the feeder (after placing paper in the ADF and pressing the Start key).
ON
OFF
–
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