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Canon iR1600, iR1610, iR2000, iR2010 Series, Service Manual

Service Manual Canon iR1600, iR1610, iR2000, iR2010 Series;
This manual is in the PDF format and have detailed Diagrams, pictures and full procedures to diagnose and repair your Canon iR1600, iR1610, iR2000, iR2010 Series copier.
You can print, zoom or read any diagram, picture or page from this Service Manual. Every chapter on this manual is fully detailed and contain all the simulation codes, trouble codes, maintenance procedures, reset procedures, diagnose procedures of Canon iR1600, iR1610, iR2000, iR2010 Series photocopier. You can find easily everything what do you need.
To see what contain, please read table of contents:

CHAPTER 1: INTRODUCTION
1 Features
1.1 Features
2 Specifications
2.1 Copier
2.1.1 Type
2.1.2 System
2.1.3 Functions
2.1.4 Others
2.2 Cassette Unit
2.3 Inner 2-Way Tray
3 Names of Parts
3.1 External View
3.1.1 Copier
3.1.2 Cassette Unit
3.1.3 Inner 2-Way Tray
3.2 Cross Section
3.2.1 Copier
3.2.2 Cassette Unit
3.2.3 Inner 2-Way Tray
4 Control Panel
4.1 Control Panel
4.1.1 Control Panel for a Non-Fax Model
4.1.2 Control Panel for a Fax Model
4.1.3 Master Password
4.2 Basic Operation
4.2.1 Basic Operation for a Non-Fax Model
4.2.2 Basic Operation for a Fax Model
4.3 Extended Operation
4.3.1 Extended Operation for a Non-Fax Model
4.3.2 Extended Operation for a Fax Model
4.4 User Mode
4.4.1 User Mode for a Non-Fax Model
4.4.2 User Mode for a Fax Model
5 Cleaning by the User
5.1 Cleaning by the User
5.1.1 Cleaning the Fixing Roller 1-59
5.1.2 Cleaning the Copyboard Glass, Reading Glass, and Copyboard Cover White Plate
5.1.3 Cleaning the ADF Roller/Guide Assembly
6 Safety and Warnings
6.1 Safety of Laser Light
6.2 CDRH Requirements
6.3 Handling the Laser Unit
6.4 Safety of the Toner
7 Reproduction Processes
7.1 Outline

CHAPTER 2: BASIC OPERATION
1 Basic Operation
1.1 Functional Construction
1.2 Outline of Electrical Circuitry
1.2.1 Image Processor PCB
1.2.2 DC Controller PCB
1.2.3 Power Supply PCB
1.2.4 Analog Processor PCB
1.3 Inputs to and Outputs from Electrical Components
1.3.1 Wiring Diagram of the Major PCBs
1.3.2 Wiring Diagram of the Electrical Components (1/2)
1.3.3 Wiring Diagram of Electrical Components (2/2)
1.4 Basic Sequence of Operation
1.4.1 Outline
1.4.2 Basic Sequence of Operation (power-on)
1.4.3 Basic Sequence of Operation (printing)
1.5 Controlling the Main Motor (M101)
1.5.1 Outline

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

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

CHAPTER 5: IMAGE FORMATION SYSTEM
1 Outline of Processes
1.1 Sequence of Operation (image formation system)
2 1 Controlling the Primary Charging Roller Bias
2.1 Outline
2.2 Turning On and Off the Bias
2.2.1 DC Bias
2.2.2 AC Bias
2.3 Bias Constant Voltage/Constant Current Control
2.3.1 DC Bias Constant Voltage Control
2.3.2 AC Bias Constant Current Control
3 Controlling the Developing Bias
3.1 Outline
3.2 Turning On/Off the Bias
3.2.1 DC Bias
3.2.2 AC Bias
3.3 Controlling the Bias to a Constant Voltage Level
3.3.1 Controlling the Developing DC Bias to a Constant Level
3.3.2 Controlling the Developing AC Bias to a Constant Voltage Level
3.4 Controlling the Voltage Level of the Developing DC Bias
4 Controlling the Transfer Charging Roller Bias
4.1 Outline
4.2 Turning On and Off the Bias
4.2.1 Turning On and Off the Positive DC Bias
4.2.2 Turning On and Off the Negative DC Bias
4.3 Controlling the Bias to a Constant Current /Voltage Level
4.3.1 Controlling the DC Bias to a Constant Current Level
4.3.2 Controlling the DC Bias to a Constant Level
4.4 Correcting the Voltage Level (ATVC control)
4.5 Controlling the Output According to Operation Mode
4.5.1 Type of Mode
5 Detecting the Presence/Absence of a Cartridge and the Level of Toner
5.1 Outline
5.2 Sequence of Detection (level of toner)
6 Monitoring the Waste Toner Case
6.1 Outline
6.2 Sequence of Operation
7 Disassembly and Assembly
7.1 Photosensitive Drum
7.1.1 Removing the Drum Unit
7.1.2 Cleaning the Photosensitive Drum
7.2 Developing Assembly
7.2.1 Removing the Developing Assembly
7.3 Transfer Roller
7.3.1 Removing the Transfer
Roller

CHAPTER 6: PICKUP/FEEDING SYSTEM
1 Outline
1.1 Specifications and Constructions
1.2 Arrangement of Major Rollers and Sensors
2 Controlling the Pickup Assembly
2.1 Controlling the Pickup from the Cassette
2.1.1 Outline
2.1.2 Pickup form the Cassette
2.1.3 Pickup Retry
2.1.4 Detecting the Size of Paper in the Cassette
2.2 Controlling the Pickup from the Multifeeder Tray
2.2.1 Outline
2.2.2 Pickup from the Multifeeder Tray
2.2.3 Multifeeder Retry Operation
2.2.4 Setting the Paper Size for the Multifeeder Tray (user mode)
3 Controlling the Registration Roller
3.1 Detecting the Leading Edge of Paper
4 Detecting Jams
4.1 Outline
4.2 Sequence of Jam Detection
4.2.1 Delay Jam
4.2.2 Stationary Jams
4.2.3 Cover Open Jam
4.2.4 Jam History
5 Disassembly and Assembly
5.1 Cassette Pickup Assembly
5.1.1 Remove the Cassette Pickup Assembly
5.1.2 Removing the Cassette Pickup Roller
5.1.3 Removing the Feeding/Separation Roller
5.1.4 Removing the Cassette Pickup Solenoid
5.1.5 Removing the Paper Size Detecting Switch
5.1.6 Removing the Cassette Paper Sensor
5.1.7 Removing the Retry Sensor
5.1.8 Removing the Pickup Motor (20 cpm model only)
5.2 Multifeeder Tray Assembly
5.2.1 Removing the Multifeeder Tray
5.2.2 Removing the Multifeeder Pickup Roller
5.2.3 Removing the Separation Pad
5.2.4 Removing the Multifeeder Paper Sensor
5.2.5 Removing the Multifeeder Pickup Solenoid
5.3 Drive Assembly
5.3.1 Removing the Drive Assembly
5.4 Registration Roller Assembly
5.4.1 Removing the Registration Roller
5.4.2 Removing the Registration Paper Sensor
5.4.3 Removing the Registration Clutch

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

CHAPTER 8: EXTERNALS AND AUXILIARY CONTROL SYSTEM
1 Control Panel
1.1 The machine's control panel has the following construction
2 Power supply
2.1 Power Supply
2.1.1 Outline
2.1.2 Rated Outputs from the Power Supply PCB
2.2 Protective Mechanisms
2.3 High-Voltage Power Supply Circuit
3 Control at Time of Energy Save Mode
3.1 Outline
3.2 Control
3.3 Operation
4 Fan
4.1 Outline
4.2 Control
4.2.1 Controlling the Speed
4.2.2 Error Detection
4.2.3 Sequence of Operation (fan drive)
5 Back-Up Battery
5.1 Back-Up Mechanism
5.1.1 Outline
5.1.2 Vanadium Lithium Secondary Battery (BAT2)
5.1.3 Lithium Battery (BAT1)
5.2 Back-Up Data
5.2.1 Types of Data
5.2.2 Printing Out the Back-Up Data List
6 Disassembly and Assembly
6.1 External Covers
6.1.1 Removing the Front Cover
6.1.2 Removing the Control Panel Lower Cover
6.2 Control Panel
6.2.1 Removing the Control Panel
6.3 Main Motor
6.3.1 Removing the Main Motor
6.4 Fan
6.4.1 Removing the Heat Discharge fan
6.5 PCBs
6.5.1 Removing the DC Controller PCB
6.5.2 After Replacing the DC controller PCB
6.5.3 Removing the Image Processor PCB
6.5.4 When Replacing the Image Processor PCB
6.5.5 Removing the RAM DIMM
6.5.6 Removing the ROM DIMM
6.5.7 Removing the Analog Processor PCB
6.5.8 After Replacing the Analog Processor PCB
6.5.9 Removing the Power Supply PCB
6.5.10 Removing the Original Detection/Reader Motor PCB
6.5.11 Removing the Printer Board Unit (if equipped with printer functions)
6.5.12 Removing the Cassette controller PCB (20 cpm model only)

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

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

CHAPTER 11: INSTALLATION
1 Selecting the Site of Installation
2 Unpacking and Installing the Machine
2.1 Points to Note Before Starting the Work
2.2 Installing the Machine
2.3 Unpacking and Removing the Fixing Members
2.4 Removing the Dummy Drum
2.5 Mounting the Drum Unit
2.6 Mounting the Toner Cartridge
2.7 Putting Paper in the Cassette
2.8 Placing Paper in the Multifeeder Tray
2.9 Checking the Copy Images
2.10 Selecting the Country/Region through Service Operation
2.11 Setting the Date/Time (user mode)
2.12 Storing the Specifications Report
2.13 Setting the Fax Functions (if equipped with fax functions)
2.13.1 Connecting the Line
2.13.2 Setting the Dialing Method
2.13.3 Communications Test
2.14 Checking the Printer Functions (if equipped with printer functions)
3 Relocating the Machine
4 Flow of accessory installation (if equipped with a fax function)
5 Installing the Card Readere-E1 (accessory)
5.1 Points to Note for Installation
5.2 Installation
5.3 Setting and Checking After Installation
6 Installing the Image RAM (accessory)
6.1 Non-Fax Model
6.1.1 Installation
6.2 FAX Model
6.2.1 Before Starting the Work 11-36
6.2.2 Mounting the RAM
7 Installing the Remote Diagnostic Device II (accessory)
7.1 Parts to Procure
7.2 Unpacking
7.3 Installation to the Copier

CHAPTER 12: MAINTENANCE AND INSPECTION
1 Periodically Replaced Parts
1.1 Copier
1.2 Cassette Unit
1.3 Inner 2-Way Tray
2 Guide to Durables
2.1 Checking the Timing of Replacement
2.2 Copier
2.3 Cassette Unit
2.4 Inner 2-Way Tray
3 Basic Service Work
3.1 Basic Service Work
4 Cleaning During a Visit
5 Points to Note When Storing/Handling the Drum Unit
5.1 Outline
5.2 Storage and Handing After Removing the Packaging Seal
5.2.1 Storage After Removing the Packaging Seal
5.2.2 Points to Note When Handling the Drum Unit

CHAPTER 13: TROUBLESHOOTING
1 Image Adjustment Basic Procedure
1.1 Image Adjustment Basic Procedure
2 Standards and Adjustments
2.1 Image Adjustments
2.1.1 Standards for Image Position
2.1.2 Adjusting the Image Position
2.1.3 Adjusting the Leading Edge Margin for the Printer Unit (if equipped printer functions)
2.1.4 Adjusting the Image Position for Copying
2.1.5 Adjusting the Image Position for ADF Copying
2.2 Fixing System
2.2.1 Checking the Fixing Roller Pressure (nip)
2.3 Electrical Parts
2.3.1 When Replacing the Major Parts
2.3.2 Gain Auto Adjustment
2.3.3 When Replacing the Contact Sensor
2.3.4 When Replacing the Image Processor PCB
2.3.5 When Replacing the DC Controller PCB
2.3.6 When Replacing the Analog Processor PCB
2.4 Checking the Sensors
2.4.1 Checking the Sensors
3 Troubleshooting Image/Operation Faults
3.1 Making Initial Checks on Image Faults
3.1.1 Site of Installation
3.1.2 Checking the Originals
3.1.3 Copyboard Cover and Copyboard Glass (standard white plate)
3.1.4 Checking the Transfer Charging Roller/Static Eliminator
3.1.5 Checking the Drum Unit
3.1.6 Checking the Paper
3.1.7 Image Adjustment Basic Procedure
3.1.8 Others
3.2 Image Fault Samples
3.3 Troubleshooting Image Faults
3.3.1 The copy is too light (halftone only)
3.3.2 The copy is too light (both halftoneand solid black)
3.3.3 The copy is too light (entire copy, appreciably)
3.3.4 The copy has uneven density (darker along front)
3.3.5 The copy has uneven density (lighter along front)
3.3.6 The copy is foggy (entire copy)
3.3.7 The copy is foggy (feeding direction)
3.3.8 The copy has black lines (feeding direction, fuzzy, thick)
3.3.9 The copy has black lines (feeding direction, fine)
3.3.10 The copy has white strips(feeding direction)
3.3.11 The copy has white lines (feeding direction)
3.3.12 The output has white strips (cross-feeding direction)
3.3.13 The back of the copy is soiled
3.3.14 The copy has a poor fixing
3.3.15 The copy has displaced registration (leading edge extremely excessive margin)
3.3.16 The copy has displaced registration (leading edge, excessive margin)
3.3.17 The copy has displaced registration (leading edge, no margin)
3.3.18 The copy has blurred images
3.3.19 The copy is foggy (cross-feeding direction)
3.3.20 The copy has poor sharpness
3.3.21 The copy is blank
3.3.22 The copy is solid black
3.3.23 The copy has a black line (stream reading)
3.4 Troubleshooting Malfunctions
3.4.1 AC power is absent
3.4.2 DC power is absent
3.4.3 Pickup operation fails (cassette)
3.4.4 Pickup operation fails (multifeeder tray)
3.4.5 Pickup operation fails (cassette unit)
3.4.6 The vertical path roller fails to rotate
3.4.7 The registration roller fails to rotate
3.4.8 The contact sensor fails to go ON
3.4.9 The speaker fails to operate
3.4.10 The "Add Toner" message fails to go OFF
3.4.11 The "Add Paper" message fails to go OFF cassette unit)
3.4.12 The "Add Paper" message fails to go OFF (multifeeder tray)
3.4.13 The "Jam" message fails to go OFF
3.4.14 The "Waste Toner Full" message does not go OFF
3.4.15 The "Controller Card Set" message does not go ON
3.4.16 The "Control Card Set" message does not go OFF
3.5 Troubleshooting Feeding Faults
3.5.1 Outline
3.5.2 Pickup Assembly
3.5.3 Transfer/Feeding Assembly
3.5.4 Fixing/Delivery Assembly
3.5.5 Feeding Fault (double feeding)
3.5.6 Feeding Faults (wrinkling)
4 Arrangement and Functions of Electrical Parts
4.1 Outline
4.1.1 Outline
4.1.2 Checking the Sensors
4.2 Clutches, Solenoids, Motors, and Fans
4.3 Sensors
4.4 PCBs
4.5 Switches, Others
4.6 Cassette Unit
4.7 Inner 2-Way Tray
4.8 Variable Resistors (VR), Light-Emitting Diodes (LED), and Check Pins
4.8.1 Image Processor PCB
4.8.2 DC Controller PCB
4.8.3 Power Supply PCB
4.8.4 Analog Processor PCB
4.8.5 1-Cassette Unit Controller PCB
4.8.6 2/3-Cassette Unit Controller PCB
5 Service Mode
5.1 Outline
5.2 Using the Mode
5.3 Service Mode Menus
5.4 Setting the parameters
5.4.1 Registering the Bit Switch (#1 SSSW)
5.4.2 Menu Switch Setting (#2 MENU)
5.4.3 Setting Numeric Parameters (#3 NUMERIC Param.)
5.4.4 SPECIAL Setting (#4A SPECIAL)
5.4.5 NCU Setting (#4B NCU)
5.4.6 ISDN Setting (#4C ISDN)
5.4.7 Selecting the Country/Region of Installation (#5 TYPE)
5.4.8 Setting Original Read Functions (#6 SCANNER)
5.4.9 Setting the Printer Parameters (#7 PRINTER)
5.4.10 PDL (#8 PDL)
5.4.11 Counters (#9 COUNTER)
5.4.12 Generating a Report (#10 REPORT)
5.4.13 Downloading (#11 DOWNLOAD)
5.4.14 Clear (#12 CLEAR)
5.4.15 ROM Indication (#13 ROM)
5.4.16 Resetting the CS Unit Position (#14 CS SET)
5.5 Test Mode (TEST MODE)
5.5.1 Outline
5.5.2 Test Mode Menu
5.5.3 D-RAM Test (1: D-RAM)
5.5.4 CCD Test (2: CCD TEST)
5.5.5 PRINT Test (3: PRINT)
5.5.6 MODEM NCU Test (4: MODEM NCU)
5.5.7 Faculty Test (6: FACULTY TEST)
5.5.8 Book Read Test (8: BOOK TEST)
5.6 Report
5.6.1 User Report
5.6.2 Service Report
6 Self Diagnosis
6.1 Outline
6.2 Error Codes
6.2.1 Error Codes Used for the Machine
6.2.2 Finisher Error Codes
6.3 Fax Error Code
6.3.1 Service Error Code Output
6.3.2 Error Codes
6.3.3 Causes and Remedies for
User Error Codes
6.3.4 Causes and Remedies for
Service Error Codes

CHAPTER 14: VERSION UP
1 Upgrading
1.1 Outline
2 Upgrading by Downloading
2.1 Before Starting the Work
2.2 Installing the USB Driver (only if Windows 98 or Windows 98SE)
2.3 Installing the Firmware
2.4 Downloading the System Software
2.5 Downloading for G3 FAX
2.6 Downloading for the Finisher-L1
2.6.1 Outline
2.6.2 Downloading
3 Back Up Data
3.1 Outline
3.2 Backing Up Data
3.2.1 Making Preparations
3.2.2 Making Connections
3.2.3 Backing Up Data
3.2.4 Downloading Backup Data
3.2.5 Managing Backup Data

APPENDIX:
A General Timing Charts
B General Circuit Diagram
C 1-cassette unit
D 2/3-cassette unit
E Inner 2-way tray
F Special Tools
G Solvents and Oils

Numbers of pages: 738.
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