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Canon iR5000 User Manual
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COPYRIGHT
©
2000 CANON INC.
2000 2000 2000 2000
CANON iR5000/iR6000 REV
.0 JUL
Y 2000
CHAPTER 3 INST
ALLA
TION
3-14 S
2.9
Mounting the Dec
k Loc
king Plate (left dec
k)
Screw
Deck loc
king plate
Checks/remarks
Step
1
2
Wo
r
k
Push the releasing b
utton of the left deck,
and slide out the left deck.
Fit the deck locking plate with a screw
.
Close the left deck.
Download Free Service Manual at http://printer1.blogspot.com
77
79
Table of Contents
Table of Contents
11
Default Chapter
4
Outline of the Manual
4
System Configuration
7
Arrangement of the Switches
8
Chapter 1 General Description
13
Features
15
Hard Disk
15
High Speed, High Image Quality
15
Large-Capacity Paper Source
15
Stackless, Duplexing Mechanism
15
Variety of Delivery Processing (with Accessories)
15
Specifications
16
Copier
16
Method
16
Type
16
Functions
17
Others
22
Paper Deck-G1
25
Shift Tray-B1
26
Names of Parts
27
External View
27
Cross Section
29
Using the Machine
31
Turning on the Power Switches
31
Control Panel
32
User Mode
34
Functional Construction
38
Main Controller
38
Outline of Electrical Circuitry
39
Construction of Electrical Circuitry
39
Cleaning
41
Inspection
44
Making a Check
44
Digital Image Processing
54
Outline
54
Input Image Processing
55
Binary Processing (Error Diffusion; T-BIC)
55
Density Conversion (LUT) 2-9S
55
Edge Emphasis
55
Editing
55
Enlargement/Reduction (Main Scanning Direction)
55
Image Data from the Reader Unit
55
Binary Processing (Dither Screen)
56
Binary-Binary Density Conversion (Read Image Output Only)
57
Compression/Decompression, Rotation, Enlargement/Reduction
57
Controlling the Image Memory
57
Hard Disk Drive (HDD)
57
Output Image Processing
57
Sdram
57
Smoothing
57
Thickening (PDL Output Only)
57
Soft Counter
58
Controlling the Power Supply
60
Outline
60
Power Save Mode
60
Power Supply Mode
60
Standby Mode (Normal Operation)
60
Low Power Mode
61
Sleep Mode
61
Off Mode
62
Chapter 3 Installation
63
Selecting the Site
65
Unpacking and Installation
67
Before Starting the Work
67
Installation
68
Unpacking
69
Mounting the Scanner
70
Mounting the Fixing Assembly
71
Checking the Charging Assemblies
73
Mounting the Developing Assembly
76
Mounting the Pickup Assembly
77
Mounting the Deck Locking Plate (Left Deck)
78
Supplying Toner
79
Setting the Cassette
80
Changing the Paper Size for the Front Deck (Right/Left)
81
Checking Images/Operations and User Mode
82
Checking the Environment Switch
84
Installing the Machine
85
Relocating the Machine
86
Mounting the Delivery Roll
87
Mounting the Original Holder
88
Installing the Control Card IV
89
Installing the NE Controller-A1
90
Installation
90
Table of Contents
95
Default Chapter
97
Chapter 1 Basic Operation
97
Functional Construction
99
Outline of Electrical Circuitry
100
Outline
100
Reader Controller PCB
100
Basic Sequence of Operations at Power-On
101
Chapter 2 Original Exposure System
105
Outline of Operations
107
Outline
107
Book Mode, 1 Original, Copyboard Closed
109
Sequence of Operations (Original Exposure)
109
Copyboard Cover Open
110
Changing the Reproduction Ratio in Main Scanning Direction
111
Changing the Reproduction Ratio in Sub Scanning Direction
111
Enlargement/Reduction (Zoom)
111
Scanner Drive System
112
Outline
112
Controlling the Motor When Scanning an Image
113
Controlling the Scanner Motor
113
Reversing the Scanner after Scanning in Main Reading Direction
114
Controlling the Scanning Lamp (LA2)
115
Outline
115
Reader Controller PCB
115
Scanning Lamp
115
Turning On/Off the Lamp
115
Detecting an Error
116
Detecting the Size of Originals
117
Outline
117
Outline of Detection
117
Points of Detection
117
Book Mode, 1 Original, Copyboard Cover Open
118
Outline of Detection Operation
118
Scanning Lamp
121
Removing the Scanning Lamp
121
After Replacing the Scanning Lamp
122
Points to Note When Replacing the Scanning Lamp
122
Scanner Drive Block
123
Removing the Scanner Motor
123
Scanner Motor
123
Mounting the Scanner Motor
124
Removing the Scanner System Drive Cable
125
Scanner System Drive Cable
125
Routing the Scanner Drive Cable
127
Positioning the No. 1/2 Mirror Base
128
Others
130
Removing the Original Size Sensor
130
Chapter 3 Image Processing System
137
Outline
139
Analog Image Processing
140
Driving the CCD
140
Outline
140
Gain Correction and Offset Correction of the CCD Output
141
Output
141
Digital Image Processing
142
Outline
142
Shading Correction
142
Shading Adjustment
143
Shading Correction
143
Edge Gain Correction (ADF in Use)
144
ABC Circuit
145
Auto Density Adjustment (AE)
145
Related Service Mode
146
External Covers
147
Removing the Reader
147
Removing the Reader Rear Cover
149
CCD/Ap Pcb
150
Removing the CCD Unit
150
When Replacing the CCD/AP PCB
151
Reader Controller PCB
152
Removing the Reader Controller PCB
152
When Replacing the Reader Controller PCB
152
Table of Contents
155
Default Chapter
165
Chapter 1 General Description
165
Safety
167
Regulations under the Center for Devices and Radiological Health
167
Safety of Laser Light
167
Handling the Laser Unit
169
Safety of Toner
172
Image Formation
173
Chapter 2 Sequence of Operations
175
Basic Operations
177
Functional Construction
177
DC Controller PCB
178
Outline
178
Outline of Electrical Circuitry
178
Basic Sequence of Operations at Power-On
180
Sequence of Basic Operations
180
Controlling the Main Motor (M2)
182
Chapter 3 Laser Exposure System
199
Outline of Operations
200
Outline
200
Basic Sequence of Operations (Laser Exposure System)
202
Generating Sync Signals
203
Outline
203
Flow of Sync Signals
204
Laser Driver Circuit
205
Controlling the Laser
205
Controlling the Laser Scanner Motor
208
Outline
208
Disassembly and Assembly
209
Scanner Unit
210
Chapter 4 Image Formation System
212
Outline of Processes
214
Outline
214
Basic Sequence of Operations (Image Formation System)
216
Potential Control
218
Outline
218
Controlling Potential for Printing/Copying
219
Determining Primary Current
224
Determining the Laser Output
225
Determining the Developing Bias
226
APC Correction
227
Density Adjustment During Copying
229
Density Adjustment in each Mode
229
Density Adjustment During Printing
230
Controlling Charging
231
Controlling Pre-Exposure LED
231
Outline
231
Controlling Primary Charging
232
Outline
232
Primary Charging Assembly Cleaning Mechanism
233
Others
234
Dust-Collecting Roller Bias
235
Outline
235
Controlling the Output to Suit the Environment
236
Controlling the Pre-Transfer Charging
236
Outline
236
Cleaning Mechanism for the Pre-Transfer Charging Assembly
238
Others
239
Controlling the Output to Suit the Environment
240
Controlling Transfer Charging
240
Outline
240
Cleaning Mechanism for the Transfer Charging Assembly
242
Others
243
Controlling Separation Charging
245
Outline
245
Correcting the Output to Suit the Environment and the Density of the Original Used
247
Others
248
Hopper/Developing Assembly
249
Outline
249
Controlling the Drive to the Hopper/Developing Assembly
250
Controlling the Developing Bias
252
Detecting the Level of Toner and Controlling the Supply of Toner
254
Sequence of Operations (Toner Supply)
255
Drum Cleaner Unit
256
Outline
256
Detecting the Waste Toner
257
Controlling the Drum Heater
259
Outline
259
Disassembly and Assembly
262
Pre-Exposure Lamp Unit
263
Removing the Pre-Exposure Lamp Unit
263
Photosensitive Drum
264
Removing the Drum Unit
264
Replacing the Drum Heater
265
Mounting the Photosensitive Drum
266
Setting the DIP Switch for the Drum Heater Control PCB
266
Process Unit
267
Removing the Process Unit
267
Mounting the Process Unit
269
Potential Sensor/Potential Control PCB
270
Removing the Potential Sensor/Potential Control PCB
270
Adjusting the Potential Sensor
272
Primary Charging Assembly
274
Removing the Primary Charging Assembly
274
Pre-Transfer Charging Assembly
275
Removing the Pre-Transfer Charging Assembly
275
Transfer/Separation Charging Assembly
276
Mounting the Transfer/Separation Charging Assembly
276
Removing the Transfer/Separation Charging Assembly
276
Charging Wire
279
Outline
279
Removing the Wire Cleaner of the Primary Charging Assembly
279
Routing the Charging Wire
279
Routing the Grid for the Primary Charging Assembly
282
Adjusting the Height of the Charging Wire
284
Cleaning the Primary Anti-Stray Sheet
285
Developing Assembly
286
Removing the Developing Assembly from the Machine
286
Removing the Blade Unit
287
Mounting the Blade
288
Removing the Developing Cylinder/Magnetic Seal
288
Cleaning the Developing Anti-Stray Sheet
290
Hopper Assembly
291
Removing the Hopper Assembly from the Machine
291
Drum Cleaner
292
Construction
292
Removing the Cleaning Blade
292
Mounting the Cleaning Blade
293
Mounting the Side Seal
295
Cleaning the Cleaner Side Scraper
296
Separation Claw/Separation Claw Drive Assembly
297
Removing from the Drum Unit
297
Chapter 5 Pick-Up/Feeding System
298
Outline
300
Specifications and Construction
300
Arrangement of Roller and Sensors
301
Pickup Assembly
303
Pickup Control System
303
Outline
305
Sequence of Operations (Pickup)
306
Pickup Retry Operation
308
Others
309
Lifter Movement
310
Outline
310
Lifter Limiter Control Circuit (Right/Left Deck)
312
Detecting the Presence/Absence of Paper
313
Paper
313
Cassette 3/4
316
Identifying the Size of Paper in the Cassette
316
Right/Left Deck
316
Markings on the Width Guide Rail
318
Paper Sizes
319
Manual Feed Tray Pickup Assembly
322
Pickup Operation
322
Detecting the Size of Paper on the Manual Feed Tray . 5-24P
323
Controlling the Registration Clutch
324
Control System
324
Outline
324
Double-Sided Prints
325
Control System
325
Sending Paper to the Reversing Assembly after Printing on the First Side . 5-26P
325
Sending Paper from the Revers- Ing Assembly to the Duplexing/Feeding Assembly
326
Outline
327
Sequence of Operations (Printing)
328
Outline
329
Through-Path Operation
329
Outline of Operations
330
Detecting Horizontal Registration Position
334
Outline
334
Operation
335
Controlling the Pickup Assembly
336
Pickup Assembly Motors
336
Controlling the Delivery Assembly
337
Reversal Delivery Operation
337
Controlling the Cassette Heater
339
Detecting Jams
341
Arrangement of Jam Sensors
341
Outline
341
Types of Jams
342
Delay Jam
343
Sequence of Operations (Jam Detection)
343
Stationary Jams
345
Jam History
346
Disassembly and Assembly
347
Manual Feed Tray Assembly
348
Opening of the Right Upper Cover
348
Removing the Right Upper Cover
348
Removing the Feeding Roller
349
Removing the Manual Feed Pull-Out Roller Unit
349
Removing the Separation Roller
349
Adjusting the Pressure of the Separation Roller
350
Removing the Manual Feed Tray Paper Sensor
351
Attaching the Side Guide Timing Belt in the Manual Feed Tray Assembly
352
Removing the Manual Feed Pull-Out Roller
352
Deck Pickup Assembly
353
Removing the Left Deck Pickup Assembly
353
Removing the Right Deck Pickup Assembly
353
Removing the Cassette 3 Pickup Assembly
354
Removing the Cassette 4 Pickup Assembly
354
Removing the Pickup Roller
354
Removing the Feeding Roller
355
Orientation of the Feeding Roller of the Deck/Cassette Pickup Assembly
356
Removing the Separation Roller
356
Adjusting the Separation Roller Pressure
358
Orientation of the Separation Roller
358
Adjusting the Left/Right Registration for the Front Deck
359
Adjusting the Registration for the Cassette 3/4
359
Adjusting the Position of the Lifter Motor M20 (M21) of the Cassette 3 (Cassette 4)
360
Removing the Lifter Motor M20 (M21) of the Cassette 3 (4)
360
Adjusting the Position of the Cassette 3/4 Pickup Solenoid (SL3, 4)
362
Vertical Path Roller Assembly
363
Removing the Vertical Path Roller 1
363
Removing the Vertical Path Roller 2
363
Removing the Vertical Path Roller 3/4
364
Registration Feeding Assembly
365
Removing the Registration Clutch
365
Removing the Registration Roller
365
Feeding Assembly
367
Removing the Feeding Belt
367
Removing the Fixing/Feeding Unit Releasing Lever Switch
368
Duplex Unit
369
Removing the Duplex Unit
369
Removing the Reversal Motor
369
Removing the Reversing Flapper Solenoid
369
Mounting the Reversal Motor
370
Removing the Duplex Feeding Right Motor
371
Removing the Duplexing Feeding Left Motor
371
Removing the Duplex Pre-Registration Sensor
372
Removing the Horizontal Registration Motor
372
Removing the Duplex Paper Sensor
373
Removing the Reversal
374
Removing the Reversal Sensor
374
Removing the Left Deck Feed Paper Sensor
375
Removing the Duplex Driver PCB
376
Removing the Horizontal Registration Sensor
376
Removing the Duplex Feeding Fan
377
Removing the Horizontal Registration Unit
377
Chapter 6 Fixing System
380
Outline of Operation
382
Outline
382
Basic Sequence of Operations (Fixing System)
385
Fixing Drive System
386
Outline
386
Controlling the Drive of the Fixing Roller
387
Controlling the Drive of the Cleaning Web
388
Controlling the Drive of the Fixing Assembly Inlet Guide
389
Controlling the Reciprocating Mechanisms of the Thermistor
390
Controlling the Reciprocating Mechanism of the Upper Separation Claw
391
Controlling the Fixing Temperature
392
Outline
392
Temperature Control
393
Normal Sequence
394
Temperature Control by Mode
396
Detecting Errors
399
Disassembly and Assembly
401
Fixing Assembly
402
Removing the Fixing/Feeding Unit
402
Removing the Fixing Assembly
403
Fixing Roller Cleaning Assembly
405
Removing the Fixing Web
405
Mounting the Fixing Web
406
Adjusting the Fixing Web Solenoid (SL9)
407
Fixing Heater and the Control Parts
408
Removing the Main/Sub Heater
408
Mounting the Main/Sub Heater
409
Removing the Thermal Switch
409
Removing the Main Thermistor
410
Removing the Sub Thermistor
412
Fixing Roller Assembly
413
Removing the Fixing Upper Roller
413
Mounting the Fixing Upper Roller
414
Removing the Fixing Lower Roller
414
Adjusting the Nip
415
Fixing Separation Assembly
416
Removing the Lower Separation Claw
416
Removing the Upper Separation Claw
416
Delivery Assembly
417
Removing the External Delivery Roller
417
Removing the Internal Delivery Roller
418
Adjusting the Position of the Delivery Flapper Solenoid (SL5)
419
Paper Sensor
420
Removing the Claw Jam Sensor
420
Removing the Delivery Jam Sensor
421
Chapter 7 Externals and Controls
424
Control Panel
426
Outline
426
Fans
427
Arrangement, Functions, and
427
Controlling the Speed
429
Operation
429
Sequence of Operations
429
Power Supply
430
Outline
430
Distribution of Power Among Switches
431
Output of Power Supplies
433
Rated Outputs of the DC Power Supply
434
Protection Mechanism
435
Others
437
Silent Mode
437
Disassembly and Assembly
438
External Covers
439
Removing the
440
Arrangement of Electrical Parts (Rear of the Machine)
441
Removing the Control Panel
443
Removing the Touch
445
DC Controller PCB
446
Power Supply PCB
448
High-Voltage Power Supply PCB
449
AC Driver PCB
450
Accessories Power Supply PCB
450
Anti-Rush Current PCB
451
Motor Driver PCB
451
Serial Number PCB
452
Fans
453
Exhaust Fan
453
Feeding Fan
453
DC Power Supply Fan
454
HDD Fan
454
Drive System
455
Left Deck Drive Assembly
455
Vertical Path Duplex/Right Deck Drive Assembly
455
Main Motor Drive Assembly
456
Manual Feed Pickup Drive Assembly
456
Drum Drive Assembly
457
Left Deck Pull-Out Roller Drive Assembly
457
Waste Toner Drive Assembly
457
Drive Assembly, and
458
Waste Toner Bottle
458
Left Deck Lifter Drive Assembly
460
Main Motor (M2)
461
Motor
461
Vertical Path Lower Motor (M27)
461
Pickup Motor (M12)
462
Vertical Path Duplex Motor
462
Chapter 8 Paper Deck
474
Pickup
479
Pickup Operation
479
Detecting Paper in the Deck
482
Detecting the Presence/Absence of Power
482
Switching the Deck Paper Size
482
Detecting the Level of Paper in the Deck
483
Removing the Rear Cover
498
Removing the Right Cover
498
Removing the Upper Cover
499
General Descriptions
500
Maintenance and Inspection
528
Troubleshooting
534
Table of Contents
536
Chapter 1 Maintenance and Inspection
542
Periodically Replaced Parts
544
Guide to Timing of Replacement
544
Reader Unit
544
Printer Unit
545
Consumables and Durables
546
Guide to Timing of Replacement
546
Reader Unit
546
Printer Unit
547
Points to Note for Periodical Servicing
555
Cleaning the Photosensitive Drum
556
Making Pre-Checks
560
Making Checks on the Printer Unit (1/2)
561
Making Checks on the Reader Unit
563
Chapter 3 Standards and Adjustments
564
Image Adjustments
566
Standards of Image Position
566
Checking the Image Position
567
Adjusting the Left/Right Image Margin
567
Duplex Feeding Unit
567
Manual Feed Tray
567
Side Paper Deck
567
Adjusting the Image Leading Edge Margin
570
Adjusting the Left/Right Non-Image Width
570
Scanning System
572
Mounting the Drum Cleaning Blade
573
Mounting the Developing Blade
573
Replacing the Potential Sensor/Potential Control PCB
573
Pickup/Feeding System
574
Orientation of the Deck/Cassette Pickup Roller
574
Orientation of the Deck/Cassette Separation Roller
575
Orientation of the Feeding Roller of the Deck/Cassette Pickup Assembly
575
Orientation of the Pickup Roller of the Side Paper Deck
576
Orientation of the Feeding Roller of the Side Paper Deck
577
Adjusting the Pressure of the Separation Roller of the Deck/Cassette
578
Adjusting the Pressure of the Separation Roller of the Manual Feed Tray
579
Adjusting the Fixing Inlet Guide Solenoid (SL1)
580
Adjusting the Position of the Pickup Solenoid (SL3, SL4) of the Cassette 3/4
581
Adjusting the Position of the Delivery Flapper Solenoid (SL5)
582
Adjusting the Position of the Right Deck Pickup Solenoid (SL6)
582
Adjusting the Position of the Left Deck Pickup Solenoid (SL7)
583
Adjusting the Position of the Reversing Flapper Solenoid (SL8)
583
Adjusting the Position of the Fixing Web Solenoid (SL9)
584
Existing Fixing Web
584
New Fixing Web
584
Position of the Side Paper Deck Pickup Roller Releasing Solenoid
585
Attaching the Timing Belt of the Manual Feed Tray Assembly
585
Attaching the Drive Belt
586
Fixing System
587
Points to Note When Mounting the Fixing Heater
587
Position of the Fixing Inlet Guide
587
Adjusting the Lower Roller Pressure (Nip)
588
Making Adjustments
588
Standards
588
Taking Measurements
588
Laser Exposure System
589
When Replacing the Scanner Unit
589
Electrical Parts
590
When Replacing the CCD Unit
590
When Replacing the Reader Controller PCB
590
When Replacing the Main Controller PCB
591
When Replacing the HDD Unit
591
When Replacing the DC Controller PCB
592
When Replacing the High-Voltage PCB
593
Checking the Surface Potential Control System
594
Outline
594
Disabling the Auto Control Mechanism
594
Zero Level Check
595
Method 1
595
Method 2
597
Checking the Potential System
600
Conversion Table for the Potential Control System
602
Emergency Measures for a Fault in the Potential Sensor
606
Checking the Environment Sensor
607
Procedure
607
Checking the Photointerrupters
608
Chapter 4 Troubleshooting Image Faults
612
Making Initial Checks in the Event of an Image Fault
614
Site Environment
614
Checking the Originals for Symptoms
614
Copyboard Cover, Copyboard Glass, and Standard White Plate
614
Checking the Charging Assemblies
614
Checking the Developing Assembly
615
Checking the Paper
615
Checking the Periodically Replaced Parts
615
Image Adjustment Basic Procedure
615
Others
615
Samples of Image Faults
617
Troubleshooting Image Faults
618
The Image Is too Light (Halftone)
618
The Print Is too Light (Including Solid Black Area)
619
The Print Is too Light (Overall, Appreciably)
619
The Print Has Uneven Density (Darker at Front)
620
The Print Has Uneven Density (Lighter at Front)
620
The Print Is Foggy (Overall)
621
The Print if Foggy Vertically
622
The Print Has Black Lines (Vertical, Blurred, Thick)
622
The Print Has Black Lines (Vertical, Fine)
623
The Print Has White Spots (Vertical)
624
The Print Has White Lines (Vertical)
624
The Print Has White Spots (Horizontal)
625
The Back of the Print Is Soiled
626
The Print Has Fixing Faults
627
The Print Has a Displaced Leading Edge (Appreciably Large Margin)
628
The Print Has a Displaced Leading Edge (Large Margin)
628
The Print Has a Displaced Leading Edge (no Margin)
628
The Print Has a Blurred Image
629
The Print Is Foggy (Horizontally)
630
The Print Has Poor Sharpness
630
The Print Is Blank
631
The Print Is Solid Black
632
E000
633
Malfunction
633
Troubleshooting Malfunctions
633
E005
634
E010
635
E012
635
E013
636
E014
636
E020
637
E032
637
E061
637
E100
638
E110
638
E121
638
E196
639
E202
639
E204
640
E220
640
E225
640
E240
641
E243
641
E248
641
E302
642
E601
642
E602
643
E607
643
E677
643
E710
644
E711
644
E717
646
E719
646
E732
646
E733
646
E740
647
E741
647
E742
648
E743
648
E804
648
Ac Power Is Absent
651
DC Power Is Absent
651
Turn on
656
Pickup Fails (Paper Deck)
662
The Deck Lifter Fails to Move up (Side Paper Deck)
663
Troubleshooting Feeding Faults
665
Paper Jams
665
Fixing/Delivery Assembly
665
Pickup Assembly
665
Separation/Feeding Assembly
665
Fixing/Delivery Assembly (Face-Down Delivery Assembly)
668
Cleaning Assembly
669
Feeding Assembly
669
Feeding Faults
671
Double Feeding
671
Wrinkles
671
Arrangement and Functions of Electrical Parts
672
Clutches
672
Printer Unit
672
Reader Unit
672
Solenoids and Switches
673
Reader Unit
676
Hvt Pcb
690
Chapter 5 Service Mode
692
Organization of Service Mode
694
Outline
694
Starting Service Mode and Making Selections
695
Ending Service Mode
696
Backing up Service Mode
696
Basic Operations
697
Initial Screen
697
Level 1/Level 2 Screen
697
Mode)
697
Copier
697
Feeder
697
DC Controller PCB
700
Main Controller PCB
700
Pcb
723
Mn-Con
724
Feeder
726
Sorter
729
Finisher Block
729
Saddle Stitcher Unit
734
ADJUST (Adjustment Mode)
737
Copier
737
Feeder
750
Sorter
751
FUNCTION (Operation/Inspection Mode)
752
Copier
752
Feeder
768
OPTION (Settings Mode)
769
Copier
769
Cst
781
Feeder
785
Sorter
785
Chapter 6 Self Diagnosis
796
Error Codes
798
Self Diagnosis of the Finisher
811
Self Diagnosis of the Saddle Stitcher
815
Shift Tray General Circuit Diagram
833
List of Special Tools
834
Appendix
836
List of Solvents/Oils
836
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Canon iR5000 Specifications
General
Brand
Canon
Model
iR5000
Category
All in One Printer
Language
English
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