Page 2
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.
Page 3
• This service handbook 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 handbook. Model Type Multi- Single Zoom Default Cassette Copying Density code feeder feeder...
CONTENTS CHAPTER 1 MAINTENANCE AND INSPECTION A. Periodically Replaced Parts ..1-1 D-2.Storing and Handling the Cartridge B. Durables and Consumables ..1-1 with the Packaging Seal C. Scheduled Servicing ....1-1 Removed ........1-3 D. Storing and Handling E. Image Adjustment Basic the Cratridge ........1-2 Procedure........1-7 D-1.Storing the Cartridge with Points to Note for Servicing ..1-8...
CHAPTER 1 MAINTENANCE AND INSPECTION CHAPTER 1 MAINTENANCE AND INSPECTION Periodically Replaced Parts The machine does not have parts which must be replaced on a periodical basis. Durables and Consumables The machine does not have items designated as durables or consumables. Scheduled Servicing The machine does not have any parts which require scheduled servicing.
CHAPTER 1 MAINTENANCE AND INSPECTION Storing and Handling the Cartridge The cartridge is subject to the effects of the environment whether its packing seal is intact or removed or whether it is inside the machine or otherwise, changing over time regardless of the number of copies made.
Page 9
CHAPTER 1 MAINTENANCE AND INSPECTION D-2. Storing and Handling the Cartridge with the Packaging Seal Removed The photosensitive medium is an organic photoconducting (OPC) material, which would dete- riorate if subjected to storing light. The cartridge also holds toner, requiring the user to exercise care when storing or handling it. (Be sure that the user stores it in an appropriate storage box for storage.) Storage after Removing the Packaging Seal a.
Page 10
CHAPTER 1 MAINTENANCE AND INSPECTION Handling the Cartridge a. Before setting the cartridge in the machine or if copies have white spots as when it starts to run out of toner, hold the cartridge level and shake it about 90° several times as shown in Figure 1- 1 to even out the toner inside.
Page 11
CHAPTER 1 MAINTENANCE AND INSPECTION c. Do not touch the surface of the photosensitive drum as by opening the shutter for the photosen- sitive drum cover found at the bottom of the cartridge. (If you have soiled the surface of the photosensitive drum, wipe it with a flannel cloth coated with toner.
Page 13
Image Adjustment Basic Procedure Making Pre-Checks Adjusting the Optimum Density Clean the parts. Scanning system, Is gray scale No. 9 pickup/feeding system, barely visible? delivery assembly Is the copy density correction switch (SW101) set to the middle index? Can the (Note 1) deviation be corrected using the copy density correction...
Page 14
Points to Note for Servicing Copyboard, Scanner Item Tools/solvent Work/remarks Copyboard cover Alcohol Cleaning. Cartridge Copyboard glass Alcohol Cleaning. Item Tools/solvents Work/remarks Lens Blower brush Cleaning. Drum cover Most cloth Cleaning; be sure to Scanning lamp Lint-free paper Dry wiping. shutter remove all toner to prevent Reflecting plate...
CHAPTER 2 STANDARDS AND ADJUSTMENTS CHAPTER 2 STANDARDS AND ADJUSTMENTS Mechanical Copier Leading Edge Non-Image Width Make adjustments so that the leading edge non-image width is 2.0 ±1.5 mm when the Test Sheet is copied in Direct. Caution: If you have performed this adjustment, be sure to adjust the image leading edge margin. 2.0 ±...
Page 16
CHAPTER 2 STANDARDS AND ADJUSTMENTS Image Leading Edge Margin (registration activation timing) Make adjustments so that the leading edge margin is 2.5 ±1.5 mm when the Test Sheet is copied. Caution: Be sure to check that the leading edge non-image width is as indicated before performing this adjustment.
Page 17
CHAPTER 2 STANDARDS AND ADJUSTMENTS Adjusting the Mirror Position (optical length between No. 1 mirror and No. 2 mirror) If you have replaced the scanner drive cable, you must adjust the mirror position, by changing the position of the cable retainer of the No. 1 mirror mount. Reference: 1.
Page 18
CHAPTER 2 STANDARDS AND ADJUSTMENTS 4) Turn the cable drive pulley [3] so that the three shafts [2] of the mirror positioning tool for the front and the rear may be arranged as shown. Figure 2-7 (rear) Figure 2-8 (front)
Page 19
CHAPTER 2 STANDARDS AND ADJUSTMENTS 5) While keeping the condition of 4), tighten the positioning screw at the rear and the front of the No. 1 mirror mount [1]. Figure 2-9 (rear) Figure 2-10 (front)
Page 20
CHAPTER 2 STANDARDS AND ADJUSTMENTS Checking the Force of the Cassette Spring If the force of the spring used to hold up the holding plate of the cassette is not correct, pickup faults or the like can occur. If a fault is suspected, check the force of the spring using a spring gauge (CK-0054), and replace the spring if it is not as indicated: Standard: 970 ±150 g Making Measurements...
Page 22
CHAPTER 2 STANDARDS AND ADJUSTMENTS e-2. Routing the Scanner Drive Cable 1. Before Starting the Work Prepare the following: • Mirror positioning tool (FY9-3009) • Cable clip (FY9-3017) • Adhesive tape 1) Set the mirror positioning tool as shown. Figure 2-13 2) Prepare about five strips of adhesive tape (each one about 20 ×...
Page 23
CHAPTER 2 STANDARDS AND ADJUSTMENTS 5) If the machine is equipped with an ADF, free the hook [2], and disconnect the two relay connec- tors [3] from the left upper stay [4]. Figure 2-15 6) Remove the three screws [5], and detach the left upper stay [4]. Figure 2-16...
Page 24
CHAPTER 2 STANDARDS AND ADJUSTMENTS 7) Remove the four screws [7], and detach the lens cover [8]. Figure 2-17 2-10...
Page 25
CHAPTER 2 STANDARDS AND ADJUSTMENTS 2. Routing the Reversing Cable 1) Wind the reversing cables (silver-colored) [2] on the cable drive pulley [1] 7.5 times with the longer of the two on top; then, secure it in position with a cable clip [3]. Longer end Shorter end Face with a marking...
Page 26
CHAPTER 2 STANDARDS AND ADJUSTMENTS 2) Put the cable drive pulley [1] into the shaft [4], and secure it in position with an E-ring [5]. When putting the cable drive pulley into the shaft, be sure that the hook is at the front. Hook (front) Figure 2-20...
Page 27
CHAPTER 2 STANDARDS AND ADJUSTMENTS 4) Lead the shorter end [6] under the No. 1 mirror mount [8] and the No. 2/3 mirror mount [9]; then, hook it on the left rear pulley [10] and the pulley [11] of the No. 2/3 mirror mount. [11] [10] Figure 2-22...
Page 28
CHAPTER 2 STANDARDS AND ADJUSTMENTS 6) Lead the longer end [14] along the cable drive pulley [1], and hook it on the pulley [15] on the right front side. [14] [15] Figure 2-24 7) Lead the longer end [14] under the No. 1 mirror mount [8] and the No. 2/3 mirror mount [9]; then, hook it on the pulley [16] on the left front side and the pulley [17] of the No.
Page 29
CHAPTER 2 STANDARDS AND ADJUSTMENTS 8) Hook the longer cable [14] on the cable hook [18]; then, secure its end to the left side with adhesive tape [19]. Be sure that the secured end of the cable is found where the hole in the left side plate and the tip of the cable matches.
Page 30
CHAPTER 2 STANDARDS AND ADJUSTMENTS 3. Routing the Forwarding Cable 1) Fit the longer end forwarding cable (black) [2] on the top hook of the cable drive pulley [1], and wind it 1.5 times. Then, secure the shorter end [3] as shown with adhesive tape [4]. Face without a marking Figure 2-27 2) Lead the longer end [5] along the cable drive pulley [1] as shown, and hook it on the pulley [6]...
Page 31
CHAPTER 2 STANDARDS AND ADJUSTMENTS 3) Lead the longer end [5] under the No. 1 mirror mount [7]; then, hook it on the pulley [8] of the No. 2/3 mirror mount, and lead it between the No. 1 mirror mount [7] and the scanning lamp [9]. Figure 2-29 4) Hook the end of the longer end [5] on the hole [10] on the right side.
Page 32
CHAPTER 2 STANDARDS AND ADJUSTMENTS 5) Free the shorter end [3], and hook it on the pulley [11] on the right rear side. [11] Figure 2-31 6) Lead the shorter end [3] under the No. 1 mirror mount [7], and hook it on the pulley [12] of the No.
Page 33
CHAPTER 2 STANDARDS AND ADJUSTMENTS 7) Hook the end of the shorter end [3] on the hole [13] on the right side. [13] Figure 2-33 8) Free the shorter end [3] and the longer end [5] (reversing cable), and connect both with a spring [14];...
Page 34
CHAPTER 2 STANDARDS AND ADJUSTMENTS 9) Detach the pulley clip [16] from the cable drive pulley [1]. [16] Figure 2-35 2-20...
Page 35
CHAPTER 2 STANDARDS AND ADJUSTMENTS 4. Positioning the No. 1 Mirror Mount 1) Fix the rear and the front of the No. 1 mirror mount [1] temporarily to the metal fixing [2] of the forwarding cable. Figure 2-36 (rear) Figure 2-37 (front) 2-21...
Page 36
CHAPTER 2 STANDARDS AND ADJUSTMENTS 2) Turn the cable drive pulley [4] so that the three shafts [3] of the mirror positioning tool for rear and front is as shown. Figure 2-38 (rear) Figure 2-39 (front) 2-22...
Page 37
CHAPTER 2 STANDARDS AND ADJUSTMENTS 3) While keeping the condition of step 2), tighten the positioning screw on the rear and front of the No. 1 mirror mount [1]. Figure 2-40 (rear) Figure 2-41 (front) 2-23...
Page 38
CHAPTER 2 STANDARDS AND ADJUSTMENTS Point to Note When Mounting the Scanning Lamp When mounting the scanning lamp, be sure that its logo mark (manufacturer’s name) is toward the front. Further, be sure that the protrusion near its middle is as shown. Logo mark (front) Scanning lamp...
Page 39
CHAPTER 2 STANDARDS AND ADJUSTMENTS Points to Note When Mounting the Fuse When mounting the thermal fuse of the No. 1 mirror mount, be sure that the fuse is oriented as shown. Make sure that the fuse is in contact with the reflecting plate. Reflecting plate (front) Thermal fuse...
Page 40
CHAPTER 2 STANDARDS AND ADJUSTMENTS Adjusting the Original Stop Position Adjust the original stop position in the following order: 1. Correcting original skew 2. Adjusting the rear/front original stop position 3. Adjusting the original leading edge stop position Correcting Original Skew 1) Obtain a sheet of A4 or LTR white copy paper, and draw two lines as indicated.
Page 41
CHAPTER 2 STANDARDS AND ADJUSTMENTS 3) Press the Copy Start key to make a copy. 4) Check to make sure that the difference between L1 and L2 on the copy is 1.8 mm (standard) or less. 280mm Copy image L1-L2=0 ± 1.8mm Figure 2-46 5) If the difference is not as specified, turn the adjusting screw found to the side of the left hinge unit to make adjustments.
Page 42
CHAPTER 2 STANDARDS AND ADJUSTMENTS Adjusting the Rear/Front Original Stop Position You must first correct original skew before adjusting the rear/front original stop position. 1) Obtain a sheet of A4 or LTR white copy paper, and draw two lines as indicated. •...
Page 43
CHAPTER 2 STANDARDS AND ADJUSTMENTS 3) Turn on the machine, and place the test sheet prepared in step 1) on the original tray. Figure 2-50 4) Press the Copy Start key to make a copy. 5) Check to make sure that the distance L3 on the copy image indicated is 10 ±2.5 mm (standard) or less.
Page 44
CHAPTER 2 STANDARDS AND ADJUSTMENTS 6) If the distance is not as specified, loosen the pinion gear positioning screw under the original tray, and adjust the position of the pinion gear. Pinion gear Pinion gear positioning screw Figure 2-52 Relationship between Pinion Gear Position and L3 Direction of pinion gear Increases Decreases...
Page 45
CHAPTER 2 STANDARDS AND ADJUSTMENTS Adjusting the Original Leading Edge Stop Position You must first correct original skew and adjust the rear/front original stop position before adjusting the original leading edge stop position. 1) Obtain a sheet of A4 or LTR white copy paper, and draw two lines as indicated. •...
Page 46
CHAPTER 2 STANDARDS AND ADJUSTMENTS 3) Turn on the machine, and place the test sheet prepared in step 1) on the original tray. Figure 2-55 4) Press the Copy Start key to make a copy. 5) Check to make sure that the distance L4 on the copy image indicated is 10 +2.0, -2.5 mm (standard) or less.
Page 47
CHAPTER 2 STANDARDS AND ADJUSTMENTS 6) If the distance is not as specified, shift bit 1 of the DIP switch (SW1) on the ADF controller PCB to ON, and place an A4 or LTR white copy paper on the original tray. Figure 2-57 7) Press the push switch (PSW) on the ADF controller PCB.
Page 48
CHAPTER 2 STANDARDS AND ADJUSTMENTS 8) Use the rotary switch (SW2) on the ADF controller PCB to adjust the original leading edge stop position. Moving the rotary switch by a single notch changes the original stop position by about 0.3 mm. Press the push switch (PSW) after deciding on a position to discharge the copy paper and store the optimum value.
Page 49
CHAPTER 2 STANDARDS AND ADJUSTMENTS Example: If L4 is 13 mm, You must shift the original stop position toward the leading edge by 3 mm. 1) Place a sheet of A4 or LTR white copy paper on the original tray. 2) Shift bit 1 of the DIP switch (SW1) on the ADF controller PCB to ON;...
Page 50
CHAPTER 2 STANDARDS AND ADJUSTMENTS 4) Press the push switch (PSW) on the ADF controller PCB. • The copy paper on the copyboard will be discharged, and the optimum value will be stored. Figure 2-62 2-36...
CHAPTER 2 STANDARDS AND ADJUSTMENTS Electrical After Replacing the Major Parts Parts Adjustment Scanning lamp 1. Intensity of the scanning lamp 2. AE mechanism AE sensor PCB 1. AE mechanism Composite power supply (1. Intensity of the scanning lamp) (2. AE mechanism) DC controller PCB 1.
Page 52
CHAPTER 2 STANDARDS AND ADJUSTMENTS Adjusting the Intensity of the Scanning Lamp Adjust the intensity of the scanning lamp if you have replaced any of the following: • DC controller PCB • Composite power supply PCB (See p.2-37.) • Scanning lamp Caution: If you have performed this adjustment, you must always perform AE adjustment.
Page 53
CHAPTER 2 STANDARDS AND ADJUSTMENTS AE Adjustment Perform this adjustment if you have replaced any of the following: • DC controller PCB • Composite power supply PCB (See p.2-37.) • AE sensor PCB • Scanning lamp Making Adjustments Before Starting the Work •...
Page 54
CHAPTER 2 STANDARDS AND ADJUSTMENTS 4) Turn VR103 on the DC controller PCB fully clockwise. J130 J114 J102 VR104 VR105 VR106 VR107 J106 J107 J103 J104 VR103VR102 J105 J109 VR103 Figure 2-66 5) Place a newspaper on the copyboard, and close the copyboard cover. 6) Turn VR102 so that the display indicates ‘A3’...
Page 55
CHAPTER 2 STANDARDS AND ADJUSTMENTS 9) Repeat steps 5) through 8) so that the values of both VR102 and VR103 are target values. Caution: If you cannot set VR102 and VR103 to the target values at the same time, turn VR103 fully counterclockwise, and go back to step 5) and make adjustments once again.
Page 56
CHAPTER 2 STANDARDS AND ADJUSTMENTS Adjusting the Reproduction Ratio (fine adjustment) Adjust the reproduction ratio if you have replaced the following: • DC controller PCB Making Adjustments Before Starting the Work • Meter 1) Before replacing the DC controller PCB, turn on the power; then, connect the meter probes to CP23 and GND on the DC controller PCB, and measure the voltage.
Page 57
CHAPTER 2 STANDARDS AND ADJUSTMENTS Checking the Photointerrupters 1) Set the meter range to 12 VDC. 2) Connect the - probe to GND (CPGND1) on the DC controller PCB. VR104 VR105 VR106 VR107 Figure 2-71 3) Make checks as instructed. Reference: The photointerrupers other than those shown in Table 2-8 are connected in a matrix, hence the omission from the table.
Page 59
CHAPTER 3 ARRANGEMENT AND FUNCTIONS OF ELECTRICAL PARTS CHAPTER 3 ARRANGEMENT AND FUNCTIONS OF ELECTRICAL PARTS Sensors and Solenoids Q751 Figure 3-1 Symbol Name Notation Description Remarks Photointerrupters Scanner home position detection Lens home position detection Delivery assembly paper detection Vertical path assembly paper detection Single-feeder paper detection...
Page 60
CHAPTER 3 ARRANGEMENT AND FUNCTIONS OF ELECTRICAL PARTS Switches SW309 SW101 Figure 3-2 Symbol Name Notation Description Remarks Switch Door switch SW309 Power switch Switch SW101 Density correction switch...
Page 61
CHAPTER 3 ARRANGEMENT AND FUNCTIONS OF ELECTRICAL PARTS Lamp, Heater, Motor, Etc. Figure 3-3 Symbol Name Notation Description Remarks Lamp Scanning lamp Heater Fixing heater Motor Main motor Scanner/lens drive motor Fan motor Scanner cooling fan Thermistor Fixing heater temperature detection Scanner temperature detection Thermal fuse Lamp overheating detection...
Page 62
CHAPTER 3 ARRANGEMENT AND FUNCTIONS OF ELECTRICAL PARTS PCBs Figure 3-4 Ref. Name Description Noise filter PCB Removes noise from the power supply. DC controller PCB Controls sequence of operations. Composite power supply PCB Supplies DC power, generates high voltage, and controls the scanning lamp.
CHAPTER 3 ARRANGEMENT AND FUNCTIONS OF ELECTRICAL PARTS Figure 3-5 Symbol Name Notation Description Remarks Photointerrupter Delivery paper detection Registration roller paper detection Original placement detection Microswitch ADF open/close switch Motor Belt motor Pickup motor Controls sequence of operations ADF controller...
CHAPTER 3 ARRANGEMENT AND FUNCTIONS OF ELECTRICAL PARTS Variable Resistors (VR) and Check Pins by PCB Of the variable resistors (VR) and check pins, those needed in the field are discussed herein. Those not found in the discussions are for the factory only, requiring special tools and adjustment to an extremely accuracy.
Page 65
CHAPTER 3 ARRANGEMENT AND FUNCTIONS OF ELECTRICAL PARTS ADF Controller PCB FACE Soldered side PSW SW1 Figure 3-8...
Page 67
CHAPTER 4 SELF DIAGNOSIS CHAPTER 4 SELF DIAGNOSIS Self Diagnosis The microprocessor on the machine’s DC controller PCB is equipped with a self diagnostic mechanism that checks the condition of the machine (particularly, sensors) and indicates an error code in the count/ratio indicator on the control panel upon detection of a fault. In the case of ‘E001’, ‘E0’...
Page 68
CHAPTER 4 SELF DIAGNOSIS Code Cause Description • The main motor (M1) is fault. • The rotation of the main motor deviates • The DC controller PCB is faulty. (indicated by MLOCK=0) for 1 sec or more while the main motor drive signal (MMD=1) is being generated.
Page 69
CHAPTER 4 SELF DIAGNOSIS Caution: 1. If the self-diagnosis has turned on, turn off the power switch to reset the machine. In the case of ‘E000’, ‘E001’, ‘E002’, or ‘E003’, however, the machine must be reset as follows: this consideration is to prevent feeding power to the fixing heater otherwise oc- curring if the thermistor has an open circuit: 2.
Page 71
APPENDIX (A4, 2 copies, DIRECT, from cassette) A. General Timing Chart Copyboard Type Power switch Copy Start key Sequence STBY INTR SCFW SCRV SCFW SCRV LSTR STBY Main motor (M1) Scanner / lens drive motor (M2) Scanner home position sensor (PS1) Lens home position sensor (PS2) Lens solenoid (SL3)
Page 72
2. ADF Type Power switch Copy Start key (A4, 2 copies, DIRECT, from cassette) Original set SCFW SCRV LSTR STBY Sequence STBY INTR ORGST SCFW SCRV ORGST Preparing for Pickup motor (M2) pickup Belt motor (M1) Original detection sensor (PI3) Registration paper sensor (PI2) Delivery sensor (PI1)
Page 73
B. Signals and Abbreviations What follows below is a list of signals and abbreviations used in the chapters of the manual and circuit diagrams. The abbreviations within parentheses represent analog signals, which cannot be expressed in terms of ‘1’ or ‘0’. T_FW_ON TRANSFER DC BIAS ON signal Signals...
Page 75
C. General Circuit Diagram Fixing heater Copier MAIN MOTOR DRIVER PCB J901 [220/240V] Scanning lamp Thermal fuse 1 Main motor Line filter J502 J501 J434 Door switch NOISE FILTER PCB BP701 BP705 Thermal fuse 2 3 2 1 [120V] BP703 BP707 J910 J207...
Page 76
Delivery Registration Original placement sensor sensor sensor J201 J202 J203 J105 Pickup motor 1 2 3 5 6 7 8 9 Belt motor ADF CONTROLLER PCB To DC controller Color coding 4 3 2 1 BK BLACK BL BLUE BR BROWN GY GRAY GN GREEN To composite power supply...
APPENDIX D. Special Tools You will need the following special tool(s) in addition to the standard tools set when servicing the machine. Tool Tool No. Shape Rank* Remarks Mirror position- FY9-3009 For adjusting the dis- ing tool (pair for tance between the No.1 front and rear) and No.2 mirrors.
APPENDIX F. Specifications Copier Type Item Descriptions Body Desk top Copyboard Fixed Source of light Halogen lamp (80 V/110 W for 120V-model; 150 V/160 W for 220/240 V-model) Lens Fixed focal point lens Photosensitive medium OPC drum (24-mm dia.) Table A-1 Mechanisms Item Descriptions...
Page 80
APPENDIX Performance Item Descriptions Original type Sheet, book, 3-D object (2kg max.) A4 (297 × 210 mm)/LGL (216 × 356 mm) Maximum original size Reproduction ratio Inch/AB-configuration: 2R2E Inch-configuration: 3R1E Zoom 70% to 141% (in 1% increments Wait time 0 sec (at 20°C room temperature) First copy time 10 sec or less (at 20°C room temperature;...
Page 81
APPENDIX Applies only to models with a zoom function. Applies only to single pickup if the multifeeder is used. Applies only to vertical feeding. Upon delivery, be sure to remove each from the copy tray. Be sure to remove any curling before feeding for a second time. If stopped because paper ran out during copying operation, 1 hr.
Page 82
APPENDIX Others Item Descriptions Operating condition Temperature 7.5°C to 32.5°C/44.5°F to 90.5°F Humidity 5% to 85% RH Atmospheric pressure 607.95 to 1013.25 hPa (0.6 to 1 atm) Power source 120 V 60 Hz 220/240 V 50 Hz, 60 Hz Serial number TVBxxxxx PUDxxxxx PUHxxxxx...
Page 83
APPENDIX Default Ratios Item 2R2E (Inch/AB-configuration) 3R1E (Inch-configuration) Direct 1:1.000 1:1.000 Reduce I 1:0.707 1:0.707 Reduce II 1:0.786 Reduce III 1:0816 Reduce IV 1:0.860 Enlarge I 1:1.154 Enlarge II 1:1.414 1:1.414 Table A-5 A-13...
Page 84
APPENDIX Copying Speed Copying speed Reproduction ratio Copy size Number of copies at Direct ( Multifeeder (Copies / min) Direct LTRR 13 (9) 11 (8) STMTR 13 (9) Reduce I (70.7%) 13 (9) LGL → LTRR Reduce II (78.6%) 13 (9) Reduce IV (86.0%) MARJIN 13 (9)
Page 85
APPENDIX Item Descriptions Original pickup Auto pickup/delivery Original orientation Face-down Original position Center reference Original separation Top separation Original type Single-sided (50 to 128 g/m A5 (STMT) to A4R (LTRR), LGL Length: 139.7 to 355.6 mm (feeding direction) Width: 139.7 to 215.9 mm Stack 30 sheets (80 g/m or less;...