Canon All in One Printer NP7161 User Manual

SERVICE

MANUAL

REVISION 0

FY8-13FB-000

AUG. 1998

1998 CANON INC.

CANON NP7161/NP7160 REV.0 AUG. 1998 PRINTED IN JAPAN (IMPRIME AU JAPON)

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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.

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,

signal name accompanies the symbol

direction of the electric signal.

represents the path of mechanical drive—where a

, the arrow indicates the

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.

1998 CANON INC.

CANON NP7161/NP7160 REV.0 AUG. 1998 PRINTED IN JAPAN (IMPRIME AU JAPON)

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System Configuration

The copier is designed to accommodate the following accessories:

*NP7161 only.

ADF-G1*

Feeds a stack of original

pages to the copyboard

page by page.

Control

Card IV N

Controls volumes

of copying work.

MS-C1*

Stapler Sorter-L1*

Sorts and groups up to In addition to the functions

10 sets of pages

automatically.

of a 10-bin sorter, staples

sorted pages automatically.

Cassette Feeding Module-C1

Provides an additional cassette.

1998 CANON INC.

CANON NP7161/NP7160 REV.0 AUG. 1998 PRINTED IN JAPAN (IMPRIME AU JAPON)

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1998 CANON INC.

CANON NP7161/NP7160 REV.0 AUG. 1998 PRINTED IN JAPAN (IMPRIME AU JAPON)

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CONTENTS

CHAPTER 1 GENERAL DESCRIPTION

I. FEATURES .............................................. 1-1

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

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

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

DC Controller (1/3) ....................... 2-9

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

1. Outline ........................................ 3-10

2. Detection of the Original Size

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

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

Sensor and Signals ............................ 3-7

D. Basic Sequence of Operations

of the Mirror ................................ 3-16

5. Adjusting the Tension

(scanner) ........................................... 3-8

E. Scanner Movement in

Page Separation Mode ...................... 3-9

IV. OTHERS................................................. 3-10

A. Detecting the Original Size .............. 3-10

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

CHAPTER 4 IMAGE FORMATION SYSTEM

I. OUTLINE OF THE PROCESSES............ 4-1

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

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/

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

Transfer Bias ................................ 4-6

E. Controlling the Developing/Separation

Static Eliminator Bias ......................... 4-7

1. Outline .......................................... 4-7

2. Turning On/Off the Developing

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/

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

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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CANON NP7161/NP7160 REV.0 AUG. 1998 PRINTED IN JAPAN (IMPRIME AU JAPON)

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1. Outline ........................................ 4-32

2. Stringing the Charging Wires..... 4-32

3. Adjusting the Height of the

1. Removing the Drum Unit ........... 4-28

2. Cleaning the Photosensitive

Drum........................................... 4-29

3. Removing the Cleaner

Charging Wires .......................... 4-36

G. Developing Assembly....................... 4-37

1. Removing the Developing

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

Assembly.................................... 4-37

2. Removing the Developing

Blade .......................................... 4-37

3. Removing the Developing

Cylinder ...................................... 4-38

Charging Assembly .................... 4-31

F. Charging Wire .................................. 4-32

CHAPTER 5 PICK-UP/FEEDING SYSTEM

I. OUTLINE OF OPERATION ..................... 5-1

2. Mounting the Pick-Up Roller ...... 5-16

II. PICK-UP FROM THE CASSETTE .......... 5-2

A. Pick-Up Operation .............................. 5-2

B. Sequence of Operations

3. Removing the Pick-Up Drive

Assembly.................................... 5-17

4. Removing the Pick-Up

(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

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

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

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

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

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

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

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

Assembly.................................... 6-11

CHAPTER 7 EXTERNALS/AUXILIARY MECHANISMS

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/

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

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

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

Right Cover ................................ 7-10

3. Removing the Upper

Left Cover................................... 7-11

4. Removing the Delivery

Lower Cover ............................... 7-11

5. Removing the Delivery

Power Supply PCB .................... 7-20

I. Removing the High-Voltage

Upper Cover ............................... 7-11

6. Removing the Lower

Power Supply PCB........................... 7-20

1. Removing the High-Voltage

Inside Cover ............................... 7-12

B. Control Panel.................................... 7-13

1. Removing the Control Panel ...... 7-13

C. Copyboard Glass ............................. 7-14

Power Supply PCB .................... 7-20

J. Lamp Regulator PCB ....................... 7-21

1. Removing the Lamp

Regulator PCB ........................... 7-21

viii

1998 CANON INC.

CANON NP7161/NP7160 REV.0 AUG. 1998 PRINTED IN JAPAN (IMPRIME AU JAPON)

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CHAPTER 8 INSTALLATION

I. SELECTING THE SITE............................ 8-1

IV. INSTALLING THE CONTROL

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

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

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

III. SCHEDULED SERVICING CHART ........ 9-3

IV. SCHEDULED SERVICING TABLE ......... 9-5

A. Copier ................................................. 9-5

CHAPTER 10 TROUBLESHOOTING

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

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

Width (blank exposure lamp

off timing).................................... 10-5

2. Image Leading Edge Margin

(registration on timing) ............... 10-5

3. Left/Right Registration

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

(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

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

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

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B. Image Fault Samples ..................... 10-28

C. Troubleshooting Image Faults ....... 10-29

1. The copy is too light.

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

(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

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,

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

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

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1. DC Controller PCB ................... 10-77

2. Power Supply PCB .................. 10-80

3. Lamp Regulator PCB ............... 10-80

4. High-Voltage Power Supply

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

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

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

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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

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

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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.

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CHAPTER 1 GENERAL DESCRIPTION

II. SPECIFICATIONS

A. Copier

1. Type

Body

Desktop

Copyboard

Light source

Lens

Fixed

Halogen lamp (120V:200W/230V:220W)

Lens array

Photosensitive material

OPC (30 dia.)

2. Mechanisms

Copying

Charging

Exposure

Indirect electrostatic

Corona

Slit (moving light source)

Copy density adjustment Auto or manual

Development Dry (toner projection)

Auto

Front cassette (1 pc.)

Pick-up

Manual

Multifeeder (5 mm deep approx.; about 50 sheets of 80 g/m²paper)

Transfer

Corona

Separation

Cleaning

Fixing

Curvature + static eliminator

Blade

Heat roller (1000 W for 120V model; 1050 W for 230V model)

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CHAPTER 1 GENERAL DESCRIPTION

3. Performance

Original type

Maximum original size

Direct

Sheet, book, 3-D object (2 kg max.)

A3/279 × 432 mm (11"×17")

1:1.000

1:0.5000

1:0.707

Reduce I

Reduce II

Reduce III 1:0.0816

Reproduction Reduce IV 1:0.0865

ratio

Enlarge I

1:1.154

Enlarge II 1:1.224

Enlarge III 1:1.414

Enlarge IV 1:2.000

Zoom

1:0.500 to 2.000 (in 1% increments)

Wait time

First copy

30 sec or less (at 20°C room temperature)

5.8 sec or less (A4, Direct, non-AE, cassette)

999 sheets max.

Continuous copying

Copy size

A3/279×432 mm (11"×17") max. B5R/STMTR min.

Cassette

• Plain paper (64 to 80 g/m²)

A3, B4, A4R, A4, B5R,B5, 279 × 432 mm (11"×17"), LTRR, LTR, LGL

• Colored paper (recommended by Canon)

B4, A4

• Plain paper (64 to 80 g/m²)

A3, B4, A4R, A4, B5R, B5, A5, 279X432 mm (11"×17"), LTRR,

LTR, LGL, STMTR

Copy paper

type

Multifeeder

• 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

• Heavy paper (up to 128 g/m²)

*May be used, but may not feed properly.

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CHAPTER 1 GENERAL DESCRIPTION

Claws

Frame

Used

Cassette

55 mm deep (500 sheets of 80 g/m²paper; 250 sheets if B5)

100 sheets approx. (plain paper ; 64 to 80 g/m²)

Copy tray

Leading edge Direct 2.0 ±1.0 mm

Trailing edge Direct 2.5 ±1.5 mm

Non-image

width

Left/right

Direct 2.5 ±2.0 mm

Auto clear

Provided (2 min standard; may be changed between 1 and 9 min

in 1-min increments)

Auto power-off

Auto pre-heat

Accessories

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*

• Cassette Feeding Module-C1

• Stapler Sorter-L1*

• Control Card IV N

• Remote Diagnostic Device II

*Applies to the NP7161 only.

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CHAPTER 1 GENERAL DESCRIPTION

4. Others

Temperature

Humidity

7.5° to 32.5°C/45.5° to 90.5°F

Operating

conditions

5% to 80% RH

Atmospheric

pressure

810.6 to 1013.3 hPa (0.8 to 1.0 atm)

NP7160

NLB xxxxx

----

NP7161

----

120V

Power

source

120V (UL)

127V

NLD xxxxx

----

NLC xxxxx

230V

PHQ xxxxx

PHS xxxxx

1.5 kW or less

Maximum

Standby

Continuous

Copying

Standby

Power

consumption

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)

0.05 ppm or less

Noise

Ozone (8-hr average)

Width

566 mm/22.3 in

541 mm/21.3 in

Dimensions Depth

Height

389 mm/15.3 in

NP7160

NP7161

42 kg/92.6 lb (approx.)

Weight

42 kg/92.6 lb (approx.)

Keep wrapped, and avoid humidity.

Copy paper

Consumables

Avoid direct sunlight, and store at 40°C, 85% or less.

Toner

Specifications subject to change without notice.

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CHAPTER 1 GENERAL DESCRIPTION

Reproduction mode

Size

Copy paper

Copies/min

A3 (297 × 420mm)

A4 (210 × 297mm)

B4 (257 × 364mm)

B5 (182 × 257mm)

A4R (297 × 210mm)

B5R (257 × 182mm)

A3 → A4R

Direct

(100%)

A4R

B5R

A4R

B5R

A4R

(70.7%)

B4 → B5R

B4 → A4R

Reduce

(81.6%)

A3 → B4

A4 → B5

A5R → A3

III

(86.5%)

(200%)

A4R → A3

B5R → B4

A4R → B4

(141.4%)

Enlarge

III

(122.4%)

(115.4%)

B4 → A3

B5 → A4

Specifications subject to change without notice.

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CHAPTER 1 GENERAL DESCRIPTION

Reproduction mode

Size

Copy paper

11" × 17"

LTR

Copies/min

11" × 17" (279 × 432mm)

LTR (297 × 216mm)

LGL (216 × 356mm)

LTRR (216 × 297mm)

11" × 17" → LTRR

Direct

(100%)

LGL

LTRR

(64.7%)

11" × 17" → LGL

LGL → LTRR

LGL

Reduce

(73.3%)

III

LTRR

(78.6%)

STMTR → 11" × 17"

LTRR → 11" × 17"

LGL → 11" × 17"

11" × 17"

(200%)

Enlarge

(129.4%)

III

(121.4%)

Specifications subject to change without notice.

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CANON NP7160/NP7161 REV.0 AUG. 1998 PRINTED IN JAPAN (IMPRIME AU JAPON)

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CHAPTER 1 GENERAL DESCRIPTION

III. NAMES OF PARTS

A. External View_[1]

[2]

[3] [4]

[5] [7]

[6]

[11]

[12]

[10]

[9]

[8]

[9] Right door

[10] Right cover

[11] Front door

[12] Cassette

[5] Upper right cover

[6] Upper rear cover

[7] Multifeeder

[1] Control panel

[2] Copyboard glass

[3] Copyboard cover

[4] Power switch

[8] Waste toner box

Figure 1-301

[1] [2]

[3]

[4] [5]

[6]

[7]

[8]

[9]

[7] Open/close lever

[4] Lower delivery cover

[5] Front fixing cover

[6] Inside cover

[1] Copy tray

[8] Lower inside cover

[9] Static eliminator

[2] Upper left cover

[3] Upper delivery cover

Figure 1-302

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CHAPTER 1 GENERAL DESCRIPTION

B. Cross Section

1. Copier

[1]

[2]

[3] [4]

[5]

[6] [7] [8] [9] [10] [11] [12] [13] [14] [15]

[26]

[25]

[24]

[23] [22] [21] [20]

[19] [18] [17] [16]

[1] No. 3 mirror

[2] No. 2 mirror

[3] Scanning lamp

[4] No. 1 mirror

[5] Copyboard glass

[6] Lens

[11] Dust-proofing glass

[12] Developing cylinder

[13] No. 4 mirror

[21] Transfer charging assembly

[22] Separation static eliminator

[23] Heat discharging roller

[24] Lower fixing roller

[14] No. 5 mirror

[15] Multifeeder pick-up roller

[16] Feed roller

[25] Upper fixing roller

[26] Delivery roller

[7] Pre-exposure lamp

[17] Separation roller

[18] Vertical path roller

[19] Pick-up roller

[8] Primary charging assembly

[9] Blank exposure lamp

[10] No. 6 mirror

[20] Registration roller

Figure 1-303

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CHAPTER 1 GENERAL DESCRIPTION

IV. OPERATING THE MACHINE

A. Control Panel

[1]

[5] [6]

[8] [9][10] [11]

[12][13] [14]

[16][17]

[18]

1[9]

[2] [3]

[4]

[7]

[15]

[20]

[21]

Energy Saver

Max. 200%

A4/LTR A3 B5 B4

A4/LTR B4

B4 A3 B5 A4/LTR

1 : 1

A3 B4 A4/LTR B5

B4 A4/LTR

Reset

Image Combination

Fit Image

Photo

Stop

Sort

Auto Paper

A3/1117

A4/LTR

Two-page Separation

ON/OFF

Staple-

Sort

Start

Auto Zoom

Additional

Functions

A4/LTR

B4/LGL

Group

A3 A4/LTR B4 B5

Min. 50%

Zoom

Interrupt

Reduce

1 : 1

Enlarge

Paper Select

Clear

[23]

[24][25] [26][27] [28]

[22]

Figure 1-401

Ref.

[1]

Name

Sorter key*

Description

Remarks

*Requires a sorter or

stapler sorter.

Press it to select or deselect Sort, Staple Sort, or

Group Sort mode.

Sorter indicator*

Indicates the selected delivery mode. It remains

off in non-sort mode.

[2]

[3]

*Requires an ADF.

2-on-1*/Page

Separate key

Press it to select or deselect 2-on-1 or Page

Separate mode.

Fit Page key

Press to select or deselect Fit Page mode. Use

the mode to make a copy covering all image area

of the original.

[4]

[5]

[6]

Photo key

Press it to select or deselect Photo mode.

Reduce/Direct/

Enlarge key

Press it to select Reduce/Enlarge (default ratio) or

reset any ratio to Direct.

Default Ratio indicator Indicates the selected default reproduction ratio.

Control Card indicator Flashes when the control card is not set properly.

[7]

Requires a Control

Card Unit.

Jam indicator

Flashes when a jam occurs.

[8]

Toner indicator

Flashes when toner is running out. It stops

flashing and remains on when toner runs out

completely.

Paper indicator

Flashes if paper runs out in the selected cassette

or the manual feed tray (or, when the cassette is

not set properly).

Paper Source/Jam

Indicates the selected cassette or the manual tray;

flashes the location of a jam, if any. (It also

[9]

flashes when a jam occurs in the ADF or when the

sorter or the right door needs to be checked.)

* Applies to the NP7161 only

Table 1-401

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CHAPTER 1 GENERAL DESCRIPTION

Ref.

[10]

Name

Description

Remarks

Location indicator

Flashes when the waste toner box needs to be

replaced. When the case becomes full, it stops

flashing and remains on.

Paper Size indicator

Paper Select key

Indicates the size of the paper in the cassette

selected by the Paper Select key.

[11]

[12]

[13]

*Requires an ADF.

Press it to select Auto Paper Select*, Cassette, or

Manual Feed Tray mode.

Copy Count/Ratio

indicator

Indicates the copy count/ratio and the selected

user mode.

Auto Ratio key*

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.

[14]

[15]

[16]

[17]

% key

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.

Reset key

Keypad

[18] Start key

[19]

Stop key

Press it to stop continuous copying.

[20] Power Save key

[21] Power switch

Press it to select or deselect power save mode.

Press it to turn on or off the power.

Copy Density

[22]

Slide it to adjust the copy density manually.

lever

AE key

[23]

Press it to select or deselect AE (auto density

adjustment) mode.

Zoom key

[24]

Press it to select a reproduction ratio (50% to

200%) in 1% increments. Hold it down to

increase/decrease the ratio continuously.

[25] User Mode key

Press it to set or change user mode settings.

Interrupt key

[26]

Press it to stop an ongoing copying run to make a

copy of a different original.

ID key

[27]

Press it after entering an appropriate ID number.

Press it also after entering a number for ID

registration.

Clear key

[28]

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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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.

Factory settings

(default)

Notation

Item

Description

Resetting

user mode

Use it to reset new settings made in user

mode to default settings.

–

U00

Changing auto

clear time

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.

2 min

U01

Changing auto

Use it to select an appropriate auto power-

power-save time save time length: 10, 15, 20, 30, 40, 50, 60,

or 90 min (8 lengths).

15 min

30 min

±0.0%

U02

U03

Changing auto

power-off time

Use it to select an appropriate auto power-

off time length: 10, 15, 20, 30, 40, 50, 60, 90

(8 lengths).

Fine-adjusting

Zoom

Use it to adjust vertical and horizontal

reproduction ratios over ±5 grades in 0.2%

increments.

U04

U05

Rang: -1.0% to +1.0% in units of 0.2%

Turning on/off

auto cassette

change

Use it to turn on/off the auto cassette change ON

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.

Turning on/off

auto sort

Use it to turn on/off the auto sort function, in ON

which sorting takes place when making

multiple copies of multiple originals using

an ADF.

U06

O N : Enable auto sort.

OFF : Disable auto sort.

Turning on/off

ADF jam

recovery

Use it to turn on/off auto counting of

originals in ADF jam recovery.

O N : Enable auto count.

OFF

–

U07

U08

OFF : Disable auto count.

Cleaning feeder

Use it to clean the feeder (after placing

paper in the ADF and pressing the Start

key).

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CHAPTER 1 GENERAL DESCRIPTION

Factory settings

Notation

Item

Description

(default)

Changing Page

Fit mode (ratio)

Use it to change the reproduction ratio used 93%

in Page Fit mode between 90% and 99% in

1% increments.

U09

Changing Page

Fit mode

(centering)

Use it to turn on/off the centering function in ON

Fit Page mode.

O N : Enable centering.

U10

U11

OFF : Disable centering.

Changing Page

Fit mode

(non-image width)

Use it to turn on/off the non-image width

function in Page Fit mode.

OFF

O N : Enable (create non-image width).

OFF : Disable (do not create non-image

width).

Correcting

density

Use it to select an appropriate standard value 0

(F5) for manual density adjustment between

-17 and +6 (24 grades).

U12

U13

Setting special

paper mode

Use it to select an appropriate fixing

temperature control mode for special paper

when pick-up is from the multifeeder.

0: Standard

1: Rough surface paper (against poor fixing)

2: Tracing paper (against high-temperature

offset)

Drum cleaning

mode

Use it to turn ON/OFF the drum cleaning

function.

OFF

To remove dirt from the surface of the

photosensitive drum, toner is deposited on

the surface after copying operation and the

cleaning blade is used to collect the toner

together with the dirt. (In addition, LSTR is

extended by 6.5 sec)

U14*

O N : Enable drum cleaning.

OFF : Disable drum cleaning.

* If the drum cleaning settings in service mode No. 519 is turned ON.

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CHAPTER 1 GENERAL DESCRIPTION

V. ROUTINE MAINTENANCE (BY THE USER)

Instruct the user to clean the following parts at least once a week.

1. Copyboard Glass

Wipe with a moist cloth (moistened with water or mild detergent solution); then, dry wipe.

2. Copyboard Cover

Wipe it with a moist cloth (moistened with water or mild detergent solution); then, dry wipe.

3. Primary Charging Assembly

Pull out and then push in the wire cleaner several times to clean the charging wire.

4. Transfer Charging Assembly

Pull out and then push in the wire cleaner several times to clean the charging wire.

5. Static Eliminator

If separation jams occur frequently, clean the static eliminator using the special brush.

(Cleaning need not be as often as every week.)

6. Waste Toner Box

If the Waste Toner Box indicator on the control panel flashes or turns on, replace the waste

toner box.

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CHAPTER 1 GENERAL DESCRIPTION

VI. POINTS TO NOTE (BY THE USER)

• Toner Cartridge

Instruct the user to dispose of any used (empty) toner cartridge according to governmental

guidelines.

• Waste Toner Box

Instruct the user to keep any waste toner box for collection during a servicing visit.

Caution:

Do not dispose of the toner cartridge or the waste toner box into fire. Toner can catch

fire, causing implosion or explosion.

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CHAPTER 1 GENERAL DESCRIPTION

VII.IMAGE FORMATION

A. Outline

The copier is constructed as shown in Figure 1-701.

Copyboard glass

Scanning

lamp

Lens

Developing

assembly

Blanking exposure

lamp

Primary charging

assembly

Pre-exposure

Fixing

assembly

lamp

Pick-up

(multifeeder)

Pick-up

(cassette)

Static

eliminator

Transfer charging

assembly

Figure 1-701

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CHAPTER 1 GENERAL DESCRIPTION

The copier's image formation processes consist of the following eight steps:

Step 1 Pre-exposure

Step 2 Primary charging (negative DC)

Step 3 Image exposure

Step 4 Development (AC + negative DC)

Step 5 Transfer (negative DC)

Step 6 Separation (curvature + static eliminator)

Step 7 Fixing

Step 8 Drum cleaning

Static latent image formation block

2. Primary charging

1. Pre-exposure

3. Image exposure

4. Development

5. Transfer

Flow of copy paper

Rotation of drum

8. Drum cleaning

Multifeeder

Registration

7. Fixing

6. Separation

Delivery

Cassette

Figure 1-702

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CHAPTER 2

BASIC OPERATION

This chapter provides outlines of the copier’s various mechanical workings.

Process speed

105 mm/s

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

D. Main Motor (M1) Control Circuitry...... 2-8

E. Inputs to the DC Controller ................ 2-9

F. Outputs from the DC Controller ....... 2-12

G. Inputs to and Outputs from

Accessories (1/1) ............................. 2-16

1998 CANON INC.

CANON NP7161/NP7160 REV.0 AUG. 1998 PRINTED IN JAPAN (IMPRIME AU JAPON)

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CHAPTER 2 BASIC OPERATION

I. BASIC MECHANISMS

A. Functional Construction

The copier can broadly be divided into the following four functional blocks: pick-up,

feeding, exposure, image formation, and control.

Control system

Exposure system

Copyboard

Control panel

Scanning

assembly

Optical

Control circuitry

assembly

Image formation system

Primary

charging

Waste

toner

container

Drum

cleaning

assembly

Developing

assembly

Photosensitive

drum

Multifeeder

Fixing

assembly

Separation

Transfer

Pick-up

control

Copy

tray

assembly

Cassette 1

Pick-up feeding assembly

Cassette 2

Cassette feeding module

(*accessory)

Figure 2-101

1998 CANON INC.

CANON NP7161/NP7160 REV.0 AUG. 1998 PRINTED IN JAPAN (IMPRIME AU JAPON)

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CHAPTER 2 BASIC OPERATION

B. Outline of the Electrical Circuitry

The copier's major electrical mechanisms are controlled by the microprocessor on the DC

controller PCB. The ICs on the DC controller PCB are shown below.

IC121 (ROM)

• Controls copying sequence.

JC113 (gate array)

• Controls scanning lamp (LA1) error detection.

• Controls thermistor (TH1, TH2) error detection.

• Controls triac short circuit error detection.

• Controls power at time of error.

• Turns on/off the scanning lamp (LA3).

• Controls the I/O port.

IC114 (IPC; NP7161 only)

• Controls communication with the ADF and the sorter.

JC116 (RAM)

• Records settings data (service mode, etc.).

IC117 (RESET IC)

• Resets at power-on.

Figure 2-102 is a block diagram showing the relationship between the copier's major circuits.

Reference:

The NP7161 possesses a communications IC (IPC) on its DC controller PCB. The copier

communicates with the ADF and the sorter using the communications IC on each controller

PCB (IPC communication) and the communications PCB on the DC controller PCB (IPC

communication 2).

2–2

1998 CANON INC.

CANON NP7161/NP7160 REV.0 AUG. 1998 PRINTED IN JAPAN (IMPRIME AU JAPON)

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CHAPTER 2 BASIC OPERATION

<Loads>

Motors

DC controller PCB

Sensors

Switches

IC119

(CPU)

Toner

sensor

Fans

Clutches

Solenoids

Counter

LEDs

sensor

IC121

(ROM)

Thermistors

IC116

(RAM)

IC117

(RESET)

Control

panel

IC113

(GA)

Charging

assembly

HVT

IC114

(IPC)

Developing

cylinder

Lamp

Scanning

regulator

PCB

lamp

Power

supply

PCB

Heaters

Sensors

Switches

Cassette relay

Cassette feeding

module

PCB

ADF controller PCB

Sensors

Switches

Micro-

ADF

IPC

processor

Sorter controller PCB

Sensors

Switches

Stapler sorter

or Sorter

Micro-

IPC

processor

Figure 2-102

1998 CANON INC.

CANON NP7161/NP7160 REV.0 AUG. 1998 PRINTED IN JAPAN (IMPRIME AU JAPON)

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CHAPTER 2 BASIC OPERATION

C. Basic Sequence of Operations

1. Basic Sequence of Operations at Power-On

Power switch

120°C

160°C

Sequence

WMUP

WMUPR

Green

STBY

(flashing)

Wait indicator

Fixing heater (H1)

Main motor (M1)

Primary charging assembly

Transfer charging assembly

Static eliminator

Developing AC bias

Developing DC bias

Pre-exposure lamp (LA2)

Blank exposure lamp (LA3)

Scanning lamp (LA1)

Scanner motor (M2)

Scanner home position

sensor (PS1)

Lens motor (M3)

Lens home position

sensor (PS2)

Mirror motor (M4)

Mirror home position

sensor (PS3)

Figure 2-103

2–4

1998 CANON INC.

CANON NP7161/NP7160 REV.0 AUG. 1998 PRINTED IN JAPAN (IMPRIME AU JAPON)

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CHAPTER 2 BASIC OPERATION

Period

Description

Remarks

WMUP

(warm-up)

From when the power

switch is turned on until

the surface temperature

of the upper fixing roller

reaches 120˚C.

Waits until the upper fixing Moves the lens, mirror,

roller warms up.

and scanner to home

position.

WMUPR

From when WMUP ends

• Evens out the surface

temperature of the upper

fixing roller.

• Stirs the toner inside the

developing assembly.

• Discharges copy paper,

if any, inside the copier.

Starts copying operation

when the surface

temperature of the upper

fixing roller reaches 140˚C

if Auto Start has been

selected.

(warm-up rotation) until the surface temper-

ature of the upper fixing

roller reaches 160˚C.

STBY

(standby)

From when WMUPR ends Waits for a press on an

until the Copy Start key is operation key

Turns on Auto Clear

if no operation key is

pressed (i.e., resets to

standard mode after a

specific period of time).

pressed. Or, from when

LSTR ends until the power

switch is turned off.

(Start key, etc.).

Table 2-101

1998 CANON INC.

CANON NP7161/NP7160 REV.0 AUG. 1998 PRINTED IN JAPAN (IMPRIME AU JAPON)

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CHAPTER 2 BASIC OPERATION

2. Basic Sequence of Operations at Copy Start

Start key

Sequence

STBY

INTR

AER

SCFW SCRV SCFW SCRV LSTR STBY

Orange

Green

Wait indicator

Target temperature control

Fixing heater (H1)

Main motor (M1)

Primary charging assembly

Transfer charging assembly

Static eliminator

Developing AC bias

Developing DC bias

Pre-exposure lamp (LA2)

Blank exposure lamp (LA3)

Scanning lamp (LA1)

Scanner motor (M2)

Voltage control

Partial activation

Scanner home position

sensor (PS1)

Lens motor (M3)

Lens home position

sensor (PS2)

Mirror motor (M4)

Mirror home position

sensor (PS3)

Figure 2-104

2–6

1998 CANON INC.

CANON NP7161/NP7160 REV.0 AUG. 1998 PRINTED IN JAPAN (IMPRIME AU JAPON)

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CHAPTER 2 BASIC OPERATION

Period

Description

Remarks

INTR

(initial rotation)

From when the Start key

is pressed until the

scanner starts to move

forward.

Stabilizes the drum

sensitivity in preparation

for copying operation.

AER

(AE rotation)

From when the Start key

is pressed until the

scanner finishes

Measures the density of

the original while the

scanner is moving forward.

Used only in AE mode.

measuring densuty.

SCFW

While the scanner is

Uses the scanning lamp to Generates the registration

shine the original, and signal, and moves the

(scanner forward) moving forward.

directs the reflected optical copy paper to the transfer

image to the photosensitive assembly.

drum by way of mirrors

and lenses.

SCRV

While the scanner is

Returns the scanner to

home position in

(scanner reverse) moving in reverse.

preparation for the next

copying operation.

LSTR

From when SCRV ends

Rids the surface of the

Discharges the last copy.

(last rotation)

until the main motor stops. photosensitive drum of

charges (surface potential)

as post-copying operation.

Table 2-102

1998 CANON INC.

CANON NP7161/NP7160 REV.0 AUG. 1998 PRINTED IN JAPAN (IMPRIME AU JAPON)

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CHAPTER 2 BASIC OPERATION

D. Main Motor (M1) Control Circuitry

1. Outline

Figure 2-105 shows the circuit used to control the main motor (M1), and the circuit has the

following functions:

• Turning on and off the main motor.

• Controlling the rotation of the main motor.

DC controller

PCB

Power supply

PCB

Main motor

Clock pulse

generator

J209 J601

+24V

-4

-2

-1

-3

Phase

control

drive

Drive

current

J106

-17

J212

-8

MM DR

–

-2

-1

-3

circuit

-16

MM LKDT* -9

–

Hall IC output

Clock pulse

Reference signal

Figure 2-105

2. Operation

The main motor is a DC motor equipped with a built-in clock pulse generator, which

generates clock pulses according to the rotation of the motor while the motor rotates. The phase

control drive circuit matches the phases of the clock pulses and the reference signals to control

the rotation of the main motor.

When the main motor drive signal (MM_DR) from the DC controller PCB goes '1', the phase

control drive circuit turns on, thereby rotating the main motor at a specific speed.

3. Detecting an Error

The phase control drive circuit sends the main motor lock detection signal (MM_LKDT*)=0

to the DC controller PCB as long as the main motor is rotating at a constant speed. If the rotation

of the main motor becomes irregular for some reason, MM_LKDT* goes '1'.

If MM_LKDT*=1 continues for 1 sec or more when MM_DR is '1', the DC controller PCB

will identify the condition as a main motor error, and will immediately stop the main motor and

indicate "E010" on the control panel.

2–8

1998 CANON INC.

CANON NP7161/NP7160 REV.0 AUG. 1998 PRINTED IN JAPAN (IMPRIME AU JAPON)

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CHAPTER 2 BASIC OPERATION

E. Inputs to the DC Controller

1. Inputs to the DC Controller (1/3)

DC controller PCB

J12

-1

J103

-B3

-B2

-B1

+5V

Scanner home

position sensor

When the scanner is at home position, '1'.

(When the light-blocking plate is at PS1.)

-2

SCHP

PS1

-3

J10

-1

+5V

-B6

-B5

-B4

Lens home

position sensor

When the lens is at home position, '1'.

(When the light-blocking plate is at PS2.)

-2

LNSHP

PS2

PS3

PS4

PS5

PS6

PS7

PS8

PS9

PS10

-3

J11

-1

+5V

-B9

-B8

-B7

Mirror home

position sensor

When the mirror is at home position, '1'.

(When the light-blocking plate is at PS3.)

-2

MRRHP

-3

J19

-3

J40

J107

-B10

-B12

-B11

+5V

-3 -6

-5 -4

-4 -5

Cassette paper

sensor

When PS4 has detected paper, '1'.

(When the light-blocking plate is at PS4.)

-1

CSTPDT

-2

J17

-1

J700

+5V

-3 -1

-2 -2

-1 -3

-A3

-A2

-A1

Registration

paper sensor

When PS5 has detected paper, '1'.

(When the light-blocking plate is at PS5.)

-2

RGPDT

-3

J21

-1

J124

-3

+5V

Delivery paper

sensor

When PS6 has detected paper, '1'.

(When the light-blocking plate is at PS6.)

-2

EXITPD

-3

-1

J18

-3

J796

J107

-A6

-A8

-A7

+5V

-3 -9

-5 -7

-4 -8

Multifeeder

paper sensor

When PS7 has detected paper, '1'.

(When the light-blocking plate is at PS7.)

-1

MLTPD0

-2

HVT

+5V

Power supply

PCB

J34 J302

J301

-3

-1

-2

-1

-3

-2

J210

J212 J106

Waste toner

feeding screw

locked sensor

-2

-9

-15

-10

TRQMLDT

See p. 4-17.

J742

-3

J796

J107

-A9

+5V

-6 -6

-8 -4

-7 -5

Multifeeder

paper widh

sensor 1

-1

-A11

-A10

MLTPD1

-2

See p. 5-9.

J743

-3

+5V

-9 -3

-11 -1

-10 -2

-A12

-A14

-A13

Multifeeder

paper widh

sensor 2

-1

MLTPD2

-2

Figure 2-106

1998 CANON INC.

CANON NP7161/NP7160 REV.0 AUG. 1998 PRINTED IN JAPAN (IMPRIME AU JAPON)

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CHAPTER 2 BASIC OPERATION

2. Inputs to the DC Controller (2/3)

DC controller PCB

J47

J797

J48

-3

J107

-B5

-B7

-B6

+5V

-1 -3

-3 -1

-2 -2

-5 -3

-7 -1

-6 -2

Right door

open sensor

When the right door is closed, '1'.

(When the light-blocking plate is at PS11.)

-1

RDOPDT

PS11

-2

HVT

+5V

Power supply

PCB

J303

-1

J301

J106

-9

J210

J212

Waste toner

sensor

When the waste toner box is identified as

being fullor the waste toner box is absent,'1'.

-3

-1 -10

-16

TNFDT

-2

J15

J721

J720

J102

-B3

-B2

-B1

+5V

-1 -3

-2 -2

-3 -1

-3 -3

-2 -2

-1 -1

-3 -1

-2 -2

-1 -3

When the level of toner drops below a

specific level, '1'.

Toner sensor

TS1

TNEMP

Figure 2-107

2–10

1998 CANON INC.

CANON NP7161/NP7160 REV.0 AUG. 1998 PRINTED IN JAPAN (IMPRIME AU JAPON)

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CHAPTER 2 BASIC OPERATION

3. Inputs to the DC Controller (3/3)

DC controller PCB

J531

-4 -1

-3 -2

J103

-A4

-A3

-A2

-A1

+24V

AE_DATA

AE_REF

AE sensor

See p. 4-21.

-2 -3

-1 -4

J16

-2

J110

-4

CSTS0

CSTS1

CSTS2

CSTS3

SW651

SW652

SW653

SW654

-3

Cassette size

switch PCB

-4

-2

See p. 5-7.

-5

-1

-5

J108

-1

+5V

When the temperature of the fixing roller

increases, the voltage lowers.

(analog signal)

TH1

-2

-3

-4

TH1

Main

thermistor

When the main thermistor is connected to

the DC controller PCB, '1'.

TH1_DT

TH2

J109

-1

TH2

TH3

When the temperature of the fixing roller

increases, the voltage lowers.

(analog signal)

Sub

thermistor

-2

J23

J112

-1

-2 -1

CLTH

When the temperature of the drum cleaner

assembly increases, the voltage lowers.

(analog signal)

Cleaner

thermistor

-1 -2

-2

Figure 2-108

1998 CANON INC.

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CHAPTER 2 BASIC OPERATION

F. Outputs from the DC Controller

1. Outputs from the DC Controller (1/4)

Power supply PCB

DC controller PCB

Heater switch

(SW1) (accessory)

CB2 CB1

J53

Cassette/Drum

heater (H2)

(accessory)

-2 -2

-1 -1

DS1

J208

-1

J105

-1

+24V

GND

+5VU

+5VR

GND

-2

-3

J204

-1

J52

Cassette

heater (H4)

(accessory)

-4

-5

-2 -2

-1 -1

-5

-4

-5

J212

J106

-22

See p.7-4.

J54

+24V -3

ZRCRSS

5V_ON

Mirror heater

(H3)

-2 -2

-1 -1

-2

-1

-23

-24

AC_24V_ON

(accessory)

J212

-6

J106

-19

J201

See p.6-5.

Fixing heater

(H1)

-1 -1

-2 -2

driver

HEAT_ERR

HEAT_DR

-4

-21

RL1

To HVT

Thermo switch

(TSW1)

(J307)

J501

J51

J55

Scannimg lamp (LA1)

-1 -1 -1 -1 -1

-3 -3 -3 -3 -3

Lamp

regulator

PCB

J203

Thermal fuse (FU1)

-4

-6

-1

-3

+5V

J503-1

J211-5

J212

-21

J106

-4

See p.4-3.

-2

-3

-4

-5

-4

-3

-2

-1

LMPDR

-17

-8

LMP_PWM

-19

-6

LMPDT

J307

J301

-10

-3

J210

-1

To RL1

+24V

+5V

-1

-3

-8

J212

-14

-13

-12

-11

-10

J106

-11

-12

-13

-14

-15

See p.4-6.

-4

-7

DV_DC_CNT

DV_DC_DR

DV_AC_CNT

DV_AC_DR

HVT_DR

-5

-6

HVT

-6

-5

-7

-4

-8

-3

-9

-2

Figure 2-109

2–12

1998 CANON INC.

CANON NP7161/NP7160 REV.0 AUG. 1998 PRINTED IN JAPAN (IMPRIME AU JAPON)

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CHAPTER 2 BASIC OPERATION

2. Outputs from the DC Controller (2/4)

DC controller PCB

Power supply

PCB

J601

-4

J209

-4

+24V

J212

-9

J106

-16

-1

MM_LKDT*

See p. 2-8.

MM_DR

Main motor

-2

-8

-17

-3

J37

-3

J104

-A3

-A5

-A2

-A4

-A1

SC_COM

SC_A

SC_A*

SC_B

SC_B*

-1

-4

-2

-5

Scanner motor

See p. 3-7.

J38

J101

-A3

-A1

-A2

-A4

-A5

-3 -3

-1 -5

-2 -4

-4 -2

-5 -1

LNS_COM

LNS_A

LNS_A*

LNS_B

Lens motor

Mirror motor

See p. 3-4.

LNS_B*

J39

J103

-A7

-A5

-A6

-A8

-A9

-3 -3

-1 -5

-2 -4

-4 -2

-5 -1

MMR_COM

MMR_A

MMR_A*

MMR_B

MMR_B*

Figure 2-110

1998 CANON INC.

CANON NP7161/NP7160 REV.0 AUG. 1998 PRINTED IN JAPAN (IMPRIME AU JAPON)

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CHAPTER 2 BASIC OPERATION

3. Outputs from the DC Controller (3/4)

DC controller PCB

J14

J104

-B1

-B2

-B3

FM1

-1 -3

SCFAN_DR

SCFAN_DT*

-2 -2

Cooling fan 1

-3 -1

J20

FM2

-1 -3

-B10

-B11

-B12

EXFAN1_DR

EXFAN1_DT*

-2 -2

Exhaust fan 1

-3 -1

See p. 7-2.

J22

FM4

-1 -3

-B7

-B8

-B9

EXFAN0_DR

EXFAN0_DT*

-2 -2

Exhaust fan 2

-3 -1

J123

-1

J24

-1 -3

FM5

STFAN0_DR

STFAN0_DT*

Sorter kit fan

(accesory)

-2 -2

-3 -1

-2

-3

Power supply

PCB

J211

J29

-2 -1

+24V

-7

Registration

roller clutch

J212

-22

J106

-3

CL1

CL2

CL3

-1 -2

-6

RG_CL*

+24V

When '0', CL1 turns on.

J35

-2

J796

J107

-A4

-1 -11

Feed roller

clutch

-1

-2 -10

-A5

FEED_CL* When '0', CL2 turns on.

J31

-2

J797

+24V

-1 -7

-B1

-B2

Multifeed

roller clutch

-1

-2 -6

MLT_CL*

When '0', CL3 turns on.

Figure 2-111

2–14

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CHAPTER 2 BASIC OPERATION

4. Outputs from the DC Controller (4/4)

DC controller PCB

J36

-2

J40

J107

-B8

+24V

-1 -8

Pick-up

solenoid

SL1

SL2

-1

J30

-2 -7

-B9

PU_SL*

+24V

When '0', SL1 turns on.

When '0', SL3 turns on.

J797

-2

-3 -5

-B3

-B4

Multifeed

solenoid

-1

-4 -4

MLT_SL*

J33

J102

-A11

+24V

-2 -1

Total counter

CNT1

CNT2

-1 -2

-A10

TCNT_DR* When '0', CNT1 turns on.

J32

+24V

-3 -1

-A13

-A12

Accessory

counter

(accessory)

-1 -3

OPCNT_DR* When '0', CNT2 turns on.

J501

J104

-A6

+24V

LA2

LA3

-1 -2

Pre-exposure

lamp

-2 -1

-A7

PREXP_DR* When '0', LA2 turns on.

J551

-1 -10

-3 -8

-5 -6

-6 -5

-7 -4

-8 -3

-9 -2

-10 -1

-2 -9

-4 -7

J101

-A6

+24V

+5V

-A8

-A10

-A11

-A12

-A13

-A14

-A15

-A7

BLK_SD

BLK_SCK

Blank exposure

lamp

BLK_LCK

See p. 4-12.

BLK_DEN*

BLK_CNDR*

BLK_PW

-A9

Figure 2-112

1998 CANON INC.

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CHAPTER 2 BASIC OPERATION

G. Inputs to and Outputs from Accessories (1/1)

DC controller PCB

J750

J120

-1

J754

-4 -4 -4

-2 -2 -2

-3 -3 -3

-1 -1 -1

DF-TXD See the ADF Service Manual.

DF-RXD

-3

-2

-4

Accesory power

supply PCB

Power supply

PCB

J955

-1

J752

-9 -1 -1

-10 -2 -2

-11 -3 -3

-12 -4 -4

To ADF

+24V1

+24V2

-2

-3

GND1

J951

GND2

-1

J206

-4

-1

-4

-3

J952

-1

J753

J755

-9 -1 -1

-10 -2 -2

-11 -3 -3

-12 -4 -4

+24V1

+24V2

GND1

GND2

-2

-3

-4

J751

-4 -4 -4

-2 -2 -2

-3 -3 -3

-1 -1 -1

J120

-5

To Sorter

ST-TXD See the Sorter Service Manual.

ST-RXD

-7

-6

-8

J701

J122

To Cassette

Feeding

Module-C1

J104

-A9

J790

-2

+5V

-4

-3

-1

-A11

-A10

-A8

To Control

Card IV N

CCD*

CCDT*

When '0', control card turns on.

When '0', the card is detected.

J121

-2

J722

+24V

+5V

-7

-2

-5

-4

-3

-8

-6

-1

-7

-4

See the Remote Diagnostic

Device II Service Manual.

AS_TXD

AS_RXD

AS_CNTP

To Remote

Diagnostic

Device II

-5

-6

-1

-3

-8

Figure 2-113

2–16

1998 CANON INC.

CANON NP7161/NP7160 REV.0 AUG. 1998 PRINTED IN JAPAN (IMPRIME AU JAPON)

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CHAPTER 3

EXPOSURE SYSTEM

This chapter 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.

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

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

V. DISASSEMBLY/ASSEMBLY ................. 3-11

A. Scanner Drive Assembly.................. 3-12

B. Lens Drive Assembly ....................... 3-18

1998 CANON INC.

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CHAPTER 3 EXPOSURE SYSTEM

I. OUTLINE OF OPERATION

A. Changing the Reproduction Ratio

The reproduction ratio in the axial direction of the photosensitive drum is varied by the lens

drive system and the mirror drive system, and that in the peripheral direction of the

photosensitive drum is changed by the scanner drive system.

The lens drive system uses a lens array and, as shown in Figure 3-101, the lens position and

the optical length are varied to change the reproduction ratio in the axial direction of the

photosensitive drum.

The optical length is varied, as shown in Figure 3-102, by changing the location of the No. 4/

No. 5 mirror unit.

The scanner drive system moves the No. 1 mirror relatively faster (in Reduce) or slower (in

Enlarge) than the photosensitive drum (peripheral speed) to change the reproduction ratio in the

peripheral direction of the photosensitive drum.

Note:

1. In Direct, the speed of the No. 1 mirror is made identical to the peripheral speed of the

photosensitive drum.

2. In both Reduce and Enlarge, the optical length is longer than in Direct.

Direct

Optical length

Reduce

Optical length

Enlarge

Optical length

Figure 3-101

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CHAPTER 3 EXPOSURE SYSTEM

Copyboard glass

Enlarge/reduce

Enlarge Reduse

Lens

No.4/No.5 mirror unit

Photosensitive

drum

Figure 3-102

3–2

1998 CANON INC.

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CHAPTER 3 EXPOSURE SYSTEM

II. LENS DRIVE SYSTEM

A. Driving the Lens

1. Outline

The lens is driven by the lens motor (M3) and the mirror motor (M4).

As shown in Figure 3-201, when the lens motor rotates in normal direction, the lens moves in

the direction of Enlarge by the drive coming through gears and drive belt.

At this time, the No. 4/No. 5 mirror unit moves by the drive coming from the mirror motor in

the direction of Enlarge/Reduce according to how much the lens moves (reproduction ratio),

thereby varying the optical length.

Mirror motor (M4)

Mirror motor drive command

Mirror home position

sensor (PS3)

Mirror home position

detection signal (MRRHP)

Enlarge/Reduce

Direct

Enlarge

controller

PCB

Reduce

Lens home position

sensor (PS2)

Lens

motor (M3)

Lens

motor

drive command

CCW

Lens home position detection signal (LNSHP)

Figure 3-201

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CHAPTER 3 EXPOSURE SYSTEM

2. Motor Control Circuit

The lens motor (M3) and the mirror motor (M4) are 4-phase stepping motors, and are

controlled by the motor drive power supply signal (COM) and four drive pulse signals (A, B, A*,

B*) generated by the DC controller PCB.

The direction of rotation of the motor is switched by changing the timing at which the four

drive pulse signals (A, B, A*, B*) are generated.

The motor drive power supply signal (COM) is used to supply +24 V when rotating each

motor. It is used to provide +5 V when the motors are at rest, thereby ensuring that the lens and

the No. 4/No. 5 mirror unit remain still against vibration.

DC controller PCB

+24V

J101

-A3

-A1

-A2

-A4

-A5

J38

LNS COM

-3 -3

-5 -1

-4 -2

-2 -4

-1 -5

Lens

motor

drive

LNS A

LNS A*

Lens motor

+5V

LNS B

LNS B*

circuit

IC119

(CPU)

+24V

+5V

J103

-A7

-A5

-A6

-A8

-A9

J39

MMR COM

-3 -3

-5 -1

-4 -2

-2 -4

-1 -5

Mirror

motor

drive

MMR A

MMR A*

M4 Mirror motor

MMR B

MMR B*

circuit

Figure 3-202

3–4

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CHAPTER 3 EXPOSURE SYSTEM

3. Moving the Lens

The lens and the No. 4/ No. 5 mirror unit are moved with reference to the points at which

the lens home position sensor (PS2) and the mirror home position sensor (PS3) turn on.

The number of pulses (indicating the positions of the lens and the No. 4/ No. 5 mirror)

applied to each motor is stored in memory by the microprocessor on the DC controller PCB.

When the lens and the No. 4/ No. 5 mirror unit need to be moved, the appropriate number of

pulses that suits the selected reproduction ratio is generated.

When the lens and the No. 4/ No. 5 mirror unit need to be moved in the direction of

reduction (e.g., from Direct to Reduce), each motor is rotated in reverse first to move the lens

and the No. 4/ No. 5 mirror unit past the position found for the selected reproduction ratio.

Thereafter, the motors are rotated in normal direction so as to move the lens and the No. 4/ No. 5

mirror unit to their appropriate positions. Ending the motor rotation when they are rotating in

normal direction ensures accurate positioning of the lens and the No. 4/ No. 5 mirror unit.

Power switch

Reduce

key ON

Enlarge

key ON

Start key

Sequence

WMUP

WMUPR

STBY

INTR

Scanner motor (M2)

Lens motor (M3)

Mirror motor (M4)

Scanner home position

sensor (PS1)

Lens home position

sensor (PS2)

Mirror home position

sensor (PS3)

: Motor CW/sensor ON

: Motor CCW

*Length varies depending on the selected reproduction ratio.

Figure 3-203

The copier enables adjustment of the lens or the No. 4/No. 5 mirror unit home position in

service mode.

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CHAPTER 3 EXPOSURE SYSTEM

III. SCANNER DRIVE SYSTEM

A. Outline

The scanner is driven by the scanner motor (M2)

As shown in Figure 3-301, when the scanner motor rotates in reverse direction, the scanner

moves forward by the drive coming through the gears, drive belt, and cable. The scanner motor is

rotated in the opposite direction to move the scanner in reverse.

The speed of rotation of the scanner motor when the scanner is moved forward is varied

according to the selected reproduction ratio. The speed when the scanner is moved in reverse,

however, is the same regardless of the selected reproduction ratio—it is about 2.5 times the speed

used in Direct when the scanner is moved forward.

The distance over which the scanner is moved varies according to the length of copy paper

and the selected reproduction ratio.

DC controller PCB

Scanner

motor (M2)

CCW

Scanner home

position sensor

Foward

(PS1)

Reverse

Figure 3-301

3–6

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CHAPTER 3 EXPOSURE SYSTEM

B. Scanner Motor Control Circuit

The scanner motor (M2) is a 4-phase stepping motor, and is controlled by four pulse signals

(SC_A, SC_B, SC_A*, SC_B*) generated by the DC controller PCB.

The scanner motor is turned on/off and its direction of rotation are controlled by changing

the timing at which these four pulse signals are generated. The speed of rotation, on the other

hand, is controlled by switching the current supplied to the scanner motor.

DC controller PCB

+24V

J104

-A3

-A5

-A2

-A4

-A1

J37

-3

-1

-4

-2

-5

SC_COM

SC_A

SC_A*

SC_B

Scanner

motor

SC_B*

Scanner

motor

control

circuit

IC119

(CPU)

(IC117)

Figure 3-302

C. Relationship between Scanner Sensor and Signals

Scanner

Sensor

Signal

SCHP

Description

Foward

Reverse

• The scanner is at home position.

• The scanner has reached home position.

Scanner

home position

sensor (PS1)

Table 3-301

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CHAPTER 3 EXPOSURE SYSTEM

D. Basic Sequence of Operations (scanner)

The scanner is moved forward over a distance determined by the microprocessor based on

the selected paper size, reproduction ratio, and copying mode.

The microprocessor computes the dimensions of the original in reference to the selected

paper size and reproduction ration to determine how much the scanner should be moved forward.

Power switch

Start key

Sequence

WMUP

INTR

AER

SCFW SCRV SCFW SCRV LSTR STBY

Scanner motor (M2)

Scanner home position

sensor (PS1)

Scanning lamp (LA1)

Figure 3-303

3–8

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CHAPTER 3 EXPOSURE SYSTEM

E. Scanner Movement in Page Separation Mode

Start key Leading edge of

Leading edge of Leading edge of

ON 1st page (original) 1st page (original) 2nd page (original)

Sequence

INTR

AER

SCFW1 SCRV2

SCFW2

SCRV2

LSTR

III

Scanner motor (M2)

Scanner home position

sensor (PS1)

18mm

Scanning lamp (LA1)

Figure 3-304

I, II, and III shown in Figure 3-304 are controlled by the microprocessor on the DC controller

PCB with reference to the wait position of the scanner.

The length from wait position to the leading edge is 18 mm. The microprocessor determines

how much the scanner should be moved (including the distance to the leading edge) according to

the selected reproduction ratio and the original size or cassette size.

I, II : The distance over which the scanner is moved forward for the 1st page is determined

according to the selected reproduction ratio and the original size or cassette size.

III : The distance over which the scanner is moved forward is determined as follows: the

microprocessor divides the detected original size by 2, and assumes the result of the

division to be the middle of the original (assuming the middle to be the leading edge

of the 2nd page).

If original size detection is not performed, the microprocessor uses the cassette size when

determining the distance over which the scanner should be moved.

Reference:

The copier does not require paper size registration for the multifeeder. For this reason, it

cancels Page Separate mode if the Start key is pressed after selecting the multifeeder.

1998 CANON INC.

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CHAPTER 3 EXPOSURE SYSTEM

IV. OTHERS

A. Detecting the Original Size

1. Outline

The NP7161 is equipped with auto paper selection and auto reproduction selection

functions, and these functions require identification of the size of originals.

To enable identification, the copier uses the following:

• original size detection by the ADF (NP7161)

2. Detection of the Original Size by the ADF

The size of originals is detected when originals are fed by the ADF. (For details, see the

ADF Service Manual.)

3–10

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CHAPTER 3 EXPOSURE SYSTEM

V. DISASSEMBLY/ASSEMBLY

The copier may be disassembled and assembled as shown here. Pay attention to the copier's

mechanical characteristics along with the steps for disassembly/assembly.

Important:

1. Turn off the power and disconnect the power plug to ensure safety whenever disassembling/

assembling the copier.

2. Unless otherwise noted, assemble the parts by reversing the steps used to disassemble them.

3. Identify the screws by type (length, diameter) to avoid use in the wrong location.

4. Use a washer where needed. The mounting screws used for the grounding wire and varistor

come with a washer to ensure electric continuity. Do not forget to use these washers.

5. As a rule, do not operate the copier with any of its parts removed.

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CHAPTER 3 EXPOSURE SYSTEM

A. Scanner Drive Assembly

1. Removing the Scanner Motor

1) Remove the rear upper cover.

2) Disconnect the connector [1] and the two

mounting screws [2].

[2]

[1]

Figure 3-501

[A]

3) Slide the scanner motor [3] to the right to

detach from the motor mount; then, move

it to the cut-off [A] to remove.

[3]

Figure 3-502

3–12

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CHAPTER 3 EXPOSURE SYSTEM

2. Removing the Scanner Drive Cable

1) In standby state, press the Reduce key so

that the lens and the No.4 /No.5 mirror

unit move to 70% reproduction position.

2) Turn off the power switch, and disconnect

the power plug.

Caution:

Whenever you need to perform

disassembly/assembly work, be sure to

turn it off and disconnect its power

plug.

3) Remove the lens hood.

(See p. 3-20.)

4) Remove the scanner motor.

(See p. 3-12.)

5) Remove the control panel

(See p. 7-13.)

6) Remove the upper left cover.

(See p.7-11.)

7) Remove the upper right cover.

(See p.7-10.)

8) Detach the lock support [1] from the

connector base [2].

9) Remove the two mounting screws [3], and

pull out the connector base [2].

[3]

[1]

[2]

Figure 3-503

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CHAPTER 3 EXPOSURE SYSTEM

[6]

[4]

[5]

10) Remove the three mounting screws [4],

and detach the motor base [5] and the

timing belt [6].

Caution:

When detaching the motor base, be

sure to mark its position at its four

corners. When mounting it, on the

other hand, be sure to refer to these

markings.

Figure 3-504

[7]

11) Holding the bent [A], pull the scanner

until it reaches the hole [B]; then, remove

the two screws [7].

[B]

[A]

Figure 3-505

[9]

12) Remove the two tension springs [8], and

detach the scanner drive cable (front) [9]

and the scanner drive cable (rear) [10].

[10]

[8]

Figure 3-506

3–14

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CHAPTER 3 EXPOSURE SYSTEM

3. Routing the Scanner Drive Cable

Route the scanner drive cable following the sequence indicated in Figure 3-507, i.e., [1]

through [7].

Be sure to adjust the mirror position and the tension as indicated later after routing the

scanner drive cable.

[3]

[4]

Secure temporarily.

[1]

Steel

ball

Wind 11 times.

[2]

[6]

[5]

[2]

[7]

[6]

Figure 3-507

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CHAPTER 3 EXPOSURE SYSTEM

4. Adjusting the Position of the Mirror

Be sure to adjust the position of the mirror

as follows after you have mounted the

scanner drive cable.

1) Keep the mirror positioning tool nearby.

Arrange the mirror positioning tool (FY9-

3009-050) as shown to adapt it to the

copier.

Figure 3-508b (Front)

Figure 3-508a (Rear)

2) Fit the mirror positioning tool [1] to the

No. 1 mirror base and the No. 2 mirror

base (both front and rear).

3) Tighten the mounting screw [2] on the

cable metal fixing of the No. 1 mirror

base (both front and rear).

[2]

[1]

[2]

[1]

Figure 3-509a (Rear)

Figure 3-509b (Front)

4) Detach the mirror positioning tool.

3–16

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CHAPTER 3 EXPOSURE SYSTEM

5. Adjusting the Tension of the

Scanner Drive Cable

Be sure to adjust the tension as follows

after routing the scanner drive cable.

1) Move the scanner to home position.

2) Pull the center of the scanner drive cable

with a spring gauge about 10 mm. At this

time, adjust the position [A] of the tension

spring [1] so that the reading of the spring

gauge is 95 ±15 g.

[A]

[1]

10mm

Figure 3-511

Figure 3-510

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CHAPTER 3 EXPOSURE SYSTEM

B. Lens Drive Assembly

1. Removing the Lens Drive Motor

1) Remove the copyboard glass. (See p.7-14)

2) Holding the bend [A], slide out the

scanner as far as the cut-off [B].

[B]

[A]

[B]

Figure 3-512

3) Remove the inside cover and the delivery

upper cover. (See p.7-11)

4) Disconnect the connector [1].

[1]

Figure 3-513

5) Remove the two screws [2], and remove

the lens motor [3].

[2]

[3]

[2]

Figure 3-514

3–18

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CHAPTER 3 EXPOSURE SYSTEM

2. Removing the Mirror Motor

1) While the copier is in standby state, press

the Enlarge key to move the lens and the

No. 4/No. 5 mirror unit to 200% position.

2) Turn off the power switch, and disconnect

the power plug.

Caution:

Whenever you are disassembling/

assembling the copier, be sure to turn

off the power switch and disconnect

the power plug.

3) Remove the copyboard glass. (See p.7-14)

4) Remove the developing assembly.

(See p.4-37)

5) Remove the drum unit. (See p.4-28)

6) Remove the upper right cover. (See p.7-

10)

7) Disconnect the connector [1].

[1]

Figure 3-515

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CHAPTER 3 EXPOSURE SYSTEM

8) Remove the two mounting screws [2], and

remove the lens hood [3].

[2]

Caution:

When mounting the lens hood, take

care not to trap the wire.

[3]

[2]

Figure 3-516

[5]

9) Remove the two mounting screws [4], and

remove the mirror motor [5].

[4]

Figure 3-517

3–20

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CHAPTER 4

IMAGE FORMATION SYSTEM

This chapter 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.

I. OUTLINE OF THE PROCESSES............ 4-1

A. Outline ................................................ 4-1

B. Basic Sequence of Operations

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

F. Auto Density Adjustment (AE) ......... 4-21

III. DISASSEMBLY/ASSEMBLY ................. 4-23

A. Scanning Lamp Assembly ............... 4-24

B. Exposure Assembly ......................... 4-26

C. Drum Unit ......................................... 4-28

D. Primary Charging Assembly ............ 4-30

E. Transfer Charging Assembly ........... 4-31

F. Charging Wire .................................. 4-32

G. Developing Assembly....................... 4-37

(image formation system) .................. 4-2

C. Controlling the Intensity of the

Scanning Lamp .................................. 4-3

D. Controlling the Primary/Transfer Bias .. 4-6

E. Controlling the Developing/Separation

Static Eliminator Bias ......................... 4-7

F. Controlling the Blank Exposure Lamp ... 4-12

II. DEVELOPING ASSEMBLY/DRUM

CLEANER ASSEMBLY .......................... 4-14

A. Outline .............................................. 4-14

B. Detecting and Controlling

the Level of Toner ............................ 4-16

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CHAPTER 4 IMAGE FORMATION SYSTEM

I. OUTLINE OF THE PROCESSES

A. Outline

Figure 4-101 shows the copier's basic construction in reference to image formation. Image

formation consists of the following functions:

• Scanning lamp control

• Primary corona current control

• Transfer control current control

• Separation static eliminator bias control

• Developing bias control

• Blank exposure lamp control

Copy board glass

Lamp regulator

PCB

No.2

mirror

Lens

No.1

Scanning lamp (LA1)

mirror

No.4 mirror

No.3

No.6

mirror

AE sensor

Pre-

exposure

Blank

exposure

No.5 mirror

lamp (LA2) lamp (LA3)

Developing

assembly

Primary

corona

assembly

Static

Transfer

eliminator

corona

assembly

HVT

DC controller PCB

Figure 4-101

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CHAPTER 4 IMAGE FORMATION SYSTEM

B. Basic Sequence of Operations (image formation system)

Start key

Sequence

STBY

INTR

AER

SCFW SCRV SCFW SCRV LSTR STBY

Main motor (M1)

Primary charging assembly

Developing DC bias

Voltage control

Developing AC bias

Transfer charging assembly

Static eliminator

Pre-exposure lamp (LA2)

Blank exposure lamp (LA3)

Scanning lamp (LA1)

Partial activation

Figure 4-102

4–2

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CHAPTER 4 IMAGE FORMATION SYSTEM

C. Controlling the Intensity of the Scanning Lamp

1. Outline

Figure 4-103 shows the circuit used to control the intensity of the scanning lamp, and the

circuit has the following functions:

1. Turning on/off the scanning lamp

2. Controlling the intensity of the scanning lamp

• controlling the light to a specific intensity against fluctuations in power supply voltage

DC controller

PCB

Power supply

PCB

Lamp regulator

PCB

Scanning lamp

(LA1)

J203

-1

J501

-4

J501

-1

IC119

(CPU)

Drive

circuit

-3

-6

-3

Thermal fuse

(FU1)

+24V

J106

-24

J106

Error

detection

circuit

AC_24V_ON

-24

J211

-5

-4

J503

-1

+5V

J106

-4

J212

-21

LMPDR

-2

Lamp

detection

Control

circuit

LMP_PWM

LMPDT

-8

-6

-17

-19

-3

-2

-1

-3

-4

-5

IC113

Figure 4-103

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CHAPTER 4 IMAGE FORMATION SYSTEM

2. Operation

a. Turning On/Off the Scanning Lamp

When the scanning lamp drive signal (LMPDR) is ‘0’, the output of the control circuit goes

‘0’, keeping the drive circuit from turning on and therefore not supplying the scanning lamp

(LA1) with AC power.

When LMPDR is ‘1’, the output of the control circuit will be ‘1’, turning on the drive circuit

and thereby supplying the scanning lamp (LA1) with AC power.

b. Controlling the Intensity of the Scanning Lamp

The intensity of the scanning lamp is increased/decreased by controlling the voltage of the

power supplied to the scanning lamp according to the level of the pulse width modulation signal

(LMP_PWM) from the DC controller PCB.

LMP_PWM varies the pulse duty between 10% and 90% to suit the selected reproduction

ratio so as to control the voltage of the power supplied to the scanning lamp as shown in Table 4-

101 (actual value).

Pulse duty (%) = t / T x 100

Figure 4-104

Power supply

Pulse duty

10 to 90%

DC output

45 to 80V

98 to 175V

120V

230V

Table 4-101

c. Detecting the Activation of the Scanning Lamp

The control circuit on the lamp regulator PCB generates the drive detection signal

(LMPDT) at all times while the scanning lamp remains on, and sends the signal to the lamp

activation detection IC (IC113) on the DC controller PCB.

If the scanning lamp remains on for 21 sec or more, the error detection circuit will cause the

AC_24V_ON signal to go ‘0’, thereby cutting the supply of AC power to the lamp regulator

PCB.

If an error is identified in the scanning lamp, the DC controller PCB will cut the AC power

to the lamp regulator and, at the same time, will indicate ‘E220’ on the control panel.

4–4

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CHAPTER 4 IMAGE FORMATION SYSTEM

3. Protection Mechanisms

To prevent malfunction of the scanning lamp (LA1), the copier is equipped with a fuse

(FU1).

If the temperature around the scanning lamp increases abnormally (about 141°C or more)

because of a short circuit or the like, the thermal fuse (FU1) will melt to cut the power to the

scanning lamp.

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CHAPTER 4 IMAGE FORMATION SYSTEM

D. Controlling the Primary/Transfer Bias

1. Outline

Figure 4-108 shows the circuit used to control the primary/transfer bias, and the circuit has

the following functions:

1. Turning on/off the primary/transfer bias

2. Controlling the grid bias to a specific voltage

3. Controlling the primary shield current to a specific current

To eliminate the effects of changes in the environment to corona charging, the output to the

primary charging assembly is controlled by controlling the shield current to a specific current.

The primary/transfer bias is turned on/off using the following signal from the DC controller

PCB.

• HVT_DR (HVT drive command)

DC controller

PCB

Power supply

PCB

HVT

Transformer

J106 J212

-15 -10

HVT DR

J210

-3

J301

-8

Oscillation

control circuit

Short circuit/noload

detection circuit

Reference

Current

voltage circuit

detection circuit

Figure 4-108

2. Turning On/Off the Primary/Transfer Bias

a. When the primary/transfer bias is off,

• When HVT_DR is 0,

Oscillation control circuit turns off

Primary/transfer high-voltage transformer turns off

b. When the primary/transfer bias is on,

• When HVT_DR is 1,

Oscillation control circuit turns on

Primary/transfer high-voltage transformer turns on

4–6

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CHAPTER 4 IMAGE FORMATION SYSTEM

E. Controlling the Developing/Separation Static Eliminator Bias

1. Outline

Figure 4-109 shows the circuit used to control the developing/static eliminating bias, and the

circuit has the following functions:

1. Turning on/off the developing DC bias

2. Turning on/off the developing AC bias/separation static eliminator bias

3. Controlling the developing DC bias to a specific voltage to suit copy density

The above control mechanisms are driven by the following signals:

• DV AC DR (developing AC bias drive signal)

• DV AC CNT (developing AC bias control signal)

• DV DC DR (developing DC bias drive signal)

• DV DC CNT (developing DC bias control signal)

Power supply

PCB

DC controller

PCB

HVT

Transformer

J210 J301

J106 J212

-13 -12

Frequency

switching circuit

Oscillation

circuit

-5

-6

DV AC CNT

Control

circuit

Amplifier

circuit

-4

-7

-14

-11

DV AC DR

Short circuit

detection circuit

Reference

Voltage

voltage circuit

detection circuit

Dev

Transformer

-6

-7

-5

-4

-12

-13

Oscillation

control circuit

DV DC DR

-11

-14

DV DC CNT

Voltage

Short circuit

detection circuit

Transformer

Oscillation

control circuit

Voltage

Short circuit

detection circuit

Figure 4-109

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CHAPTER 4 IMAGE FORMATION SYSTEM

2. Turning On/Off the Developing DC Bias

a. Turning On/Off the Developing DC Bias

• When DV_DC_DR is 0,

Oscillation control circuit turns off

DC high-voltage transformer turns off

The above condition deprives the developing cylinder of developing DC bias.

• When DV_DC_DR is 1,

Oscillation control circuit turns on

DC high-voltage transformer turns on

The above condition supplies the developing cylinder with developing DC bias.

b. Control Timing

As shown in Figure 4-110, a specific developing DC bias (-300 V) is applied to the

developing cylinder to prevent adhesion of excess toner to the photosensitive drum when copies

are not being made.

Start key

Sequence

STBY

INTR

AER

SCFW SCRV SCFW SCRV LSTR STBY

Voltage

control

Developing DC bias

Developing AC bias

Figure 4-110

4–8

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CHAPTER 4 IMAGE FORMATION SYSTEM

3. Turning On/Off the Developing AC Bias/Separation Eliminator Bias

a. Turning On/Off the Developing AC Bias

• When DV_AC_DR is 0,

control circuit turns off

oscillation circuit turns off

amplification circuit turns off

AC high-voltage transformer turns off

The above condition deprives the developing cylinder of developing AC bias.

• When DV_AC_DR is 1,

control circuit turns on

oscillation circuit turns on

amplification circuit turns off

AC high-voltage transformer turns on

The above condition supplies the developing cylinder with AC bias.

b. Turning On/Off the Separation Static Eliminator

• When DV_AC_DR is 0,

oscillation control circuit turns off

high-voltage transformer turns off

The above condition deprives the static eliminator of separation static eliminator bias.

• When DV_AC_DR is 1,

oscillation control circuit turns on

high-voltage transformer turns on

The above condition supplies the static eliminator with separation static eliminator bias.

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CHAPTER 4 IMAGE FORMATION SYSTEM

4. Controlling the Developing DC Bias to a Specific Voltage to Suit Copy Density

While copies are being made, developing AC bias and developing DC bias are applied to the

developing cylinder. The developing AC bias is 1400 Vp-p, and the developing DC bias may be

varied by sliding the Copy Density lever on the control panel.

When the Copy Density lever on the control panel is slid, the CPY_DNS signal will vary

between 1 and 5 V. The developing DC bias will then vary between -110 and -550 V.

Normally, the optimum image is obtained when the developing DC bias is set at -270 V

(CPY_DNS is 2.45V).

(V)

CPY DNS

Developing

DC bias (V)

-600

-500

-400

-300

-200

-100

Darker

Copy density

Lighter

Figure 4-111

4–10

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CHAPTER 4 IMAGE FORMATION SYSTEM

Copy density

Developing DC bias [V]

-110

CPY DNS [V]

1.00

1.09

1.18

1.27

1.36

1.45

1.54

1.63

1.72

1.81

1.91

2.00

2.09

2.18

2.27

2.36

2.45

2.54

2.63

2.72

2.81

2.90

3.00

3.16

3.32

3.48

3.64

3.86

4.09

4.32

4.55

4.77

5.00

F1.25

F1.5

F1.75

F2.25

F2.5

F2.75

F3.25

F3.5

F3.75

F4.25

F4.5

F4.75

F5.25

F5.5

F5.75

F6.25

F6.5

F6.75

F7.25

F7.5

F7.75

F8.25

F8.5

F8.75

-120

-130

-140

-150

-160

-170

-180

-190

-200

-210

-220

-230

-240

-250

-260

-270

-280

-290

-300

-310

-315

-330

-347.5

-365

-382.5

-400

-425

-450

-475

-500

-525

-550

Table 4-102

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CHAPTER 4 IMAGE FORMATION SYSTEM

F. Controlling the Blank Exposure Lamp

1. Outline

The blank exposure lamp is an LED array (40 built-in LEDs), and its activation is controlled

by a static method.

All LEDs of the blank exposure lamp are turned on while the photosensitive drum is rotating

and, in addition, the scanner is not exposing an original so as to prevent adhesion of excess toner

to the photosensitive drum. (The farthest LED (each at front and rear) is kept on at all times as

long as the photosensitive drum is rotating.)

The charges on the photosensitive drum are removed in appropriate widths according to

reproduction ratios and paper sizes while the scanner is exposing an original, thereby preventing

adhesion of unwanted toner.

The copier turns on/off the ten LEDs at the center using the blank exposure lamp center

activation signal (BLK_CNDR*), and controls the 15 LEDs (each at front and rear) by means of

serial data communication using the following signals:

• blank exposure lamp serial data signal (BLK_SD)

• blank exposure lamp serial data clock signal (BLK_SCK)

• blank exposure lamp serial data latch signal (BLK_LCK)

• blank exposure lamp drive enable signal (BLK_DEN*)

• blank exposure lamp power supply line (BLK_PW)

DC controller PCB

J101

Blank exposure lamp (LA3)

J551

-10

+24V

-A6

+5V

-A8

-8

-6

-5

-4

-3

-7

LED circuit

(40 pcs)

-A10

-A11

-A12

-A13

-A9

BLK SD

BLK SCK

Control

circuit

Center

(10 pcs)

BLK LCK

BLK DEN*

-A14 BLK CNDR* -2

_PW

-A15

-A7

BLK

-1

-9

Figure 4-112

4–12

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CHAPTER 4 IMAGE FORMATION SYSTEM

2. Turning On the Blank Exposure Lamp in Reduce Mode

While the original is being illuminated in Reduce mode, as many LEDs (both front and rear)

as suited to the selected reduction ratio are turned on to blank out the non-image widths on the

photosensitive drum regardless of the selected paper size.

3. Turning On the Blank Exposure Lamp in Direct/Enlarge Mode

While the original is being illuminated in Direct/Enlarge mode, as many LEDs (both front

and rear) as suited to the selected paper size (Table 4-101) are turned on to blank out the non-

image widths on the photosensitive drum.

LEDs (number of)

Paper size

Front

Rear

A3, A4

279 × 432mm (11"×17"), LTR

B4, B5

A4R, A5, LGL, LTRR

B5R

A5R

Table 4-103

4. Turning On the Blank Exposure Lamp in Multifeeder Mode

When copies are made on paper picked up from the multifeeder, the blank exposure lamp is

turned on to suit the paper width obtained by combinations of the states of the multifeeder paper

width sensors 1 and 2 (PS9, 10); see p. 5-9.

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CHAPTER 4 IMAGE FORMATION SYSTEM

II. DEVELOPING ASSEMBLY/DRUM CLEANER

ASSEMBLY

A. Outline

The developing assembly and the drum cleaner are rotated by the drive from the main motor

(M1) through drive gears.

The level of toner inside the developing assembly is monitored by the toner sensor (TS1);

when the amount drops below a specific level, the copier turns on or flashes the Toner indicator

on the control panel.

The drum cleaner assembly collects waste toner using the cleaning blade, and moves it to the

waste toner case using the waste toner feeding screw. The waste toner feeding screw locked

detection sensor (PS8) serves to monitor the rotation of the waste toner feeding screw.

The level of the waste toner inside the waste toner case is monitored by the waste toner

sensor; when the amount of the waste toner exceeds a specific level, the copier flashes the Waste

Toner indicator on the control panel.

The cleaner thermistor (TH3) serves to detect overheating of the drum cleaner assembly.

Cleaning blade

Waste toner

feeding screw

Developing assembly

Waste toner feeding

screw locked sensor

Waste toner

sensor

PS8

TS1

TH3

Main motor

DC controller PCB

Figure 4-201

4–14

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The copier is designed to collect more waste toner than existing models, and is equipped with

a paddle at the bottom of the waste toner box.

The paddle is linked to the movement of the cassette, and is designed to tap on the bottom of

the waste toner box to even out the toner inside it.

Waste toner assembly

Paddle

Waste toner

assembly

Paddle

Cassette

Waste toner

assembly

Paddle

Figure 4-202

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CHAPTER 4 IMAGE FORMATION SYSTEM

B. Detecting and Controlling the Level of Toner

The toner inside the developing assembly is monitored by the toner sensor (TS1).

The toner sensor uses a piezoelectric oscillator which oscillates in the absence of toner over

the sensor at several kHz and sends an oscillation signal (TNEMP) to the DC controller PCB. In

the presence of toner over the sensor, on the other hand, the weight will prevent oscillation.

AMP

Output

TNEMP

Integration

circuit

Piezoelectric oscillator

Figure 4-203

The copier detects the absence of toner in two stages.

The DC controller PCB monitors the output of the toner sensor at all times as long as the

main motor is rotating. If the sum of periods of the toner absent signal is 70 sec (consecutive two

periods), it will identify the condition as a condition preceding the absence of toner and will flash

the Toner indicator on the control panel.

Thereafter, if the period of the toner absent signal reaches 180 sec or more, the DC controller

PCB will assume the condition to be the absence of toner, and will stop flashing the Toner

indicator to keep it on. At this time, the copy being made is processed as would a normal copy

and discharged, and then the operation will be stopped.

Sequence

Toner sensor (TS1)

Toner absent

Figure 4-204

Toner indication

Flashing

Conditions

Copying

(T1+T2) or (T2+T1)

T1 or T2

70sec

Possible

No possible

180sec

Table 4-201

Note:

When the DC controller identifies a condition preceding the absence of toner, there is

likely to be as much as 10 g of toner inside the developing assembly. In terms of A4

copies, about 200 copies may be made without the addition of toner.

4–16

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CHAPTER 4 IMAGE FORMATION SYSTEM

C. Monitoring the Waste Toner Feeding Screw

If the waste toner inside the drum cartridge cakes and, as a result, hinders the rotation of the

waste toner feeding screw, waste toner can start to leak from the pipe. To prevent such a

problem, the copier is equipped with a waste toner feeding screw detection mechanism

constructed as shown in Figure 4-206.

The waste toner feeding screw is linked with a spring clutch and a flag, and is rotated by the

engagement of the spring clutch with the gear A.

The rotation of the flag is monitored by the waste toner feeding screw sensor (PS8) at all

times while the main motor (M1) is rotating.

When the waste toner feeding screw locks, the spring clutch is subjected to force in the axial

direction and moves in the direction of the arrow, causing the flag to stop rotating. If the waste

toner feeding screw lock signal (TRQMLDT) remains unchanged for 0.5 sec or more, the DC

controller PCB will assume that the waste toner feeding screw became locked, and will

immediately indicate ‘E013’ on the control panel and stop responding to a press on the Start key.

Main motor drive command

DC controller PCB

Waste toner feeding screw locked detection signal (TRQMLDT)

Flag

PS8

Cleaning blade

Waste toner feeding

screw

Spring clutch

Gear A

Photosensitve drum

Figure 4-205

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CHAPTER 4 IMAGE FORMATION SYSTEM

D. Monitoring the Waste Toner Box

The copier monitors the waste toner box in two levels.

The amount of waste toner inside the waste toner box is checked by the waste toner sensor.

The waste toner sensor is a pair of photosensors (light-emitting cell and light-receiving cell), and

is designed to generate the waste toner full detection signal (TNFDT) when waste toner blocks

the light between the two photosensors.

The DC controller PCB monitors the state of the waste toner sensor at all times; when the

voltage of the waste toner full detection signal (TNFDT) drops below the reference voltage, it

will identify the condition as “pre-waste toner full condition” and will flash the Waste Toner

indicator on the control panel.

When the waste toner box is not set, the light-blocking plate blocks the light between the

photosensors, causing the copier to flash the Waste Toner indicator.

HVT

+5V

Power

supply

PCB

DC controller

PCB

J303

-1

J301

J210

-1 -10

J106

-9

J212

-16

-2

Comparator

circuit

-3

Reference

voltage

circuit

Light-blocking plate

Stopper

Waste toner sensor

(light-receiving unit)

Waste toner box

Waste toner sensor

(light-emitting unit)

Figure 4-206

4–18

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CHAPTER 4 IMAGE FORMATION SYSTEM

When as many as 100 copies (A4) have been made during a pre-waste toner full condition,

the DC controller PCB will identify the condition as “waste toner full,” stopping to flash the

Waste Toner indicator and instead keeping it on. The copier will not accept the Start key while

the Waste Toner indicator remains on.

Reference:

If the DC controller PCB identifies a waste toner full condition during continuous copying,

the copier will discharge copies being processed and turn on the Waste Toner indicator.

1998 CANON INC.

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CHAPTER 4 IMAGE FORMATION SYSTEM

E. Control by the Cleaner Thermistor

The copier is equipped with a thermistor (cleaner thermistor TH3) used to detect overheating

of the drum cleaner assembly, and is designed to perform the following according to the

temperature detected by the thermistor.

• controlling the rotation of the exhaust fan (See p. 7-2.)

• controlling the copying speed down sequence

The cleaner thermistor checks for overheating of the drum cleaner at all times, and will

indicate error code ‘E821’ on the control panel when it identifies a temperature of 55°C or more.

1. Copying Speed Down Sequence

The copier’s normal copying speed is 16 cpm (A4, Direct, non-AE).

To prevent overheating of the drum cleaner assembly in continuous copying mode or

overheating of the copyboard glass in enlargement mode, the copier adjusts the sheet-to-sheet

distance according to the selected copy count and the reading of the cleaner thermistor (TH3).

• A4 Original, A4 Copy

Reading by cleaner

thermistor (TH3)

Copy count at lower than 500

50 to100% 101 to141% 142 to200% 50 to100% 101 to141% 142 to200%

Copy count at 500 or more

Less than 40°C

40°C or more

16cpm

12cpm

8cpm

12cpm

8cpm

Table 4-202

4–20

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CHAPTER 4 IMAGE FORMATION SYSTEM

F. Auto Density Adjustment (AE)

1. Outline

The copier is equipped with an automatic density adjustment mechanism (AE), which

controls the developing DC bias to suit the density of originals. As long as the original is of even

density, the AE mechanism is capable of ensuring copies free of fogging by changing the

developing DC bias to suit the density of the original.

2. Measuring the Density of the Original

In initial rotation state (INTR), the scanning lamp (LA1) is turned on at a specific intensity

and the scanner is moved forward 70 mm to expose the original. When the scanner has stopped,

the light reflected by the area shown in Figure 4-208 (in reference to the original butting

position) is measured by the AE sensor (photodiode), whose output is sent to the DC controller

PCB as the AE sensor output signal (AE_DATA).

Based on the signal, the DC controller PCB computes the optimum level of the developing

DC bias for copying, and sends the result to the high-voltage power supply PCB as the

developing bias control signal (DV_DC_CNT).

Area of AE detection

28 mm (approx.)

56 mm (approx.)

Center of image

20 mm

(approx.)

70 mm

(distance of scanner travel)

Figure 4-208

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CHAPTER 4 IMAGE FORMATION SYSTEM

Figure 4-209 shows changes in the developing DC bias in relation to the density of different

originals. If the density of the original is higher (darker) than the Test Sheet and lower (lighter)

than a newspaper, the developing DC bias will vary between F5.0 and F7.5 in terms of Copy

Density lever position.

If the original is lighter than the Test Sheet, copies are made at an F5.0 equivalent (-270 V);

if it is darker than a newspaper, on the other hand, copies are made at an F7.5 equivalent (-400

V).

Developing bias DC (V)

F7.5 equivalent

F5.0 equivalent

Density of original

Lighter

Test Sheet

Darker

Newspaper

Figure 4-209

F7.5

F5.0

Figure 4-210

4–22

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CHAPTER 4 IMAGE FORMATION SYSTEM

III. DISASSEMBLY/ASSEMBLY

The copier may be disassembled and assembled as shown here. Pay attention to the copier's

mechanical characteristics along with the steps for disassembly/assembly.

Important:

1. Turn off the power and disconnect the power plug to ensure safety whenever disassembling/

assembling the copier.

2. Unless otherwise noted, assemble the parts by reversing the steps used to disassemble them.

3. Identify the screws by type (length, diameter) to avoid use in the wrong location.

4. Use a washer where needed. The mounting screws used for the grounding wire and varistor

come with a washer to ensure electric continuity. Do not forget to use these washers.

5. As a rule, do not operate the copier with any of its parts removed.

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CHAPTER 4 IMAGE FORMATION SYSTEM

A. Scanning Lamp Assembly

1. Removing the Scanning Lamp

1) Remove the copyboard glass. (See .7-14)

2) Holding the bend [A], pull out the scanner

as far as the cut-off [B].

[B]

[A]

[B]

Figure 4-301

3) Remove the mounting screw [1], and

remove the reflecting cover [2].

[1]

[2]

Figure 4-302

4–24

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CHAPTER 4 IMAGE FORMATION SYSTEM

4) Wrap both ends of the scanning lamp [3]

with lint-free paper. Then, remove the

lamp while pushing toward the rear end.

Caution:

1. Do not work if the surface of the

scanning lamp is hot.

2. Do not leave fingerprints on the

surface of the scanning lamp.

3. If the surface of the scanning lamp

is soiled, dry wipe it.

[3]

Figure 4-303

4. Do not leave fingerprints on the

reflecting cover.

5. Do not deform the reflecting cover.

2. Mounting the Scanning Lamp

Mount the scanning lamp by reversing the

steps used to remove it. However, keep the

following in mind:

• Orient the scanning lamp so that the

side with the shorter boss-to-terminal

length is toward the rear.

45˚

• Orient the scanning lamp so that the

boss is at the angle indicated in Figure

4-304.

Figure 4-304

[1]

3. Removing the Thermal Fuse

1) Remove the scanning lamp.

2) Remove the two mounting screws[1], and

remove the thermal fuse [2].

Caution:

Mount the thermal fuse by reversing

the steps used to remove it. Be careful

of the orientation of the fuse.

[2]

Figure 4-305

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CHAPTER 4 IMAGE FORMATION SYSTEM

B. Exposure Assembly

1. Removing the Pre-Exposure/Blank

Exposure Lamp Assembly

1) Remove the developing assembly. (See

p.4-37)

[3]

[2]

2) Remove the drum unit. (See p.4-28)

3) Remove the inside over.

4) Disconnect the two connectors [1], and

remove the mounting screw [2] ; then,

remove the pre-exposure/blank exposure

lamp assembly [3].

[1]

Figure 4-306

2. Removing the Dust-Proofing Glass

1) Remove the inside cover.

2) Remove the mounting screws [1], and

remove the dust-proofing glass [2].

[1]

[2]

Figure 4-307

4–26

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CHAPTER 4 IMAGE FORMATION SYSTEM

3. Cleaning the No. 6 Mirror

1) Remove the developing assembly. (See p.

4-37.)

2) Remove the drum unit. (See p. 4-28.)

3) Remove the dust-proofing glass. (See p.

4-26.)

4) Remove the mounting screw [1], and

remove the developing assembly rail [2].

[1]

[2]

Figure 4-308

5) Clean the No. 6 mirror [3].

[3]

Figure 4-309

1998 CANON INC.

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CHAPTER 4 IMAGE FORMATION SYSTEM

C. Drum Unit

1. Removing the Drum Unit

1) Open the top unit, release the developing

assembly.

[1]

[2]

2) Remove the thumb screw [1], and slide

out the drum unit [2] to the front to remove.

Caution:

• The photosensitive drum is

susceptible to strong light. If it was

subjected to strong light for a long

time, it can cause copies to have

white spots or black lines.

Whenever you have taken out the

drum unit from the copier, be sure to

keep it in the bag used at time of

installation. If the bag is not at hand,

substitute several sheets of fresh

copy paper to wrap the drum unit,

and keep it in a dark place.

Figure 4-310

• When mounting the drum unit to the

copier, be sure to slide it along the

rails and work with extra care.

4–28

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CHAPTER 4 IMAGE FORMATION SYSTEM

2. Cleaning the Photosensitive Drum

If the surface of the photosensitive drum

is soiled, wipe it with a flannel cloth coated

with toner.

Caution:

• Do not dry wipe the surface of the

photosensitive drum. Do not use

solvent.

• Do not use paper, lint-free or

otherwise, to avoid damaging the

surface of the photosensitive drum.

• Work briskly when cleaning the

photosensitive drum to avoid

unnecessarily subjecting it to light

and thus affecting images.

• If you must rotate the photosensitive

drum, be sure to rotate it in the same

direction as it would when making

copies.

[1]

[3]

[2]

3. Removing the Cleaner Thermistor

1) Remove the drum unit. (See p. 4-28.)

2) Remove the fixing assembly. (See p. 6-8.)

3) Disconnect the connector [1], and remove

the mounting screw [2]; then, remove the

cleaner thermistor [3].

Figure 4-311

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CHAPTER 4 IMAGE FORMATION SYSTEM

D. Primary Charging

Assembly

1. Removing the Primary Charging

Assembly

[3]

1) Remove the drum unit. (See p. 4-28.)

2) Pull the charging wire cleaning lever [1]

slightly to the front.

[2]

3) Detach the hook [2], and detach the drum

front cover [3].

[1]

Figure 4-312

4) Remove the mounting screw [4], and

remove the primary charging assembly

[5].

[5]

[4]

Figure 4-313

4–30

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CHAPTER 4 IMAGE FORMATION SYSTEM

E. Transfer Charging

Assembly

1. Removing the Transfer Charging

Assembly

[4]

1) Open the copier top, and remove the front

door.

2) Pull the charging wire cleaning lever [1]

slightly to the front.

3) Remove the mounting screw [2], and lift

the stopper [3] to remove.

4) Pull the transfer charging assembly [4] to

the front to remove.

[1]

[3]

[2]

Figure 4-314

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CHAPTER 4 IMAGE FORMATION SYSTEM

F. Charging Wire

1. Outline

As many as two charging wires are

located around the photosensitive drum.

(These charging wires are 0.06 mm in

diameter.)

2. Stringing the Charging Wires

Basically, all charging wires are strung in

the same way. (The following uses the

primary charging wire as an example.)

1) Remove the mounting screw [1], and

remove the stopper [2] and the grid plate

[3].

To remove the transfer charging

assembly, remove the three hooks [a], and

remove the guide wire plate [b].

• Transfer Charging Assembly

• Primary Charging Assembly

[1]

[a]

[3]

[2]

[b]

Figure 4-315b

Figure 4-315a

4–32

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CHAPTER 4 IMAGE FORMATION SYSTEM

2) Remove the sheet (front) [4] and the sheet

(rear) [5].

To remove the transfer charging

assembly, remove the sheet (front) [c] and

the sheet (rear) [d].

• Primary Charging Assembly

• Transfer Charging Assembly

[c]

[d]

[5]

[4]

Figure 4-316a

Figure 4-316b

3) Remove the spring [6], and remove the

charging wire [7].

To remove the transfer charging

assembly, remove the spring [e], and

remove the charging wire [f].

• Primary Charging Assembly

• Transfer Charging Assembly

[e]

[7]

[6]

[f]

Figure 4-317b

Figure 4-317a

1998 CANON INC.

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CHAPTER 4 IMAGE FORMATION SYSTEM

4) Free a length of about 5 cm from the

charging wire reel (0.06 mm wire).

Reference:

To form a loop, wind the charging wire

around a hex key once, and turn the hex

key three to four times; then, twist the

charging wire.

5) Cut the end (excess) of the twisted

charging wire with a nipper.

6) Hook the loop on the charging electrode

at the rear.

Figure 4-318

7) Hook the charging wire on the charging

wire positioner at the rear, and hook the

charging wire tension spring on the

charging wire by the distance A; then,

twist it.

Figure 4-319

Primary charging assembly : 13.0 ±0.5 mm

Transfer charging assembly : 12.0 ±0.5 mm

4–34

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CHAPTER 4 IMAGE FORMATION SYSTEM

8) Cut the excess charging wire with a

nipper.

9) Pick the end of the charging wire

tensioning spring with tweezers, and hook

it on the charging electrode.

Figure 4-320

Note:

Go through the following:

• Be sure that the charging wire is free

of bending and twisting, and its gold

plating has not peeled.

• Be sure that the charging wire is in

the V-groove of the charging wire

positioner.

(correct)

(wrong)

Figure 4-321

10) Wipe the charging wire with lint-free

paper moistened with alcohol.

Caution:

• Do not use a cloth carrying metal

powder for cleaning.

• Do not use a moist cloth for

cleaning.

• Dry wipe with lint-free paper; then,

mount only after making sure that

alcohol has completely evaporated.

11) Mount the sheet (front) and the sheet

(rear).

12) Mount the stopper and the grid plate.

For the transfer charging assembly, mount

the guide wire plate.

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CHAPTER 4 IMAGE FORMATION SYSTEM

3. Adjusting the Height of the

Charging Wires

Charging

assembly

Height of charging

wire (mm)

Range

1.0mm

To adjust each charging wire, turn its

respective height adjusting screw. A full turn

on the screw will change the height of the

primary charging wire by about 0.5 mm and

that of the transfer charging wire by about 0.7

mm.

11.0 0.2mm

Primary

Transfer

1.0mm

9.5 0.2mm

Figure 4-322

• Transfer Charging Assembly

• Primary Charging Assembly

Height adjusting

screw

Height adjusting

screw

Height adjusting

screw

Height adjusting

screw

Figure 4-323b

Figure 4-323a

4–36

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CHAPTER 4 IMAGE FORMATION SYSTEM

G. Developing Assembly

[2] [1]

[3]

1. Removing the Developing

Assembly

1) Open the front door, and release the

developing assembly.

2) Remove the mounting screw [1], and

remove the stopper [2].

3) Pull the developing assembly [3] to

remove.

Figure 4-324

Caution:

Take care not to damage the

developing cylinder.

2. Removing the Developing Blade

1) Remove the developing assembly.

2) Remove the mounting screw [1] and the

three hooks [2]; then, remove the

developing front cover [3].

[1]

[3]

[2]

Figure 4-325

[4]

3) Remove the three mounting screws [4],

and detach the developing blade cover [5].

[5]

Figure 4-326

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CHAPTER 4 IMAGE FORMATION SYSTEM

4) Lift the front of the developing upper

cover [6] slightly, and slide it in the

direction of the arrow to remove.

[6]

Figure 4-327

5) Place a newspaper or the like on the floor,

and empty the developing assembly of

toner.

6) Put copy paper between the developing

blade and the developing cylinder.

7) Remove the two mounting screws [7], and

remove the developing blade [8].

[8]

Caution:

When mounting the developing blade,

be sure to put copy paper on the

developing cylinder before mounting

the developing blade so as to protect

the cylinder.

[7]

Figure 4-328

3. Removing the Developing Cylinder

1) Remove the developing blade. (See p. 4-

37.)

2) Remove the mounting screw [1], and

remove the magnet positioning plate [2].

[1]

[2]

Figure 4-329

4–38

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CHAPTER 4 IMAGE FORMATION SYSTEM

3) Remove the grip ring [3], and remove the

developing roll [4].

4) Remove the two mounting screws [5], and

remove the bearing holder (front) [6] and

the bearing [7].

[5]

[7]

[6]

[5]

[4]

[3]

Figure 4-330

5) Remove the two mounting screws [8], and

remove the gear support plate [9].

Caution:

Take extra care when removing the

gear support plate. The gear will be

freed.

[8]

[9]

Figure 4-331

6) Remove the E-ring [10], and remove the

gear [11].

7) Remove the grip ring [12], and remove

the gear [13].

[11]

[10]

8) Remove the gear [14].

[14]

[12]

[13]

Figure 4-332

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CHAPTER 4 IMAGE FORMATION SYSTEM

9) Remove the two mounting screws [15];

then, remove the bearing holder (rear)

[16], bearing [17], and developing roll

[18].

[16]

[15]

[18]

[17]

Figure 4-333

10) Remove the developing cylinder [19].

Caution

Do not leave fingerprints or oils on

the surface of the developing cylinder.

As necessary, dry wipe the surface

with lint-free paper.

[19]

Figure 4-334

4–40

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CHAPTER 5

PICK-UP/FEEDING SYSTEM

This chapter 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.

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

III. PICK-UP FROM THE MULTIFEEDER .... 5-8

A. Pick-Up Operation .............................. 5-8

B. Detecting the Size of Paper

IV. CONTROLLING THE REGISTRATION

CLUTCH ................................................. 5-11

V. DETECTING JAMS ................................ 5-12

A. Outline .............................................. 5-12

B. Sequence of Operations

(jam detection).................................. 5-13

VI. DISASSEMBLY/ASSEMBLY ................. 5-15

A. Pick-Up Assembly ............................ 5-16

B. Multifeeder Assembly....................... 5-20

C. Registration Roller Assembly........... 5-23

D. Cassette Assembly .......................... 5-24

in the Multifeeder................................ 5-9

C. Sequence of Operations

(pick-up from multifeeder) ................ 5-10

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CHAPTER 5 PICK-UP/FEEDING SYSTEM

I. OUTLINE OF OPERATION

The copier uses a center reference feeding method, in which copy paper is moved along the

center of the pick-up/feeding path to ensure stable movement.

The pick-up system consists of the cassette No. 1 holder and the multifeeder. Copy paper

picked up from the cassette or the multifeeder is controlled by the registration roller so that it is

aligned with the leading edge of the image on the photosensitive drum, and is sent through the

transfer, separation, and fixing assemblies and then to the copy tray.

As many as two sensors are used to monitor the movement of the copy paper.

No.

PS5

PS6

Sensor

Description

Registration paper sensor

Delivery paper sensor

Detects delay/stationary jams, measures paper length.

Detects delay/stationary jams.

Table 5-101

Registration

roller

Fixing

assembly

Photosensitive

drum

Multifeeder

PS6

PS5

Cassette

Figure 5-101

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CHAPTER 5 PICK-UP/FEEDING SYSTEM

II. PICK-UP FROM THE CASSETTE

A. Pick-Up Operation

The pick-up roller and the feed roller are controlled by the pick-up solenoid (SL1).

The stack of copy paper inside the cassette is held up by the lifter, and the pick-up roller is

controlled by the pick-up solenoid and is kept away from the surface of the stack.

When the pick-up solenoid turns on, the claws move away from the pick-up gear, and the

drive of the main motor (M1) is transmitted to the pick-up roller and the feed roller.

A single sheet of copy paper is picked up and sent to the feed roller by the work of the pick-

up roller and the separation claws. If multiple sheets should be picked up, the feed roller and the

separation roller would serve to make sure that no more than a single sheet is sent forward to the

vertical path roller.

The copy paper is then moved by the vertical path roller to the registration roller. In response,

the registration roller controls the movement of the copy paper so that its leading edge matches

the image on the photosensitive drum.

Power supply

Feed roller

Registration roller

PCB

Main motor drive

command

Vertical

path roller

Pick-up

roller

Registration paper detection signal (RGPDT)

CL2

Photosensitive

Feed roller clutch drive command (FEED CL*)

drum

controller

PCB

Registration roller

Power supply

clutch drive

PCB

command

CL1

SL1

PS5

(RG CL*)

Pick-up solenoid drive command (PU SL*)

Cassette paper detection signal (CSTPDT)

PS4

Separation roller

Figure 5-201

5–2

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CHAPTER 5 PICK-UP/FEEDING SYSTEM

B. Sequence of Operations (pick-up/feeding)

•

A4, 2 Copies

Start key

Sequence

STBY

INTR

AER

SCFW SCRV SCFW SCRV LSTR STBY

Main motor (M1)

Scanner motor (M2)

Scanner home position

sensor (PS1)

Pick-up solenoid (SL1)

Registlation paper sensor

(PS5)

Registlation roller clutch

(CL1)

Feed roller clutch (CL2)

Delivery paper sensor (PS6)

Figure 5-202

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CHAPTER 5 PICK-UP/FEEDING SYSTEM

C. Operation of the Cassette Lifter

When the cassette is pushed inside the copier, the lifter stopper will be freed, and the lifter

will move up by the force of a spring. At this time, the copy paper will push up the paper

detecting lever of the cassette paper sensor (PS4) to enable detection of the presence/absence of

copy paper.

The rear end guide plate is slid in conjunction with the upward movement of the lifter to

improve pick-up performance.

Paper detection lever

Lifter stopper

PS4

Lifter

Rear guide plate

Figure 5-205

5–4

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CHAPTER 5 PICK-UP/FEEDING SYSTEM

The copier’s cassette is designed to apply auxiliary pressure on paper of B4 or wider. The

auxiliary tension spring acts on the lifter through the cut-off in the bottom of the cassette when

the side guide plate is slid to the outside. In the case of paper narrower than B4, the spring

remains slack and therefore does not act on the lifter.

Auxiliary pressure spring

Cut-off

Auxiliary pressure lever

Lifter

Figure 5-206

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CHAPTER 5 PICK-UP/FEEDING SYSTEM

D. Detecting the Size of the Cassette

1. Outline

The presence of paper and the size of paper inside the cassette are checked by the cassette

size switch PCB mounted to the left of the cassette slot.

When the cassette is set in the copier, the cassette paper size switching block and the AB/

Inch switching block act on the cassette size switch PCB to enable detection of the presence/

absence of a cassette and the size of paper inside it.

The cassette paper size switching block slid to the front and rear by the work of the cam

linked to the cassette paper size dial, causing the cassette paper size switching block to turn on/

off the cassette size switch PCB.

The AB/Inch switching block, on the other hand, turns on/off the switch on the cassette size

switch PCB according to how it is positioned. (The AB and Inch size notations are switched over

by sliding the AB/Inch switching lever.)

AB/Inch

changing lever

Cassette paper

size display

Cassette paper size

changing block

A4R

Cassette paper size

setting knob

Cam

AB/Inch changing block

Figure 5-207

5–6

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CHAPTER 5 PICK-UP/FEEDING SYSTEM

2. Detecting the Cassette Size

The AB configuration and the Inch configuration are distinguished by the switch (SW654) on

the cassette switching PCB.

The size of the paper inside the cassette is identified with reference to the states (on/off) of

the switches (SW651 through 653) on the cassette size switch PCB.

Table 5-201 shows the combinations used to identify specific paper sizes.

Cassette size switch PCB

SW651

SW652

SW653

SW654

Figure 5-208

•AB size (SW654=0)

•Inch size (SW654=1)

Result of detection

SW651 SW652 SW653

Result of detection

No cassette

LGL

SW651 SW652 SW653

No cassette

U2*

LDR

B5R

LTR

LTR-R

A4R

U1*

No cassette

*Non-AB/Inch configuration sizes may be registered

(default sizes only) in service mode [5].

Table 5-201

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CHAPTER 5 PICK-UP/FEEDING SYSTEM

III. PICK-UP FROM THE MULTIFEEDER

A. Pick-Up Operation

The presence/absence of copy paper in the multifeeder is detected by the multifeeder paper

sensor (PS7).

When the multifeeder is selected and the Start key is pressed, the multifeeder solenoid (SL2)

turns on to butt the paper guide plate against the multifeeder pick-up roller.

Then, the multifeeder roller clutch (CL3) turns on to transmit the drive of the main motor

(M1) to the multifeeder pick-up roller. A single sheet of copy paper is picked up from the stack

by the work of the multifeeder pick-up roller and the separation pad, and is sent to the

registration roller.

This sequence of operations is repeated for each pick-up operation.

DC controller PCB

Stopper

CL3

SL2

Multifeed

roller

clutch (CL3)

Multifeed

solenoid

(SL2)

Control ring

Cam

Paper guide

plate

Control ring

Cam

Multifeeder paper

sensor (PS7)

Multifeed roller

Separation pad

Paper guide plate

Figure 5-301

5–8

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CHAPTER 5 PICK-UP/FEEDING SYSTEM

B. Detecting the Size of Paper in the Multifeeder

When the user sets the slide guide of the multifeeder to the width of copy paper, the

multifeeder paper width sensor 1 (PS9) and the multifeeder paper width sensor (PS10) operating

in conjunction with the movement of the side guide detect the width of the copy paper.

The identified width is used for blank exposure and fixing temperature control. The length of

copy paper in multifeeder mode is detected with reference to how long the registration paper

sensor (PS5) remains on.

Slide guide (front)

PS10

PS9

Tape

Slide guide (rear)

Multifeeder paper width

detection signal 1 (MLTPD1)

controller

PCB

PS9

Multifeeder paper width

detection signal 2 (MLTPD2)

PS10

Slide guide (front)

Multifeeder tray

Figure 5-302

Paper width (mm)

Paper width > 257

PS9

PS10

257 Paper width > 216

216 Paper width > 182

182 Paper width

Table 5-301

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CHAPTER 5 PICK-UP/FEEDING SYSTEM

C. Sequence of Operations (pick-up from multifeeder)

•

A4, 2 Copies

Start key

Sequence

STBY

INTR

AER

SCFW SCRV SCFW SCRV LSTR STBY

Main motor (M1)

Scanner motor (M2)

Scanner home position

sensor (PS1)

Multifeed solenoid (SL2)

Registration paper sensor

(PS5)

Registration roller clutch

(CL1)

Multifeed roller clutch (CL3)

Delivery paper sensor (PS6)

Figure 5-303

5–10

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CHAPTER 5 PICK-UP/FEEDING SYSTEM

IV. CONTROLLING THE REGISTRATION CLUTCH

The registration clutch exerts the following control so as to match copy paper with the image

on the photosensitive drum at a specific location.

Selected copy mode

Control timing

Image area on copy paper

Remarks

Standard copying

Page separation

The size of margin

C varies to suit the

Centering

OFF

selected reproduction

ratio and copy paper

size. The size of margin

D is 21.6 mm maximum.

Fit to page

C-D

Centering

Copy paper

Image area

Drum

Image on drum

Copy paper

Image on drum

Copy paper

Copy paper behind image

on drum

Copy paper ahead of

image on drum

Figure 5-401

If centering is turned on in Fit Page mode, control is exerted so that half of the trailing edge

C resulting in relation to the selected reproduction ratio and copy paper size will be the leading

edge margin. The maximum leading edge margin in such cases, however, is 21.6 mm.

If centering is turned off in Fit Page mode, control is exerted so that the leading edge of copy

paper and the leading edge of the image on the photosensitive drum match.

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CHAPTER 5 PICK-UP/FEEDING SYSTEM

V. DETECTING JAMS

A. Outline

The copier is equipped with the following two sensors used to check the movement of copy

paper.

• Registration paper sensor (PS5)

• Delivery paper sensor (PS6)

Jams are identified in relation to the presence/absence of copy paper over each sensor at such

times as programmed in the microprocessor. As soon as a jam is identified, the microprocessor

will immediately stop the operation, and flash the Jam indicator on the control panel.

The microprocessor identifies any of the following conditions as a jam:

a. Paper exists over a specific sensor at power-on, at end of warm-up, or during standby

(power-on jam).

b. Paper fails to reach a specific sensor within a specific period of time (delay jam).

1. Registration delay jam detected by the registration paper sensor (PS5).

2. Delivery delay jam detected by the delivery paper sensor (PS6).

c. Paper does not move past a specific sensor within a specific period of time (stationary jam).

1. Registration stationary jam detected by the registration paper sensor (PS5).

2. Delivery paper stationary jam detected by the delivery paper sensor (PS6).

Registration

roller

Multifeed

roller

Fixing

assembly

Multifeeder

Photo-

sensitive

drum

Vertical path

roller

PS6

PS5

Cassette

Pick-up

roller

Feed Separation

roller roller

Figure 5-501

5–12

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CHAPTER 5 PICK-UP/FEEDING SYSTEM

B. Sequence of Operations (jam detection)

1. Registration Delay Jam

Start key

Jam indicator

flashed

Sequence

STBY

INTR

SCFW SCRV SCFW

approx

1.5sec

approx

1.5sec

Jam check

Pick-up solenoid (SL1)

Feed roller clutch (CL2)

Registration paper sensor

(PS5)

Normal

Error

Main motor (M1)

Figure 5-502

2. Registration Stationary Jam

Start key

Jam indicator

flashed

Sequence

STBY

INTR

SCFW SCRV SCFW

Jam check

Pick-up solenoid (SL1)

Feed roller clutch (CL2)

Registration paper sensor

(PS5)

Normal

Error

Main motor (M1)

*1:Varies according to paper size.

Figure 5-503

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CHAPTER 5 PICK-UP/FEEDING SYSTEM

3. Delivery Delay Jam

Start key

Jam indicator

flashed

Sequence

Jam check

STBY

INTR

SCFW SCRV SCFW SCRV

approx 2.2sec

Registration roller clutch

(CL1)

Normal

Error

Delivery paper sensor (PS6)

Main motor (M1)

Figure 5-504

4. Delivery Stationary Jam

Start key

Jam indicator

flashed

Sequence

Jam check

STBY

INTR

SCFW SCRV SCFW SCRV LSTR

Registration roller clutch

(CL1)

Normal

Error

Delivery paper sensor (PS6)

Main motor (M1)

*1:Varies according to paper size.

Figure 5-505

5–14

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CHAPTER 5 PICK-UP/FEEDING SYSTEM

VI. DISASSEMBLY/ASSEMBLY

The copier may be disassembled and assembled as shown here. Pay attention to the copier’s

mechanical characteristics along with the steps for disassembly/assembly.

Important:

1. Turn off the power and disconnect the power plug to ensure safety whenever disassembling/

assembling the copier.

2. Unless otherwise noted, assemble the parts by reversing the steps used to disassemble them.

3. Identify the screws by type (length, diameter) to avoid use in the wrong location.

4. Use a washer where needed. The mounting screws used for the grounding wire and varistor

come with a washer to ensure electric continuity. Do not forget to use these washers.

5. As a rule, do not operate the copier with any of its parts removed.

1998 CANON INC.

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5–15

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CHAPTER 5 PICK-UP/FEEDING SYSTEM

A. Pick-Up Assembly

1. Removing the Pick-Up Roller

1) Remove the cassette.

[3]

[2]

[1]

2) Remove the stepped screw [1], and pull

the roller support plate [2] to the front to

remove.

3) Remove the pick-up roller assembly [3].

Figure 5-601

4) Push the section indicated by an arrow,

and remove the two pick-up rollers [4].

[4]

Figure 5-602

2. Mounting the Pick-Up Roller

Mount the pick-up roller by reversing the

steps used to remove it and with the following

in mind:

• Match the boss on the pick-up roller and the

cut-off in the holder.

• Do not detach the rubber section of the

pick-up roller.

• When mounting the pick-up roller assembly

to the copier, be sure to position it securely

face up.

5–16

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CHAPTER 5 PICK-UP/FEEDING SYSTEM

3. Removing the Pick-Up Drive

Assembly

[1]

1) Remove the registration roller assembly.

(See p. 5-23.)

2) Remove the E-ring [1], and slide the

vertical path roll [2] in the direction of the

arrow.

3) Remove the bushing [3], and then vertical

path roller [2] together with the gear [4].

[3]

[2]

[4]

Figure 5-603

[5]

4) Remove the four mounting screws [5],

and remove the pick-up drive assembly

[6].

[6]

[5]

Figure 5-604

4. Removing the Pick-Up Assembly

1) Remove the separation roller assembly.

(See p. 5-18.)

2) Remove the registration roller assembly.

(See p. 5-23.)

[2]

3) Disconnect the connector [1], and remove

the two screws [2].

[1]

[2]

Figure 5-605

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CHAPTER 5 PICK-UP/FEEDING SYSTEM

4) Slide the pick-up assembly [3] to the rear,

and remove the hook.

[3]

Figure 5-606

5. Removing the Feed Roller

1) Remove the separation roller assembly.

2) While holding the claw [A], move the

feed roller [2] in the direction of the arrow

to remove.

[A]

[2]

Figure 5-607

6. Removing the Separation Roller

1) Remove the cassette.

2) Remove the right door. (See p.7-10)

3) Remove the two mounting screws [1], and

remove the separation roller assembly [2].

[1]

[2]

[1]

Figure 5-608

5–18

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CHAPTER 5 PICK-UP/FEEDING SYSTEM

4) Remove the roller cover [3].

[3]

Figure 5-609

[5]

5) Remove the two bushings [4], and remove

the two springs [5].

[4]

Figure 5-610

[6]

6) While pushing the claw [A] with a flat-

blade screwdriver, remove the separation

roller [6].

[A]

Figure 5-611

7. Mounting the Separation Roller

Mount the separation roller by reversing

the steps used to remove it and with the

following in mind:

[1]

[2]

• When mounting the separation roller, be

sure to fit the pin [1] in the groove [2]

of the holder.

• When mounting the roller cover, be sure

so that the roller cover will push against

the bushing.

Figure 5-612

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CHAPTER 5 PICK-UP/FEEDING SYSTEM

B. Multifeeder Assembly

1. Removing the Multifeeder Tray

1) Open the multifeeder tray, and remove the

face cover [1] using a flat-blade

screwdriver.

[1]

Figure 5-613

2) Remove the guide pin [2], and remove the

multifeeder tray [3].

[2]

[3]

Figure 5-614

2. Removing the Multifeeder

Assembly

1) Remove the rear cover, and open the right

door.

[1]

2) Remove the lower inside cover. (See p.7-

12.)

3) Disconnect the two connectors [1], and

remove the mounting screw [2].

[2]

Figure 5-615

5–20

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CHAPTER 5 PICK-UP/FEEDING SYSTEM

4) Disconnect the two connectors [3], and

remove the three mounting screws [4];

then, detach the multifeeder assembly [5].

[3]

The two holes each

(upper/lower) are

spare holes.

[5]

[4]

Figure 5-616

3. Removing the Multifeeder Pick-Up

Roller

1) Remove the developing assembly. (See p.

4-37.)

[1]

2) Remove the drum unit. (See p. 4-28.)

3) Remove the E-ring [1]; then, while

pushing down the multifeeder separation

pad [2] to free it from pressure, detach the

multifeeder pick-up roller [3].

[3]

[2]

Figure 5-617

4. Removing the Separation Pad

1) Execute service mode 402 (multifeeder

holding plate release) in standby state so

as to lift the multifeeder holding plate [1].

[1]

Figure 5-618

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CHAPTER 5 PICK-UP/FEEDING SYSTEM

2) Turn off the copier, and disconnect the

power plug.

Caution:

Whenever you need to perform

disassembly/assembly work, be sure

to turn off the copier and disconnect

its power plug.

[2]

[3]

3) Open the right door.

4) Remove the mounting screw [2], and slide

the multifeeder separation pad assembly

[3] in the direction of the arrow to

remove.

Figure 5-619

[4]

[5]

5) Detach the multifeeder separation pad [5]

from the holder [4].

Figure 5-620

5. Adjusting the Pressure of the

Separation Pad

If double feeding or pick-up failure

occurs, loosen the adjusting screw [1] and

relocate the holder [2] to adjust the force of

the separation pad tension spring.

• If pick-up failure occurs, move the holder in

the direction of [A].

[2]

[A]

[B]

• If double feeding occurs, move the holder

in the direction of [B].

[1]

Figure 5-621

5–22

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CHAPTER 5 PICK-UP/FEEDING SYSTEM

C. Registration Roller

Assembly

[1]

1. Removing the Registration Roller

Assembly

1) Remove the developing assembly. (See p.

4-37.)

2) Remove the drum unit. (See p. 4-28.)

3) Remove the multifeeder assembly. (See p.

5-20.)

4) Disconnect the connector [1], and remove

the grip right [2]; then, detach the

registration roller clutch [3].

[3]

[2]

Figure 5-622

[5]

5) Disconnect the connector [4], and remove

the three mounting screws [5]; then,

detach the registration roller assembly [6].

[5]

[6]

[4]

Figure 5-623

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CHAPTER 5 PICK-UP/FEEDING SYSTEM

D. Cassette Assembly

1. Removing the Cassette Size Switch

1) Remove the cassette.

2) Remove the delivery lower cover. (See

p.7-11)

3) Disconnect the connector [1] (J110) of the

DC controller PCB, and remove the

mounting screw [2] ; then, free the

harness from the harness guide.

[2]

[1]

Figure 5-624

[5]

[4]

[3]

4) Remove the mounting screw [3], and

remove the stopper [4].

5) Remove the cassette switch assembly [5].

Figure 5-625

[7]

[8]

[6]

6) Remove the hook [6], and remove the

cassette size switch [7].

Caution:

When mounting the cassette size

switch assembly, check to make sure

that the cassette size switch assembly

slides normally by the work of the

spring [8] pressure.

Figure 5-626

5–24

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CHAPTER 5 PICK-UP/FEEDING SYSTEM

2. Changing the Cassette Size (AB/

INCH)

•AB

1) Slide out the cassette.

[2] [1]

2) Loosen the mounting screw [1] on the left

side of the cassette; then, slide the size

switching block [2] to the desired size

position, and fix it in place.

[1]

[2]

•INCH

•AB

Figure 5-627

3) Remove the mounting screw [3]; then,

slide the size switching lever [4] to the

desired size position, and fix it in place.

[4]

[3]

[4]

[3]

•INCH

Figure 5-628

1998 CANON INC.

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CHAPTER 5 PICK-UP/FEEDING SYSTEM

3. Adjusting the Left/Right

Registration

Turn the adjusting screw [1] until the

cassette locking lever plate [2] and the

cassette locking lever [3] engage.

When the adjusting screw [1] is turned

clockwise, the cassette locking plate moves to

the front.

[1]

When the adjusting screw [1] is turned

counterclockwise, the cassette locking lever

plate [2] moves to the rear.

[2]

[3]

Figure 5-629

(-)

(+)

Figure 5-630

5–26

1998 CANON INC.

CANON NP7161/NP7160 REV.0 AUG. 1998 PRINTED IN JAPAN (IMPRIME AU JAPON)

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CHAPTER 6

FIXING SYSTEM

This chapter explains the principles used to fuse toner images to transfer medium in view of the func-

tions 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.

I. OUTLINE OF OPERATION ..................... 6-1

A. Outline ................................................ 6-1

B. Controlling the Fixing Temperature ... 6-2

C. Error Detection Circuit........................ 6-5

II. DISASSEMBLY/ASSEMBLY ................... 6-7

A. Fixing Assembly ................................. 6-8

B. Delivery Assembly............................ 6-16

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CHAPTER 6 FIXING SYSTEM

I. OUTLINE OF OPERATION

A. Outline

The upper roller and the lower roller of the fixing assembly and the delivery roller of the

delivery assembly are operated by the drive from the main motor (M1) coming through gears.

The upper roller has a built-in heater which is kept on during WMUP after power-on at 1000

W (120 V)/1050 W (230 V). Other than WMUP, the heater is subjected to phase control, and is

turned on at 805 w (120/230 V) or off.

The fixing temperature is detected with reference to the surface temperature of the upper

roller rear end detected by the main thermistor (TH1) and the sub thermistor (TH2), and is

communicated to the microprocessor on the DC controller PCB.

Based on the thermistor signal (TH1, TH2), the DC controller PCB turns on/off the fixing

heater drive signal (HEAT_DR) to turn on/off the fixing heater (H1), thereby keeping it at the

target temperature. To cut off AC power to the heater in the event of overheating, a thermal

switch (TSW1) is mounted at the front of the fixing upper roller.

The copier is designed to remove toner adhering to the upper or the lower roller; for this

reason, its heat discharge roller is kept in firm contact with the lower roller.

Fixing sub thermistor signal (TH2)

+24V GND

RL1

HEAT DR

Power

supply

PCB

controller

PCB

TSW1

HEAT ERR

TH1

TH2

Fixing main thermistor signal (TH1)

Fixing upper

roller

Delivery

roller

Pressure

roller

Heat discharge

roller

Figure 6-101

Reference:

Fixing heater:

Thermal switch:

1000 W for the 120 V model, 1050 W for the 230 V model.

230 ±10°C.

1998 CANON INC.

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CHAPTER 6 FIXING SYSTEM

B. Controlling the Fixing Temperature

The copier uses two thermistors mounted at the rear ends of the upper roller to monitor

surface temperature. When copies are made continuously using sheets of B4 or less, the

temperature of the area (center) coming into contact with the paper will be lower than the

temperature of the areas (ends) not coming into contact with the paper. To prevent such a

problem, the target temperature is varied in steps to suit the width of copy paper and the

temperature detected by the thermistor during copying operation.

To improve fixing on rough surface paper or tracing paper, a special paper mode (U13) has

been added to user mode, thereby enabling a target temperature unique to these types of paper.

• Paper Width >257 mm

Target temperature immediately

after Start key on

Target temperature during

continuous copying (upper limit)

Temperature detected by

thermistor at Start key on

General plain paper Paper with rough surface

Tracing paper

General plain paper Paper with rough surface

Tracing paper

Less than 170°C

171°C

181°C

196°C

200°C

206°C

209°C

161°C

171°C

170°C or more, less than 180°C

180°C or more, less than 190°C

190°C or more

181°C

209°C

171°C

Table 6-101

• 257 mm > Paper Width > 216 mm

Target temperature immediately

after Start key on

Target temperature during

continuous copying (upper limit)

Temperature detected by

thermistor at Start key on

General plain paper Paper with rough surface

Tracing paper

General plain paper Paper with rough surface

Tracing paper

169°C

Less than 170°C

179°C

188°C

193°C

196°C

201°C

206°C

211°C

170°C or more, less than 180°C

180°C or more, less than 190°C

190°C or more

178°C

193°C

211°C

183°C

Table 6-102

• 216 mm > Paper Width > 182 mm

Target temperature immediately

after Start key on

Target temperature during

continuous copying (upper limit)

Temperature detected by

thermistor at Start key on

General plain paper Paper with rough surface

Tracing paper

General plain paper Paper with rough surface

Tracing paper

167°C

Less than 170°C

177°C

186°C

192°C

200°C

196°C

202°C

207°C

214°C

170°C or more, less than 180°C

180°C or more, less than 190°C

190°C or more

176°C

200°C

214°C

190°C

182°C

190°C

Table 6-103

6–2

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CHAPTER 6 FIXING SYSTEM

• 182 mm > Paper Width

Target temperature immediately

after Start key on

Target temperature during

continuous copying (upper limit)

Temperature detected by

thermistor at Start key on

General plain paper Paper with rough surface

Tracing paper

General plain paper Paper with rough surface

Tracing paper

165°C

Less than 170°C

175°C

186°C

194°C

200°C

196°C

204°C

208°C

215°C

170°C or more, less than 180°C

180°C or more, less than 190°C

190°C or more

176°C

200°C

215°C

190°C

184°C

190°C

Table 6-104

• From Power-On to End of Copying

Power switch

Start key

Sequence

WMUP WMUPR STBY INTR

COPY

LSTR STBY

(flashing) Green

Orange

Wait indicator

Main motor (M1)

Fixing heater (H1)

Target temperature control

220°C

200°C

180°C

160°C

140°C

120°C

Paper with rough surface mode

General plain paper mode

Tracing paper mode

*1:Varies according to paper width.

Figure 6-102

1998 CANON INC.

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CHAPTER 6 FIXING SYSTEM

• Power Save Key ON or Auto-Power OFF

Start key

Energy saver Auto power

key ON OFF

Sequence

STBY

INTR

COPY

LSTR

STBY

Energy saver

indicator

Main motor (M1)

Fixing heater (H1)

Target temperature control

220°C

200°C

180°C

160°C

140°C

120°C

*1:Varies according to paper width.

*2:May be varied in user mode.

Figure 6-103

6–4

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CHAPTER 6 FIXING SYSTEM

C. Error Detection Circuit

1. Outline

The copier’s error detection circuit is constructed as shown in Figure 6-104, and monitors the

following items for an error:

• Surface temperature of the upper fixing roller

• Activation of the fixing heater (H1)

AC power line

DC signal line

Fixing assembly

CB1

CB2

TH1

TH2

J201

-2

TSW

RL1

DS1

-1

driver

J210

-1

+24V

-2

Power supply PCB

HVT

+5V

Buffer

+5V

Buffer

Error

detection

circuit

+5V

Gate

array

timer

IC113

Heater ON

detection

IC119

CPU

Converter

DC controller PCB

Figure 6-104

1998 CANON INC.

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CHAPTER 6 FIXING SYSTEM

2. Surface Temperature of the Fixing Upper Roller

The main thermistor (TH1) and the sub thermistor are arranged nearby at the rear of the

fixing upper roller, and are used to monitor the difference in voltage between two thermistor

signals (TH1, TH2).

If either thermistor suffers an open circuit, the CW input terminal of the differential amplifier

circuit will be about 5 V. At this time, the voltage of the other thermistor will decrease as the

surface temperature of the fixing upper roller increases, gradually increasing the output of the

differential amplifier circuit.

When the output of the differential amplifier circuit exceeds the value set on the comparator,

the comparator will send a signal to the gate array. When the gate array detects the signal from

the comparator for a specific period of time, the DC controller PCB will cut off 24 V and AC

power supply and, at the same time, will indicate ‘E000’, ‘E002’, or ‘E003’.

If the connector of the main thermistor is not connected or both thermistors suffer an open

circuit, the microprocessor will not be able to detect any excess increases in the surface

temperature of the fixing upper roller, causing it to indicate ‘E000’, ‘E002’, or ‘E003’ on the

control panel.

3. Activation of the Fixing Heater (H1)

The fixing heater error signal (HEAT_ERR) from the AC drier is monitored by IC113 on the

DC controller PCB, and its reading is compared against the fixing heater drive signal

(HEAT_DR) to find out whether the power to the fixing heater is normal or not.

If the microprocessor on the DC controller PCB identifies the state of the fixing heater to be

faulty, it will cut the power supplied to the fixing heater and, at the same time, will indicate

‘E001’ on the control panel.

6–6

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CHAPTER 6 FIXING SYSTEM

II. DISASSEMBLY/ASSEMBLY

The copier may be disassembled and assembled as shown here. Pay attention to the copier’s

mechanical characteristics along with the steps for disassembly/assembly.

Important:

1. Turn off the power and disconnect the power plug to ensure safety whenever

disassembling/assembling the copier.

2. Unless otherwise noted, assemble the parts by reversing the steps used to disassemble

them.

3. Identify the screws by type (length, diameter) to avoid use in the wrong location.

4. Use a washer where needed. The mounting screws used for the grounding wire and

varistor come with a washer to ensure electric continuity. Do not forget to use these

washers.

5. As a rule, do not operate the copier with any of its parts removed.

1998 CANON INC.

CANON NP7161/NP7160 REV.0 AUG. 1998 PRINTED IN JAPAN (IMPRIME AU JAPON)

6–7

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CHAPTER 6 FIXING SYSTEM

[1]

A. Fixing Assembly

1. Construction

[1] Upper roller

[2] Lower roller

[3] Heat discharge roller

[4] Delivery roller

[4]

[2]

[3]

Figure 6-201

2. Locking Mechanism

Fulcrum

Locking arm

Figure 6-202

[1]

3. Removing the Fixing Assembly

1) Remove the rear cover.

2) Disconnect the connector [1].

Figure 6-203

6–8

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CHAPTER 6 FIXING SYSTEM

3) Remove the drum unit. (See p. 4-28.)

4) Remove the delivery upper cover. (See p.

7-11.)

5) Remove the delivery lower cover. (See p.

7-11.)

6) Disconnect the two connectors [2] (J108,

J109) on the DC controller PCB, and free

the wires from the harness guide.

[2]

Figure 6-204

[4]

7) Remove the front door.

[6]

[3]

8) Turn the screw [3] counterclockwise, and

remove the fixing knob [4].

9) Remove the two mounting screws [5], and

remove the fixing front cover [6].

[5]

Figure 6-205

[7]

10) Disconnect the connector [7], and free the

harness from the harness guide.

11) Remove the two mounting screws [8].

[8]

Figure 6-206

1998 CANON INC.

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CHAPTER 6 FIXING SYSTEM

12) Lift the front of the fixing assembly [9]

slightly to remove.

Caution:

When removing the fixing assembly,

take care not to damage the feeding

assembly.

[9]

Figure 6-207

[1]

4. Removing the Fixing Heater

1) Remove the fixing assembly. (See p. 6-8.)

2) Disconnect the two connectors [1], and

free the harness from the harness guide.

3) Remove the mounting screw [2], and

detach the heater support plate (front) [3].

[3]

[2]

Figure 6-208

4) Remove the mounting screw [4], and free

the harness from the harness guide; then,

detach the connector support plate [5].

5) Disconnect all connectors [6] from the

connector support plate [5].

[8]

6) Remove the mounting screw [7], and free

the harness; then, detach the harness guide

[8].

[7]

[6]

[5]

[4]

Figure 6-209

6–10

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CHAPTER 6 FIXING SYSTEM

7) Free the harness from the harness retainer

[9].

8) Remove the two mounting screws [10],

and detach the heater support plate (rear)

[11].

[10]

[9]

[11]

[10]

Figure 6-210

9) Free the harness from the harness guide

[12], and detach the fixing heater [13].

Caution:

1.Do not start work if the surface of

the fixing heater is hot.

2.Do not touch the surface of the

fixing heater.

3.If the surface of the fixing heater is

soiled, dry wipe it.

[12]

[13]

Figure 6-211

[1]

5. Removing the Thermal Switch

Assembly

1) Remove the fixing assembly. (See p. 6-8.)

2) Disconnect the two connectors [1].

Figure 6-212

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CHAPTER 6 FIXING SYSTEM

3) Remove the mounting screw [2], and

detach the thermal switch assembly [3].

[2]

[3]

Figure 6-213

6. Removing the Main Thermistor

1) Remove the fixing assembly. (See p. 6-8.)

2) Remove the mounting screw [1], and free

the harness from the harness guide; then,

detach the main thermistor [2].

[2]

[1]

[A]

Figure 6-214

7. Removing the Sub Thermistor

1) Remove the fixing assembly. (See p. 6-8.)

2) Open the upper delivery assembly, and

insert a screwdriver into the hole [A] to

keep the upper delivery assembly from

closing.

Figure 6-215

3) As shown, pick the hook assembly with

pincers, and remove the tension spring

[1].

[1]

Figure 6-216

6–12

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CHAPTER 6 FIXING SYSTEM

[3]

4) Remove the mounting screw [2].

5) Free the harness from the harness guide,

and remove the sub thermistor [3].

[2]

Figure 6-217

[2]

8. Removing the Fixing Upper Roller

1) Remove the fixing heater. (See p. 6-10.)

2) Remove the upper delivery assembly.

(See p. 6-16.)

[1]

3) Remove the lower delivery assembly (See

p. 6-17.)

4) Remove the three mounting screws [1],

and remove the fixing upper inlet guide

assembly [2].

[1]

Figure 6-218

[6]

5) Remove the double gear [3] and the C-

ring [4]; then, detach the gear [5] and the

bushing [6].

[5]

[4]

[3]

Figure 6-219

[9]

[8]

6) Remove the C-ring [7], and detach the

gear [8] and the bushing [9].

[7]

7) Remove the fixing upper roller [10].

[10]

Figure 6-220

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CHAPTER 6 FIXING SYSTEM

9. Removing the Fixing Lower Roller

1) Remove the fixing upper roller. (See p. 6-

13.)

2) Remove the bearing [1] and the fixing

lower roller [2].

[1]

[2]

[1]

Figure 6-221

10.Removing the Heat Discharge

Roller

[1]

1) Remove the fixing assembly. (See p. 6-8.)

2) Remove the two mounting screws [1], and

detach the fixing inlet guide assembly [2].

[2]

Figure 6-222

[3]

3) Remove the heat discharge roller [3].

Caution:

If you have removed the height

adjusting screw of the inlet guide, be

sure to perform the steps under

“Adjusting the Height of the Fixing

Inlet Guide.”

Figure 6-223

11.Adjusting the Height of the Fixing

Inlet Guide

[1]

Loosen the two adjusting screws [1], and

adjust the height of the fixing inlet guide [2].

[2]

Figure 6-224

6–14

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CHAPTER 6 FIXING SYSTEM

12. Adjusting the Nip

The nip is appropriate if it is as indicated

in Table 6-201.

[1]

If it is not as indicated, relocate the

tension spring [1].

Note:

a and c are points 10 mm from both

ends of copy paper.

Figure 6-225

Dimensions

Measurements*

4.8 ± 0.3mm

Feeding

direction

Center of

copy paper

I a - c I

0.5mm or less

*Be sure both upper and lower rollers are

sufficiently warm before taking measurements.

Table 6-201

Figure 6-226

a. Measuring the Nip

When the copier finishes warm-up, wait

for 15 minutes. Then, make 20 A4 copies

before measuring the nip.

1) Place A3 copy paper in the multifeeder,

and select the multifeeder as the source of

paper.

2) Open the copyboard over.

3) Execute service mode 406 (fixing nip

check).

• The copy paper will be stopped when its

leading edge is about 100 mm, and will

automatically be discharged (See Figure

6-226).

1998 CANON INC.

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CHAPTER 6 FIXING SYSTEM

[A]

B. Delivery Assembly

1. Removing the Upper Separation

Claw

1) Remove the fixing assembly. (See p. 6-8.)

2) Remove the stepped screw [1], and detach

the bend [A]); then, detach the upper

delivery assembly [2].

[2]

[1]

Figure 6-227

[3]

3) Remove the two stepped screws [3], and

slide the upper separation claw assembly

[4] in the direction of the arrow to

remove.

[3]

[4]

Figure 6-228

4) Detach the spring [5], and detach the

upper separation claw [6].

[6]

[5]

Figure 6-229

[2]

2. Removing the Lower Separation

Claw

1) Remove the delivery roller. (See p. 6-17.)

2) Remove the two stepped screws [1], and

free the harness; then, detach the lower

separation claw assembly [2].

[1]

Figure 6-230

6–16

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CHAPTER 6 FIXING SYSTEM

[4]

3) Detach the spring [3], and detach the

lower separation claw [4].

[3]

Figure 6-231

3. Removing the Delivery Roller

1) Remove the two tension springs [1] and

the two mounting screws [2]; then,

remove the delivery roller assembly [3].

[2] [1]

[3]

[1] [2]

Figure 6-232

2) Remove the grip ring [4], and remove the

gear [5].

3) Remove the two E-rings [6] and the two

bushings [7]; then, detach the delivery

roller [8].

[6]

[7]

[6]

[7]

[5]

[4]

Figure 6-233

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CHAPTER 7

EXTERNALS/AUXILIARY MECHANISMS

This chapter 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.

I. FANS ........................................................ 7-1

II. POWER SUPPLY..................................... 7-4

A. Outline of Power Supply .................... 7-4

B. Power Supply Circuitry....................... 7-5

C. Protection Mechanisms of the

Power Supply Circuitry....................... 7-7

III. DISASSEMBLY/ASSEMBLY ................... 7-8

A. External Covers.................................. 7-9

B. Control Panel.................................... 7-13

C. Copyboard Glass ............................. 7-14

D. Fans.................................................. 7-15

E. Counter Assembly ............................ 7-18

F. Main Motor Assembly....................... 7-18

G. DC Controller PCB ........................... 7-19

H. Removing the Power Supply PCB ... 7-20

I. Removing the High-Voltage Power

Supply PCB ...................................... 7-20

J. Lamp Regulator PCB ....................... 7-21

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CHAPTER 7 EXTERNALS/AUXILIARY MECHANISMS

I. FANS

The copier is equipped with three fans for cooling and discharging ozone.

When a sorter is installed, the vent for the exhaust fan (FM2, FM4) is blocked, preventing

discharge of ozone to the left of the copier. To enable discharge, use a sorter kit fan (FM5) to the

front of the copier to route the ozone from the exhaust fan (FM2, FM4) to the front.

Table 7-101 shows the function of each fan and the orientation of the fan. Figure 7-102

shows the timing at which each fan turns on.

FM4

FM2

FM5

FM1

Figure 7-101

Notation

FM1

Name

Cooling fan 1

Exhaust fan 1

Exhaust fan 2

Sorter kit fan

Orientation

Blowing

Filter

Function

Cools the scanner.

Discharges exhaust.

Air

Ozone

FM2

FM4

FM5

Drawing

Ozone

Air

*1:If a sorter kit is installed.

Table 7-101

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CHAPTER 7 EXTERNALS/AUXILIARY MECHANISMS

The exhaust fan (FM2) and the sorter kit fan (FM5) are rotated at half speed during standby

to prevent heating inside the machine. If the reading of the cleaner thermistor (TH3) is 50°C or

more (38°C or more if the sorter kit is installed), all fans will be rotated at full speed.

Power switch

Start key

Power switch

OFF

Sequence

WMUP WMUPR STBY

INTR

SCFW

SCRV

LSTR STBY

Cooling fan 1 (FM1)

Exhaust fan 1 (FM2)

Exhaust fan 2 (FM4)

Sorter kit fan (FM5)

*1:If sorter kit is installed.

: Full-speed rotation.

: Half-speed rotation.

Figure 7-102

The speed of the exhaust fans is switched between full speed and half speed by switching the

drive voltage of the exhaust fans as shown in Figure 7-103.

When the CPU generates FMON=1, +24 V is supplied so that the exhaust fans (FM2, FM4,

FM5) rotate at full speed. In response to FMHLF=1, on the other hand, +15.4 V will be supplied

so that the exhaust fans (FM2, FM5) rotate at half speed.

+15.4v

+24v

FMHLF

IC119

CPU

IC113

FMON

FM-DRIVE

FM-DETECT

GND

Fan

DC controller PCB

Figure 7-103

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CHAPTER 7 EXTERNALS/AUXILIARY MECHANISMS

If the heat exhaust fan rotation detection signal (FM2ROT) is not detected 0.5 sec after the

exhaust fan (FM2, FM4) starts to rotate, error code E805 will be indicated on the control panel.

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CHAPTER 7 EXTERNALS/AUXILIARY MECHANISMS

II. POWER SUPPLY

A. Outline of Power Supply

Figure 7-201 is a block diagram showing distribution of power inside the machine.

CB1

CB2

SW1

Cassette/Drum

heater

DS1

Accessory

cassette heater

Mirror heater

Fixing heater

LA1

driver

RL1

Lamp regulator PCB

ADF

+24V

Accessory power

supply PCB

Sorter

+24V

+5VU

+24V

AE sensor

Sensor

+24V

DC power

circuit

Solenoid/Clutch

Fan

RMT

Motor

DC controller

PCB

+5VU

+5VR

Control panel PCB

Pre-exposure lamp

+24V

J208-1

+24V

+5VU

+5VR

-3

-4

Blank-exposure

lamp

+5VU

+24V

CC-IVN

Counter

Power supply PCB

J210-1

-8

+5VU

+24V

HVT

J209-4

+24V

Main motor

Figure 7-201

1998 CANON INC.

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CHAPTER 7 EXTERNALS/AUXILIARY MECHANISMS

B. Power Supply Circuitry

1. AC Power Supply

AC power is supplied to the power supply PCB when the power plug is connected and the

front door switch (DS1) is turned on.

2. DC Power Supply

The power supply PCB provides three types of DC outputs: +24 V, +5 VR, and +5 VU.

When the power plug is connected and the front door switch (DS1) is turned on, the power

supply PCB supplies the DC controller PCB with +5 VR.

The copier uses a soft switch as its power switch so that it continues to supply the DC

controller PCB with +5 VR even when the power switch is off.

When the power switch is turned on, the CPU generates the DC power supply signal.

In response to the DC power supply signal, the power supply PCB generates +24 V and

+5VU. This condition turns on the AC power supply relay (RL) on the power supply PCB,

thereby making a switch-over to the fixing heater and the lamp regulator PCB.

When the power switch is turned off, the AC power supply relay (RL) on the power supply

PCB switches over to the options heater.

Reference:

The tolerance of DC voltage is as follows:

• +24 V

• +5 VU

• +5 VR

±5%

+5%, -7%

±5%

However, the above applies only when the inaccuracy of the AC input is limited to ±10%.

Caution:

Be sure to disconnect the power plug whenever you have to replace the DC controller

PCB.

1998 CANON INC.

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CHAPTER 7 EXTERNALS/AUXILIARY MECHANISMS

3. Mirror Heater, Cassette/Drum Heater, and Accessory Cassette Heater

The following three heaters are made available as accessories to the copier, designed to

prevent condensation of the scanner and the drum and to keep paper inside the cassette dry.

Table 7-201 shows the function of each heater. Figure 7-202 shows the timing at which each

heater turns on.

Notation

Name

Function

Mirror heater

Prevents condensation on the scanner.

Prevents condensation on the drum and keeps copy paper dry.

Keeps copy paper dry.

Cassette/Drum heater

Accessory cassette heater

Table 7-201

Power switch

Start key

Power switch

OFF

Sequence

WMUP WMUPR STBY

INTR

SCFW

SCRV

LSTR STBY

Mirror heater (H2)

Cassette/Drum heater (H3)

Accessory Cassette heater (H4)

Figure 7-202

Each heater is supplied with power when the copier’s power switch is turned off. The mirror

heater and the cassette/drum heater and the accessory cassette heater may be deprived of power

by turning off the heater switch (SW1).

4. ADF and Sorter

For the ADF and the sorter, the copier’s power supply PCB supplies AC power to the

accessory power supply PCB, which generates DC power.

1998 CANON INC.

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CHAPTER 7 EXTERNALS/AUXILIARY MECHANISMS

C. Protection Mechanisms of the Power Supply Circuitry

The copier’s power supply PCB is equipped with a circuit breaker (CB1, CB2) and a fuse

(FU1, FU2) on its AC input side. To protect against overcurrent and over voltage, the copier is

also equipped with an overcurrent protection circuit and an over-voltage protection circuit.

When an overcurrent or an over-voltage occurs as a result of a short circuit in the power line,

the respective protection mechanism will turn on to stop the output of the power supply PCB.

When the output is stopped, disconnect the copier’s power plug, and turn off the AC power

to the power supply PCB to reset the protection mechanism.

Caution:

Be sure to correct the cause that turned on the protection circuit before resetting.

Repeated short-circuiting and resetting can cause the fuse built into the power supply

PCB to melt.

1998 CANON INC.

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CHAPTER 7 EXTERNALS/AUXILIARY MECHANISMS

III. DISASSEMBLY/ASSEMBLY

The copier may be disassembled and assembled as shown here. Pay attention to the copier’s

mechanical characteristics along with the steps for disassembly/assembly.

Important:

1. Turn off the power and disconnect the power plug to ensure safety whenever

disassembling/assembling the copier.

2. Unless otherwise noted, assemble the parts by reversing the steps used to disassemble

them.

3. Identify the screws by type (length, diameter) to avoid use in the wrong location.

4. Use a washer where needed. The mounting screws used for the grounding wire and

varistor come with a washer to ensure electric continuity. Do not forget to use these

washers.

5. As a rule, do not operate the copier with any of its parts removed.

1998 CANON INC.

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CHAPTER 7 EXTERNALS/AUXILIARY MECHANISMS

A. External Covers

[3]

[1] Front cover

[2] Right door (5)

[3] Upper right cover (2)

[4] Right cover (2)

[4]

[5] Rear cover (5)

[6] Upper rear cover (4)

[7] Upper left cover (2)

[8] Delivery lower cover (2)

[9] Delivery upper cover (2)

[2]

[1]

Figure 7-301

[6]

[7]

The number in parentheses indicates the

number of mounting screws used.

[9]

[8]

[5]

Figure 7-302

[1]

[1] Inside cover (2)

[2] Lower inside cover (3)

[2]

The number in parentheses indicates the

number of mounting screws used.

Figure 7-303

1998 CANON INC.

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CHAPTER 7 EXTERNALS/AUXILIARY MECHANISMS

Remove the appropriate covers as follows

when cleaning, checking, or repairing the

inside of the copier.

Covers which may be detached by mere

removal of mounting screws are omitted from

the discussions.

1. Removing the Right Door

1) Open the right door.

[4]

2) Remove the four mounting screws [1],

and remove the right door [2] and the

paper guide [3].

Caution:

[3]

When mounting the paper guide, be

sure to fit the foot of the spring [4] at

the rear into its hole.

[2]

[1]

Figure 7-304

[1]

2. Removing the Upper Right Cover

1) Open the top unit.

[3]

[4]

2) Remove the two mounting screws [1], and

remove the right cover [2].

3) Remove the two mounting screws [3], and

remove the upper right cover [4].

[2]

Figure 7-305

1998 CANON INC.

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CHAPTER 7 EXTERNALS/AUXILIARY MECHANISMS

3. Removing the Upper Left Cover

1) Remove the copyboard glass.

[1]

[2]

2) Remove the two mounting screws [1], and

detach the upper left cover [2].

Figure 7-306

4. Removing the Delivery Lower

Cover

1) Open the copier top, and remove the copy

tray.

2) Remove the two mounting screws [1], and

detach the delivery lower cover [2].

[1]

[2]

Figure 7-307

5. Removing the Delivery Upper

Cover

1) Open the copier top, and remove the

inside cover.

2) Remove the two mounting screws [1], and

slide the delivery upper cover [2] to the

front to remove.

Caution:

When mounting the delivery upper

cover, be sure to engage the two cut-

offs in the delivery upper cover with

the copier’s hooks.

[2]

Figure 7-308

1998 CANON INC.

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CHAPTER 7 EXTERNALS/AUXILIARY MECHANISMS

[2]

6. Removing the Lower Inside Cover

1) Remove the front door and the transfer

charging assembly.

[1]

[4]

2) Slide out the registration knob [1] to the

front.

3) Remove the mounting screw [2].

4) Loosen the two mounting screws [3], and

remove the lower inside cover [4].

[3]

Figure 7-309

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CHAPTER 7 EXTERNALS/AUXILIARY MECHANISMS

B. Control Panel

1. Removing the Control Panel

[2]

1) Open the copyboard cover, and remove

the two mounting screws [1]; then, detach

the two ADF metal catches [2].

2) Remove the inside cover.

[1]

Figure 7-310

[4]

3) Remove the three mounting screws [3].

4) Slide the control panel [4] to the front to

remove; then, turn over the control panel.

[3]

Figure 7-311

[5]

5) Disconnect the three connectors [5], and

remove the control panel.

Figure 7-312

1998 CANON INC.

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CHAPTER 7 EXTERNALS/AUXILIARY MECHANISMS

C. Copyboard Glass

1. Removing the Copyboard Glass

1) Remove the two mounting screws [1], and

detach the glass retainer (right) [2].

[2]

[1]

Figure 7-313

2) Slide the copyboard glass [3] to the right.

3) Remove the two mounting screws [4], and

[4]

detach the glass retainer (left) [5].

4) Remove the copyboard glass [3].

[3]

[5]

Caution:

When mounting the NP7161’s

copyboard glass, make sure that the

blue marking on the side of the glass

is to the front left.

Figure 7-314

1998 CANON INC.

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CHAPTER 7 EXTERNALS/AUXILIARY MECHANISMS

D. Fans

1. Removing the Scanner Cooling Fan

1) Remove the two mounting screws [1], and

detach the filter [2].

[2]

[1]

Figure 7-315

2) Disconnect the connector [3], and remove

the scanner cooling fan [4].

[3]

[4]

Figure 7-316

1998 CANON INC.

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CHAPTER 7 EXTERNALS/AUXILIARY MECHANISMS

2. Removing the Exhaust Fan

1) Remove the developing assembly, drum

unit, inside cover, and delivery upper

cover.

2) Disconnect the two connectors [1].

[1]

Figure 7-317

3) Remove the two mounting screws [2], and

slide the exhaust fan assembly [3] to the

front to remove.

[2]

[3]

Figure 7-318

4) Disconnect the two connectors [4], and

remove the two exhaust fans [5].

[4]

Caution:

When mounting the exhaust fan

assembly, be sure to engage the two

hooks on the exhaust fan assembly

with the copier’s cut-offs.

[5]

Figure 7-319

1998 CANON INC.

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CHAPTER 7 EXTERNALS/AUXILIARY MECHANISMS

3. Remove the Ozone Filter

1) Open the top unit.

2) Shift down the lever [1], and remove the

ozone filter assembly [2].

[2]

[1]

Figure 7-320

3) Remove the ozone filter [3].

[3]

Figure 7-321

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CHAPTER 7 EXTERNALS/AUXILIARY MECHANISMS

E. Counter Assembly

1. Removing the Counter Assembly

1) Remove the control panel.

[4]

2) Remove the two mounting screws [1], and

remove the magnet [2].

3) Disconnect the two connectors [3], and

remove the two mounting screws [4];

then, detach the counter assembly [5].

Caution:

When removing the magnet, mark its

position and mount it with reference

[2]

[5]

[3]

[1]

to the markings.

Figure 7-322

[1]

[4]

F. Main Motor Assembly

1. Removing the Main Motor

Assembly

[3]

1) Remove the rear cover and the rear upper

cover.

2) Disconnect the connector [1], and remove

the four mounting screws [2].

3) Remove the two locking supports [3], and

detach the main motor assembly [4].

[2]

Figure 7-323

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CHAPTER 7 EXTERNALS/AUXILIARY MECHANISMS

G. DC Controller PCB

[1]

1. Removing the DC Controller PCB

1) Remove the delivery lower cover.

2) Disconnect all connectors of the DC

controller PCB; then, free the harness

from the harness guide.

3) Remove the six mounting screws [1], and

remove the DC controller PCB [2]

together with the base plate.

[2]

Caution:

Take extra care not to damage the

harness whenever you are removing

the DC controller PCB.

Figure 7-324

The DC controller PCB is equipped with

a built-in battery (BAT101). Keep the

following in mind to prevent its both ends

from short circuiting and heating:

2. Points to Note When Replacing the

DC Controller PCB

• When sending the DC controller to the

workshop or the factory, put it in a

conducting bag intact with its base

plate.

Use a conducting bag whose one side is

transparent, and be sure that the face of

the DC controller PCB shows through

the transparent side.

• After replacement, make adjustments

and settings in service mode and make

settings in user mode once again.

• For settings in service mode, enter the

values recorded in the Service Label

stored behind the front door.

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CHAPTER 7 EXTERNALS/AUXILIARY MECHANISMS

H. Removing the Power

Supply PCB

[4]

1. Removing the Power Supply PCB

1) Remove the rear cover.

2) Disconnect the fixing heater connector

[1].

3) Disconnect all connectors of the power

supply PCB.

[3]

4) Free the AC harness [2] from the harness

guide.

5) Remove the four mounting screws [3],

and detach the power supply PCB [4].

[1]

[2]

Figure 7-325

I. Removing the High-Voltage

Power Supply PCB

1. Removing the High-Voltage Power

Supply PCB

[5]

1) Remove the rear cover and the rear upper

cover.

2) Disconnect all connectors of the high-

voltage power supply PCB, and remove

the faston [1] and the high-voltage

harness [2].

[4]

[2]

[1]

3) Remove the mounting screw [3] and the

four locking supports [4]; then, detach the

high-voltage power supply PCB [5].

[3]

Figure 7-326

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CHAPTER 7 EXTERNALS/AUXILIARY MECHANISMS

J. Lamp Regulator PCB

1. Removing the Lamp Regulator PCB

1) Remove the rear cover.

2) Disconnect the two connectors [1] of the

lamp regulator PCB.

[1]

3) Remove the three locking supports [2],

and detach the lamp regulator PCB [3].

[2]

[3]

Figure 7-327

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CHAPTER 8

INSTALLATION

This chapter introduces requirements for the site of installation, and shows how the copier may be

installed using step-by-step instructions.

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

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

User Mode .......................................... 8-8

F. Supplying Toner ............................... 8-10

III. RELOCATING THE MACHINE .............. 8-12

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

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CHAPTER 8 INSTALLATION

I. SELECTING THE SITE

Check the site of installation against the following requirements. If possible, visit the site in

advance of the delivery of the machine.

1. There must be a dedicated power outlet for exclusive use by the copier capable of providing

the rated voltage (±10%).

2. The temperature must be 7.5° to 32.5°C (45.5° to 90.5°F), and humidity must be 5% to 85%

RH. (Avoid areas near a water faucet, water boiler, humidifier, and refrigerator.)

3. Avoid areas near a source of fire and areas subject to dust or ammonia gas. Avoid direct rays

of the sun. As necessary, provide curtains.

4. The amount of ozone generated by the copier is of a level not affecting the health of the

individuals around it. Some individuals, however, may find its smell unpleasant. Be sure that

the room is properly ventilated.

5. Select a well-ventilated area. If multiple copiers are to be installed, in particular, make sure

that the exhaust from one will not be drawn into the vent of another.

6. Make sure that the copier will be level.

7. Keep the copier 10 cm (3.9 in) or more away from any wall to provide adequate space for

machine operation.

10cm/3.9in.

min.

50cm/19.7in.

min.

50cm/19.7in.

min.

50cm/19.7in.

min.

Figure 8-101

1998 CANON INC.

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CHAPTER 8 INSTALLATION

II. UNPACKING AND INSTALLATION

When a piece of metal is brought in from a cold to warm place, droplets of water tend to

form on its surface. This phenomenon is known as condensation, and copiers suffering from

condensation can generate blank copies.

If the copier has been brought in from a cold place, keep it unpacked for one hour or more

before starting the installation work.

The copier weighs about 42 kg/92.4 lb. Be sure to work in a group of two when lifting it.

A. Unpacking

Step

Work

Checks/remarks

Open the shipping box, and take out

the two cardboard boxes.

Open the cardboard boxes, and take

out the attachments.

Check to make sure that none of the following is

missing:

• copy tray

• power cord

• drum unit

• User’s Manual

• waste toner case (3 pc.)

• waste toner case bag (4 pc.)

• top unit close label

Holding the grips at the bottom (both

sides), move the copier to the site of

installation.

Grips

8–2

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CHAPTER 8 INSTALLATION

B. Removing the Metal Fixings

Step

Work

Checks/remarks

Remove the packing tape, cushioning Check to make sure that the covers are free of

material, protective sheet of the

copyboard glass, and protective sheet

of the size index.

scratches and dents.

Slide out the cassette, and remove the

packing tape and the cushioning

material from inside.

Slide the cassette into the copier.

Scanner fixing

screws

Remove the two scanner fixing screws

from the copier’s left side. (Store

away the scanner fixing screw for

possible relocation of the machine.)

Open the front door, and shift up the

opening/closing lever to open the

copier top.

Main unit lever

Remove the metal fixing from the

opening/closing hook (right). (You

will not be using the removed metal

fixing.)

Cushioning material

Pressure

release plate (front)

While opening the delivery assembly,

remove the fixing assembly releasing

plate (1 each at front and rear). (You

will not be using the removed fixing

assembly releasing plate.)

Pressure

release plate (rear)

Fixing

delivery

assembly

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CHAPTER 8 INSTALLATION

C. Mounting the Drum Unit

Step

Work

Checks/remarks

Turn the toner supply lever

counterclockwise to unlock the

developing assembly.

Toner supply

lever

Remove the thumb screw, and remove

the dummy drum. (You will be using

the thumb screw when mounting the

drum unit. Store away the dummy

drum for possible relocation of the

machine.)

Thumb screw

Dummy

drum

Take out the drum unit from the box, Keep the labels for later use.

and remove the cushioning material

and the protective sheet.

Caution:

• Take care not to damage the

surface of the photosensitive

drum.

• Take care not to subject the

photosensitive drum to light

unnecessarily.

Set the drum unit to the copier by

sliding it along the rails, and secure it

in place using the thumb screw used

to fix the dummy drum in place.

Thumb screw

Drum

unit

8–4

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CHAPTER 8 INSTALLATION

Step

Work

Checks/remarks

Fill out the label that came with the

drum unit, and attach the label to the

front cover of the drum unit.

date

counter

notes

Notiz

date

Datum compteur Zahler

note

Turn the toner supply lever clockwise

to lock the developing assembly in

place; then, close the copier top.

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CHAPTER 8 INSTALLATION

D. Cleaning the Parts and Making Checks

Step

Work

Checks/remarks

Clean the charging wire using the

primary charging wire cleaning lever.

Clean the charging wire using the

transfer charging wire leaning lever.

Take out the static eliminator, and

clean it using the static eliminator

cleaner stored behind the front door.

Thereafter, set the static eliminator

and the static eliminator cleaner back

to their initial positions.

Clean as if to sweep the inside of the groove of

the static eliminator.

Static eliminator

cleaning brush

Remove the inside cover (2 screws).

Screws

8–6

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CHAPTER 8 INSTALLATION

Step

Work

Checks/remarks

Take out the dust-proofing glass (1

screw), and dry wipe it with lint-free

paper. Then, mount it back to the

copier.

Screw

Mount the inside cover.

Turn the toner supply lever

counterclockwise to unlock the

developing assembly.

Toner

supply

lever

Remove the stopper (1 screw), and

take out the developing assembly.

Check to make sure that the developing cylinder

is free of soiling and scratches.

Stopper

Screw

Caution:

• Do not touch the developing

cylinder.

• Take care not to damage the

developing cylinder.

Developing

assembly

Set the developing assembly in the

copier by sliding it along the rails;

then, mount the stopper.

10 Turn the toner supply lever clockwise

to lock the developing assembly in

place.

11 Close the front door.

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CHAPTER 8 INSTALLATION

E. Checking the Images/Operations and User Mode

Step

Work

Checks/remarks

Connect the power cord to the copier,

and connect the power plug to the

outlet.

Turn on the power switch.

• Check to make sure that the Paper indicator

flashes.

• Press the keys on the numeric keypad and

the Clear key to make sure that copy counts

are indicated correctly.

Supply toner.

See F. “Supplying Toner.”

In standby state, execute service mode

401 (stir toner).

• This mode lasts about 4 min.

• While this mode is effective, ‘401’ is

indicated; upon completion, ‘4’ of ‘401’ is

flashed.

Steps

1) Press the User mode key.

2) Hold down ‘2’ and ‘8’ on the

numeric keypad at the same time

for 0.5 sec or more.

Caution:

While the mode remains on, do not turn off

the power or open the front door.

3) Press the user mode key.

4) Check to see that ‘1’ is indicated.

5) Press ‘4’ on the numeric keypad.

6) Check to see that ‘4’ is indicated.

7) Press the AE key.

8) Check to make sure that ‘401’ is

indicated.

9) Press the Start key to start

stirring toner.

Execute service mode 403 drum unit

installation mode.

• This mode lasts about 40 sec.

• While this mode is effective, ‘403’ is

indicated; upon completion, ‘4’ of ‘403’ is

flashed.

Steps

1) Check to see that ‘401’ is

indicated.

2) Press ‘3’ on the numeric keypad.

3) Check to see that ‘403’ is

indicated.

Caution:

While the mode remains on, do not turn off

the power or open the front door.

4) Press the Start key to start drum

unit installation mode.

8–8

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CHAPTER 8 INSTALLATION

Step

Work

Checks/remarks

While the toner is being stirred,

perform the following:

To switch the cassette between AB and Inch, see

the instructions under “Changing the Cassette

Size (AB/Inch). (See p. 5-25.)

1)Set the cassette size to suit the

needs of the user, and put copy

paper inside the cassette.

2)Mount the copy tray to the

copier.

Copy tray

When drum unit installation mode has

been executed, press the Reset key to

end service mode.

Place the Test Sheet on the copyboard

glass, and make copies using each

cassette. Then, check the copy images.

• Check to make sure that there is no

abnormal noise.

• Check to make sure that as many copies as

set are made normally.

• Check the copies (images) made at each

default reproduction ratio.

If images are not optimum, perform the

“Image Adjustment Basic Procedure.” (p.

10-3)

• Check to make sure that copying operation

in each copying mode is normal.

• Check to make sure that the counter operates

normally.

Make user mode settings and service

mode settings 5 to suit the user's

needs.

10 Clean up the area around the machine.

11 If you are installing accessories (e.g.,

sorter), install them according to their

respective Installation Procedures.

12 Fill out the Service Sheet.

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CHAPTER 8 INSTALLATION

F. Supplying Toner

Step

Work

Open the front door.

Checks/remarks

Turn the toner supply lever

counterclockwise to unlock the

developing assembly.

Tonner

supply lever

Holding the grip, pull the developing

assembly to the front until it stops.

Handle

Holding the toner cartridge horizontal,

shake it left and right several times.

Put the toner cartridge over the

developing assembly, and push it in

fully to the rear.

8–10

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CHAPTER 8 INSTALLATION

Step

Work

Checks/remarks

Push the toner cartridge from above to Check to make sure that the opening tab of the

lock it to the developing assembly.

toner cartridge has sprung to the front.

Pull the opening tab to the front until

the STOP line is in view.

Tap lightly on the top of the toner

cartridge so that the toner falls into the

developing assembly.

Push in the grip of the developing

assembly so that the toner cartridge

may be detached.

The toner cartridge will detach itself from the

developing assembly when the grip of the

developing assembly is pushed in to its initial

position.

10 Slide the developing assembly into the

copier, and turn the toner supply lever

clockwise to lock the developing

assembly in place.

11 Close the front door.

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CHAPTER 8 INSTALLATION

III. RELOCATING THE MACHINE

If you need to relocate the machine by truck or any other means of transportation, perform

the following:

Step

Work

Checks

Remarks

Make a copy in Direct.

Take out all copy paper from the

cassette.

Excute ‘403’ in service mode.

The scanner, lens, and No.4/No.5

mirror unit move to the position for

transportation.

Turn off the power switch, and

disconnect the power plug from the

power outlet.

Secure the scanner in place using the

two scanner fixing screws from the

left side of the copier.

Use the screws

removed during

installation work.

Take out the drum unit, and mount the The drum unit must be

dummy drum.

transported separately.

Remove the copy tray.

Tape the front door, multifeeder tray,

and cassette in place.

Place A3 copy paper on the

copyboard glass, and tape the

copyboard in place.

8–12

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CHAPTER 8 INSTALLATION

IV. INSTALLING THE

CONTROL CARD IV N

1) Remove the screw [1] from the right side

of the upper rear cover, and detach the

face cover [2].

2) Cut off the face plate [3].

[3]

[2]

[1]

Figure 8-401

3) Lead out the harness, and disconnect the

shorting connector [4]; then, connect the

connector [5] of the Control Card IV N to

the copier’s connector [6].

[6]

[4]

[5]

Figure 8-402

4) Push in the harness and the connector into

the copier, and install the Control Card IV

N to the copier using the screw [7].

[7]

Figure 8-403

5) Connect the copier’s power plug, and turn

on the power switch to check the

operation of the Control Card IV N.

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CHAPTER 8 INSTALLATION

V. INSTALLING THE REMOTE DIAGNOSTIC DEVICE II

Keep the following in mind when installing the Remote Diagnostic Device II to the copier:

1. Be sure to observe the relevant laws and regulations of the country.

2. Be sure to check that the copier has properly been installed before starting the work.

3. Be sure to keep the copier’s power plug disconnected during the work.

4. Be sure to identify the screws by type (length, diameter) and location.

5. Be sure to set the settings data to the computer at the service station in advance.

8–14

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CHAPTER 8 INSTALLATION

[2]

1) Remove the two screws [1], and detach

the top cover [2].

[1]

Figure 8-501

[4]

2) Connect the connector [3] of the power

supply unit to the connector [4] as shown.

[3]

Figure 8-502

3) Remove the copier’s rear cover; then,

remove the sheet [5], and cut off the face

plate [6].

[5]

[6]

Figure 8-503

1998 CANON INC.

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CHAPTER 8 INSTALLATION

4) Lead the harness through the opening in

the rear cover made by cutting off the face

plate in step 3), and connect the connector

[7] and the copier’s connector [8] (8P).

(At this time, be sure to fit the harness in

the harness guide as shown.)

[8]

[7]

Figure 8-504

5) Mount the rear cover and the grounding

wire [9] (attachment) to the copier, and

secure the device to the rear cover

together with the grounding wire [9] with

four screws [10] (use the screws that

come with the device).

[10]

[9]

Figure 8-505

6) Remove the slack from the cable between

the copier and the device, and bundle

together any excess length and secure it in

place with the harness band [11].

[11]

Figure 8-506

8–16

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CHAPTER 8 INSTALLATION

7) Shift bits 4 of the DIP switch (SW2) [12]

on the device’s PCB to ON (so that the

communication with the copier will be

IPC communication).

[12]

LED1 LED2 LED3

BAT1

SW3

SW2

LED5

LED6

LED4

SW4

IC6

CN4

SW1

CN3

CN2

Figure 8-507

8) If IC6 [13] is mounted on the PCB, shift

bit 7 of the DIP switch (SW2) to ON;

otherwise, keep bit 7 at OFF.

[14]

Caution:

LED1 LED2 LED3

BAT1

1.If the ROM (IC6) [13] is not mounted,

you need not mount one newly.

2.If you want to mount the ROM (IC6)

[13] for upgrading or replace it, be sure

to shift bit 7 of the DIP switch [14]

(SW2) to ON.

SW3

SW2

LED5

LED6

LED4

SW4

IC6

CN4

SW1

[13]

CN3

CN2

Figure 8-508

9) Set each bit of the DIP switch (SW3) [15]

as indicated in Table 8-501.

[15]

Switch Setting

Description

SW3-1

SW3-2

SW3-3

AII

OFF

LED1 LED2 LED3

BAT1

SW3

SW2

LED5

SW4

LED6

LED4

selects push pulse for RDD circuit

confihuration

IC6

CN4

SW1

SW3-4

selscts dial pulse for RDD circuit

confihuration

OFF

CN3

CN2

sets dial pulse speed to 20 PPS

sets dial pulse speed to 10 PPS

reserved

OFF

–

SW3-5

SW3-6

Figure 8-509

Table 8-501

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CHAPTER 8 INSTALLATION

[16]

10) Connect the power supply unit to the

power plug, and check to make sure that

LED1 [16] (green) turns on.

LED1 LED2 LED3

BAT1

SW3

SW2

LED5

LED6

LED4

SW4

IC6

CN4

SW1

CN3

CN2

Figure 8-510

11) Execute RAM clear.

[17]

Set each bit of the DIP switch [17] (SW2)

as indicated in Table 8-502, and press the

push switch [18] (SW4). A press should

turn on LED5 [19] (red).

[19]

LED1 LED2 LED3

BAT1

SW3

SW2

LED5

SW4

LED6

LED4

SW2 bits

SW2-1

SW2-2

SW2-3

SW2-4

SW2-5

SW2-6

SW2-7

SW2-8

Settings

OFF

IC6

[18]

CN4

SW1

OFF

CN3

CN2

OFF

Figure 8-511

See step 9).

OFF

Table 8-502

8–18

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CHAPTER 8 INSTALLATION

12) After making sure that LED5 [19] (red)

has turned on, set each bit of the DIP

switch [17] (SW2) as indicated in Table

8-503, and press the push switch [18]

(SW4). A press should turn off LED5 [19]

(red), indicating that RAM clear has

ended.

[17]

[19]

LED1 LED2 LED3

BAT1

SW3

SW2

LED5

SW4

LED6

LED4

[18]

IC6

CN4

SW1

SW2 bits

SW2-1

SW2-2

SW2-3

SW2-4

SW2-5

SW2-6

SW2-7

SW2-8

Settings

OFF

CN3

CN2

OFF

Figure 8-512

OFF

See step 9).

OFF

Table 8-503

13) Shift bit 6 of the DIP switch [20] (SW2)

to OFF.

[20]

LED1 LED2 LED3

BAT1

SW3

SW2

LED5

LED6

LED4

SW4

IC6

CN4

SW1

CN3

CN2

Figure 8-513

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CHAPTER 8 INSTALLATION

14) Connect the telephone line to the device.

If the device is connected on its own,

connect the modular jack cable to the

connector LINE [21].

LED1 LED2 LED3

BAT1

SW3

SW2

LED5

LED6

LED4

SW4

IC6

CN4

SW1

If the extension function of the device is

used, connect the existing telephone or

fax to the connector TEL [22], and

connect the telephone line to the

connector LINE [21].

CN3

CN2

[21]

[22]

Figure 8-514

15) Call the service station, and request initial

settings for the device. (Upon reception,

LED4 [23] (red) will start to flash.)

LED1 LED2 LED3

BAT1

SW3

SW2

LED5

LED6

LED4

SW4

[23]

IC6

CN4

SW1

CN3

CN2

Figure 8-515

16) Call the service station to find out whether

the initial settings have been successfully

made. Otherwise, execute RAM clear

(steps 11) through 13) ) once again and

start over.

Caution:

Upon completion of each try, check

with the service station to make sure

that the settings have been made

successfully.

8–20

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CHAPTER 8 INSTALLATION

17) Check if the device is capable of ringing

up the computer at the service station.

Press the push switch [18] (SW4).

A press will turn on LED6 [24] (red): it

will turn off upon completion of

transmission, and it will flash upon

failure.

LED1 LED2 LED3

BAT1

SW3

SW2

LED5

LED6

LED4

SW4

[24]

IC6

CN4

[18]

SW1

[25]

CN3

CN2

Another press on the push switch (SW4)

[18] while LED6 [24] is flashing will

initiate transmission once again.

A press on the push switch (SW1) [25]

while LED 6 [24] is flashing will cancel

transmission attempts.

Figure 8-516

18) Check to make sure that the

[26]

communication with the copier is normal.

Connect the copier’s power plug, and turn

on the power switch to see that LED2 [26]

(orange) flashes.

LED1 LED2 LED3

BAT1

SW3

SW2

LED5

LED6

LED4

SW4

IC6

CN4

SW1

CN3

CN2

Figure 8-517

19) Press the copier’s Copy Start key so that

LED3 [27] (pink) flashes in response.

[27]

LED1 LED2 LED3

BAT1

SW3

SW2

LED5

SW4

LED6

LED4

IC6

CN4

SW1

CN3

CN2

Figure 8-518

1998 CANON INC.

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CHAPTER 8 INSTALLATION

[30]

20) Attach the switch settings label [28] on

the device, and record the settings of each

switch.

[28]

[29]

21) Secure the top cover [29] in place with

two screws [30]. At this time, check to

make sure that the cable is fixed in place

with the cable guide and is not trapped by

the top cover [29].

[30]

Figure 8-519

8–22

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CHAPTER 8 INSTALLATION

VI. INSTALLING THE

ACCESSORY

COUNTER

[1]

1) Open the front door; then, remove the

inside cover, and cut off the face plate [1].

Figure 8-601

[2]

2) Remove the delivery lower cover, and

mount the accessory counter [2] to the

counter assembly.

Figure 8-602

[3]

[4]

3) Connect the connector [3] of the

accessory counter to the connector [4] of

the counter assembly.

Figure 8-603

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CHAPTER 8 INSTALLATION

4) Remove the delivery lower cover, and set

the DIP switch (SW102) on the DC

controller PCB as indicated in Table 8-

601.

SW102-5 SW102-6

Settings

OFF

Accessory counter not

connected.

Uses the accessory

counter as a small-size

copy counter.

OFF

Uses the accessory

counter as a large-size

copy counter.

Not used

Table 8-601

5) Mount the delivery lower cover and the

inside cover, and close the front door.

6) Connect the copier’s power plug, and turn

on the power switch to check the

operation of each counter.

8–24

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CHAPTER 8 INSTALLATION

VII.INSTALLING THE

ACCESSORY HEATER

A. Installing the Heater Switch

1) Remove the rear cover, and cut off the

face plate [1].

[1]

Figure 8-701

[3]

[2]

2) Mount the heater switch [2] with two

screws [3].

Figure 8-702

[4]

3) Lead the heater switch harness through

the clamp, and connect it to the connector

[4].

Figure 8-703

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CHAPTER 8 INSTALLATION

B. Mounting the Cassette/

Drum Heater

1) Remove the front door, drum unit,

developing assembly, transfer charging

assembly, and cassette.

2) Engage the two hooks [1] of the cassette/

drum heater on the cut-off, and slide to

the rear to mount.

[1]

Figure 8-704

[2]

3) Secure with two mounting screws [2].

Figure 8-705

[3]

4) Lead the cassette/drum heater harness [3]

through the harness guide, and connect

the connector [4].

[4]

Figure 8-706

8–26

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CHAPTER 8 INSTALLATION

C. Installing the Mirror Heater

[1]

[2]

1) Mount the inside cover and the delivery

upper cover.

2) Mount the mirror heater [1] with two

screws [2].

Figure 8-707

3) Lead the mirror heater harness [3] through

the harness guide, and connect the

connector [4].

[3]

[4]

Figure 8-708

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CHAPTER 9

MAINTENANCE AND SERVICING

This chapter provides tables of periodically replaced parts and consumables/durables and scheduled

servicing charts.

I. PERIODICALLY REPLACED PARTS ..... 9-1

A. Copier ................................................. 9-1

II. CONSUMABLES AND DURABLES ........ 9-2

A. Copier ................................................. 9-2

III. SCHEDULED SERVICING CHART ........ 9-3

IV. SCHEDULED SERVICING TABLE ......... 9-5

A. Copier ................................................. 9-5

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CHAPTER 9 MAINTENANCE AND SERVICING

I. PERIODICALLY REPLACED PARTS

Some of the parts of the copier need to be replaced on a periodical basis to ensure a specific

level of performance (regardless of external appearance or presence/absence of damage).

Plan replacement so that it coincides with a scheduled servicing visit.

A. Copier

As of August 1998

Remarks

Q’ty

Expected life (copies)

60,000

No.

Parts name

Parts No.

Transfer charging wire

Ozone filter (exhaust)

FY3-0040-000

FE5-3956-000

60,000

Or, 1 yr.

Note:

The above values are estimates only, and are subject to change based on future data.

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CHAPTER 9 MAINTENANCE AND SERVICING

II. CONSUMABLES AND DURABLES

Some of the parts of the copier may need to be replaced once or more because of wear or

damage over the period of machine warranty. Replace them when they fail.

A. Copier

As of August 1998

Remarks

Q’ty

Expected life (copies)

No.

Parts name

Scanning lamp

Parts No.

120V

230V

FH7-3360-000

FH7-3361-000

FE5-4199-000

RF5-2490-000

FB1-8581-000

FE5-4132-000

FL5-0581-000

120,000

60,000

Pick-up roller

Feed roller

Separation roller

Multifeeder pick-up roller

Multifeeder separation pad

Static eliminator

Come with

the packing

of drum unit

Developing cylinder

Fixing upper roller

FM5-0721-000

FE5-3912-000

FE5-3905-000

FB1-7075-000

FA2-9037-000

FE5-3932-000

FE5-3927-000

180,000

120,000

10 Fixing lower roller

11 Fixing upper separation claw

12 Fixing lower separation claw

13 Heat discharge roller

14 Delivery roller

Note:

The above values are estimates only, and are subject to change based on future data.

9–2

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CHAPTER 9 MAINTENANCE AND SERVICING

III. SCHEDULED SERVICING CHART

Note:

1. As a rule, provide scheduled servicing every 60,000 copies.

2. Before setting out for a visit, check the Servicing Book, and take parts for which

replacement is expected.

Step

Work

Checks

Remarks

Check the general condition.

Report to the person in charge.

Record the counter reading.

Check the faulty copies.

a. density of images

b.soiling of the background

c. clarity of characters

d.margin along the leading

edge

Make test copies (in Direct, Reduce,

Enlarge).

e. margin on the left/right

f. fixing, registration

(displacement), soling of

backs

g.abnormal noise

h.counter operation

Clean the optical assembly:

• canning reflecting plate

• lens

Use a blower brush; if dirt is

excessive, use alcohol.

• No. 1/2/3/4/5/6 mirror

• dust-proofing glass

Collect the waste toner case is full.

Check the waste toner case.

Replace the transfer charging wire,

clean the transfer charging guide, and

clean the transfer guide:

Dry wipe with lint-free paper ;

if necessary use alcohol.

• transfer guide (upper/lower) plate

• transfer/separation charging

assembly guide rail

Clean the separation/feeding assembly:

• separation static eliminator

• feeding assembly

Clean the fixing/delivery assembly:

• fixing (upper/lower) roller

• separation claw (upper/lower)

Lubricant

Provide scheduled servicing according

to the number of copies made.

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CHAPTER 9 MAINTENANCE AND SERVICING

Step

Work

Checks

Remarks

Use alcohol.

Clean the copyboard cover and the

copyboard glass.

Make test copies.

Make sample copies.

Put the sample copies in order, and

clean up the area around the machine.

Record the latest counter reading.

Fill out the Service Sheet, and report to

the person in charge.

9–4

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CHAPTER 9 MAINTENANCE AND SERVICING

IV. SCHEDULED SERVICING TABLE

A. Copier

Caution:

1. Do not use solvents/oils other than those mentioned herein.

2. Keep the following in mind when cleaning/checking each charging assembly:

• Do not use a cloth having metal powder.

• Do not use a moist cloth. Dry wipe with lint-free paper, and use alcohol thereafter. Be

sure that alcohol has dried completely before mounting back to the copier.

: Adjust

Intervals

: Inspect

yearly

: Clean

: Replace

Item

: Lubricate

Unit

Remarks

every

60,000 120,000 180,000

Copyboard glass

Copyboard cover

Ozone filter

Externals

Or, 1 yr.

Scanner drive

assembly

Scanner drive cable

(front/rear)

Scanner rail

Use alcohol, and apply lubricant.

Use a blower brush.

If the dirt is excessive,

use alcohol.

Scanning lamp

No. 1 to 16 mirrors

Dust-proofing glass

Scanner reflecting cover

Scanner side reflecting

plate

Optical path

Lens

Developing assembly roll

Developing cylinder

Waste toner box

Developing

assembly

Replaced by the user in

response to an alarm.

Cleaner

Pick-up roller

Pick-up

assembly

Pick-up feed roller

Pick-up separation roller

Multifeeder pick-up roller

Multifeeder separation pad

Transfer guide

Feeding assembly

Fixing assembly

Fixing upper roller

Fixing lower roller

Separation claw

(upper/lower)

Look for damage on the claw

tip and for soiling by toner.

Heat roller

Delivery roller

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CHAPTER 9 MAINTENANCE AND SERVICING

Intervals

Unit

Others

Item

Remarks

every

yearly

60,000 120,000 180,000

Transfer charging wire

Static eliminator

9–6

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CHAPTER 10

TROUBLESHOOTING

This chapter provides tables of maintenance/inspection, standards/adjustments, and identification of

problems (image fault/malfunction).

I. GUIDE TO TROUBLESHOOTING

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

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

B. Exposure System ............................. 10-7

C. Image Formation System ............... 10-10

D. Pick-Up/Feeding System ............... 10-14

E. Fixing System ................................. 10-16

F. Electrical System............................ 10-18

III. IMAGE FAULTS ................................... 10-25

A. Initial Checks .................................. 10-25

B. Image Fault Samples ..................... 10-28

C. Troubleshooting Image Faults ....... 10-29

IV. TROUBLESHOOTING

MALFUNCTIONS ................................. 10-42

A. Copier ............................................. 10-42

V. TROUBLESHOOTING FEEDING

PROBLEMS.......................................... 10-66

A. Copy Jams ..................................... 10-66

B. Faulty Feeding................................ 10-69

VI. ARRANGEMENT AND FUNCTIONS

OF ELECTRICAL PARTS .................... 10-70

Diodes, and Check Pins by PCB ... 10-77

VII. SERVICE MODE .................................. 10-82

A. Outline ............................................ 10-82

B. Using Service Mode ....................... 10-82

C. Using Adjust Mode and

Function Mode................................ 10-83

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

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CHAPTER 10 TROUBLESHOOTING

I. GUIDE TO TROUBLESHOOTING TABLES

The troubleshooting tables in this chapter are based on more commonly used troubleshooting

flow charts.

Study the following for an idea of how you may take advantage of the tables.

EX:

AC power is absent.

Cause

Step

Checks

Yes/No

Actions

Power plug

Is the power plug connected to

the power outlet?

Connect the power

plug.

Covers

Are the front door and delivery

cover closed properly?

Close the door and

the cover properly.

Power source

Is the rated voltage present at the

power outlet?

This is not the copier's

problem. Inform the

user accordingly.

Is the rated voltage present between YES

J1-1 and J1-2? (J1 is found near

the power cord mount.)

Go to step 6.

Rest omitted.

■

If you want to find out the possible causes (faulty parts) associated with a specific problem,

see the items under “Cause.”

In the case of the above, i.e., “AC power is absent,” you may suspect the power plug,

doors and covers, or power source.

If you want to find out the checks to make or the actions to take for a specific problem,

follow the instructions under “Checks” and “Actions” in sequence. Answer the question

Yes or No, and if your answer matches the answer given under “Yes/No,” take the action

given under “Actions”; otherwise, go to the next step and work likewise.

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CHAPTER 10 TROUBLESHOOTING

Step

Checks

Yes/No

Actions

Is the

power plug connected

to the power outlet?

Connect the power plug.

YES

Is the front

Close the door properly.

door closed properly?

YES

Is the rated

voltage present

at the power outlet?

This is not the copier’s

problem. Inform the user

accordingly.

YES

Rest omitted

■

The instruction “Measure the voltage between J109-1 (+) and J109-2 (-) on the DC

controller PCB” means you are expected to make the following connections:

Connect the positive probe of your meter to J109-1 (+), and

Connect the negative probe of your meter to J109-2 (-).

10–2

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A. Image Adjustment Basic Procedure

Non-AE, Copy Density at 5

Pre-Checks

Density Slope Adjustment

Solid Black Density Adjustment Optimum Exposure Adjustment

Clean the charging wires.

Is there

Is the density

of gray scale No. 1

too low (light)?

Is the density

of gray scale No.

10 optimum?

Is the white

background

foggy?

YES

a difference in density

between front and

rear?

YES

Check the height of

the charging wire.

*1*2

See “Preventing Image

Faults.” (p. 10-32)

Turn the adjusting screw at

the front/rear of the primary

charging assembly counterc

lockwise so that the primary

charging wire is closer to

the photosensitive drum.

Is the density

of gray scale No. 10 too

high (dark)?

Is the rear

lighter?

Set the setting of ‘U12:

density correction’ in

user mode to a standard

setting.

Perform AE

adjustment. (p. 10-19)

YES

*1*2

Turn the adjusting screw at

the rear of the primary

changing assembly counter-

clockwise and the adjusting

screw at the front clockwise

(1.0 mm max. each).

Turn the adjusting screw at

Increase the setting of

‘scanning lamp ON

voltage adjustment’

in service mode (326).

Decrease the setting of

‘scanning lamp ON

voltage adjustment’

in service mode (326).

the rear of the primary

Make two to three copies

of the Test Sheet (NA-3).

Make a copy.

charging assembly clockwise

and the adjusting screw at

the front counterclockwise

(1.0 mm max. each).

Make a copy.

1: If there still is a difference after turning the adjusting screw 1.0 mm

each*, check the charging assembly, scanning lamp, and scanner for dirt.

*A full turn causes a change of 0.5 mm.

2: When turning the adjusting screw clockwise, be careful that the height

of the charging wire is not less than 10.0 mm.

1998 CANON INC.

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B. Points to Note for Scheduled Servicing

Part

Copyboard glass

Lens

Scanner rail

Reflecting plate

No. 1 to 3 mirrors

Tool/solvent

Alcohol

Blower brush

Lubricant

Blower brush

Blower brush; or,

alcohol and lint-free brush; if excessive,

Remarks

Part

Static eliminator

Dust-proofing glass Blower brush or

No. 4 to 6 mirrors

Tool/solvent

Brush (attachment) Cleaning

Remarks

Cleaning

Cleaning with a blower

alcohol and lint-free brush; if excessive,

paper cleaning with alcohol.

Alcohol and lint-free Dry wiping; then, cleaning

Lubricate

Cleaning

Charging wire

Cleaning with a blower

paper

with lint-free paper

moistened with alcohol

paper

cleaning with alcohol

Developing rol

Cleaning

Part

Separation claw

(upper/lower)

Fixing upper roller,

Fixing lower roller

Tool/solvent

Remarks

Cleaning

Part

Tool/solvent

Remarks

Cleaning

Separation roller

Feed roller

Pick-up roller

Multifeeder pick-up roller

Transfer guide

Lubricant and

lint-free paper

Lint-free paper

Dry wiping

Moist cloth

Cleaning

Part

Tool/solvent

Remarks

Waste toner box

Checking/collecting

10–4

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CHAPTER 10 TROUBLESHOOTING

II. STANDARDS AND ADJUSTMENTS

A. Mechanical

1. Leading Edge Non-Image Width (blank exposure lamp off timing)

Select No. 306 in service mode.

Make adjustments so that non-image width on copies made of the Test Sheet in Direct is 2.0 ±1.0mm.

[unit: 0.21 mm]

[settings: 0 to 500]

2.0±1.0mm

Figure 10-201

2. Image Leading Edge Margin (registration on timing)

Select No. 305 in service mode.

Make adjustments so that the image leading edge margin on copies made of the Test Sheet in

Direct is 2.5 ±1.5 mm.

[unit: 0.21 mm]

[settings: 0 to 500]

2.5±1.5mm

Figure 10-202

1998 CANON INC.

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CHAPTER 10 TROUBLESHOOTING

3. Left/Right Registration (cassette)

Make adjustments by moving the horizontal registration adjusting screw of the cassette so

that the distance between the copy image and the copy paper is 0 ±2.0 mm on copies made of the

Test Sheet in Direct.

Turn the adjusting screw [1] until the cassette locking lever plate [2] and the cassette locking

lever [3] engage.

When the adjusting screw [1] is turned clockwise, the cassette locking plate moves to the

front.

When the adjusting screw [1] is turned counterclockwise, the cassette locking lever plate [2]

moves to the rear.

[1]

[2]

[3]

Figure 10-203

(-)

(+)

Figure 10-204

10–6

1998 CANON INC.

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CHAPTER 10 TROUBLESHOOTING

B. Exposure System

1. Routing the Scanner Drive Cable

Route the cable following steps [1] through [7], and perform the steps under “Adjusting the

Tension of the Cable” and “Adjusting the Position of the Mirror.”

[3]

[4]

Secure temporarily.

[1]

Steel ball

Wind 11 times.

[2]

[6]

[5]

[2]

[7]

[6]

Figure 10-205

1998 CANON INC.

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CHAPTER 10 TROUBLESHOOTING

2. Adjusting the Position of the Mirror

Be sure to adjust the position of the mirror as follows after you have mounted the scanner

drive cable.

1) Keep the mirror positioning tool nearby.

Arrange the mirror positioning tool (FY9-3009-050) as shown to adapt it to the copier.

Figure 10-206b (Front)

Figure 10-206a (Rear)

2) Fit the mirror positioning tool [1] to the No. 1 mirror base and the No. 2 mirror base (both

front and rear).

3) Tighten the mounting screw [2] on the cable metal fixing of the No. 1 mirror base (both front

and rear).

[2]

[1]

Figure 10-207a (Rear)

Figure 10-207b (Front)

4) Detach the mirror positioning tool.

10–8

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CHAPTER 10 TROUBLESHOOTING

3. Adjusting the Tension of the Scanner Drive Cable

Be sure to adjust the tension as follows after routing the scanner drive cable.

1) Move the scanner to home position.

2) Pull the center of the scanner drive cable with a spring gauge about 10 mm. At this time,

adjust the position [A] of the tension spring [1] so that the reading of the spring gauge is 95 ±15 g.

10mm

Figure 10-208

[A]

[1]

Figure 10-209

1998 CANON INC.

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CHAPTER 10 TROUBLESHOOTING

C. Image Formation System

1. Outline

As many as two charging wires are located around the photosensitive drum. (These charging

wires are 0.06 mm in diameter.)

2. Stringing the Charging Wires

Basically, all charging wires are strung in the same way. (The following uses the primary

charging wire as an example.)

1) Remove the mounting screw [1], and remove the stopper [2] and the grid plate [3].

To remove the transfer charging assembly, remove the three hooks [a], and remove the guide

wire plate [b].

• Transfer Charging Assembly

• Primary Charging Assembly

[1]

[a]

[3]

[2]

[b]

Figure 10-210b

Figure 10-210a

2) Remove the sheet (front) [4] and the sheet (rear) [5].

To remove the transfer charging assembly, remove the sheet (front) [c] and the sheet (rear) [d].

• Transfer Charging Assembly

• Primary Charging Assembly

[c]

[d]

[5]

[4]

Figure 10-211b

Figure 10-211a

10–10

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CHAPTER 10 TROUBLESHOOTING

3) Remove the spring [6], and remove the charging wire [7].

To remove the transfer charging assembly, remove the spring [e], and remove the charging

wire [f].

• Transfer Charging Assembly

• Primary Charging Assembly

[e]

[7]

[6]

[f]

Figure10-212a

Figure 10-212b

4) Free a length of about 5 cm of charging wire (0.06-mm dia.) from the reel, and form a loop at

the end (2-mm dia.).

Note:

To form a loop easily, wind the charging wire around a hex key once; then, turn the hex

key three to four times, and twist the charging wire.

5) Cut the excess end of the twisted charging wire with a nipper.

6) Hook the loop on the charging electrode at the rear.

Figure 10-213

7) Hook the charging wire on the charging wire positioner at the rear; then, pull on the charging

wire as indicated, and hook the charging wire tension spring on the charging wire by the

distance A ; then, twist it.

• Primary charging assembly : 13.0 ± 0.5 mm

• Transfer charging assembly : 12.0 ± 0.5 mm

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Figure 10-214

8) Cut the excess charging wire with a nipper.

9) Pick the end of the charging wire tensioning spring with tweezers, and hook it on the

charging electrode.

Figure 10-215

Note:

Go through the following:

• Be sure that the charging wire is free of bending and twisting, and its gold plating has

not peeled.

• Be sure that the charging wire is in the V-groove of the charging wire positioner.

(correct)

(wrong)

Figure 10-216

10) Wipe the charging wire with lint-free paper moistened with alcohol.

Caution:

• Do not use a cloth carrying metal powder for cleaning.

• Do not use a moist cloth for cleaning.

• Dry wipe with lint-free paper; then, mount only after making sure that alcohol has

completely evaporated.

11) Mount the sheet (front) and the sheet (rear).

12) Mount the stopper and the grid plate.

For the transfer charging assembly, mount the guide wire plate.

10–12

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3. Adjusting the Height of the Charging Wires

To adjust each charging wire, turn its respective height adjusting screw. A full turn on the

screw will change the height of the primary charging wire by about 0.5 mm and that of the

transfer charging wire by about 0.7 mm.

Charging

assembly

Height of charging

wire (mm)

Range

1.0mm

11.0 0.2mm

Primary

Transfer

1.0mm

9.5 0.2mm

Figure 10-217

• Transfer Charging Assembly

• Primary Charging Assembly

Height adjusting

screw

Height adjusting

screw

Height adjusting

screw

Height adjusting

screw

Figure 10-218a

Figure 10-218b

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CHAPTER 10 TROUBLESHOOTING

D. Pick-Up/Feeding System

1. Adjusting the Pressure of the Separation Pad

If double feeding or pick-up failure occurs, loosen the adjusting screw [1] and relocate the

holder [2] to adjust the force of the separation pad tension spring.

• If pick-up occurs, move the holder in the direction of [A].

• If double feeding failure occurs, move the holder to in the direction of [B].

[2]

[A]

[B]

[1]

Figure 10-219

2. Changing the Cassette Size (AB/INCH)

1) Slide out the cassette.

2) Loosen the mounting screw [1] on the left side of the cassette; then, slide the size switching

block [2] to the desired size position, and fix it in position.

•AB

[2] [1]

[1]

[2]

•INCH

Figure 10-220

10–14

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CHAPTER 10 TROUBLESHOOTING

3) Remove the mounting screw [3]; then, slide the size switching lever [4] to the desired size

position, and fix it in place.

•AB

[4]

[3]

[4]

[3]

•INCH

Figure 10-221

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CHAPTER 10 TROUBLESHOOTING

E. Fixing System

1. Adjusting the Height of the Fixing Assembly Inlet Guide

1) Loosen the two adjusting screws [1], and adjust the height of the fixing assembly inlet guides

[2].

[1]

[2]

Figure 10-222

2. Adjusting the Pressure of the Lower Roller (nip)

If the nip is as indicated in Table 10-201, no adjustment is necessary.

If the nip is not as indicated, change the position of the pressure spring [1].

[1]

Figure 10-223

10–16

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CHAPTER 10 TROUBLESHOOTING

Caution:

a and c represent points 10 mm from both ends of copy paper.

Feeding

direction

Center of

copy paper

Figure 10-224

Dimensions

Measurements*

4.8 ± 0.3mm

I a - c I

0.5 mm or less

*Be sure both upper and lower rollers are

sufficiently warm before taking measurements.

Table 10-201

a. Measuring the Nip

Before measuring the nip, wait for 15 min after the end of warm-up and make 20 A4 copies:

1) Set A3 copy paper.

2) Open the copier cover.

3) Execute nip measurement mode (service mode).

The above steps will deliver a measurement sheet like the one shown in Figure 10-224.

Note:

When you execute nip measurement mode (service mode), the copy paper will stop half

way through the delivery slot. It will then be discharged fully in about 15 sec.

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CHAPTER 10 TROUBLESHOOTING

F. Electrical System

1. Obtaining Optimum Exposure

You can adjust the intensity of the scanning lamp (LA1) at F5 as follows (effective for both

AE and manual):

1) Set the setting of ‘U12’ (density correction) in user mode to its initial value.

2) Place the Test Sheet (NA-3) on the copyboard, and select non-AE and Direct.

3) Select ‘216’ (density adjusting volume voltage display) in service mode.

4) Slide the density adjusting volume until the copy count indicator indicates ‘245’ as the F5

voltage.

5) Make a copy.

6) Check the copy image, and change the setting of ‘326’ (scanning lamp on voltage

adjustment) in service mode using the keypad.

[1] A higher setting will increase the intensity, making the image lighter.

[2] A lower setting will decrease the intensity, making the image darker.

Intensity (manual)

Intensity (AE)

[1]

[2]

[1]

[2]

Copy

density

Copy

density

Original

density

Test Chart

Figure 10-225

7) Press the Start key, and store the setting.

• Repeat steps 5) through 7) until an optimum image is obtained.

8) Press the Reset key to end service mode.

10–18

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2. AE Adjustment

If copies of a newspaper are foggy or if you have replaced the scanning lamp (LA1), AE

sensor, or DC controller PCB, perform the following:

(Be sure that the image is an optimum image before starting the work.)

a. AE Auto Adjustment

1. AE Scanning Intensity Auto Adjustment

1) Select ‘301’ (AE auto adjustment) in service mode.

2) Place the Test Chart (white background original) on the copyboard glass.

3) Press ‘0’ of the keypad so that the copy count indicator indicates ‘0’.

4) Press the Start key.

• The scanner moves to the AE scan position, stops, and performs AE exposure. Then, the

scanner moves in reverse to home position. (15 sec from start of forward movement and

the end of reverse movement)

• The output of the AE sensor will be indicated in the copy count indicator. Check to make

sure it is 80 ±5. If not, execute ‘302’ (AE scanning intensity adjustment) in service mode.

2. AE Slope Auto Adjustment

5) Select ‘301’ (AE auto adjustment) in service mode.

6) Place a newspaper on the copyboard glass.

7) Press ‘1’ of the keyboard so that the copy count indicator indicates ‘1’.

8) Press the Start key.

• The scanner moves to the AE scan position, stops, and performs AE exposure. Then, the

scanner moves in reverse to home position. (15 sec from start of forward movement and

the end of reverse movement)

• The output of the AE sensor will be indicated in the copy count indicator. Check to make

sure it is between 0 and 255. If not, execute ‘303’ (AE slope adjustment) in service mode.

9) Press the Reset key to end service mode.

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b. AE Scanning Intensity Adjustment

If an optimum image cannot be obtained by executing ‘301’ (AE auto adjustment) in service

mode, perform the following:

1) Place a white background original on the copyboard glass, and select AE and Direct.

2) Make a copy, and check the copy image.

3) Select ‘302’ (AE scanning intensity adjustment) in service mode.

• The copy count indicator will indicate the present setting.

4) Change the setting using the keypad or the +/- key.

[1] A higher setting will increase the intensity, making the copy image lighter.

[2] A lower setting will decrease the intensity, making the copy image darker.

[1]

Intensity

[2]

Copy

density

Original

density

Test Chart

Figure 10-226

5) Press the Start key to store the new setting.

• Repeat steps 2) through 5) until an optimum image is obtained.

6) Press the Reset key to end service mode.

10–20

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c. AE Slope Adjustment

If an optimum image cannot be obtained by executing ‘301’ (AE auto adjustment) in service

mode, perform the following:

1) Place a newspaper on the copyboard glass, and select AE and Direct.

2) Make a copy, and check the copy image.

3) Select ‘303’ (AE slope adjustment) in service mode.

• The copy counter will indicate the present setting.

4) Change the setting using the keypad or +/- key.

[1] A higher setting will increase the intensity, making the copy image lighter.

[2] A lower setting will decrease the intensity, making the copy image darker.

Intensity (AE)

[1]

[2]

Copy

image

Original

density

Test

Chart

Newspaper

Figure 10-227

5) Press the Start key to store the new setting.

• Repeat steps 2) through 5) until an optimum image is obtained.

6) Press the Reset key to end service mode.

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CHAPTER 10 TROUBLESHOOTING

3. After Replacing the DC Controller PCB

1) Set the DIP switch (SW102) on the new DC controller PCB so that its settings are the same

as the old DC controller PCB.

2) Mount the new DC controller PCB.

3) Press the User Mode key, hold down ‘2’ and ‘8’ of the numeric keypad for 0.5 sec or more,

and then press the User Mode key.

• The copier starts service mode, and indicates ‘[1]’ on the control panel.

4) Press ‘4’ on the numeric keypad, and press the AE key.

• The copier enters FUNCTION mode, and indicates ‘401’ on the control panel.

5) Press ‘5’ and ‘0’ on the numeric keypad in sequence, and press the Start key.

• The copier turns off once, and initializes the RAM (IC116).

6) Press ‘1’ of the keypad and the Start key in sequence.

• The power turns off, and the data in RAM (IC116) will be initialized.

7) Enter the settings of each service mode by referring to the service mode label kept behind the

front door.

8) Press the Reset key to end service mode.

10–22

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CHAPTER 10 TROUBLESHOOTING

4. Checking the Photointerrupters

The copier allows you to use its service mode when checking its photointerrupters. (You may

also use a conventional meter.)

a. Using a Meter

1) Put the copier in standby state.

2) Set the range of the meter to 30 VDC.

3) Connect the - probe of the meter to J105-5 (GND) of the DC controller PCB.

4) Connect the + probe of the meter to the appropriate terminal on the DC controller PCB

indicated in the tables that follow.

5) Make checks as instructed.

b. Using Service Mode

1) Press the User Mode key.

2) Press ‘2’ and ‘8’ of the keypad at the same time. (Hold them down for 0.5 sec or more.)

3) Press the User Mode key once again.

• The copier starts service mode, and indicates ‘1’ on the copy count indicator.

4) Press ‘2’ and then the AE in sequence.

• The copier starts I/O DISPLAY mode, and indicates ‘201’.

5) Enter the appropriate service mode No. indicated in the tables that follow, and press the Start

key.

6) Make checks as instructed.

• Refer to the state of the copy count indicator LEDs. (Tables use ‘1’ to indicate ON, and ‘0’

to indicate OFF.)

Figure 10-228

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CHAPTER 10 TROUBLESHOOTING

Connector

Sensor

Checks

LED

Voltage

Service mode

In standby,

move the

scanner by

hand.

PS1

Scanner home

position sensor 220

J103-B2

1a=1

1a=0

1c=1

1c=0

1b=1

1b=0

1b=1

1b=0

1g=1

1g=0

1f=1

1f=0

2b=1

2b=0

1f=1

1f=0

When the light-blocking plate is at PS1,

When the light-blocking plate is not at PS1,

PS2

Lens home

position sensor 219

J103-B5

In standby,

move the lens

by hand.

When the light-blocking plate is at PS2,

When the light-blocking plate is not at PS2,

In standby,

move the

No. 4/No. 5

mirror by hand.

PS3

J103-B8

When the light-blocking plate is at PS3,

When the light-blocking plate is not at PS3,

When the light-blocking plate is PS4,

Mirror home

position sensor 219

In standby,

move the

detecting lever

by hand.

PS4

Cassette

paper sensor

J107-B12

202

When the light-blocking plate is not at PS4,

When the light-blocking plate is at PS5,

When the light-blocking plate is not at PS5,

When the light-blocking plate is at PS6,

When the light-blocking plate is not at PS6,

In standby,

move the

detecting lever

by hand.

PS5

Registration

paper sensor

J107-A2

222

In standby,

move the

detecting lever

by hand.

PS6

Delivery

paper sensor

J124-2

222

In standby,

move the

detection lever

by hand.

PS7

Multi paper

sensor

J107-A8

202

When the light-blocking plate is at PS7,

When the light-blocking plate is not at PS7,

When the light-blocking plate is at PS8,

When the light-blocking plate is not at PS8,

PS8

J106-10

223

In standby,

move the

detecting lever

by hand.

Waste toner

feeding screw

locked sensor

In standby,

move the slide

guide by hand.

When the light-blocking plate is at PS9,

PS9

Multi wide

sensor 1

J107-A11

202

2c=1

2c=0

2d=1

2d=0

1d=1

1d=0

1a=1

1a=0

When the light-blocking plate is not at PS9,

When the light-blocking plate is at PS10,

In standby,

move the slide

guide by hand.

PS10

Multi wide

sensor 2

J107-A14

202

When the light-blocking plate is not at PS10,

When the light-blocking plate is at PS11,

When the light-blocking plate is not at PS11,

When the light-blocking plate is at sensor,

When the light-blocking plate is not at sensor,

In standby,

open the right

door.

PS11

Right door

open sensor

J107-B7

202

In standby,

remove the

waste toner

box.

Waste toner

sensor

J106-9

222

10–24

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CHAPTER 10 TROUBLESHOOTING

III. IMAGE FAULTS

A. Initial Checks

1. Checking the Site Environment

a. The power outlet must be exclusive, and must provide the rated voltage. (The power plug

must remain connected throughout day and night.)

b. The copier must not be installed in a high-temperature/-humidity environment (near a water

faucet, water boiler, humidifier), near a source of fire, or in a dusty area.

c. The copier must not be subjected to ammonium gas.

d. The copier must be kept away from direct sunshine. As necessary, provide curtains.

e. The site must be well ventilated.

f. The copier must be kept level.

g. The copier must remain powered throughout day and night.

Check to make sure that all above conditions are met.

2. Checking the Originals

Identify the problem as to its cause—original page or the copier.

a. As a rule, the Copy Density adjusting lever must be at the median graduations, and ‘U12:

density correction’ in user mode must be set to ‘0’.

b. Original pages with a reddish background can cause poor contrast.

EX. Slips (invoices) made on reddish paper.

c. Diazo copies and original pages with a high transparency can produce copies mistakenly

identified as “foggy” copies. Original pages prepared in light pencil, on the other hand, can

produce copies mistakenly identified as “light” copies.

3. Checking the Copyboard Cover and Copyboard Glass

If soiled, clean it using a solution of mild detergent or alcohol. If scratches are found, replace it.

1998 CANON INC.

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CHAPTER 10 TROUBLESHOOTING

4. Checking the Charging Assembly

a. Check each charging assembly for soiling and a fault on its charging wire (scratches).

b. Clean the charging wire and shield plate of each charging assembly. (If dirt cannot be

removed, replace it.)

c. Check the height of each charging wire.

d. Check to make sure that each charging wire is not rusted.

f. Check to make sure that the anti-vibration rubber (of each charging assembly) is not

displaced.

5. Checking the Developing Assembly

a. Check to make sure that the rollers on both ends of the developing assembly are in contact

with the drum.

b. Check to make sure that the surface of the developing cylinder is coated with an even layer of

toner.

6. Checking the Paper

a. Check if the paper is of a type recommended by Canon.

b. Check if the paper is not moist.

Try using paper fresh out of package.

7. Checking the Periodically Replaced Parts

Replace those parts that have reached their service life as indicated in the Scheduled

Servicing Chart and the Periodically Replaced Parts Table.

8. Others

Keep in mind that bringing in a copier from a cold to warm room, as during installation in

winter, can cause condensation in its inside, causing various problems.

a. Condensation on the scanning system (glass, mirror, lens, etc.) can cause light images.

b. Condensation in the charging system can cause electric leakage.

c. Condensation on the pick-up/feeding guide plate can cause faulty feeding.

If condensation is noted, dry wipe the part or leave the copier powered for about one hour.

Caution:

If a discrepancy in density (between separation side and rear), light image, of fogging

occurs, try to correct the problem by following the “Image Adjustment Basic Procedure.”

10–26

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CHAPTER 10 TROUBLESHOOTING

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CHAPTER 10 TROUBLESHOOTING

B. Image Fault Samples

not available

10–28

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CHAPTER 10 TROUBLESHOOTING

C. Troubleshooting Image Faults

1. The copy is too light. (halftone area only)

Cause

Step

Checks

Yes/No

YES

Actions

Perform the Image Adjustment Basic

Procedure. Is the problem corrected?

End.

Scanner

Clean the mirror, lens, and dust-

proofing glass. Is the problem

corrected?

YES

Developing

assembly

Are the rollers of the developing

assembly in firm contact with the

drum during copying operation?

Check the developing assembly

locking lever.

Developing

assembly

Is the coating of toner on the

developing cylinder even?

Check the developing assembly.

Lamp regulator PCB

DC controller PCB

Replace the lamp regulator PCB. Is

the problem corrected?

YES

End.

Replace the DC controller PCB.

1998 CANON INC.

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CHAPTER 10 TROUBLESHOOTING

2. The copy is too light. (including solid black area)

3. The copy is too light. (entirely, considerably)

Cause

Step

Checks

Yes/No

YES

Actions

End.

Perform the Image Adjustment Basic

Procedure. Is the problem corrected?

Go to step 7.

Turn off the power switch in the

middle of copying operation. Then,

open the front door, and open the top

unit. Is the toner image on the

photosensitive drum before transfer

more or less normal?

Transfer

charging

assembly

1.Hook the charging wire correctly.

2.Adjust the height of the charging

wire.

Is the charging wire of the transfer

charging assembly hooked correctly?

Are its height and position normal?

1.Clean the charging wire.

2.Set the charging assembly securely.

Is the transfer charging assembly set

securely?

Copy paper

1.The paper may be moist. Instruct

the user on the correct method of

storing copy paper.

Try paper fresh out of package. Is the

problem corrected?

YES

2.Inform the user that the use of

paper of a type not recommended

by Canon may not always bring

about good results.

Lower transfer

guide/varistor

1.Check to make sure that the

transfer guide is not in contact with

the metal area of the feeding

assembly (e.g., side plate).

2.Replace the varistor.

Measure the resistance between the

lower transfer guide and the metal

portion of the feeding assembly. Is it

0 Ω?

YES

High-voltage

cord, DC

controller PCB

1.Check the continuity of the high-

voltage cord.

2.Check the high-voltage power

supply (primary/transfer) and the

DC controller PCB.

Developing

assembly

Check the developing assembly

locking lever.

Is the developing assembly set

securely? Are the rolls of the

developing assembly firmly in

contact with the photosensitive drum?

Toner sensor

(TS1)

Check the tone sensor. Then, supply

toner.

Is toner in the developing assembly?

Photosensitive

drum

End.

Replace the drum unit. Is the problem YES

corrected?

Developing

bias control

Check the control system of the

developing bias.

10–30

1998 CANON INC.

CANON NP7161/NP7160 REV.0 AUG. 1998 PRINTED IN JAPAN (IMPRIME AU JAPON)

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CHAPTER 10 TROUBLESHOOTING

4. The copy has uneven density. (front side dark)

5. The copy has uneven density. (front side light)

Cause

Step

Checks

Yes/No

YES End.

Actions

Perform the Image Adjustment Basic

Procedure. Is the problem corrected?

Developing

assembly

Are the developing rolls of the

developing assembly in firm contact

with the photosensitive drum?

NO Check the developing assembly

locking lever.

Scanner

Clean the scanning lamp, reflecting

plate, side reflecting plate, mirror,

lens, and dust-proofing glass. Is the

problem corrected?

YES End.

Pre-scanning lamp

(LA2)

Does the pre-exposure lamp remain

on during copying?

1.Replace the pre-exposure lamp.

2.Replace the DC controller PCB.

Developing

assembly

Is the developing cylinder coated

with a uniform layer of toner?

1.Clean the tip of the blade of the

developing assembly. (dry wiping)?

2.Clean the surface of the developing

cylinder.

3.Check to make sure that the toner

inside the developing assembly is

not displaced to one side.

Charging assembly,

Copy paper

YES

1.Clean all charging wires once

again, and check the height of the

charging wires once again.

2.Try replacing the copy paper.

1998 CANON INC.

CANON NP7161/NP7160 REV.0 AUG. 1998 PRINTED IN JAPAN (IMPRIME AU JAPON)

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CHAPTER 10 TROUBLESHOOTING

6. The copy is foggy. (overall)

Cause

Step

Checks

Yes/No

Actions

Perform the Image Adjustment Basic

Procedure. Is the problem corrected?

YES End.

Scanner

Clean the scanning lamp, reflecting

plate, side reflecting plate, mirror,

lens, and dust-proofing glass. Is the

problem corrected?

YES End.

Pre-exposure lamp

(LA2),

Does the pre-exposure lamp remain

on during copying?

1.Replace the pre-exposure lamp.

2.Replace the DC controller PCB.

DC controller PCB

Developing roll

Are the developing rolls worn?

Is the developing cylinder worn?

YES Replace the developing rolls.

YES Replace the developing cylinder.

YES End.

Developing cylinder

Scanner lamp (LA1)

Replace the scanning lamp. Is the

problem corrected?

High-voltage power

supply PCB

Replace the high-voltage power

supply PCB. Is the problem

corrected?

YES End.

Lamp regulator PCB

DC controller PCB

Replace the lamp regulator PCB. Is

the problem corrected?

Replace the DC controller PCB.

10–32

1998 CANON INC.

CANON NP7161/NP7160 REV.0 AUG. 1998 PRINTED IN JAPAN (IMPRIME AU JAPON)

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CHAPTER 10 TROUBLESHOOTING

7. The copy is foggy. (vertical)

8. The copy has black lines. (vertical, fuzzy, thick)

Cause

Step

Checks

Yes/No

Actions

Primary charging

assembly

Clean the primary charging wire, grid

plate, and shielding plate. Is the

problem corrected?

YES End.

Scanner

Clean the scanning lamp, reflecting

plate, side reflecting plate, mirror,

lens, and dust-proofing glass. Is the

problem corrected?

YES End.

Pre-exposure lamp

(LA2)

Clean the pre-exposure lamp. Is the

problem corrected?

Developing

assembly

Is the developing cylinder coated

with a uniform layer of toner?

Check and clean the edge of the blade

of the developing assembly.

Fixing assembly

YES Check the fixing assembly.

9. The copy has black lines. (vertical, thin)

Cause

Step

Checks

Yes/No

Actions

Press the Copy Start key, and turn off

the power switch while the copy

paper is in the feeding assembly. At

this time, does the copy image before

it goes through the fixing assembly

have black lines?

Go to step 4.

Transfer guide

Is the transfer guide soiled

(particularly the transfer upper guide)?

YES Clean the transfer guide.

Photosensitive drum

Are there scratches or black lines in

the peripheral direction of the surface

of the photosensitive drum?

YES Replace the drum unit. If scratches

are found, be sure to find out the

cause.

Developing system,

Exposure system

YES

Check the developing system and the

exposure system.

Fixing assembly

Are there scratches or black lines in

the peripheral direction of the surface

of the fixing upper roller?

1.Replace the upper roller.

2.Check the separation claw.

Check to make sure that the fixing

assembly inlet is not soiled.

1998 CANON INC.

CANON NP7161/NP7160 REV.0 AUG. 1998 PRINTED IN JAPAN (IMPRIME AU JAPON)

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CHAPTER 10 TROUBLESHOOTING

10.The copy has white spots. (vertical)

11.The copy has white lines. (vertical)

Yes/No

Cause

Step

Checks

Actions

Fixing assembly

Press the Copy Start key with the

copyboard cover open, and turn off

the power switch while the copy

paper is moving through the feeding

assembly. At this time, does the copy

image before it goes through the

fixing assembly have white spots or

lines?

1.Clean the fixing assembly inlet

guide.

2.Check the upper fixing roller.

3.Clean the separation claw.

Primary charging

assembly

Clean the primary charging wire, grid

plate, and shield plate. Is the problem

corrected?

YES Clean the part thoroughly with

alcohol. If the dirt cannot be removed,

remove the charging wire.

Developing

assembly

Is the developing cylinder coated with

an even layer of toner?

NO Check the edge of the blade of the

developing assembly for paper 1int.

Copy paper

Try copy paper fresh out of package.

Is the problem corrected?

YES The copy paper is moist. Instruct the

user on the correct method of storing

copy paper.

Photosensitive drum

Are there scratches in the peripheral

direction corresponding to the

developing image?

YES Replace the drum unit. If scratches are

found, be sure to identify the cause.

Blank exposure

lamp (LA3),

DC controller PCB

Is the blank exposure lamp LED

corresponding to the white spot or line

on the copy on while the scanner is

moving forward?

YES Check the wiring from the blank

exposure lamp to the DC controller

PCB: if normal, replace the DC

controller PCB.

External light

NO Check to make sure that the

photosensitive drum is free of external

light.

Transfer charging

assembly

Clean the transfer charging wire and

the shield plate. Is the problem

corrected?

YES End.

Separation static

eliminator

Clean the separation static eliminator.

Is the problem corrected?

YES End.

10–34

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CANON NP7161/NP7160 REV.0 AUG. 1998 PRINTED IN JAPAN (IMPRIME AU JAPON)

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CHAPTER 10 TROUBLESHOOTING

12.The copy has white spots. (vertical)

Yes/No

YES

Cause

Step

Checks

Actions

Developing

assembly

Is the problem noted at intervals of

about 3.2 cm? (scratch on the

developing cylinder)

1.Clean the developing roller.

2.Clean the surface of the developing

cylinder.

3.If scratches are found on the

surface of the developing cylinder,

replace the developing cylinder or

the developing assembly.

Photosensitive drum

Copy paper

Is the problem noted at intervals of

about 9.4 cm? (scratch on the

photosensitive drum)

YES

1.Clean the photosensitive drum.

2.If the scratches are found on the

photosensitive drum, replace the

drum unit.

Try copy paper fresh out of package.

Is the problem corrected?

YES

The copy paper is moist. Instruct the

user on the correct method of storing

copy paper.

Scanner rail,

Scanner cable

Is the problem noted at the same

location on all copies?

1.Check the scanner rail for a foreign

object.

2.Adjust the tension of the scanner

cable.

Charging wire

Clean each charging wire.

1998 CANON INC.

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CHAPTER 10 TROUBLESHOOTING

13.The back of the copy is soiled.

Yes/No

Cause

Step

Checks

Actions

Go to step 3.

Turn off the power switch while the

copy paper is moving through the

feeding assembly. At this time, is the

back of the copy paper soiled?

1.Clean the registration roller.

2.Clean the transfer guide.

3.Check the developing assembly for

leakage of toner.

Developing

assembly

Is the problem noted at intervals of

about 5 cm?

YES

1.Clean the feeding assembly.

2.Check the drum cleaner assembly

for leakage of toner.

Drum cleaner

assembly

1.Clean the fixing roller (upper,

lower).

Fixing assembly

Is the fixing roller (upper, lower)

soiled with toner?

YES

2.Check to make sure that the toner

adhering to the heat discharging

roller is not soiling the fixing

roller.

If so, replace the heat discharging

roller.

3.Clean the fixing assembly inlet

guide.

Clean the delivery roller and the

separation claw.

Delivery assembly

10–36

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CANON NP7161/NP7160 REV.0 AUG. 1998 PRINTED IN JAPAN (IMPRIME AU JAPON)

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CHAPTER 10 TROUBLESHOOTING

14.The copy has faulty fixing.

Yes/No

Cause

Step

Checks

Actions

Fixing roller (upper/

lower)

Is the problem noted vertically?

YES Check the fixing roller (upper, lower)

for scratches.

Fixing heater (H1)

Does the fixing heater (H1) turn on

immediately after power-on?

See the “Fixing heater fails to turn

on.”

Fixing lower heater

pressure

Is the nip of the fixing assembly as

indicated?

Adjust the fixing lower roller

pressure.

Copy paper

YES Try recommended paper. If the results

are good, advise the user to use

recommended paper.

1998 CANON INC.

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CHAPTER 10 TROUBLESHOOTING

15.

16.The copy has a displaced leading edge.

17.

Yes/No

Cause

Step

Checks

Actions

Original page

Is the original page placed correctly?

Place the original page correctly.

Copy paper

Is the paper of a type recommended

by Canon?

Try recommended paper. If the results

are good, advise the user to use

recommended paper.

Make copies using the cassette and the

multifeeder tray? Is the displacement on

the leading edge the same regardless of

the source of paper?

YES If the results are the same, go to step 4.

NO Check each pick-up system.

Pick-up roller

Has the pick-up roller reached its

life?

YES If wear is noted on the pick-up roller,

replace it.

Leading edge

margin

Adjust the leading edge margin. Is

the problem corrected?

YES End.

Registration clutch

(CL1), Registration

roller

Set the meter range to 30 VDC, and

measure the voltage between J211-7

(+) and J211-6 (-) on the power

supply PCB. Does it change from 0

to 24 V while the scanner is moving

forward?

YES

1.Replace the registration clutch.

2.Check the registration roller for

deformation and wear.

DC controller PCB

Check the wiring from J106 on the

DC controller PCB to CL1; if normal,

replace the DC controller PCB.

10–38

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CHAPTER 10 TROUBLESHOOTING

18.The copy has a blurred image.

Yes/No

YES

Cause

Step

Checks

Actions

Scanner cable

Does the cable wind on the cable

pulley in layers while the scanner is

moving?

1.Route the cable once again.

2.If the cable is twisted or frayed,

replace it.

Scanner rail

Move the No. 1 mirror mount slowly

by hand. Does it move smoothly?

Clean the surface of the scanner rail

with alcohol. Then, apply a small

amount of lubricant.

Photosensitive drum

Is the problem noted at intervals of

about 9.4 cm?

YES

1.Check the drum gear.

2.Check the end of the drum (in

contact with the developing roller)

for scratches and protrusions.

Developing gear

Is the problem noted at intervals of

about 3.2 cm?

YES

Check the developing assembly.

Check the drum drive system.

Drum drive system

19.The copy is foggy. (horizontally)

Yes/No

YES

Step

Cause

Checks

Actions

Is the problem noted at the same

Go to step 4.

location on all copies made in Direct?

Scanning lamp

(LA1), Lamp

regulator PCB

Does the scanning lamp flicker when

the scanner is moving forward?

Check the scanning lamp and the

lamp regulator PCB.

YES

Developing roller

Is the developing roller soiled with

toner, is the roller deformed, or is the

area in contact with the developing

roller (photosensitive drum) soiled

with toner?

Clean or, if necessary, replace the

developing roller.

Developing bias

Is the developing bias applied

correctly?

Remove the developing assembly,

and check the wiring; then, set it once

again.

Scanner

Make a copy in Reduce, and compare

it with a copy made in Direct. Is the

problem noted in a different location?

Check the scanning system.

Check the feeding assembly.

YES

Feeding assembly

1998 CANON INC.

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CHAPTER 10 TROUBLESHOOTING

20.The copy has poor sharpness.

Yes/No

YES Clean the copyboard glass.

Cause

Actions

Step

Checks

Copyboard glass

Is the copyboard glass soiled with oil

or the like?

Mirror

Is the horizontal reproduction ratio in

Direct as indicated?

Adjust the distance between the No. 1

mirror and the No. 2 mirror.

Scanner

Clean the scanning lamp, reflecting

plate, mirror, lens, and dust-proofing

glass. Is the problem corrected?

YES End.

Lens drive assembly,

No. 4/No. 5 mirror

drive assembly

Is there dirt or foreign object in the

path of the lens and the No. 4/ No. 5

mirror? Does the part, when pushed

by hand, move smoothly?

YES Remove the dirt and foreign object.

As necessary, clean and lubricate.

Photosensitive drum

Replace the drum unit.

10–40

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CHAPTER 10 TROUBLESHOOTING

21.The copy is blank.

Yes/No

Cause

Drum unit

Actions

Step

Checks

Is the drum unit set securely?

Remove and set the drum unit once

again.

Developing

assembly

Is the developing assembly set

securely?

Remove and set the developing

assembly securely.

Primary charging

assembly

Is the primary charging wire broken?

YES Spring the charging wire.

Developing

assembly

Is the developing assembly locked to

the drum?

Check the developing assembly

locking lever.

DC controller PCB

Does the blank exposure lamp remain

off while the scanner is moving

forward?

Check the DC controller PCB.

Scanning lamp

(LA1)

Does the scanning lamp remain on

during copying operation?

Make checks as instructed under “The

scanning lamp fails to turn on.”

Connector

Are the connectors on each PCB

connected securely?

Connect the connectors securely.

Replace the high-voltage cord.

High-voltage cord

Is there continuity between high-

voltage cords connected to each

charging assembly?

High-voltage power

supply (primary/

transfer)

YES Check the high-voltage power supply

(primary/transfer).

22.The copy is solid black.

Yes/No

Cause

Actions

Step

Checks

Does the scanning lamp remain on

during copying operation?

Make checks according to the

instructions under “The scanning

lamp fails to turns off.”

1998 CANON INC.

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CHAPTER 10 TROUBLESHOOTING

IV. TROUBLESHOOTING MALFUNCTIONS

A. Copier

1. E000

Yes/No

Cause

Actions

Step

Checks

Execute service mode ‘412’ (error clear) to

clear E000. Open the front door and the top

unit, and let the fixing roller cool sufficiently.

Turn off the power switch, and disconnect

and then connect the power plug.

See “The Fixing heater fails to

turn on.”

Turn on the power switch. Does the fixing

heater turn on?

Caution:

Do not repeat the steps without cooling

the fixing roller sufficiently, or abnormal

increase in the fixing temperature will

damage the fixing roller and the

separation claw.

Turn off the power switch, and let the fixing

roller cool sufficiently. Turn on the power

switch, and select service mode ‘109’ (fixing

main thermistor detection temperature

display). Does the reading remain unchanged

at ‘109’?

Check the wiring on the DC

controller PCB to the

thermistor; if normal, replace

the thermistor.

Main thermistor

(TH1)

YES

(After the check, be sure to turn off the

power switch.)

Turn off the power switch, and let the fixing

roller cool sufficiently. Turn on the power

switch, and select service mode ‘110’ (fixing

sub thermistor detection temperature

display). Does the reading remain unchanged

at ‘110’?

Check the wiring from J109

on the DC controller PCB to

the thermistor; if normal,

replace the thermistor.

Sub thermistor

(TH2)

YES

(After the check, be sure to tun off the power

switch.)

Is the thermistor in even contact with the

upper fixing assembly?

Mount the thermistor

correctly.

Thermistor (TH1,

TH2)

YES

Clean the area of contact of the thermistor. Is

the problem corrected?

End.

Thermistor (TH1,

TH2)

Is the operating environment as specified?

• Inform the user that the

operating environment

does not meet the

Operating

environment

requirements.

• Instruct the user not to turn

on the copier before the

room is warm enough.

Replace the DC controller.

DC controller PCB

YES

10–42

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CANON NP7161/NP7160 REV.0 AUG. 1998 PRINTED IN JAPAN (IMPRIME AU JAPON)

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CHAPTER 10 TROUBLESHOOTING

2. E001

Yes/No

Cause

Actions

Go to step 3.

Step

Checks

Execute service mode ‘412’ (error clear) to

clear E001. Open the front door and the top

unit, and let the fixing roller cool

sufficiently.

Turn on the power switch. Is E001 indicated

immediately after power-on?

Replace the thermistor.

Thermistor (TH1,

TH2)

Turn off the power switch, and disconnect

J108 and J109 on the DC controller PCB.

Connect the probes to J108-2 and J108-3

and then J109-1 and J109-2 on the harness

side. Is the resistance about 0 Ω? (After the

check, be sure to connect J108 and J109.)

YES

Replace the DC controller

PCB.

DC controller PCB

End.

Triac

Replace the power supply PCB. Is the

problem corrected?

YES

Check the wiring from the

power supply PCB to the DC

controller PCB; if normal,

replace the DC controller PCB.

DC controller PCB

1998 CANON INC.

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CHAPTER 10 TROUBLESHOOTING

3. E002/E003

Yes/No

YES

Cause

Actions

Step

Checks

Execute service mode ‘412’ (error clear) to

clear E002 or E003. Open the front door and

the top unit, and let the fixing roller cool

sufficiently.

See the appropriate section.

Turn on the power switch. Does any of the

following apply?

• The fixing heater fails to turn on.

• E000

YES

Main thermistor

Turn off the power switch, and let the fixing

roller cool sufficiently. Turn on the power

switch, and select service mode ‘109’.

(fixing main thermistor detection

temperature display)

Check the wiring from J108

on the DC controller PCB to

the thermistor; if normal,

replace the thermistor.

Does the reading remain unchanged at

‘109’? (After the check, be sure to turn off

the power switch.)

YES

Sub thermistor

(TH2)

Check the wiring from J109

on the DC controller PCB to

the thermistor; if normal,

replace the thermistor.

Turn off the power switch, and let the fixing

roller cool sufficiently. Turn on the power

switch, and select service mode ‘110’.

(fixing sub thermistor temperature display)

Does the reading remain unchanged at

‘110’? (After the check, be sure to turn off

the power switch.)

YES

Thermistor

(TH1, TH2)

Is the thermistor in even contact with the

upper fixing roller?

Mount the thermistor

correctly.

Thermistor

(TH1, TH2)

End.

Clean the area of contact of the thermistor. Is

the problem corrected?

Operating

environment

Is the operating environment as indicated?

• Inform the user that the

operating environment

does not meet the

requirements.

• Instruct the user not to turn

on the copier before the

room is warm enough.

YES

DC controller PCB

Replace the DC controller

PCB.

10–44

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CANON NP7161/NP7160 REV.0 AUG. 1998 PRINTED IN JAPAN (IMPRIME AU JAPON)

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CHAPTER 10 TROUBLESHOOTING

4. E004

Yes/No

Cause

Actions

Step

Checks

Fixing heater (H1)

Execute service mode ‘412’ (error clear) to

clear E004.

See “The fixing heater fails to

turn on.”

Turn on the power switch. Does the fixing

heater turn on?

Triac

Replace the power supply PCB. Is the

problem corrected?

YES End.

DC controller PCB

Check the wiring from the

power supply PCB to the DC

controller PCB; if normal,

replace the DC controller

PCB.

5. E010

Yes/No

Cause

Actions

Step

Checks

Connector

Are all connectors of the main motor (M1)

connected?

NO Connect the connectors.

Power supply PCB

Turn on the power switch. Set the meter

range to 30 VDC, and connect the probes to

J209-4 (+) and J209-3 (-) on the DC

NO See “DC power is absent.”

controller PCB. Is the voltage about 24 V?

Main motor (M1)

DC controller PCB

Replace the main motor. Is the problem

corrected?

YES End.

NO Replace the DC controller

PCB.

1998 CANON INC.

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CHAPTER 10 TROUBLESHOOTING

6. E013

Yes/No

Cause

Actions

Step

Checks

Waste toner feeding

screw

Is the flag of the waste toner feeding screw

locked sensor rotating when the main motor

is rotating?

Remove the drum unit, and

turn the feeding screw by

hand. If it rotates easily, check

how it is mounted. If it does

not turn, replace the drum unit,

and remove the cause.

Waste toner feeding

screw locked sensor

(PS8)

Is the waste toner feeding screw locked

sensor normal? (See the instructions on how

to check the photointerrupters.)

Check the wiring from the DC

controller PCB to PS8; if

normal, replace PS8.

DC controller PCB

YES Replace the DC controller

PCB.

7. E030

Yes/No

Cause

Actions

Step

Checks

Total copy counter

(CNT1)

Turn off the power switch, and disconnect

J102 from the DC controller PCB. Set the

meter range to 1 KΩ, and connect the probes

to J102-A11 and J102-A10. Is the resistance

about 500 Ω?

Check the wiring from the DC

controller PCB to the counter;

if normal, replace the counter.

Total copy counter

(CNT1)

Connect J102 to the DC controller PCB, and

turn on the power switch. Set the meter range

to 30 VCD, and connect the probes J102-

A11 (+) and J102-A10 (-) on the DC

controller PCB. Does the voltage change

from about 0 to about 24 and then to about 0

V when the Start key is pressed?

YES Replace the counter.

DC controller PCB

Replace the DC controller

PCB.

10–46

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CANON NP7161/NP7160 REV.0 AUG. 1998 PRINTED IN JAPAN (IMPRIME AU JAPON)

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CHAPTER 10 TROUBLESHOOTING

8. E031

Yes/No

Cause

Actions

Step

Checks

Accessory counter

(CNT2)

Turn off the power switch, and disconnect

J102 from the DC controller PCB. Set the

meter range to 1 KΩ, and connect the probes

to J102-A13 and J102-A12. Is the resistance

about 500 Ω?

Check the wiring from the DC

controller PCB to the counter;

if normal, replace the counter.

Accessory counter

(CNT2)

Connect J102 to the DC controller PCB, and

turn on the power switch. Set the meter range

to 30 VDC, and connect the probes to

J102A13 (+) and J102-A12 (-) on the DC

controller PCB. Does the voltage change

from about 0 to about 24 and then to about

0 V when the Start key is pressed?

YES Replace the counter.

DC controller PCB

Replace the DC controller

PCB.

9. E202 (The keys on the control panel fail to operate.)

Yes/No

Cause

Actions

Step

Checks

Does the scanner move forward or in reverse

until E202 is detected?

See “The scanner fails to

move.”

Scanner home

position sensor

(PS1)

Is the scanner home position sensor normal?

(See the instructions on how to check the

photointerrupters.)

Check the wiring from the DC

controller PCB to the sensor;

if normal, replace the sensor.

DC controller PCB

Replace the DC controller

PCB.

YES

1998 CANON INC.

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CHAPTER 10 TROUBLESHOOTING

10.E208

Yes/No

Cause

Actions

Step

Checks

Does the mirror move when the power

switch is turned on?

See “The mirror fails to

move.”

Mirror home

position sensor

(PS3)

Is the mirror home position sensor normal?

(See the instructions on how to check the

photointerrupters.)

Check the wiring from the DC

controller PCB to the sensor;

if normal, replace the sensor.

DC controller PCB

YES Replace the DC controller

PCB.

11.E210

Yes/No

Cause

Actions

Step

Checks

Turn on the power switch. Does the lens

move?

See “The lens fails to move.”

Lens home position

sensor (PS2)

Is the lens home position sensor normal?

(See the instructions on how to check the

photointerrupters.)

Check the wiring from the DC

controller PCB to the sensor;

if normal, replace the sensor.

DC controller PCB

YES Replace the DC controller

PCB.

10–48

1998 CANON INC.

CANON NP7161/NP7160 REV.0 AUG. 1998 PRINTED IN JAPAN (IMPRIME AU JAPON)

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CHAPTER 10 TROUBLESHOOTING

12.E220

Yes/No

Cause

Actions

Step

Checks

Does the scanning lamp (LA1) remain off?

YES See “The scanning lamp fails

to turn on.”

Lamp regulator PCB

Set the meter range to 30 VDC, and connect

the probes to J211-2 (+) and J211-1 (-) on

the DC controller PCB. Is the voltage

between the terminals when the scanning

lamp turn on about 5 V?

Check the wiring from the DC

controller PCB to the lamp

regulator PCB; if normal,

replace the lamp regulator

PCB.

DC controller PCB

YES Replace the DC controller

PCB.

13.E261

Yes/No

Cause

Actions

Step

Checks

Power supply PCB

Replace the power supply PCB. Is the

problem corrected?

YES End.

Power supply

frequency

If E261 is indicated often,

advise the user to install a

frequency stabilizer.

14.E710/E711

Yes/No

Cause

Actions

Step

Checks

Malfunction

Turn off and then on the power switch. Is the

problem corrected?

YES End.

DC controller PCB

Replace the DC controller

PCB.

1998 CANON INC.

CANON NP7161/NP7160 REV.0 AUG. 1998 PRINTED IN JAPAN (IMPRIME AU JAPON)

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CHAPTER 10 TROUBLESHOOTING

15.E712

Yes/No

Cause

Actions

Step

Checks

Malfunction

Turn off and then on the power switch. Is the

problem corrected?

YES End.

Connector

Is the connector (J754) used between the

ADF and the copier connected securely?

Connect the connector

securely.

ADF PCB

Replace the ADF controller PCB. Is the

problem corrected?

YES End.

DC controller PCB

Replace the DC controller

PCB.

16.E717

Yes/No

Cause

Actions

Step

Checks

Malfunction

Turn off and then on the power switch. Is the

problem corrected?

YES End.

Connector

Is the connector (J722) used between the

Remote Diagnostic Device II and the copier

connected securely?

Connect the connector

securely.

DC controller PCB

Replace the DC controller PCB. Is the

problem corrected?

YES End.

Remote Diagnostic

Device II

See the Service Manual of the

Remote Diagnostic Device II.

10–50

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CANON NP7161/NP7160 REV.0 AUG. 1998 PRINTED IN JAPAN (IMPRIME AU JAPON)

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CHAPTER 10 TROUBLESHOOTING

17.E800

Yes/No

Cause

Actions

Step

Checks

Malfunction

Turn off and then on the power switch. Is the

problem corrected?

YES End.

Power supply PCB

DC controller PCB

Replace the power supply PCB. Is the

problem corrected?

YES End.

Check the wiring and

continuity from the DC

controller PCB to the control

panel PCB; if normal, replace

the DC controller PCB.

18.E805

Yes/No

Cause

Actions

Step

Checks

Check service mode '106' (E805 details)

while 'E805' is being indicated.

Make the checks in step 2 and

later to identify the fan that

caused the error.

Connector

Are the connectors from the connector on the

DC controller PCB to the exhaust fan proper?

Connect the connectors.

Exhaust fan

(FM2, FM4, FM5)

Replace the exhaust fan. Is the problem

corrected?

YES End.

DC controller PCB

Check the wiring from the DC

controller PCB to the exhaust

fan; if normal, replace the DC

controller PCB.

19.E821

Yes/No

Cause

Actions

Step

Checks

Ozone filter

Replace the ozone filter. Is the problem

corrected?

YES End.

Cleaner thermistor

(TH3)

Turn on the power switch, and select service

mode 111 (clean thermistor detection

temperature).

YES Check the wiring from J112

on the DC controller PCB to

the thermistor; if normal,

Do the reading remain as ‘111’?

replace the thermistor.

DC controller PCB

Replace the DC controller

PCB.

1998 CANON INC.

CANON NP7161/NP7160 REV.0 AUG. 1998 PRINTED IN JAPAN (IMPRIME AU JAPON)

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CHAPTER 10 TROUBLESHOOTING

20.AC power is absent.

Yes/No

Cause

Power cord

Actions

Step

Checks

Is the power cord connected to the copier?

Connect the cord.

Power plug

Is the power plug connected to the power

outlet?

Connect the power plug.

Main power supply

Is the rated AC voltage present at the power

outlet?

This is not the copier’s

problem. Inform the user

accordingly.

Front door

Is the front door closed securely?

Close the front door.

Is the rated voltage present between J204-1

and J204-3 on the DC controller PCB?

YES End.

Circuit breaker

(CB1, CB2)

Press the button on the circuit breaker (CB1,

CB2). Is AC power supplied?

Power cord

Replace the power supply cord. Is AC power

supplied?

Check the wiring of the AC

power line. Check the

connector for contact.

Fuse

Is the fuse (FU1, FU2) on the DC power

supply PCB blown? (125 V, 5 A for 120 V

model; 250 V, 2 A for 230 V model)

YES Remove the cause, and replace

the fuse.

Power supply PCB

Set the meter range to 30 VDC, and connect

the meter probes to J105-4(+) and J105-5(-)

on the DC controller PCB. Is the voltage

reading about 5 V?

Check the wiring from J105

on the DC controller PCB to

the power supply PCB; if

normal, replace the power

supply PCB.

Wiring

10 Is there continuity between J101-B15 on the

DC controller PCB and J403-1 on the DC

controller PCB?

Check the wiring.

11 Is there continuity between J212-1 on the

DC power supply PCB and J106-2 on the

DC controller PCB?

Check the wiring.

Control panel PCB

DC controller PCB

12 Replace the control panel PCB. Is the

problem corrected?

YES End.

Replace the DC power supply

PCB.

10–52

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CANON NP7161/NP7160 REV.0 AUG. 1998 PRINTED IN JAPAN (IMPRIME AU JAPON)

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CHAPTER 10 TROUBLESHOOTING

21.DC power supply is absent.

Yes/No

Cause

Actions

Step

Checks

AC power supply

Is the rated voltage present between J204-1

and J204-3 on the DC power supply PCB?

See “AC power is absent.”

Fuse (power supply

PCB)

Is the fuse (FU1, FU2, FU3, FU4, FU5) on

the power supply blown?

YES Remove the cause, and replace

the fuse.

Wiring, DC load

Turn off the power switch, and disconnect

the power plug. Disconnect J208, J209, J210

on the power supply PCB. Connect the

power plug, and turn on the power switch. At

this time, is the voltage between the

following terminals normal?

YES Check the wiring and the

connectors of the DC power

supply line.

Power supply PCB

Replace the power supply

PCB.

–

Output voltage

+24V

J208-1

J208-3

J208-4

J209-4

J210-1

J210-8

J211-7

J211-5

J208-2

J208-5

J209-3

J210-2

J211-1

+5VU

+5VR

+24V

+5VU

+24V

+5VU

1998 CANON INC.

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CHAPTER 10 TROUBLESHOOTING

22.The scanner fails to move.

Yes/No

Cause

Belt, Cable

Actions

Step

Checks

Are the scanner drive belt and cable routed

correctly?

Route the belt and cable

correctly, and check the

pulley.

Scanner path

Is the scanner rail free of soiling and object,

and does the scanner move smoothly when

pushed by hand?

Remove any dirt and object;

check for an object that may

come into contact with the

scanner. As necessary, clean

and lubricate, or repair.

Note:

If the rail is soiled, clean it

with alcohol, and then apply

a small amount of oil.

Scanner motor (M2)

DC controller PCB

Replace the scanner. Is the problem

corrected?

YES

End.

Check the wiring from the DC

controller PCB to the scanner

motor; if normal, replace the

DC controller PCB.

10–54

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CANON NP7161/NP7160 REV.0 AUG. 1998 PRINTED IN JAPAN (IMPRIME AU JAPON)

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CHAPTER 10 TROUBLESHOOTING

23.The lens fails to move.

Yes/No

Cause

Step

Checks

Actions

Bolt

Is the lens drive belt routed correctly?

Correct the belt, and check the

gears.

Lens path

Is the lens path free of dirt and foreign

object? Does the lens move smoothly when

pushed by hand?

Remove any dirt and object;

check for any object that may

come into contact with the

lens. As necessary, clean and

lubricate, or repair.

Lens motor (M3)

Replace the lens motor. Is the problem

corrected?

End.

YES

DC controller PCB

Check the wiring from the DC

controller PCB to the lens

motor; if normal, replace the

DC controller PCB.

24.The mirror fails to move.

Yes/No

Cause

Mirror path

Actions

Step

Checks

Turn off the power, and move the mirror

assembly by hand. Does it move smoothly?

Remove any dirt or foreign

object in the mirror path. As

necessary, clean and lubricate

the path.

Mirror motor (M4)

DC controller PCB

Replace the mirror motor. Is the problem

corrected?

YES End.

NO Check the wiring from the DC

controller PCB to the mirror

motor; if normal, replace the

DC controller PCB.

1998 CANON INC.

CANON NP7161/NP7160 REV.0 AUG. 1998 PRINTED IN JAPAN (IMPRIME AU JAPON)

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CHAPTER 10 TROUBLESHOOTING

25.The scanning lamp fails to turn on.

Yes/No

Cause

Actions

Step

Checks

Scanning lamp

(LA1)

Disconnect the power plug

from the power outlet, and

mount the scanning lamp

correctly.

Is the scanning lamp mounted correctly?

Thermal fuse (FU1)

Replace the thermal fuse.

Disconnect the power plug from the power

outlet, and remove the thermal fuse. Is there

electrical continuity when the probes of the

meter are connected across both terminals of

the thermal fuse?

Caution:

The scanning lamp may have

turned on abnormally, the

thermal fuse may have been

mounted incorrectly, or the

cooling fan may have

malfunctioned. Be sure to

find out the cause.

Scanning lamp

(LA1)

Replace the scanning lamp.

Set the meter range to ‘ýx1’, and disconnect

the connector J55. Does the meter index

swing when the probes of the meter are

connected across both terminals of the

scanning lamp?

Lamp regulator PCB

Wiring

End.

Replace the lamp regulator PCB. Is the

problem corrected?

YES

Check the AC harness from

the power supply PCB and the

lamp regulator PCB and the

scanning lamp. Check the DC

harness from the DC

controller PCB to the lamp

regulator PCB.

DC controller PCB

Replace the DC controller

PCB.

Set the meter range to the 30 VDC, and

connect the probes of the meter to J106-4 (+)

and J105-5 (-) on the DC controller PCB.

Does the voltage change from about 0 to 5 V

when the Start key is pressed?

10–56

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CANON NP7161/NP7160 REV.0 AUG. 1998 PRINTED IN JAPAN (IMPRIME AU JAPON)

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CHAPTER 10 TROUBLESHOOTING

26.The pre-exposure lamp fails to turn on.

Yes/No

Cause

Actions

Step

Checks

Pre-exposure lamp

(LA2)

Set the meter range to 30 VDC, and connect

the probes to J104-A6 (+) and J104-7 (-) on

the DC controller PCB. Does the voltage

change from 0 to 24 V when the Start key is

pressed?

YES Check the wiring from the DC

controller PCB to the pre-

exposure lamp; if normal,

replace the pre-exposure lamp.

DC controller PCB

Replace the DC controller

PCB.

27.The blank exposure lamp fails to turn on.

Yes/No

YES

Cause

Actions

End.

Step

Checks

Blank exposure lamp

(LA3)

Replace the blank exposure lamp. Is the

problem corrected?

DC controller PCB

Check the wiring from the DC

controller PCB to the blank

exposure lamp; if normal,

replace the DC controller

PCB.

1998 CANON INC.

CANON NP7161/NP7160 REV.0 AUG. 1998 PRINTED IN JAPAN (IMPRIME AU JAPON)

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CHAPTER 10 TROUBLESHOOTING

28.Pick-up fails. (cassette)

Cause

Copy paper

Actions

Step

Checks

Yes/No

Are the size of the copy paper in the cassette

and the size indicated by the cassette size

indicator identical?

Set the cassette size indicator

once again.

Right door

Is the right door closed securely?

Close the right door securely.

Is the leading edge of copy paper as far as

the registration roller?

See "The registration roller

fails to rotate."

YES

Pick-up roller

Is the pick-up roller soiled or worn?

If the pick-up roller is soiled,

clean it with alcohol. If it is

deformed by wear, replace it.

YES

Registration clutch

(CL1), Feeding

clutch (CL2)

Open the right door, and press the Copy

Start key while holding paper over the right

door open/closed sensor. Does the feeding

roller or the pull-out roller rotate?

Check the drive gear for

damage. Check the wiring

from the DC controller PCB

to each clutch; if normal

replace the clutch.

Pick-up solenoid

(SL1)

Set the meter range to 30 VDC, and connect

the meter probes to J107-B8(+) and J107-

B9(-). Does the voltage reading change from

0 to 24 V when the Start key is pressed?

Check the wiring from the DC

controller PCB to SL1; if

normal, replace SL1.

DC controller PCB

Replace the DC controller

PCB.

YES

10–58

1998 CANON INC.

CANON NP7161/NP7160 REV.0 AUG. 1998 PRINTED IN JAPAN (IMPRIME AU JAPON)

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CHAPTER 10 TROUBLESHOOTING

29.Pick-up operation fails. (multifeeder)

Yes/No

Cause

Actions

Step

Checks

Is the leading edge of copy paper as far as the YES See “The registration roller

registration roller?

fails to rotate.”

Multifeeder solenoid

(SL2)

Set the meter range to 30 VDC, and connect

the probes to J107-B3 (+) and J107-B4 (-) on

the DC controller PCB. Does the voltage

change from 0 to 24 V when the Start key is

pressed?

YES Check the wiring from the DC

controller PCB to the

multifeeder solenoid; if

normal, replace the solenoid.

DC controller PCB

NO Replace the DC controller

PCB.

Multifeeder roller

clutch (CL3)

Set the meter range to 30 VDC, and connect

the probes to J107-B1 (+) and J107-B2 (-).

Does the voltage change from 0 to 24 V

when the Start key is pressed?

YES Check the wiring from the DC

controller PCB to multifeeder

roller clutch; if normal,

replace the clutch.

DC controller PCB

NO Replace the DC controller

PCB.

30.The registration roller fails to rotate.

Yes/No

Cause

Actions

Step

Checks

Registration paper

sensor (PS5)

Is the registration paper sensor normal?

(See the instructions on how to check

photointerrupters.)

NO Check the wiring from the DC

controller PCB to the

registration paper sensor; if

normal, replace the sensor.

Registration roller

clutch (CL1)

Set the meter to the 30 VDC, and connect

the probes to J211-7 (+) and J211-6 (-).

Does the voltage change from 0 to 24 V

when the Start key is pressed?

YES Check the drive gear for

damage. Check the wiring

from the DC controller PCB

to registration roller clutch; if

normal, replace the clutch.

DC controller PCB

NO Replace the DC controller

PCB.

1998 CANON INC.

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CHAPTER 10 TROUBLESHOOTING

31.The fixing heater fails to turn on.

Yes/No

Cause

Actions

Step

Checks

Thermal switch

(TSW1)

Turn off the power switch, and remove the

fixing assembly. Set the meter range to

“Ωx1.” Does the meter index swing when

the probes are connected across both

terminals of the thermal switch?

Replace the thermal switch.

Fixing heater (H1)

Turn off the power switch, and remove the

fixing assembly. Is there continuity when

probes are connected across both terminals

of the fixing heater?

Replace the fixing heater.

DC controller PCB

Wiring

Set the meter range to 30 VDC, and connect

the probes to J106-21 (+) and J105-4 (-) on

the DC controller PCB. Is the resistance

about 5 V?

Replace the DC controller

PCB.

YES Check the AC harness from

the DC power supply PCB to

the fixing heater. Check the

DC harness from the DC

controller PCB to the DC

power supply PCB.

32.The Add Toner indicator does not flash/turn on.

Yes/No

Cause

Connector

Actions

Step

Checks

Are the connector J15 of the toner sensor,

relay connectors J721 and J722, and the

connector J102 on the DC controller PCB

connected securely?

Connect the connectors

securely.

Toner sensor (TS1)

Control panel PCB

Replace the toner sensor. Is the problem

corrected?

YES End.

Execute service mode ‘409’ (control panel

check). Does the Add Toner indicator turn

on?

Check the wiring from the DC

controller PC to the control

panel PCB; if normal, replace

the control panel PCB.

DC controller PCB

YES Replace the DC controller

PCB.

10–60

1998 CANON INC.

CANON NP7161/NP7160 REV.0 AUG. 1998 PRINTED IN JAPAN (IMPRIME AU JAPON)

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CHAPTER 10 TROUBLESHOOTING

33.The Add Toner indicator fails to turn off.

Yes/No

Cause

Actions

Step

Checks

Open and close the front door. Does it turn

off?

YES End.

Connector

Are the connector J15 of the toner sensor,

relay connectors J721 and 720, and

connector J102 on the DC controller PCB on

the DC controller PCB connected securely?

Connect the connectors

securely.

Toner sensor (TS1)

DC controller PCB

Replace the toner sensor. Is the problem

corrected?

YES End.

Replace the DC controller

PCB.

34.The Waste Toner Box Full indicator fails to flash/turn on.

Yes/No

Cause

Connector

Actions

Step

Checks

Are the connectors up to the waste toner

sensor connected securely?

Connect the connectors

securely.

Waste toner sensor

Control panel PCB

Replace the waste toner sensor. Is the

problem corrected?

YES End.

Execute service mode ‘409’ (control panel

check). Does the Waste Toner Box Full

indicator turn on?”

Check the wiring from the DC

controller PCB to the control

panel PCB; if normal, replace

the control panel PCB.

DC controller PCB

YES Replace the DC controller

PCB.

1998 CANON INC.

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CHAPTER 10 TROUBLESHOOTING

35.The Waste Toner Box Full indicator fails to turn off.

Yes/No

Cause

Actions

Step

Checks

Waste toner box

Is the waste toner box mounted?

Install the waste toner box.

Is the waste toner box full?

YES Replace the waste toner box.

Waste toner box

Connector

Is the mouth of the waste toner box soiled?

YES Clean it. If the dirt cannot be

removed, replace the waste

toner box.

Are the connectors to the waste toner sensor

connected securely?

Connect the connectors

securely.

Waste toner sensor

DC controller PCB

Replace the waste toner sensor. Is the

problem corrected?

YES End.

Replace the DC controller

PCB.

36.The Add Paper indicator fails to flash.

Yes/No

Cause

Actions

Step

Checks

Sensor (PS4, PS7)

Check the wiring from the

sensor lever and each sensor to

the DC controller PCB; if

normal, replace the sensor.

Are the following sensors normal? (See the

instructions on how to check the

photointerrupers.)

PS4

PS7

Cassette paper sensor

Multi paper sensor

Control panel PCB

DC controller PCB

Check the wiring from the DC

controller PCB to the control

panel PCB; if normal, replace

the control panel PCB.

Execute service mode ‘409’ (control panel

check). Does the Add Paper indicator turn

on?

Replace the DC controller

PCB.

YES

10–62

1998 CANON INC.

CANON NP7161/NP7160 REV.0 AUG. 1998 PRINTED IN JAPAN (IMPRIME AU JAPON)

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CHAPTER 10 TROUBLESHOOTING

37.The Add Paper indicator fails to turn off.

Yes/No

Cause

Cassette

Actions

Step

Checks

Is the cassette set correctly?

Set the cassette correctly.

Sensor (PS4, PS7)

Are the following sensors normal? (See the

instructions on how to check the

photointerrupers.)

Check the wiring from the

sensor lever and each sensor to

the DC controller PCB; if

normal, replace the sensor.

PS4

PS7

Cassette paper sensor

Multi paper sensor

DC controller PCB

YES Replace the DC controller.

38.The Jam indicator fails to flash.

Yes/No

Cause

Actions

Step

Checks

Sensor (PSS5, PS6)

Are the following sensors normal? (See the

instruction on how to check the

photointerrupters.)

Check the wiring from the

sensor lever and each sensor to

the DC controller PCB; if

normal, replace the sensor.

PS5

PS6

Registration paper sensor

Delivery paper sensor

Control panel PCB

DC controller PCB

Execute service mode ‘409’ (control panel

check). Does the Jam indicator turn on?

Check the wiring from the DC

controller PCB to the control

panel PCB; if normal, replace

the control panel PCB.

YES Replace the DC controller

PCB.

1998 CANON INC.

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CHAPTER 10 TROUBLESHOOTING

39.The Jam indicator fails to turn off.

Yes/No

Cause

Actions

Step

Checks

Has all paper been removed from inside the

copier?

Remove the paper.

Execute service mode ‘101’ (jam type

display) to find out which sensor detected the

jam. Is there paper around the sensor?

Remove the paper.

YES

Sensor

Is the sensor of step 2 normal? (See the

instructions on how to check the

photointerrupters.)

Check the wiring from the

sensor lever and each sensor to

the DC controller PCB; if

normal, replace the sensor.

DC controller PCB

Replace the DC controller

PCB.

40.The Set Control Card indicator fails to turn on.

Yes/No

Cause

Actions

Step

Checks

Control Card IV N

Can copies be made without setting the

Control Card IV N?

YES Check the connector of the

Control Card IV N for a short

circuit.

Control panel PCB

DC controller PCB

Replace the control panel PCB. Does the

indicator turn on?

YES End.

Replace the DC controller

PCB.

10–64

1998 CANON INC.

CANON NP7161/NP7160 REV.0 AUG. 1998 PRINTED IN JAPAN (IMPRIME AU JAPON)

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CHAPTER 10 TROUBLESHOOTING

41.The Set Control Card indicator fails to turn off.

Yes/No

Cause

Actions

Step

Checks

Control card

Is the Control Card set correctly?

YES Set the control card correctly.

DC controller PCB

Control Card IV N

Can copies be made?

YES Replace the DC controller

PCB.

Replace the Control Card IV

1998 CANON INC.

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CHAPTER 10 TROUBLESHOOTING

V. TROUBLESHOOTING FEEDING PROBLEMS

A. Copy Jams

The copier may be divided into the following in terms of where copy paper tends to jam.

[1] Pick-up/feeding assembly

[2] Fixing/delivery assembly

The instructions on how to remove copy paper in the following tables are organized

according to location.

You may find out the location and the nature of each jam in service mode (‘107’).

[2]

[1]

Figure 10-501

10–66

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CHAPTER 10 TROUBLESHOOTING

1. Pick-Up/Feeding Assembly

Yes/No

Cause

Actions

Go to step 8.

Step

Checks

Does the jam occur when paper is picked up

from the cassette?

Cassette

Is the cassette set in the copier correctly?

Set the cassette correctly.

Try a different cassette. Is the problem

corrected?

YES Check the inside of the

cassette for foreign matter.

Copy paper

Is the copy paper curled, wavy, or the like?

YES Replace the copy paper.

Instruct the user on the correct

method of storing copy paper.

Try paper of a type recommended by Canon.

Is the problem corrected?

YES Advise the user to use

recommended paper.

DC controller PCB,

Pick-up clutch

Does the pick-up roller of the selected

cassette holder rotating during copying

operation?

See “The pick-up operation

fails.”

Pick-up roller

Separation roller

Feeding roller

Is the pick-up roller deformed or worn?

Is the separation roller deformed or worn?

Is the feeding roller deformed or worn?

YES Replace the pick-up roller.

YES Replace the separation roller.

YES Replace the feeding roller.

Registration roller

drive assembly

10 Does the registration roller operate

normally?

See “The registration roller

fails to rotate.”

Registration roller

vertical path roller

11 Is the registration roller or the vertical path

roller deformed or worn?

YES Replace the roller.

Transfer charging

assembly

12 Is the transfer charging assembly set

correctly?

Check the transfer charging

assembly.

13 Is there foreign matter on the paper guide of

the transfer charging assembly?

YES Remove the foreign matter.

14 Make a copy in manual mode. Does the

main motor rotate?

See “The pick-up operation

fails.”

Copy paper

15 Try paper recommended by Canon. Is the

problem corrected?

YES Advise the user to use

recommended paper.

Pick-up roller

Check the pick-up roller for

deformation and wear.

1998 CANON INC.

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CHAPTER 10 TROUBLESHOOTING

2. Fixing/Delivery Assembly

Cause

Step

Checks

Yes/No

YES

Actions

Separation claw

(delivery assembly)

Is the separation claw worn, deformed, or

soiled?

1. Replace the separation

claw.

2. If dirt is found, clean it.

Upper/lower

fixing roller,

Heat

Is the upper/lower fixing roller or the heat

discharging roller deformed or damaged?

YES

Replace the roller.

discharging

roller

Paper guide

Is the paper guide soiled with toner or the

like?

YES Clean the paper guide.

Is the height of the paper guide correct?

YES Adjust it.

Adjust the height.

Nip

Is the lower roller pressure (nip) as

indicated?

Delivery lever

Does the delivery detecting lever move

smoothly?

Adjust the lever so that it

moves smoothly.

Delivery paper

sensor

(PS06)

Does the delivery sensor operate normally?

(See the instructions on how to check the

photointerrupters.)

Replace the sensor.

Delivery roller

drive assembly

Does the delivery roller move smoothly?

Check the delivery roller drive

assembly.

YES Check the copy to see if it has

a leading edge.

Leading edge

margin

10–68

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CHAPTER 10 TROUBLESHOOTING

B. Faulty Feeding

1. Double Feeding

Yes/No

Cause

Actions

Step

Checks

Separation pad

Is the separation pad deformed, worn, or

soiled?

YES Replace the separation pad.

Spring

Push up the separation pad,

and replace the spring.

Separation roller

Spring

Is the separation roller deformed, worn, or

soiled?

YES Replace the separation roller.

Replace the spring used to pull

the separation roller.

2. Wrinkles

Yes/No

Cause

Actions

Step

Checks

Pick-up assembly

Turn off the power while copy paper is

moving through the feeding assembly. Is the

paper wrinkled? Or, is the paper askew?

YES Check the pick-up assembly.

Check the registration roller.

Copy paper

Try copy paper fresh out of package. Is the

problem corrected?

YES The copy paper may be moist.

Instruct the user on the correct

method of storing copy paper.

Is the paper of a type recommended by

Canon?

Advise the user to use

recommended paper.

Paper guide

Is the paper guide soiled with toner or the

like?

YES Clean it.

Is the height of the paper guide correct?

Is the lower roller (nip) as indicated?

Adjust the height of the paper

guide.

Lower roller

pressure

Adjust it

Upper/lower

roller

YES Try replacing the top unit or

the lower roller.

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CHAPTER 10 TROUBLESHOOTING

VI. ARRANGEMENT AND FUNCTIONS OF

ELECTRICAL PARTS

A. Sensors and Switches

PS11

PS7

PS9

PS10

PS4

PS5

PS6

TS1

PS3

PS2

PS1

PS8

DS1

SW1

Figure 10-601

10–70

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Name

Description

Notation

TS1

Symbol

Toner sensor

Developing assembly toner level detection

Photointerrupter

PS1

PS2

PS3

PS4

PS5

PS6

PS7

PS8

PS9

PS10

PS11

Scanner home position detection

Lens home position detection

Mirror home position detection

Cassette paper detection

Registration paper detection

Delivery detection

Multifeeder paper detection

Waste toner feeding screw locked detection

Multifeeder paper width detection 1

Multifeeder paper width detection 2

Right door open/closed detection

Switch

SW1

DS1

Heater switch (accessory)

Front door switch

Table 10-601

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CHAPTER 10 TROUBLESHOOTING

B. Motors, Fans, Clutches, and Solenoids

CL3

CL2

SL2

SL1

FM5

FM4

FM2

FM1

CL1

Figure 10-602

10–72

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CHAPTER 10 TROUBLESHOOTING

Name

Description

Notation

Symbol

Main drive

Scanner drive

Lens drive

Motor

No. 4/No. 5 mirror drive

Cooling

FM1

FM2

FM4

FM5

Fan

Heat discharge

Heat discharge (accessory)

Registration roller clutch

Feeding clutch

Multifeeder pick-up clutch

CL1

CL2

CL3

Clutch

Pick-up solenoid

Multifeeder pick-up solenoid

SL1

SL2

Solenoid

Table 10-602

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CHAPTER 10 TROUBLESHOOTING

C. Heaters, Lamps, and Others

TH3

TH1

RL1

VZ1

TP1

TH2

LA3

FU1

LA2

LA1

CNT1

CNT2

Figure 10-603

10–74

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CHAPTER 10 TROUBLESHOOTING

Name

Description

Notation

Symbol

Fixing heater

Heater

Cassette/drum heater (accessory)

Mirror heater (accessory)

Scanning lamp

LA1

Lamp

LED

Pre-exposure lamp

Blank exposure lamp

LA2

LA3

LED

CNT

Total copy counter

Accessory counter

CNT1

CNT2

Counter

Fixing heater power supply control

Scanning lap overheating detection

Fixing assembly overheating detection

RL1

Relay

FU1

Thermal fuse

Thermal switch

Thermistor

Cleaner thermistor

Varistor

TSW1

Fixing roller surface temperature detection 1

Fixing roller surface temperature detection 2

TH1

TH2

Ambient temperature detection

Varistor

TH3

VZ1

Table 10-603

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CHAPTER 10 TROUBLESHOOTING

D. PCBs

Figure 10-604

Name

Description

Ref.

Sequence control

[1]

[2]

[3]

[4]

[5]

[6]

[7]

[8]

[9]

DC controller PCB

Control panel PCB

AE sensor

Lamp regulator PCB

Power supply PCB

High-voltage power supply PCB

Waste toner sensor

Cassette size switch PCB

Accessory power supply PCB

Control key/control display

Original density detection

Scanning lamp on voltage control

Power supply

High-voltage output

Waste toner full detection

Cassette size detection

ADF and sorter DC power supply

Table 10-604

10–76

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CHAPTER 10 TROUBLESHOOTING

E. Variable Resistors, Light-Emitting Diodes, and Check Pins by

PCB

Of the variable resistors (VR), light-emitting diodes (LD), and check pins used in the copier,

those needed for servicing work in the field are discussed.

Caution:

1.Some LEDs retain current even when off and emit dim light. This is a normal condition

and must be kept in mind.

2.VRs that may be used in the field.....................................................

3.VRs that must not be used in the field..............................................

Caution:

Do not use the VRs or check pins not found in the tables. They are for factory use, and

require special tools and high accuracy.

1. DC Controller PCB

B15

B12

B13

J101

J112

J104

J102

J120

J103

A15

A12

A13

J109

J108

B15

J107

A15

J124

J110

J106

A16

J105

J131

J122

SW102

J121

B16

Figure 10-605

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CHAPTER 10 TROUBLESHOOTING

Item

Remarks

SW102-1

Use to change size.

SW102-1

Settings

INCH

SW102-2

OFF

AB/INCH

OFF

SW102-2

OFF

SW102-3 Use to set power supply voltage.

ON :230V

OFF : 120V

SW102-4

—

Use to set the accessory

counter.

Settings

SW102-5

OFF

SW102-6

OFF

SW102-5

No accessory counter

Small-size copy counter

Large-size copy counter

Not used

OFF

SW102-6

SW102-7 Large size copy counting method

ON: 2 counts

OFF: 1 count

SW102-8

—

Table 10-605

Inch-configuration (4R3E)

Ratio

200%

200.0%

129.4%

121.4%

LTR→11"×17"

LGL→11"×17"

100%

100.0%

LGL→LTR

11"×17"→LGL

11"×17"→LTR

50%

78.6%

73.3%

64.7%

50.0%

Table 10-606

A-configuration (2R2E)

200%

Ratio

200.0%

A4→A3

100%

141.4%

100.0%

70.7%

50.0%

A3→A4

50%

Table 10-607

10–78

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CHAPTER 10 TROUBLESHOOTING

AB/Inch-configuration (4R4E)

200%

Ratio

200.0%

141.4%

122.4%

115.4%

100.0%

86.5%

81.6%

70.7%

50.0%

A4/LTR→A3, B5→B4

A4/LTR→B4

B4→A3, B5→A4/LTR

100%

A3→B4, A4/LTR→B5

B4→A4/LTR

A3→A4/LTR, B4→B5

50%

Table 10-608

AB-configuration (4R4E)

200%

Ratio

200.0%

141.4%

122.4%

115.4%

100.0%

86.5%

81.6%

70.7%

50.0%

A4→A3, B5→B4

A4→B4

B4→A3, B5→A4

100%

A3→B4, A4→B5

B4→A4

A3→A4, B4→B5

50%

Table 10-609

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CHAPTER 10 TROUBLESHOOTING

2. Power Supply PCB

J209

J208

J210

J212

J211

J204

J206

J203

Figure 10-606

3. Lamp Regulator PCB

J503

VR1

VR2

J501

Figure 10-607

10–80

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CHAPTER 10 TROUBLESHOOTING

4. High-Voltage Power Supply PCB

J304

J301

J305

VR82

VR83

VR81

VR52

J302

J303

VR141

VR52

J306

Figure 10-608

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CHAPTER 10 TROUBLESHOOTING

VII. SERVICE MODE

A. Outline

The copier’s service mode is divided into the following seven:

No.

[ 1 ]

[ 2 ]

[ 3 ]

[ 4 ]

[ 5 ]

[ 6 ]

[ 7 ]

Description

DISPLAY

I/O DISPLAY

ADJUST

FUNCTION

OPTION

COUNTER

APPLICATION

Table 10-701

B. Using Service Mode

1. Starting Service Mode

1) Press the User Mode key.

• If you are planning to make checks as in I/O display mode while making copies, select the

appropriate copying mode before pressing the User Mode key.

2) Hold down the ‘2’ and ‘8’ keys on the keypad at the same time for 0.5 sec or more.

3) Press the User Mode key once again.

• The copier will indicate ‘[1]’ on its control panel as soon as it enters service mode.

• The copier will end service mode in response to a press on the Reset key.

2. Selecting Service Mode

1) Select the mode you want for making checks or adjustments (Table 10-701) using the

keypad.

• The 10’s place will switch to indicate the input numeral.

• The copier will start making copies in response to a press on the Start key using the settings

that were effective immediately before the start of service mode.

2) Press the AE key.

• The copier will indicate a 3-digit number, and the 100’s place will start to flash and 10’ and

1’s places will turn on.

3) Select the mode you want to use for making checks or adjustments using the keypad.

• The 10’s and 1’s places will serve to indicate the input numerals.

• The copier will return to the condition in step 1) above in response to a press on the AE

key.

4) Press the Start key to execute the selected service mode.

• The copier will return to the condition in step 3) in response to a press on the AE key while

it is executing service mode.

10–82

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CHAPTER 10 TROUBLESHOOTING

C. Using Adjust Mode and Function Mode

In adjust mode and function mode, the copier stores the settings made on the control panel in

the RAM on the DC controller PCB and use them to simulate the functions of conventional

variable resistors and switches.

Figure 10-701 shows the information sheet stored behind the copier’s front door. Each copier

is adjusted at the factory, and the adjustment values are recorded in the sheet.

If you have replaced the DC controller PCB or initialized the RAM, you will have to enter

the values recorded in the information sheet into the RAM on the DC controller PCB. Moreover,

if you have entered any values newly in the field, be sure to record the value in this sheet.

TYP

301 AE_ADJ

302 LMP_ADJ

303 AE_SLOP

305 REGIST

306 LE_BLANK

307 PG_RGST

308 PG_BLANK

309 TE_BLANK

319 MF_ARCH

320 CST1_ARCH

321 CST2_ARCH

326 LIGHT_5

327 LNS_HP

328 MIRR_HP

329 LNS_TBL

330 MIRR_TBL

331 MLT_CL

332 MLT_TMG

519

MODEL_SW

701 DOC_ST_L

Figure 10-701

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CHAPTER 10 TROUBLESHOOTING

D. Display Mode [1]

• To select an item, use the keypad.

• To execute an item, use the Start key.

• To cancel an item, use the Clear key.

No.

101

106

Description

Indicates the type of jam.

Remarks

Indicates the type of jam. (See Table 10-702.)

E805

Indicates the code of the fan that caused E805.

“01: exhaust fan at rear (FM2)

“02: exhaust fan at fount (FM4)

“03: sorter kit fan (FM5)

107

108

Indicates a history of jams.

Indicates a history of errors.

Indicates the most recent five jams. A press on ‘1’

through ‘5’ keys will show the respective jams.

(See Table 10-702.)

Indicates the most recent five error codes. A press on

‘1’ through ‘5’ keys will show their respective error

codes and the number being pressed.

109

110

111

112

Indicates the temperature detected by the fixing

main thermistor (TH1).

unit: °C

Indicates the temperature detected by the fixing

sub thermistor (TH2).

Indicates the temperature detected by the cleaner unit: °C

thermistor (TH3).

Indicates the output voltage of the AE sensor.

A press on the Start key will execute AE scanning.

The output voltage of the AE sensor is indicated in

decimal notation using three digits (e.g., 245 V will be

indicated as ‘245’).

113

114

115

Indicates the version of the ROM.

Indicates the version of the program.

Indicates the release number of the ROM.

Indicates the jam history of the ADF.

Indicates the release number of the program.

Indicates the history of the most recent five jams. A

press on the ‘1’ through ‘5’ keys will indicate the type

of their respective jams. (See Table 10-703.)

116

Indicates the jam history of the sorter.

Indicates the history of the most recent five jams. A

press on the ‘1’ through ‘5’ keys will indicate the type

of their respective jams. (See Table 10-705.)

117

118

Indicates the type of jam in the ADF.

Indicates the type of jam. (See Table 10-703.)

Indicates the type of warning for the ADF.

Indicates alarm codes of the ADF. (See Table 10-

704.)

119

Indicates the version of the ROM of the ADF.

Indicates the version of the program.

10–84

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CHAPTER 10 TROUBLESHOOTING

No.

120

Description

Remarks

Indicates the release number of the ROM of the

ADF.

Indicates the release number of the program.

121

122

123

Indicates the type of jam in the sorter.

Indicates the tray warning for the sorter.

Indicates the stapling alarm for the sorter.

Indicates the version of the ROM of the sorter.

Indicates the type of jam in the sorter. (See Table 10-

705.)

Indicates the alarm code for the sorter. (See Table 10-

706.)

Indicates the alarm code for the sorter. (See Table 10-

707.)

124

125

Indicates the version of the program.

Indicates the release number of the ROM of the

sorter.

Indicates the release number of the program.

126

Checks the keys on the control panel.

See p. 10-87.

Guide to Jam Types (No. 101) and Jam History (No. 107)

• The type of jam is indicated using the following codes in the 10’s and 1’s places. In the case

of the history, the number corresponding to the keys on the keypad will be indicated in the

100’s place.

Code

Description

Registration delay jam

Sensor

PS5

Registration stationary jam

Registration paper sensor timing jam

Delivery delay jam

Delivery stationary jam

Right door open jam

Power-on jam

PS6

PS11

PS5, PS6

ADF jam

Sorter jam

Table 10-702

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CHAPTER 10 TROUBLESHOOTING

Guide to ADF Jam History (No. 115) and ADF Jam Type (No. 117)

• The type of jam is indicated using the following codes in the 10’s and 1’s places. In the case

of the history, the number corresponding to the keys on the keypad will be indicated in the

100’s place.

Code

Description

Separation extraction

Separation delay

Pick-up delay

Pick-up leading edge skew

Pick-up stationary

Pick-up double feeding

Pick-up trailing edge skew

Pick-up trailing edge retreat

Pick-up fault (leading edge)

Delivery delay

Delivery stationary

Open

Door open

Jam original page

Double feeding

Table 10-703

Guide to ADF Warning (No. 118)

Code

Description

Tray sensor off

Separation fault

Separation skew

Separation stopper override

Original pages-jam recovery pages mismatch

Original page in excess of 100

Original extraction

Original size error

Table 10-704

Guide to Sorter Jam History (No. 116) and Sorter Jam Type (No. 121)

• The type of jam is indicated using the following codes in the 10’s and 1’s places. In the case

of the history, the number corresponding to the keys on the keypad will be indicated in the

100’s place.

Code

Description

Feeding delay

Feeding stationary

Timing

Staple (stapler sorter only)

Power-on

Door open

Table 10-705

10–86

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CHAPTER 10 TROUBLESHOOTING

Guide to Sorter Tray Warning (No. 122)

Code

Description

Overstacking

Table 10-706

Guide to Sorter Stapling Warning (No. 123)

Code

Description

Stapler down

Staple

Stapler safety protection

Edging fault

Stapling overstacking

Staple stacking limit

Mixed paper sizes (breadthwise)

Staple unit absent

Paper in stapler

Staple absent

Table 10-707

Checking the Control Panel Keys (No. 126)

1) While the copier is in mode No. 126, press all keys on the control panel except the Start key.

2) Press the Start key.

• If ‘000’ is indicated on the control panel, all keys are normal.

• If an error key is found, the copier will indicate its respective code (Table 10-708).

If multiple keys are found to be faulty, the copier will indicate the lowest-number code

only.

Code

Key

Code

17 Interrupt key

18 Energy Saver key

19 Clear key

Key

Sorter key

Auto Zoom key

Photo key

Image Combination / Two-page Separation key 20 ID key

AE key

21 Number 0 key

Stop key

Start key

Reduce key

1:1 key

22 Number 1 key

23 Number 2 key

24 Number 3 key

25 Number 4 key

26 Number 5 key

27 Number 6 key

28 Number 7 key

29 Number 8 key

30 Number 9 key

31 Fit Image key

10 Enlarge key

11 Paper Select key

12 % key

13 + Zoom key

14 - Zoom key

15 Reset key

16 Additional Functions key

Table 10-708

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CHAPTER 10 TROUBLESHOOTING

E. I/O Display Mode [2]

• To select an item, use the keypad.

• To execute an item, use the Start key.

• To cancel an item, use the Clear key.

No.

201

202

203

204

205

206

Description

Remarks

Not used.

Indicates digit 4.

Indicates digit 5.

Indicates digit 6.

Indicates digit 7.

Indicates the state of input. (See p. 10-89.)

Indicates the voltage of the fixing main

thermistor (TH1).

Indicates the detected voltage.

(e.g., 2.78 V will be indicated as ‘278’.)

207

208

209

216

Indicates the voltage of the fixing sub thermistor Indicates the detected voltage.

(TH2).

(e.g., 2.78 V will be indicated as ‘278’.)

Indicates the voltage of the AE sensor.

Indicates the detected voltage.

(e.g., 2.78 V will be indicated as ‘278’.)

Indicates the voltage of the cleaner thermistor

(TH3).

Indicates the detected voltage.

(e.g., 2.78 V will be indicated as ‘278’.)

Indicates the voltage of the density adjusting

volume (VR1).

Indicates the detected voltage.

(e.g., 2.78 V will be indicated as ‘278’.)

219

220

221

222

223

224

225

Indicates CPU port 6.

Indicates CPU port 8.

Not used.

Indicates the state of input. (See p. 10-89.)

Indicates PIO1B.

Indicates PI03B.

Not used.

Indicates the state of input. (See p. 10-89.)

Not used.

10–88

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CHAPTER 10 TROUBLESHOOTING

Guide to Nos. 202, 203, 204, 205, 219, 220, 222, and 223

Figure 10-702

No. LED

Description

Notation

Signal

Connector

Remarks

201 1a

–

202 1a Detects the presence/absence of the CNT1 TCNT_DR* J102-A10 ON: present.

total copy counter.

1b Detects the presence/absence of

paper in cassette 1.

1c Detects the presence/absence of a

control card.

PS4

CSTPDT

J107-B12 ON: present.

J104-A10 ON: absent.

J107-B7 ON: closed.

–

CCDT*

Detects the state (open/closed) of

PS11

RDOPDT

the right door.

–

2b Detects paper in the multifeeder.

2c Detects the width of paper in the

multifeeder (1).

PS7

PS9

MLTPDT0

MLTPDT1 J107-A11

J107-A8 ON: present.

2d Detects the width of paper in the

multifeeder (2).

PS10 MLTPDT2 J107-A14

Table 10-709a

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CHAPTER 10 TROUBLESHOOTING

No. LED

Description

Notation

Signal

Connector

Remarks

–

203 1a

–

1c Detects the presence/absence of an

accessories counter.

CNT2 OPCNT_DR* J102-A12 ON: present.

–

1e Detects the rotation of the scanner

cooling fan (front).

FM1

SCFAN_DT*

J104-B2 ON: on.

–

EXFAN0_DT*

EXFAN1_DT*

1g Detects the rotation of the exhaust fan. FM4

2a Detects the rotation of the exhaust fan. FM2

J104-B8 ON: on.

J104-B11 ON: on.

–

204 1a Cassette 1 size detection 0

1b Cassette 1 size detection 1

1c Cassette 1 size detection 2

1d Cassette 1 size detection 3

SW651

SW652

SW653

SW654

CSTS0

CSTS1

CSTS2

CSTS3

J110-4

J110-3

J110-2

J110-1

ON: on.

–

205 1a DSW102-1 setting

1b DSW102-2 setting

1c DSW102-3 setting

1d DSW102-4 setting

1e DSW102-5 setting

1f DSW102-6 setting

1g DSW102-7 setting

2a DSW102-8 setting

ON: on.

–

2d IPC detection (presence/absence)

–

ON: absence.

–

219 1a

–

1b Mirror home position detection

1c Lens home position detection

PS3

PS2

–

MRRHP

LNSHP

J103-B8 OFF: at HP.

J103-B5 OFF: at HP.

–

Table 10-709b

10–90

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CHAPTER 10 TROUBLESHOOTING

No. LED

Description

Notation

Signal

Connector

Remarks

220 1a Scanner home position detection

PS1

–

SCHP

J103-B2 OFF: at HP.

–

221 1a

–

J106-9

–

222 1a Waste toner box full detection

1b Main heater triac short circuit detection

TNFDT

ON: full.

ON: on.

–

1d Scanning lamp on detection

1e Toner level detection

1f Delivery detection

LA1

TS1

PS6

PS5

–

LMPDT

TNEMP

EXITPD

RGPDT

J106-6

ON: on.

J102-B2 ON: present.

J124-2 ON: present.

J107-A2 ON: present.

1g Pre-registration paper detection

–

223 1a

1e Zero-cross direction detection

1f Waste toner feedscrew lock detection PS8

TRQMLDT J106-10

–

MM_LKDT*

2a Main motor (M1) lock detection

J106-16 ON: motor off.

–

Table 10-709c

1998 CANON INC.

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10–91

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CHAPTER 10 TROUBLESHOOTING

F. Adjust Mode [3]

• To select an item, use the keypad.

• To execute an item, press the Start key.

• To change a setting, use the keypad or the +/- Zoom key.

• To enter a value, press the Start key.

• To remove an item, press the AE key.

Settings

—

No.

301

Description

Remarks

Executes AE auto adjustment.

Use it to perform AE adjustment.

(See p. 10-19.)

302

Adjust the lamp intensity for AE mode.

A higher setting will increase the intensity of

the scanning lamp (LA1), making the copies

lighter. (Use it when performing AE

adjustment.)

450 – 750

(120V model)

0 – 590

(230V model)

303

305

Adjusts the copy density (developing

bias) slope for AE mode.

A higher setting will make the copies lighter.

(Use it when performing AE adjustment.)

0 – 255

0 – 500

Adjust the leading edge margin

(registration roller clutch CL1 activation

timing).

A higher setting will delay pick-up of copy paper

in relation to the image, thereby decreasing the

leading edge margin. (unit: 0.21 mm)

306

307

Adjusts the leading edge non-image

width (blank exposure lamp LA3 de-

activation timing).

A higher setting will delay de-activation of the

lamp, thereby increasing the leading edge non-

image width. (unit: 0.21 mm)

0 – 500

Adjusts the leading edge registration on

right pages in page separation

(registration roller clutch CL1 activation

timing).

A higher setting will delay pick-up of copy

paper in relation to the image, thereby

decreasing the leading edge margin. (unit: 0.21

mm)

308

Adjusts the leading edge margin on right

pages in page separation mode (blank

exposure lamp LA3 de-activation

timing).

A higher setting will delay de-activation of the

lamp, thereby increasing the leading edge non-

image width. (unit: 0.21 mm)

0 – 500

309

319

320

321

Adjusts the trailing edge margin (blank

exposure lamp LA3 activation timing).

A higher setting will advance activation of the

lamp, thereby increasing the trailing edge

margin. (unit: 0.21 mm)

0 – 500

0 – 200

0 – 100

Adjusts the arching in multifeeder mode

(de-activation of the multifeeder pick-up

roller clutch CL3).

A higher setting will delay deactivation of the

clutch, thereby increasing arching. (unit; 0.21

mm)

Adjusts the arching in cassette 1 pick-up

mode (de-activation of pick-up roller

clutch CL2).

A higher setting will increase the arching.

(unit: 0.42 mm)

Adjusts the arching in cassette 2 pick-up

mode (de-activation of the pick-up roller

clutch).

A higher setting will delay de-activation of the

clutch, thereby increasing the arching. (unit:

0.42 mm)

10–92

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CHAPTER 10 TROUBLESHOOTING

No.

326

Description

Settings

Remarks

Adjusts the activation voltage of the

scanning lamp.

450 – 660 A higher setting will increase the intensity of

(120V model) the scanning lamp (LA1), making the copies

0 – 390

lighter.

(230V model)

327

328

329

Adjusts the position of the lens (Direct at

100%).

0 – 200

0 – 400

0 – 3

A higher setting will enlarge the image.

(unit:0.1 mm)

Adjusts mirror home position (at 100%

ratio).

A higher setting will enlarge the image. (unit:

0.1 mm)

Selects a table for lens travel to suit

reproduction ratio.

If you replaced the DC controller PCB or

initialized the RAM, be sure to enter the value

recorded on the Service Label stored behind the

front door.

330

331

Selects a table for No. 4/No. 5 mirror

travel to suit reproduction ratio.

0 – 3

If you replaced the DC controller PCB or

initialized the RAM, be sure to enter the value

recorded on the Service Label stored behind the

front door.

Adjusts the timing of activation of the

multifeeder pick-up clutch (CL3).

0 – 999

A higher setting will delay activation of the

clutch. (unit: 0.02 sec)

• If pick-up failure occurs, decrease the

setting.

• If double feeding occurs, increase the

setting.

Use this mode if double feeding or pick-

up failure cannot be corrected by

adjusting the pressure of the separation

pad.

332

Adjusts activation of the multifeeder

pick-up clutch (CL3)

0 – 999

A higher setting will delay activation of the

clutch. (unit: 0.02 sec)

• If thick paper is not fed as far as the

registration roller, increase the setting.

Use this mode if pick-up failure occurs

when using thick paper.

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10–93

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CHAPTER 10 TROUBLESHOOTING

G. Function Mode [4]

• To select an item, use the keypad.

• To execute an item, use the Start key.

• To stop an item, use the Stop key.

• To clear an item, use the Clear key.

Caution:

Be sure that the copier is in standby state when executing any item.

No.

401

Description

Remarks

Stirs toner.

The developing assembly (main motor) will rotate 4

min. (The pre-exposure lamp LA2 and the blank

exposure lamp LA3 will turn on, and all high-voltage

outputs will turn off.)

402

403

Releases the multifeeder holding plate.

Drum unit installation mode.

Releases the multifeeder holding plate.

The drum unit and developing assembly will rotate 40

sec.

Execute this mode at the time of drum unit

installation or replacement.

406

408

Checks the fixing nip.

Checks the fixing nip. (The Stop key will be

disabled.)

Checks the activation of the scanning lamp

(LA1).

The scanning lamp will turn on for 5 sec.

409

410

Checks all indicators on the control panel.

All LEDs on the control panel will turn on for 5 sec.

Checks the forward movement of the scanning

lamp.

The scanner moves forward while the + key is held

down.

The scanner moves in reverse while the - key is held

down.

411

412

440

Checks the activation of the pre-exposure lamp

(LA2).

The pre-exposure lamp will turn on.

Initializes E000, E001, E002, E003, or E004.

Press the Start key while the error code (E000, E001,

E002, E003, or E004) is indicated.

Moves the scanner, lens, and No. 4/No. 5 mirror Execute this mode before transporting the machine so

unit.

that the scanner, lens, and No. 4/No. 5 mirror unit will

be positioned for transportation.

450

Initializes the back-up RAM.

Press ‘1’ on the keypad and the Start key in sequence.

(The power will turn off, initializing all RAM data.)

10–94

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CHAPTER 10 TROUBLESHOOTING

H. Option Mode [5]

• To select an item, use the keypad.

• To execute an item, use the Start key.

• To change settings, use the keypad or the + and - Zoom keys.

• To store settings, use the Start key.

• To cancel an item, use the Clear key.

No.

505

506

510

Description

Remarks

Sets U1 size.

Sets U2 size.

See Table 10-710.

Sets drum cleaning.

Disable drum cleaning (standard).

Execute drum cleaning for every 50 copies

(standard in Chinese mode).

To remove dirt from the surface of the

photosensitive drum, toner is deposited on the

Execute drum cleaning for every 25 copies.

Execute drum cleaning for every 10 copies.

surface after copying operation and the cleaning 3:

blade is used to collect the toner together with

the dirt. (In addition, LSTR is extended by 6.5

sec.)

511

512

513

Sets the copying start temperature for auto start

mode.

140°C (standard)

180°C

Sets the copying start temperature.

160°C (standard)

180°C

Sets the fixing target temperature for A3, A4,

279 × 432mm (11" × 17"), LTR.

Standard target temperature

Standard target temperature +10°C

Standard target temperature + 5°C

Standard target temperature - 5°C

Standard target temperature -10°C

514

515

516

Sets the fixing target temperature for B4, B5, and 0:

Standard target temperature

LGL.

Standard target temperature +10°C

Standard target temperature + 5°C

Standard target temperature - 5°C

Standard target temperature -10°C

Sets the fixing target temperature for A4R, A5,

B5R, and LTRR.

Standard target temperature

Standard target temperature +10°C

Standard target temperature + 5°C

Standard target temperature - 5°C

Standard target temperature -10°C

Sets the fixing target temperature for A5R.

Standard target temperature

Standard target temperature +10°C

Standard target temperature + 5°C

Standard target temperature - 5°C

Standard target temperature -10°C

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10–95

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CHAPTER 10 TROUBLESHOOTING

No.

517

Description

Remarks

Enables/disables retry for cassette pick-up

operation.

Make a retry (standard).

Indicates the Jam message in response to the

second registration delay jam.

Do not make a retry.

Indicates the Jam message in response to the

first registration delay jam.

In cassette pick-up mode, pick-up operation will 1:

be executed once again without indicating the

first registration delay jam.

518

519

Sets the count for the control card in multifeeder 0:

Increment by 1 for all sizes (standard).

Increment by 2 for all sizes.

pick-up.

Selects settings to suit the site of installation.

Normal (standard)

China

Making changes using this mode will change the

settings under ‘510’ as follows:

• If ‘1’ is selected instead of ‘0’ in this mode,

‘1’ will be set under ‘510’.

The standard target temperature for fixing will

be lowered by 10°C. In addition, ‘U14’ will be

added to user mode.

• If ‘0’ is selected instead of ‘1’ in this mode,

‘0’ will be set under ‘510’.

However, ‘510’ settings may be changed after

making changes in this mode.

Paper Sizes Available under No. 505/506

Code

Paper

Size (vertical x horizontal in mm)

216.0 x 355.0

220.0 x 340.0

206.0 x 337.0

215.9 x 330.2

210.0 x 330.0

203.2 x 330.2

220.0 x 320.0

216.0 x 317.0

220.0 x 280.0

190.0 x 268.0

203.2 x 266.7

280.0 x 220.0

266.7 x 203.2

268.0 x 190.0

BOLIVIA

ARGENTINE OFICIO

ARGENTINE LEGAL

AUSTRALIAN FOOLSCAP

FOOLSCAP

FOLIO

GOVERNMENT LEGAL

ECUADORAN OFICIO

OFFICIO

ARGENTINE LETTER R

KOREAN LEGAL R

GOVERNMENT LETTER R

ARGENTINE LETTER

GOVERNMENT LETTER

KOREAN LEGAL

Table 10-710

10–96

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CHAPTER 10 TROUBLESHOOTING

I. Counter Mode [6]

• To select an item, use the keypad.

• To execute an item, use the Start key.

• To cancel an item, use the Clear key.

• The result obtained by multiplying the indicated value by 100 will be the actual count.

No.

601

602

603

604

605

606

Description

Large copy counter

Remarks

Small copy counter

Total copy counter

ADF large original page counter

ADF small original page counter

Count clear

A press on the Start key will initialize the count (601

to 605), returning it to ‘0’ on the control panel.

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CHAPTER 10 TROUBLESHOOTING

J. Application Mode [7]

• To select an item, use the keypad.

• To execute an item, use the Start key.

• To change the value, use the keypad or the + and - Zoom keys.

• To store settings, use the Start key.

• To cancel an item, use the Clear key.

No.

701

Description

Settings

1–255

Remarks

Adjusts the ADF original page stop

position.

A lower setting will move the original page

stop position in the direction of delivery.

(unit: 0.116 mm)

10–98

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CHAPTER 10 TROUBLESHOOTING

VIII. SELF DIAGNOSIS

The microprocessor on the copier’s DC controller PCB is equipped with a function that

checks the condition of the machine (especially the condition of sensors). It runs checks at such

times as programmed, and will indicate any fault it finds in the form of code.

A. Copier

Cause

Description

Code

• The thermistor (TH1, TH2) has poor

contact or an open circuit.

• The fixing heater (H1) has an open circuit.

• The thermal switch (TSW1) has turned on.

• The triac is faulty.

• The surface temperature of the fixing upper

roller does not reach 40°C within 14 sec

after power-on.

E000

• The DC controller PCB is faulty.

• The thermistor (TH1, TH2) has a short

circuit.

• The triac is faulty.

• The surface temperature of the fixing upper

roller exceeded 230°C.

E001

E002

• The DC controller PCB is faulty.

• The thermistor (TH1, TH2) has poor

contact or an open circuit.

• The fixing heater (H1) has an open circuit.

• The thermal switch (TSW1) has turned on.

• The triac is faulty.

• The surface temperature of the fixing upper

roller does not reach 60°C within 10 after it

exceeded 40°C.

• The surface temperature of the fixing upper

roller does not reach 80°C within 10 sec

after it exceeded 60°C.

• The DC controller PCB is faulty.

• The surface temperature of the fixing upper

roller does not reach 100°C within 10 sec

after it exceeded 80°C.

• The surface temperature of the fixing upper

roller does not reach 120°C within 10 sec

after it exceeded 100°C.

• The surface temperature of the fixing upper

roller drops to 130°C or less after it

reached the target temperature (160°C) for

standby.

• The thermistor (TH1, TH2) has poor

contact or an open circuit.

• The fixing heater (H1) has an open circuit.

• The thermal switch (TSW1) has turned on.

• The triac is faulty.

E003

E004

• The DC controller PCB is faulty.

• The triac is identified as having a short

circuit.

• The triac has a short circuit.

• The DC controller PCB is faulty.

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CHAPTER 10 TROUBLESHOOTING

Cause

Description

Code

• The main motor (M1) is faulty.

• The DC controller PCB is faulty.

• The main motor lock detection signal

(MM_LKDT*) is detected for 1 sec

continuously while the main motor is being

driven.

E010

• The waste toner feedscrew lock detection

signal (TRQMLDT) does not switch for

0.5 sec or more while the main motor is

being driven.

• The waste toner feedscrew is locked.

• The waste toner feedscrew lock sensor

(PS8) is faulty.

E013

• The DC controller PCB is faulty.

• The total copy counter is identified to have

an open circuit when the Start key is

pressed or when the counter is driven.

• The total copy counter has an open

circuit.

• The DC controller PCB is faulty.

E030

E031

• The accessories counter is identified as

having an open circuit when the Start key

is pressed or the couter is being driven.

• The accessories counter has an open

circuit.

• The DC controller PCB is faulty.

• The scanner does not return to home

position within a specific period of time

when it is being moved.

• The scanner home position sensor (PS1)

remains on during image exposure

(forward movement).

• The scanner home position sensor (PS1)

is faulty.

• The scanner motor (M2) is faulty.

• The DC controller PCB is faulty.

(E202)

No code

indication. Keys

are disabled.

(Note 2)

• The No. 4/No. 5 mirror unit does not turn

on or off the mirror home position sensor

(PS3) within a specific period of time

while the No. 4/No. 5 mirror unit is being

moved.

• The mirror home position sensor (PS3) is

faulty.

• The mirror motor (M4) is faulty.

• The DC controller PCB is faulty.

E208

• The lens unit does not turn on or off the

lens home position sensor (PS2) within a

specific period of time when the lens unit is

being moved.

• The lens home position sensor (PS2) is

faulty.

• The lens motor (M3) is faulty.

• The DC controller PCB is faulty.

E210

E220

• The scanning lamp turns on during

standby.

• The scanning lamp turns off during

copying.

• The lamp regulator PCB is faulty.

• The DC controller PCB is faulty.

• The intervals of the zero-cross signals

exceed the allowed intervals for 50/60 Hz.

• The power supply frequency is faulty.

• The power supply PCB is faulty.

E261

10–100

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CHAPTER 10 TROUBLESHOOTING

Cause

Description

Code

• The DC controller PCB is faulty.

• IC114 (IPC) on the DC controller PCB

cannot be initialized at power -on.

E710

• The DC controller PCB is faulty.

• An IPC communication error has been

detected twice or more within 1 sec at

power-on.

E711

E712

• A communication error with the ADF

controller PCB cannot be cleared.

• The DC controller PCB is faulty.

• The ADF controller PCB is fault.

• The ADF cable is faulty.

• A condition in which a response from the

Remote Diagnostic Device II cannot be

received occurred three times

continuously.

• The DC controller PCB is faulty.

• The Remote Diagnostic Device II PCB is

faulty.

E717

• The Remote diagnostic Device II

communicates an interruption of count

pulses.

• An open circuit is detected for 5 V or 24 V

at power-on.

• The auto power-off circuit has an open

circuit.

• The DC controller PCB is faulty.

E800

E805

• The exhaust fan drive detection signal

(EXFAN1_DT*, FXFAN0_DT*) cannot

be detected 0.5 sec after the start of the

exhaust fan (FM2, FM4).

• The exhaust fan (FM2, FM4) is faulty.

• The DC controller PCB is faulty.

• The cleaner thermistor (TH3) detects 55°C

or more.

• The ozone filter is clogged.

• The cleaner thermistor (TH3) has poor

contact or an open circuit.

E821

• The DC controller PCB is faulty.

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10–101

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CHAPTER 10 TROUBLESHOOTING

Note:

1. When the diagnostic function has turned on, the copier can be reset by turning it off

once. This, however, does not apply to E000, E001, E002, E003, or E004.

This is to prevent the user from resetting the copier easily when the error is caused by

an open circuit in the thermistor, otherwise overheating and damaging the fixing

roller.

Normally, the copier will automatically turn off in about 4 sec if it is turned on

without clearing E000 through E004.

To clear E000 through E004, operate as follows:

1) Select ‘412’ (clear E000–E004) in service mode.

• The copier’s control panel indicates the respective error code.

2) Press the Start key.

3) The copier will automatically turn off, clearing the error.

2. E202 may be checked using ‘108’ in service mode (error history indication).

10–102

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CHAPTER 10 TROUBLESHOOTING

B. ADF

Code

Cause

Description

• The communication is monitored at all

times. This error occurs when the

communication with the copier stops.

• Exchange of data with the copier has a

fault.

E400

• See the ADF Service Manual.

• The separation motor does not rotate.

• The crescent sensor is faulty.

E401

E402

E403

E404

• The belt motor does not rotate.

• The belt clock is faulty.

• The feed motor does not rotate.

• The feed motor clock is faulty.

• The delivery motor does not rotate.

• The delivery clock is faulty.

• See the ADF Service Manual.

• The sensor level is faulty.

E411

E431

• The auto start separation motor does not

rotate.

• The auto start crescent sensor is faulty.

• The auto start separation clock is faulty.

Note:

When the self diagnosis function has turned on, the ADF may be reset by turning off the

copier.

To continue making copies while the ADF is out of order, disconnect the lattice

connector on the ADF side, open the ADF, and place an original on the copyboard glass.

1998 CANON INC.

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CHAPTER 10 TROUBLESHOOTING

C. Sorter

Code

Cause

Description

• Communication is monitored at all times.

This error occurs when the communication

with the copier stops.

• Exchange of data with the copier is

faulty.

E500

• See the Sorter Service Manual.

• See the Stapler Service Manual.

• See the Sorter Service Manual.

• The feed motor does not rotate.

• The feed motor rotates too slowly.

• The tandem path motor does not rotate.

• The stack motor does not rotate.

• The alignment motor does not rotate.

• The stapler drive motor does not rotate.

• The shift motor does not rotate.

• The shift motor rotates too slowly.

• A timing jam has occurred.

E510

E511

E513

E520

E530

E531

E540

E541

E550

D. Cassette Feeding Module

Code

Cause

Description

• The waste toner box swing cam does not

return to home position within a specific

period of time when the waste toner box

swing cam is being driven.

• The waste toner box swing cam home

position sensor is faulty.

• The cassette relay PCB is faulty.

E904

10–104

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APPENDIX

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

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A. GENERAL TIMING CHART

A4, 2 Copies, 100%, AE

Sequence

Power switch

Start key

Leading edge

of 1st page

Leading edge

of 2nd page

Power switch

OFF

120°C

160°C

WMUP

WMUPR

STBY

(flashing)

Green

1 Wait indicator

Target temperature control

2 Fixing heater (H1)

3 Main motor (M1)

Primary charging

0.6sec

0.1sec

0.6sec

0.4sec

assembly

Transfer charging

assembly

0.1sec

6 Static eliminator

7 Developing AC bias

8 Developing DC bias

9 Pre-exposure lamp (LA2)

10 Blank exposure lamp (LA3)

11 Scanning lamp (LA1)

12 Scanner motor (M2)

0.1sec

Voltage control

0.6sec

Partial activation

0.8sec

0.4sec

Forward

Reverse

Scanner home position

sensor (PS1)

14 Lens motor (M3)

Lens home position

sensor (PS2)

16 Mirror motor (M4)

Mirror home position

sensor (PS3)

0.5sec

18 Pick-up solenoid (SL1)

Registration paper

0.5sec

sensor (PS5)

Registration roller

clutch (CL1)

21 Feed roller clutch (CL2)

Delivery paper sensor

(PS6)

23 Cooling fan 1 (FM1)

24 Exhaust fan 1 (FM2)

25 Exhaust fan 2 (FM4)

Full-speed Half-speed

rotation rotation

Cassette / Drum heater

(H2)

27 Mirror heater (H3)

Counter 1 (CNT1)

1998 CANON INC.

CANON NP7161/NP7160 REV.0 AUG. 1998 PRINTED IN JAPAN (IMPRIME AU JAPON)

A–1

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B. SIGNALS AND ABBREVIATIONS

1. Signals

5V_ON

5VU ON signal

MLTPD1

MLTPD2

MM_DR

MM_LKDT

MMR_A

MULTIFEEDER PAPER WIDTH DETECTION signal 1

MULTIFEEDER PAPER WIDTH DETECTION signal 2

MAIN MOTOR DRIVE command

AC_24V_ON

[AE_DATA]

[AE_REF]

BLK_CNDR*

BLK_DEN*

BLK_LCK

BLK_PW

BLK_SCK

BLK_SD

AC AND 24V ON signal

AE SENSOR OUTPUT signal

AE SENSOR REFERENCE signal

MAIN MOTOR LOCK DETECTION signal

MIRROR MOTOR A command

BLANK EXPOSURE LAMP CENTER DRIVE command

BLANK EXPOSURE LAMP DRIVE ENABLE signal

BLANK EXPOSURE LAMP SERIAL DATA LATCH signal

BLANK EXPOSURE POWER line

MMR_A*

MMR_B

MIRROR MOTOR A* command

MIRROR MOTOR B command

MMR_B*

MMR_COM

MRRHP

OPCNT_DR*

PREXP_DR*

PU_SL*

MIRROR MOTOR B* command

BLANK EXPOSURE LAMP SERIAL DATA CLOCK signal

BLANK EXPOSURE LAMP SERIAL DATA signal

CLEANER THERMISTOR signal

MIRROR MOTOR DRIVE command

MIRROR HOME POSITION DETECTION signal

ACCESSORY COUNTER DRIVE command

PRE-EXPOSURE LAMP DRIVE command

PICK-UP SOLENOID DRIVE command

POWER SWITCH signal

[CLTH]

[CPY_DNS]

CSTPDT

COPY DENSITY VOLUME signal

CASSETTE PAPER DETECTION signal

CASSETTE SIZE DETECTION 0 signal

CASSETTE SIZE DETECTION 1 signal

CASSETTE SIZE DETECTION 2 signal

CASSETTE SIZE DETECTION 3 signal

DEVELOPING AC BIAS CONTROL command

DEVELOPING AC BIAS DRIVE command

DEVELOPING DC BIAS CONTROL command

DEVELOPING DC BIAS DRIVE command

EXHAUST FAN 0 DRIVE command

CSTS0

PW_SW

RDOPDT

RG_CL*

RGPDT

CSTS1

RIGHT DOOR OPEN DETECTION signal

REGISTRATION ROLLER CLUTCH DRIVE command

REGISTRATION PAPER DETECTION signal

SCANNER MOTOR A command

CSTS2

CSTS3

DV_AC_CNT

DV_AC_DR

DV_DC_CNT

DV_DC_DR

EXFAN0_DR

EXFAN0_DT*

EXFAN1_DR

EXFAN1_DT*

EXITPD

SC_A

SC_A*

SCANNER MOTOR A* command

SC_B

SCANNER MOTOR B command

SC_B*

SCANNER MOTOR B* command

SC_COM

SCFAN_DR

SCFAN_DT*

SCHP

SCANNER MOTOR DRIVE command

COOLING FAN DRIVE command

EXHAUST FAN 0 DRIVE DETECTION signal

EXHAUST FAN 1 DRIVE command

COOLING FAN DRIVE DETECTION signal

SCANNER HOME POSITION DETECTION signal

SORTER KIT FAN DRIVE command

SORTER KIT FAN DRIVE DETECTION signal

TOTAL COUNTER DRIVE command

FIXING MAIN THERMISTOR signal

FIXING MAIN THERMISTOR DETECTION signal

FIXING SUB THERMISTOR signal

EXHAUST FAN 1 DRIVE DETECTION signal

DELIVERY PAPER DETECTION signal

FEED ROLLER CLUTCH DRIVE command

FIXING HEATER DRIVE command

STFAN_DR

STFAN_DT*

TCNT_DR*

[TH1]

FEED_CL*

HEAT_DR

HEAT_ERR

HVT_DR

FIXING HEATER ERROR DETECTION signal

HVT DRIVE command

TH1_DT

[TH2]

LMP_PWM

LMPDR

SCANNING LAMP PULSE WIDTH MODIFICATION signal

SCANNING LAMP DRIVE command

SCANNING LAMP DRIVE DETECTION signal

LENS MOTOR A command

[TNEMP]

TNFDT

TONER EMPTY signal

LMPDT

WASTE TONER FULL DETECTION signal

WASTE TONER FEEDING SCREW LOCKED DETECTION signal

ZERO CROSS signal

LNS_A

TRQMLDT

ZRCRSS

LNS_A*

LENS MOTOR A* command

LNS_B

LENS MOTOR B command

LNS_B*

LENS MOTOR B* command

LNS_COM

LNSHP

LENS MOTOR DRIVE command

LENS HOME POSITION DETECTION signal

MULTIFEED ROLLER CLUTCH DRIVE command

MULTIFEED SOLENOID DRIVE command

MULTIFEEDER PAPER DETECTION signal

MLT_CL*

MLT_SL*

MLTPD0

A–2

1998 CANON INC.

CANON NP7161/NP7160 REV.0 AUG. 1998 PRINTED IN JAPAN (IMPRIME AU JAPON)

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2. Abbreviations

AER

AE ROTATION

INTR

INITIAL ROTATION

LAST ROTATION

SCANNER FORWARD

SCANNER REVERSE

STANDBY

LSTR

SCFW

SCRV

STBY

WMUP

WARM-UP

WMUPR

WARM-UP ROTATION

1998 CANON INC.

CANON NP7161/NP7160 REV.0 AUG. 1998 PRINTED IN JAPAN (IMPRIME AU JAPON)

A–3

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APPENDIX

1998 CANON INC.

CANON NP7161/NP7160 REV.0 AUG. 1998 PRINTED IN JAPAN (IMPRIME AU JAPON)

A–4

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C. GENERAL CIRCUIT DIAGRAM

PRE-

EXPOSURE

LAMP

EXHAUST EXHAUST

COOLING

FAN1

FM1

FAN 1

FM 2

FAN 2

FM 4

SCANNER

MOTOR

LA2

TO CC-IV N

HEATER SWITCH (SW1)

CONTROL PANEL PCB

ET1

J20

J22

J14

J402

J401

J403

CASSETTE/DRUM

HEATER (H2)

J790

J37

10 11 12 13 14 15

J501

TONER

SENSOR

CASSETTE

HEATER (H4)

TS1

ET2

J15

MIRROR

HEATER (H3)

ACCESSORY

COUNTER

CNT2

TOTAL

COUNTER

CNT1

LA3

MIRROR

MOTOR

SENSOR

SORTER KIT

FAN

FM5

BLANK EXPOSURE

LAMP

LENS

HOME

SCANNER

HOME

POSITION

SENSOR

PS1

MIRROR

HOME

POSITION

SENSOR

PS3

LENS MOTOR

J721

FIXING HEATER (H1)

CNT

POSITION

SENSOR

PS2

RG_CL*

LMPDR

THERMO SWIITCH (SW1)

J39

J720

J32

F13

F15

F14

F16

J24

LMPDT

J11

J10

J12

J531

J33

J38

J551

FT1

FT2

LMP_PWM

TNFDT

TRQMLDT

RL1

TO J307

DV_DC_CNT

DV_DC_DR

DV_AC_CNT

DV_AC_DR

HVT_DR

MM_LKDT*

MM_DR

SCANNING

LAMP (LA1)

THERMAL

FUSE (FU1)

MT3

MT4

MT2

J123

J51

MT1

HEAT_ERR

B12

A12

B13

A13

B15

A15

POWER SUPPLY

PCB

HEAT_DR

ZRCRSS

5V_ON

J104

J103

J102

J101

AC_24V_ON

DC CONTROLER PCB

24V

LAMP

REGULATOR

PCB

GND

5VU

J107

J122

LMPDR

5VR

LMP_PWM

LMPDT

GND

J120

J121

GND

J112

J111

J110

J109

J108

J124

B10

A10

B15

A15

MM_LKDT*

MM_DR

GND

CL1

24V

RG_CL*

24V

TO RL1

MAIN

MOTOR

REGISTRATION

ROLLER CLUTCH

J23

J750

J752

10 11

J16

4 5

J307

TH1

TNFDT

J21

J40

J797

J796

J700

TH2

SUB

MAIN

THERMISTOR

TRQMLDT

5VU

11 10

CASSETTE SIZE

SWITCH PCB

PS6

DELIVERY

PAPER

DV_DC_CNT

DV_DC_DR

DV_AC_CNT

DV_AC_DR

HVT_DR

GND

10 11 12

TH3

CLEANER

THERMISTOR

GRID

SEALED

SENSOR

J754

HIGH-VOLTAGE

TRANSFORMER

PCB

TO ADF

24V

FT7

J206

J303

J302

J47

J36

J31

J30

TRANSFER GUIDE

VZ1

J951

J48

J19

J743

J742

J18

J35

J17

ACCESORY POWER

SUPPLY PCB

J751

J753

SL1

SL2

MULTI

FEED

J955

J952

PS4

PS10

MULTI-

FEEDER

PAPER

WIDHT

PS9

PS7

PS5

REGISTRATION

PAPER

PS11

RIGHT

DOOR

OPEN

SENSOR

J722

J34

CL2

FEED

ROLLER

CLUTCH

CL3

MULTI

FEED

ROLLER

CLUTCH

PICK-UP

SOLENOID

MULTI-

FEEDER

PAPER

WIDHT

MULTI-

FEEDER

PAPER

CASSETTE

PAPER

WASTE

TONER

SENSOR

B10

A10

TO RDD

10 11 12

SENSOR

SOLENOID

SENSOR

PS8

SENSOR

J701

J755

TO SORTER

SENSOR 2 SENSOR 1

WASTE TONER FEEDING

SCREW LOCKED SENSOR

TO CFM

1998 CANON INC.

CANON NP7161/NP7160 REV.0 AUG. 1998 PRINTED IN JAPAN (IMPRIME AU JAPON)

A–5

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APPENDIX

1998 CANON INC.

CANON NP7161/NP7160 REV.0 AUG. 1998 PRINTED IN JAPAN (IMPRIME AU JAPON)

A–6

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APPENDIX

D. SPECIAL TOOLS LIST

No.

Tool description

Door switch

Tool No.

Shape

Notation

Remarks

TKN-0093

Point of use

Front

door

Mirror positioning

tool

FY9-3009

For adjusting the

No. 1/No. 2 mirror

position (front/rear

as a pair)

1998 CANON INC.

CANON NP7161/NP7160 REV.0 AUG. 1998 PRINTED IN JAPAN (IMPRIME AU JAPON)

A–7

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APPENDIX

E. SOLVENTS AND OILS

No. Description

Use

Composition

C2H5O

Description

Ethyl alcohol Cleaning:

• Do not bring near open fire.

• Procure locally.

(Etanol)

e.g., glass,

plastic,

rubber parts;

external covers

(CHZ3)2 CHOH

• Isopropyl alcohol may be

substituted.

Isopropyl

alcohol

(Isopropanol)

MEK

Cleaning:

e.g., metal;

oil or toner

CH3COC2H5

• Do not bring near fire.

• Procure locally.

Heat-resisting Lubricating; e.g., fixing

Lithium soap

• CK-0427 (500 g/can)

grease

drive assemblies

(mineral oil family)

Moblybdenum bisulfide

Lubricant oil

Mineral oil

(paraffin family)

• CK-0451 (100 cc)

• CK-0524 (100 cc)

Mineral oil

(paraffin family)

Lubricating:

scanner rail

Lubricant oil

Slicone oil

• CK-0551 (20 g)

1998 CANON INC.

CANON NP7161/NP7160 REV.0 AUG. 1998 PRINTED IN JAPAN (IMPRIME AU JAPON)

A–8

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Prepared by

OFFICE IMAGING PRODUCTS TECHNICAL SUPPORT DEPT. 1

OFFICE IMAGING PRODUCTS TECHNICAL SUPPORT DIV.

CANON INC.

Printed in Japan

REVISION 0 (AUG. 1998) [23715]

5-1, Hakusan 7-chome, Toride-shi, Ibaraki 302-8501, Japan

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This publication is printed on

70% reprocessed paper.

PRINTED IN JAPAN (IMPRIME AU JAPON)

0998S0.7-1

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