Canon ImageRunner 600 User manual

COPYRIGHT © 2000 CANON INC. CANON imageRUNNER 600 REV.1 JAN. 2000 PRINTED IN U.S.A.
DU7-1100-010
REVISION 1
JAN. 2000
SERVICE
MANUAL

COPYRIGHT © 2000 CANON INC. CANON imageRUNNER 600 REV.1 JAN. 2000 PRINTED IN U.S.A.
COPYRIGHT 2000 CANON INC.
Printed in U.S.A.
Use of this manual should be strictly
supervised to avoid disclosure of confi-
dential information.
THE INFORMATION CONTAINED HEREIN IS PUBLISHED BY CANON, INC., JAPAN.
SPECIFICATIONS AND OTHER INFORMATION CONTAINED HEREIN MAY DIFFER SLIGHTLY FROM
ACTUAL MACHINE VALUES OR THOSE FOUND IN ADVERTISING AND OTHER PRINTED MATTER.
ANY QUESTIONS REGARDING INFORMATION CONTAINED HEREIN SHOULD BE DIRECTED TO THE
COPIER SERVICE DEPARTMENT OF THE COMPANY.
IMPORTANT
Prepared by
OFFICE IMAGING PRODUCTS TECHNICAL SUPPORT DEPARTMENT 3
OFFICE IMAGING PRODUCTS TECHNICAL SUPPORT DIVISION
5-1, Hakusan 7-chome, Toride, Ibaraki, 302-8501 Japan
CANON INC.

COPYRIGHT © 1999 CANON INC. CANON GP605/605V REV.0 JAN. 1999 PRINTED IN JAPAN (IMPRIME AU JAPON)
i
This Service Manual contains basic data and figures on the imageRUNNER 600
needed to service the machine in the field. The copier is a multifunction machine designed
to provide printer functions as an option.
This Service Manual consists of the following chapters; refer to the Copier Basic
Series as necessary for common technologies:
CHAPTER 1 General Description introduces the copier’s features and specifications,
shows how to operate the printer unit, and explains how copies are made.
CHAPTER 2 Basic Operation provides outlines of the steps used to generate copies.
CHAPTER 3 Exposure System discusses the principles of operation used for the
mechanical/electrical operations of the copier’s exposure system. It also explains the
timing at which the various units involved are operated, and shows how they may be
disassembled/assembled and adjusted.
CHAPTER 4 Image Processing System discusses the principles of operation used for
the mechanical/electrical operations of the copier’s image processing system. It also
explains the timing at which the various units involved are operated, and shows how they
may be disassembled/assembled and adjusted.
CHAPTER 5 Laser Exposure System discusses the principles of operation used for
the mechanical/electrical operations of the copier’s laser exposure system. It also
explains the timing at which the various units involved are operated, and shows how they
may be disassembled/assembled and adjusted.
CHAPTER 6 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 7 Pick-Up/Feeding System discusses the principles of how the printer unit
picks up and moves paper inside it. It also explains the timing at which the various units
involved are operated, and shows how they may be disassembled/assembled and
adjusted.
CHAPTER 8 Fixing System discusses the principles of how the printer unit fuses toner
images to paper. It also explains the timing at which the various units involved are
operated, and shows how they may be disassembled/assembled and adjusted.
CHAPTER 9 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 10 Side Paper Deck discusses the principles of operation used for the
series of operations between pickup and delivery performed by the paper deck. It also
explains the timing at which the various units involved are operated, and shows how they
may be disassembled/assembled and adjusted.
CHAPTER 11 Installation introduces requirements for the site of installation, and
shows how the printer unit may be installed using step-by-step instructions.
INTRODUCTION

COPYRIGHT © 2000 CANON INC. CANON imageRUNNER 600 REV.1 JAN. 2000 PRINTED IN U.S.A.
ii
CHAPTER 12 Maintenance and Servicing provides tables of periodically replaced
parts and consumables/durables and scheduled servicing charts.
CHAPTER 13 Troubleshooting provides tables of maintenance/inspection, standards/
adjustments, and problem identification (image fault/malfunction).
APPENDIX contains a general timing chart and general circuit diagrams.
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.
This Service Manual is prepared so that a full understanding may be attained when it
is used side by side with the separately available Copier Basic Series. Refer to the
appropriate section of the document when prompted as follows:
EX. Part 2>Chapter 5>10.1
The Copier Basic Series is a combination of descriptions on the existing technologies
used in Canon copiers. It consists of the following seven volumes, and is intended to
supplement the contents of Service Manuals:
Part 1 Introduction Fundamental Technology
Part 2 Applied Technology Analog Copiers
Part 3 Applied Technology Digital Copiers
Part 4 Applied Technology Color Copiers

COPYRIGHT © 2000 CANON INC. CANON imageRUNNER 600 REV.1 JAN. 2000 PRINTED IN U.S.A.
iii
System Configuration
The imageRUNNER 600 may be configured as follows:
[1] Saddle Finisher-D2
[2] Cover Insertion Unit-A1
[3] Paper Folding Unit-B1
[4] Printer Board
[5] imageRUNNER 600
[6] Side Paper Deck-C1
[7] Copy tray
[8] Finisher-D1
[5]
[1] [2]
[8]
[3] [6]
[7]
[4]
Figure 1

COPYRIGHT © 1999 CANON INC. CANON imageRUNNER 600 REV.1 JAN. 2000 PRINTED IN U.S.A.
iv
[3]
[4]
ONOFF
1 2 3
4 5 6
7 8 9
0
C
ID
ON/OFF
COPY A MAIL BOX OPTIONS
1 2 3
4 5 6
7 8 9
0
Copying Error
COPY B
Copying Error Data DataError Error
C
ID
[2][1]
[1] Data lamp
[2] Power switch
[3] Main power switch
[4] Heater switch
Figure 2 Arrangement of the Switches
When Turning Off the Main Power Switch
Be sure to turn off the main power switch, and disconnect the power plug before starting
disassembly/assembly work with the following in mind:
1. When you turn off the main power switch for adding printer functions, any data
being processed at the time may be lost. Check to make sure that the data lamp on
the control panel is off before operating the main power switch.
After turning off the main power switch, disconnect the communication cable from
the printer board so that data will not be accepted during work.
2. Do not turn off the main power switch when downloading is taking place. Other-
wise, the machine may stop operating.
3. Some units remain powered even when the control panel power switch is turned
off. Be sure to turn off the main power switch, and disconnect the power plug
before starting disassembly/assembly work.
(If the heater switch is on, the cassette heater and the drum heater remain pow-
ered even when the main power switch is turned off.)
4. Not all power will be removed even when the front door is opened if both the control
panel power switch and the main power switch are on.

COPYRIGHT © 1999 CANON INC. CANON imageRUNNER 600 REV.1 JAN. 2000 PRINTED IN U.S.A.
v
CHAPTER 1 GENERAL DESCRIPTION
I. FEATURES ................................1-1
II. SPECIFICATIONS......................1-2
A. Copier....................................1-2
1. Type .................................1-2
2. System .............................1-2
3. Performance.....................1-3
4. Others...............................1-7
B. Side Paper Deck-C1............1-10
III. NAMES OF PARTS..................1-11
A. External View ......................1-11
B. Cross Section ......................1-14
IV. OPERATING THE COPIER .....1-16
A. Turning on the Power Switch
............................................1-16
B. Control Panel.......................1-17
C. Extension Mode...................1-18
D. User Mode...........................1-19
V. ROUTINE MAINTENANCE BY THE
USER .......................................1-21
VI. SAFETY ...................................1-22
A. Safety of Laser Light ...........1-22
B. CDRH Regulations ..............1-23
C. Handling the Laser Assembly
............................................1-24
D. Safety of Toner....................1-28
VII. IMAGE FORMATION ...............1-29
A. Outline .................................1-29
CONTENTS
CHAPTER 2 BASIC OPERATIONS
I. BASIC OPERATIONS ................2-1
A. Functional Construction.........2-1
B. Electrical Circuitry..................2-2
1. Outline..............................2-2
2. MFC PCB .........................2-2
3. Image Processor PCB......2-2
4. DC Controller PCB ...........2-3
5. Control panel CPU PCB ...2-3
6. Original Orientation Detection
PCB..................................2-3
7. Image Server....................2-3
C. Basic Sequence of Operations
..............................................2-5
1. Basic Sequence of
Operations (power-on) .....2-5
D. Controlling the Main Motor (M1)
..............................................2-6
1. Outline..............................2-6
E. Inputs to and Outputs from the
Major PCBs ...........................2-7
1. Wiring Diagram of Major
PCBs ................................2-7
2. Inputs to the DC Controller
PCB..................................2-8
3. Outputs from the DC
Controller PCB ...............2-14
CHAPTER 3 ORIGINAL EXPOSURE SYSTEM
I. OPERATIONS............................3-1
A. Outline ...................................3-1
B. Basic Sequence of Operations
..............................................3-3
C. Changing the Reproduction Ratio
..............................................3-4
II. SCANNER DRIVE SYSTEM ......3-5
A. Outline ...................................3-5
B. Controlling the Scanner Motor
..............................................3-6
III. CONTROLLING THE SCANNING
LAMP..........................................3-8

COPYRIGHT © 1999 CANON INC. CANON imageRUNNER 600 REV.1 JAN. 2000 PRINTED IN U.S.A.
vi
A. Outline ...................................3-8
B. Controlling the Temperature by a
Fluorescent Lamp Heater....3-10
C. Controlling Pre-Heat Voltage
............................................3-10
D. Initial Activation ...................3-11
E. Detecting an Error ...............3-12
IV. DETECTING THE ORIGINAL SIZE
.................................................3-14
A. Outline .................................3-14
B. Detection by Original Sensors
............................................3-14
C. Detection by the Feeder ......3-14
V. DISASSEMBLY/ASSEMBLY....3-15
A. No. 1 Mirror Mount ..............3-16
1. Removing the Scanning
Lamp/Scanning Lamp Heater
.......................................3-16
2. Points to Note When
Replacing the Scanning Lamp
.......................................3-19
3. After Replacing the Scanning
Lamp ..............................3-19
B. Scanner Drive Assembly .....3-20
1. Removing the Scanner Motor
.......................................3-20
2. Scanner Drive Cable ......3-21
C. PCBs ...................................3-28
1. Removing the Light Intensity
Control PCB ...................3-28
2. Removing the Inverter PCB
.......................................3-29
D. Others..................................3-31
1. Removing the Original Size
Sensor (1/2)....................3-31
2. Removing the Original Size
Sensor (3/4)....................3-32
3. Removing the Scanner Home
Position Sensor ..............3-33
4. Removing the Copyboard
Glass ..............................3-33
5. Removing the Image Leading
Edge Sensor ..................3-34
6. Removing the Standard White
Plate ...............................3-35
7. After Replacing the Standard
White Plate.....................3-36
CHAPTER 4 IMAGE PROCESSING SYSTEM
I. OUTLINE....................................4-1
II. ANALOG IMAGE PROCESSING4-4
A. Outline ...................................4-4
III. DIGITAL IMAGE PROCESSING 4-6
A. Outline ...................................4-6
B. Image Procesing Functional
Block......................................4-7
C. Shading Correction................4-9
D. Line Conversion ..................4-10
E. Editing .................................4-11
F. Density Processing..............4-12
1. Outline............................4-12
2. Density Adjustment during
Printing ...........................4-14
G. Binary Processing ...............4-15
1. Dither Screen Method ....4-15
2. Random Error Diffusion (R-
ED) Method ....................4-16
H. Image Memory ....................4-17
I. Detecting the Orientation of
Originals ..............................4-19
J. Black Pixel Count ................4-20
IV. DISASSEMBLY/ASSEMBLY....4-21
A. CCD PCB ............................4-22
1. Removing the CCD PCB
.......................................4-22
2. After Replacing the CCD Unit
.......................................4-23
B. Image Processor PCB.........4-24
1. Removing the Image
Processor PCB...............4-24
2. After Replacing the Image
Processor PCB...............4-25
C. Hard Disk (image server).....4-26
1. Removing the Hard Disk
(image server) ................4-26
2. After Replacing the Hard Disk
(image server) ................4-26
D. Others..................................4-27
1. Removing the System
Motherboard...................4-27
2. Removing the Memory Board
.......................................4-28
3. Removing the Various Printer
Boards............................4-28
4. Removing the Original
Detection PCB................4-29

COPYRIGHT © 1999 CANON INC. CANON imageRUNNER 600 REV.1 JAN. 2000 PRINTED IN U.S.A.
vii
CHAPTER 5 LASER EXPOSURE SYSTEM
I. OPERATIONS............................5-1
A. Outline ...................................5-1
B. Basic Sequence of Operations
(laser exposure system) ........5-4
II. GENERATING THE BD SIGNAL5-5
A. Outline ...................................5-5
B. Flow of the BD Signal............5-5
III. LASER DRIVER PCB.................5-7
A. Outline ...................................5-7
B. Controlling the Laser Activation
..............................................5-8
C. Controlling the Laser Intensity
............................................5-10
IV. Controlling the Laser Scanner Motor
.................................................5-12
A. Outline .................................5-12
V. DISASSEMBLY/ASSEMBLY....5-13
A. Laser Unit ............................5-14
1. Removing the Laser Unit
.......................................5-14
2. After Replacing the Laser Unit
.......................................5-15
B. BD Unit ................................5-16
1. Removing the BD Unit....5-16
CHAPTER 6 IMAGE FORMATION SYSTEM
I . PROCESSES .............................6-1
A. Outline ...................................6-1
B. Basic Sequence of Operations
(image formation) ..................6-3
II . POTENTIAL CONTROL .............6-5
A. Outline ...................................6-5
B. Determining the Optimum Grid
Bias .......................................6-8
C. Grid Bias Corrective Control..6-8
D. Determining the Optimum Laser
Output....................................6-9
E. Laser Output Corrective control
..............................................6-9
F. Determining the Optimum
Developing Bias ..................6-10
G. Potential Control for
Transparency Mode ............6-11
H. Target Potential Correction in
Each Mode ..........................6-12
1. Adjusting the Density during
Printing (PDL input)........6-13
2. Potential Control during High
Humidity Mode ...............6-14
3. Density Adjustment during
Printing (scanner input) ..6-15
III . CONTROLLING THE CHARGING
MECHANISMS .........................6-16
A. Controlling the Primary Charging
Mechanism ..........................6-16
1. Outline............................6-16
2. Changing the Primary
Charging Level Setting...6-17
3. Primary Charging Assembly
Cleaning Mechanism......6-18
4. Others.............................6-19
B. Dust-Collecting Roller Bias..6-20
1. Outline............................6-20
C. Controlling the Pre-Transfer
Charging Mechanism ..........6-21
1. Outline............................6-21
2. Controlling the Output to Suit
the Environment (fuzzy
control) ...........................6-22
3. Pre-Transfer Charging
Assembly Cleaning
Mechanism .....................6-23
4. Others.............................6-24
D. Controlling the Transfer Guide
Bias .....................................6-25
1. Outline............................6-25
2. Controlling the Output to Suit
the Environment .............6-26
E. Controlling the Transfer Charging
Mechanism ..........................6-27
1. Outline............................6-27
2. Controlling the Output to Suit
the Environment (fuzzy
control) ...........................6-28
3. Correcting the Output at the
Trailing Edge of Paper....6-29

COPYRIGHT © 1999 CANON INC. CANON imageRUNNER 600 REV.1 JAN. 2000 PRINTED IN U.S.A.
viii
4. Transfer charging Assembly
Cleaning Mechanism......6-30
5. Others.............................6-31
F. Controlling Separation Charging
............................................6-32
1. Outline............................6-32
2. Correcting the Output to Suit
the Environment and the
Toner Deposit.................6-33
3. Correcting the Output upon
Detection of Leakage .....6-34
4. Others.............................6-35
IV . DEVELOPING ASSEMBLY......6-36
A. Outline .................................6-36
B. Controlling the Developing
Assembly.............................6-37
C. Controlling the Toner Cartridge
Drive Mechanism.................6-38
D. Controlling the Developing Bias
............................................6-39
E. Detecting the Toner Level and
Controlling the Toner Supply
Mechanism ..........................6-41
V . DRUM CLEANER UNIT ...........6-45
A. Outline .................................6-45
B. Detecting the Waste Toner (case
full condition) .......................6-46
VI. CONTROLLING THE DRUM
HEATER...................................6-48
A. Outline .................................6-48
VII .DISASSEMBLY/ASSEMBLY....6-49
A. Photosensitive Drum Unit....6-50
1. Points to Note When Handling
the Photosensitive Drum 6-50
2. Removing the Photosensitive
Drum...............................6-51
3. Replacing the Photosensitive
Drum Heater...................6-53
4. Mounting the Photosensitive
Drum Unit .......................6-54
B. Parts Associated with the
Process Unit ........................6-55
1. Removing the Pre-Exposure
Lamp Unit.......................6-55
2. Removing the Potential
Sensor Unit.....................6-56
3. Removing the Primary
Charging Assembly ........6-57
4. Removing the Pre-Transfer
Charging Assembly ........6-57
5. Removing the Dust-Collecting
Roller..............................6-58
6. Removing the Transfer/
Separation Charging
Assembly........................6-58
C. Charging Wire .....................6-60
1. Outline............................6-60
2. Removing the Wire Cleaner of
the Primary Charging
Assembly........................6-60
3. Removing the Wire Cleaner of
the Transfer Separation
Charging Assembly ........6-61
4. Routing the Charging Wire
.......................................6-62
5. Routing the Grid Wire for the
Primary Charging Assembly
.......................................6-64
6. Adjusting the Height of the
Charging Wire ................6-65
D. Process Unit ........................6-66
1. Removing the Process Unit
.......................................6-66
2. Mounting the Process Unit
.......................................6-68
E. Developing Assembly..........6-69
1. Removing the Developing
Assembly........................6-69
2. Removing the Hopper ....6-70
3. Removing the Blade Unit
.......................................6-71
4. Mounting the Blade ........6-72
5. Removing the Developing
Cylinder ..........................6-72
F. Drum Cleaner Unit...............6-75
1. Removing the Cleaning Blade
.......................................6-75
2. Mounting the Cleaning Blade
.......................................6-77
G. Separation Claw/Separation Claw
Drive Assembly ...................6-79
CHAPTER 7 PICK-UP/FEEDING SYSTEM
I. OUTLINE....................................7-1
A. Specifications and Construction
..............................................7-1
B. Arrangement of Rollers and
Sensors .................................7-2
II. PICKUP ASSEMBLY..................7-3