Canon iR1020 Series User manual

Sep 1 2008
Service Manual
iR1020/1021/1024/1025 Series

Application
This manual has been issued by Canon Inc. for qualified persons to learn technical theory, installation, maintenance, and repair
of products. This manual covers all localities where the products are sold. For this reason, there may be information in this
manual that does not apply to your locality.
Corrections
This manual may contain technical inaccuracies or typographical errors due to improvements or changes in products. When
changes occur in applicable products or in the contents of this manual, Canon will release technical information as the need
arises. In the event of major changes in the contents of this manual over a long or short period, Canon will issue a new edition
of this manual.
The following paragraph does not apply to any countries where such provisions are inconsistent with local law.
Trademarks
The product names and company names used in this manual are the registered trademarks of the individual companies.
Copyright
This manual is copyrighted with all rights reserved. Under the copyright laws, this manual may not be copied, reproduced or
translated into another language, in whole or in part, without the written consent of Canon Inc.
COPYRIGHT © 2001 CANON INC.
Printed in Japan
Caution
Use of this manual should be strictly supervised to avoid disclosure of confidential information.

Introduction
Symbols Used
This documentation uses the following symbols to indicate special information:
Symbol Description
Indicates an item of a non-specific nature, possibly classified as Note, Caution, or Warning.
Indicates an item requiring care to avoid electric shocks.
Indicates an item requiring care to avoid combustion (fire).
Indicates an item prohibiting disassembly to avoid electric shocks or problems.
Indicates an item requiring disconnection of the power plug from the electric outlet.
Indicates an item intended to provide notes assisting the understanding of the topic in question.
Indicates an item of reference assisting the understanding of the topic in question.
Provides a description of a service mode.
Provides a description of the nature of an error indication.
Memo
REF.

Introduction
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 refer-
ence to the timing of operation.
In the diagrams, represents the path of mechanical drive; where a signal name accompanies the symbol , the arrow indicates the
direction of the electric signal.
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, how-
ever, differs from circuit to circuit.) In addition, the asterisk (*) as in "DRMD*" indicates that the DRMD signal goes on when '0'.
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 com-
municated 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."

Contents
Contents
Chapter 1 Introduction
1.1 System Construction ..................................................................................................................................1- 1
1.1.1 System Configuration..............................................................................................................................................1- 1
1.2 Product Specifications................................................................................................................................1- 4
1.2.1 Names of Parts........................................................................................................................................................1- 4
1.2.1.1 External View (Front) ............................................................................................................................................................... 1- 4
1.2.1.2 External View (Rear)................................................................................................................................................................ 1- 5
1.2.1.3 Cross-Section (Main body) ......................................................................................................................................................1- 6
1.2.1.4 Cross Section (ADF)................................................................................................................................................................1- 7
1.2.2 Using the Machine...................................................................................................................................................1- 8
1.2.2.1 Turning On the Power Switch .................................................................................................................................................. 1- 8
1.2.2.2 When Turning Off the Main Power Switch............................................................................................................................... 1- 9
1.2.2.3 Control Panel ......................................................................................................................................................................... 1- 11
1.2.3 User Mode Items...................................................................................................................................................1- 12
1.2.3.1 COMMON SETTINGS ........................................................................................................................................................... 1- 12
1.2.3.2 COPY SETTINGS..................................................................................................................................................................1- 12
1.2.3.3 TX/RX SETTINGS .................................................................................................................................................................1- 13
1.2.3.4 ADDRESS BOOK SET. ......................................................................................................................................................... 1- 14
1.2.3.5 PRINTER SETTINGS ............................................................................................................................................................1- 15
1.2.3.6 TIMER SETTINGS................................................................................................................................................................. 1- 16
1.2.3.7 ADJUST./CLEANING............................................................................................................................................................. 1- 16
1.2.3.8 REPORT SETTINGS.............................................................................................................................................................1- 17
1.2.3.9 SYSTEM SETTINGS .............................................................................................................................................................1- 17
1.2.4 Maintenance by the User.......................................................................................................................................1- 19
1.2.4.1 User Maintenance Items........................................................................................................................................................1- 19
1.2.4.2 Cleaning.................................................................................................................................................................................1- 19
1.2.5 Safety ....................................................................................................................................................................1- 21
1.2.5.1 Safety of Toner ......................................................................................................................................................................1- 21
1.2.5.2 Safety of the Laser Light........................................................................................................................................................1- 21
1.2.5.3 CDRH Regulations.................................................................................................................................................................1- 21
1.2.5.4 Handling the Laser Unit .........................................................................................................................................................1- 21
1.2.5.5 Point to Note about Fire......................................................................................................................................................... 1- 23
1.2.5.6 Cautions as to the replacement and disposal of lithium battery.............................................................................................1- 23
1.2.6 Product Specifications...........................................................................................................................................1- 24
1.2.6.1 Product Specifications ...........................................................................................................................................................1- 24
1.2.6.2 ADF Specifications................................................................................................................................................................. 1- 25
1.2.6.3 Fax Specifications..................................................................................................................................................................1- 25
1.2.7 Function List..........................................................................................................................................................1- 26
1.2.7.1 Print Speed (iR1020/1020J/1021J)........................................................................................................................................1- 26
1.2.7.2 Print Speed (iR1024A/F/J/N/i/iF, iR1025J/N/iF).....................................................................................................................1- 27
1.2.7.3 Types of Paper....................................................................................................................................................................... 1- 27
Chapter 2 Installation
2.1 Unpacking and Installation .........................................................................................................................2- 1
2.1.1 Main Body Installation Procedure............................................................................................................................2- 1
2.2 Relocating the Machine..............................................................................................................................2- 1
2.2.1 Relocating the Machine...........................................................................................................................................2- 1
2.3 Installing the Card Reader..........................................................................................................................2- 1
2.3.1 Points to Note..........................................................................................................................................................2- 1
2.3.2 Checking the Contents............................................................................................................................................2- 1
2.3.3 Installation Procedure..............................................................................................................................................2- 2
2.3.4 Registering the Card IDs.........................................................................................................................................2- 6

Contents
Chapter 3 Basic Operation
3.1 Construction ...............................................................................................................................................3- 1
3.1.1 Functional Construction...........................................................................................................................................3- 1
3.1.2 Functional Block Diagram........................................................................................................................................3- 2
3.1.3 Image Processor PCB .............................................................................................................................................3- 2
3.1.4 DC Controller PCB...................................................................................................................................................3- 3
3.1.5 Analog Processor PCB............................................................................................................................................3- 4
3.1.6 Power Supply PCB ..................................................................................................................................................3- 4
3.1.7 Relay PCB ...............................................................................................................................................................3- 4
3.1.8 Control Panel PCB...................................................................................................................................................3- 4
3.1.9 NCU PCB (if equipped with fax functions)...............................................................................................................3- 4
3.1.10 Network PCB (if equipped with network functions)................................................................................................3- 4
3.1.11 Modular Jack PCB (if equipped with fax functions)................................................................................................3- 4
3.1.12 Modem PCB (if equipped with fax functions).........................................................................................................3- 4
3.2 Basic Sequence .........................................................................................................................................3- 6
3.2.1 Basic Sequence.......................................................................................................................................................3- 6
Chapter 4 Original Exposure System
4.1 Construction ...............................................................................................................................................4- 1
4.1.1 Specifications, Control Methods, and Functions......................................................................................................4- 1
4.1.2 Major Components...................................................................................................................................................4- 1
4.2 Basic Sequence .........................................................................................................................................4- 3
4.2.1 Basic Sequence at Power-on...................................................................................................................................4- 3
4.2.2 Basic Sequence after Depression of Start Key (Book mode, One Sheet of original) ..............................................4- 3
4.2.3 Basic Sequence after Depression of Start Key (ADF Mode, One Sheet of Original)...............................................4- 4
4.3 Various Control...........................................................................................................................................4- 4
4.3.1 Enlargement/Reduction ...........................................................................................................................................4- 4
4.3.1.1 Magnification Change in Vertical Scan Direction.....................................................................................................................4- 4
4.3.1.2 Magnification Change in Horizontal Scan Direction................................................................................................................. 4- 4
4.3.2 Dirt Sensor Control ..................................................................................................................................................4- 5
4.3.2.1 Outline......................................................................................................................................................................................4- 5
4.4 Parts Replacement Procedure ...................................................................................................................4- 7
4.4.1 Copyboard glass......................................................................................................................................................4- 7
4.4.1.1 Removing the Copyboard Glass..............................................................................................................................................4- 7
4.4.1.2 Procedure after Replacing the Copyboard Glass (equipped with SEND functions) ................................................................4- 7
4.4.2 Reader Controller PCB............................................................................................................................................4- 7
4.4.2.1 Removing the Analog Processor PCB.....................................................................................................................................4- 7
4.4.3 Scanner Motor .........................................................................................................................................................4- 7
4.4.3.1 Removing the Reader Motor.................................................................................................................................................... 4- 7
4.4.4 Contact sensor.........................................................................................................................................................4- 8
4.4.4.1 Removing the Contact Image Sensor......................................................................................................................................4- 8
4.4.4.2 Procedure after Replacing the CS ........................................................................................................................................... 4- 8
4.4.5 Contact Sensor HP Sensor......................................................................................................................................4- 8
4.4.5.1 Removing the Contact Sensor Home Position Sensor............................................................................................................4- 8
Chapter 5 Laser Exposure
5.1 Construction ...............................................................................................................................................5- 1
5.1.1 Specifications and Control Mechanism....................................................................................................................5- 1
5.1.2 Main Components....................................................................................................................................................5- 2
5.2 Parts Replacement Procedure ...................................................................................................................5- 3
5.2.1 Laser Scanner Unit..................................................................................................................................................5- 3
5.2.1.1 Removing the Laser Scanner Unit ..........................................................................................................................................5- 3
Chapter 6 Image Formation

Contents
6.1 Construction ...............................................................................................................................................6- 1
6.1.1 Specifications and Control Mechanism ...................................................................................................................6- 1
6.1.2 Outline.....................................................................................................................................................................6- 2
6.2 Image Formation Process ..........................................................................................................................6- 3
6.2.1 Reproduction Processes .........................................................................................................................................6- 3
6.3 Parts Replacement Procedure ...................................................................................................................6- 4
6.3.1 Developing Assembly..............................................................................................................................................6- 4
6.3.1.1 Removing the Developing Unit ................................................................................................................................................ 6- 4
6.3.2 Transfer Charging Roller.........................................................................................................................................6- 4
6.3.2.1 Removing the Transfer Charging Roller .................................................................................................................................. 6- 4
6.3.3 Waste Toner Full Sensor.........................................................................................................................................6- 4
6.3.3.1 Removing the Waste Toner Full Sensor..................................................................................................................................6- 4
Chapter 7 Pickup/Feeding System
7.1 Construction ...............................................................................................................................................7- 1
7.1.1 Outline.....................................................................................................................................................................7- 1
7.2 Detecting Jams...........................................................................................................................................7- 2
7.2.1 Jam Detection Outline.............................................................................................................................................7- 2
7.2.1.1 Outline...................................................................................................................................................................................... 7- 2
7.2.1.2 Types of Jams.......................................................................................................................................................................... 7- 2
7.3 Cassette Pick-Up Unit ................................................................................................................................7- 4
7.3.1 Outline.....................................................................................................................................................................7- 4
7.3.2 Retry Pickup............................................................................................................................................................7- 4
7.3.3 Detecting the Size of Paper.....................................................................................................................................7- 4
7.4 Manual Feed Pickup Unit ...........................................................................................................................7- 5
7.4.1 Outline.....................................................................................................................................................................7- 5
7.4.2 Retry Pickup............................................................................................................................................................7- 5
7.4.3 Detecting the Size of Paper.....................................................................................................................................7- 5
7.5 Duplex Feeding Unit...................................................................................................................................7- 6
7.5.1 Outline.....................................................................................................................................................................7- 6
7.6 Parts Replacement Procedure ...................................................................................................................7- 7
7.6.1 Pickup Roller ...........................................................................................................................................................7- 7
7.6.1.1 Removing the Cassette Pickup Roller .....................................................................................................................................7- 7
7.6.2 Cassette Paper Sensor ...........................................................................................................................................7- 7
7.6.2.1 Removing the Cassette Paper Sensor.....................................................................................................................................7- 7
7.6.3 Cassette Pickup Solenoid........................................................................................................................................7- 7
7.6.3.1 Removing the Cassette Pickup Solenoid.................................................................................................................................7- 7
7.6.4 Manual Pickup Roller...............................................................................................................................................7- 8
7.6.4.1 Removing the Manual Pickup Roller........................................................................................................................................7- 8
7.6.5 Manual Feed Tray paper sensor .............................................................................................................................7- 8
7.6.5.1 Removing the Manual Tray Sensor .........................................................................................................................................7- 8
7.6.6 Manual Feed Pickup Solenoid.................................................................................................................................7- 8
7.6.6.1 Removing the Manual Pickup Solenoid................................................................................................................................... 7- 8
7.6.7 Manual Separation Pad...........................................................................................................................................7- 8
7.6.7.1 Removing the Manual Separation Pad .................................................................................................................................... 7- 8
7.6.8 Registration Roller...................................................................................................................................................7- 9
7.6.8.1 Removing the Registration Roller............................................................................................................................................7- 9
7.6.9 Registration Sensor...............................................................................................................................................7- 11
7.6.9.1 Removing the Registration Sensor........................................................................................................................................7- 11
7.6.10 Registration Clutch ..............................................................................................................................................7- 12
7.6.10.1 Removing the Registration Clutch........................................................................................................................................ 7- 12
7.6.11 Feeding Roller .....................................................................................................................................................7- 12
7.6.11.1 Removing the Cassete Feed Roller.....................................................................................................................................7- 12
7.6.12 Duplex Pickup Solenoid.......................................................................................................................................7- 12
7.6.12.1 Removing the Duplex Pickup Solenoid................................................................................................................................ 7- 12
7.6.13 Separation Roller.................................................................................................................................................7- 12

Contents
7.6.13.1 Removing the Cassette Separation Roller........................................................................................................................... 7- 12
Chapter 8 Fixing System
8.1 Construction ...............................................................................................................................................8- 1
8.1.1 Specifications, Control Mechanisms, and Functions ...............................................................................................8- 1
8.1.2 Outline......................................................................................................................................................................8- 1
8.2 Various Control Mechanisms .....................................................................................................................8- 3
8.2.1 Controlling the Fixing Film Temperature..................................................................................................................8- 3
8.2.1.1 Outline......................................................................................................................................................................................8- 3
8.2.1.2 Controlling the Fixing Film Temperature.................................................................................................................................. 8- 3
8.2.1.3 Target Temperatures by Mode ................................................................................................................................................8- 3
8.3 Protective Functions...................................................................................................................................8- 4
8.3.1 Outline......................................................................................................................................................................8- 4
8.3.2 Failure Detection......................................................................................................................................................8- 5
8.4 Parts Replacement Procedure ...................................................................................................................8- 6
8.4.1 Fixing Unit................................................................................................................................................................8- 6
8.4.1.1 Removing the Fixing Unit......................................................................................................................................................... 8- 6
8.4.1.2 Installing the Fixing unit ...........................................................................................................................................................8- 7
8.4.2 Pressure Roller........................................................................................................................................................8- 8
8.4.2.1 Removing the Pressure Roller.................................................................................................................................................8- 8
8.4.3 Fixing Film................................................................................................................................................................8- 9
8.4.3.1 Removing the Fixing Film Unit.................................................................................................................................................8- 9
8.4.4 Fixing Delivery Sensor...........................................................................................................................................8- 10
8.4.4.1 Removing the Delivery Sensor ..............................................................................................................................................8- 10
Chapter 9 External and Controls
9.1 Control Panel..............................................................................................................................................9- 1
9.1.1 Outline......................................................................................................................................................................9- 1
9.2 Fans ...........................................................................................................................................................9- 1
9.2.1 Outline......................................................................................................................................................................9- 1
9.3 Power Supply System ................................................................................................................................9- 2
9.3.1 Power Supply...........................................................................................................................................................9- 2
9.3.1.1 Outline......................................................................................................................................................................................9- 2
9.3.1.2 Rated Output of the Power Supply PCB..................................................................................................................................9- 2
9.3.2 Protection Function..................................................................................................................................................9- 3
9.3.2.1 Protective Functions ................................................................................................................................................................9- 3
9.4 Parts Replacement Procedure ...................................................................................................................9- 4
9.4.1 External Covers .......................................................................................................................................................9- 4
9.4.1.1 External Covers .......................................................................................................................................................................9- 4
9.4.2 Drive Unit.................................................................................................................................................................9- 7
9.4.2.1 Removing the Main Drive Unit.................................................................................................................................................9- 7
9.4.2.2 Removing the Pickup Drive Unit..............................................................................................................................................9- 8
9.4.2.3 Removing the Fixing/Duplex Drive Unit ...................................................................................................................................9- 8
9.4.3 Power Supply Unit ...................................................................................................................................................9- 8
9.4.3.1 Removing the Power Supply PCB ........................................................................................................................................... 9- 8
9.4.4 Control Panel...........................................................................................................................................................9- 8
9.4.4.1 Removing the Operation Panel Unit ........................................................................................................................................9- 8
9.4.5 Image Processor PCB .............................................................................................................................................9- 9
9.4.5.1 Removing the Image Processor PCB ...................................................................................................................................... 9- 9
9.4.5.2 Procedure after Replacing the Image Processor PCB........................................................................................................... 9- 10
9.4.6 NCU PCB...............................................................................................................................................................9- 10
9.4.6.1 Removing the NCU PCB........................................................................................................................................................ 9- 10
9.4.7 Modular Jack PCB.................................................................................................................................................9- 10
9.4.7.1 Removing the Modular Jack PCB..........................................................................................................................................9- 10
9.4.8 Modem PCB...........................................................................................................................................................9- 10
9.4.8.1 Removing the Modem PCB ...................................................................................................................................................9- 10