Canon iR1600 Series User manual

iR1600/iR2000
REVISION 1
JAN. 2002
COPYRIGHT © 2002 CANON INC. 2001 CANON iR1600/iR2000 REV.1 JAN. 2002 PRINTED IN JAPAN (IMPRIME AU JAPON)
FY8-13HJ-010

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 trade-
marks 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 © 2002 CANON INC. CANON iR1600/iR2000 REV.1 JAN. 2002 PRINTED IN JAPAN (IMPRIME AU JAPON)
Caution
Use of this manual should be strictly supervised to avoid disclosure of confidential information.
COPYRIGHT © 2002 CANON INC.
Printed in Japan
Imprimé au Japon

COPYRIGHT © 2002 CANON INC. 2001 2001 2001 2001 CANON iR1600/iR2000 REV.1 JAN. 2002
i
INTRODUCTION
1 Symbols Used
This documentation uses the following symbols to indicate special information:
Symbol Description
Refers to the Copier Basics Series for a better understanding of the contents.
Provides a description of the nature of an error indication.
Provides a description of a service mode.
Indicates an item of reference assisting the understanding of the topic in ques-
tion.
REF.
Indicates an item intended to provide notes assisting the understanding of the
topic in question.
Memo
Indicates an item requiring disconnection of the power plug from the electric
outlet.
Indicates an item prohibiting disassembly to avoid electric shocks or problems.
Indicates an item requiring care to avoid combustion (fire).
Indicates an item requiring care to avoid electric shocks.
Indicates an item of a non-specific nature, possibly classified as Note, Caution,
or Warning.

COPYRIGHT © 2002 CANON INC. 2001 2001 2001 2001 CANON iR1600/iR2000 REV.1 JAN. 2002
ii
INTRODUCTION
2 Outline of the Manual
This Service Manual provides basic facts and figures needed to service the iR1600/
iR2000. Of the machine’s accessories, this manual covers the cassette unit and inner 2-way
tray; for other accessories including the ADF, see its own Service Manual.
In this manual, the 1-Cassette Unit-F1, 2-Cassette Unit-G1 and 3-Cassette Unit-H1 are
collectively called “cassette unit,” and the Inner 2-Way Tray-B1 is referred to as the inner 2-
way tray.
This Service Manual consists of the following chapters:
Chapter 1 Introduction: features, specifications, operation, system construc-
tion, routine maintenance by the user, safety, repro-
duction processes
Chapter 2 Basic Operation: basic operation, outline of electrical circuitry, basic
sequence
Chapter 3 Image Reading/
Processing System: principles of operation of the exposure system, prin-
ciples of operation of the image processing system,
timing of operation; disassembly/assembly and ad-
justment
Chapter 4 Laser Exposure System: principles of operation of the image formation sys-
tem, timing of operation; disassembly/assembly
Chapter 5 Image formation system: standards, adjustments, troubleshooting tables
Chapter 6 Pickup/Feeding System: principles of operation of the pickup/feeding sys-
tem, timing of operation; disassembly/assembly and
adjustment
Chapter 7 Fixing System: principles of operation of the fixing system, timing
of operation; disassembly/assembly and adjustment
Chapter 8 Externals and Auxiliary
Control System: principles of operation of the externals/auxiliary
control system, timing of operation; disassembly/
assembly and adjustment
Chapter 9 Cassette Unit: principles of operation of the pickup system; disas-
sembly/assembly and adjustments
Chapter 10 Inner 2-Way Tray: principles of operation; disassembly/assembly and
adjustment
Chapter 11 Installation: site requirements and installation procedure
Chapter 12 Maintenance and
Inspection: table of periodically replaced parts, table of
durables, scheduled servicing chart
Chapter 13 Troubleshooting: maintenance and inspection, standards/adjustment,
troubleshooting image faults/malfunctions; service
mode, self diagnosis
Chapter 14 Version up: version up
Appendix: general timing chart, general circuit diagram

COPYRIGHT © 2002 CANON INC. 2001 2001 2001 2001 CANON iR1600/iR2000 REV.1 JAN. 2002
iii
INTRODUCTION
The descriptions are subject to change for product improvement, and major changes will
be communicated in the form of Service Information bulletins.
All service persons are expected to go through the contents of this Service Manual and
Service Information bulletins and have a good understanding of the machine, readying
themselves to promptly respond to the needs of the field (i.e., identifying and correcting
faults).

COPYRIGHT © 2002 CANON INC. 2001 2001 2001 2001 CANON iR1600/iR2000 REV.1 JAN. 2002
iv
INTRODUCTION
The descriptions in this Service Manual are based on he following rules:
1. In each chapter, the uses of the function in question and its relationship to electrical and
mechanical systems are discussed and the timing of operation of its associated parts is
explained by means of outlines and diagrams.
In the diagrams, the symbol represents a mechanical path, while the symbol
with a name next to it indicates the flow of an electric signal.
The expression “turn on the power” means turning on the power switch, closing the
front door, and closing the delivery door so that the machine will be supplied with
power.
2. In circuit diagrams (digital), a signal whose level is High is expressed as being ‘1’,
while a single whose level is Low is expressed as being ‘0’; the level of voltage, how-
ever, varies from circuit to circuit.
The machine uses CPUs, whose internal mechanisms cannot be checked in the field,
and, therefore, are not explained. In addition, the machine’s PCBs are not intended for
repairs at the user’s and, therefore, are explained by means of block diagrams: two types
are used, i.e., between sensors and inputs of PCBs equipped with a control or drive func-
tion and between outputs equipped with a control or drive function and loads; in addi-
tion, functional block diagrams are used at times.
Changes made to the machine for product improvement are communicated in the form of
a Service Information bulletin as needed. All service persons are expected to go through all
service documentation including the bulletins and be equipped to respond to the needs of the
field (as by being able to identify possible causes of problems).

COPYRIGHT © 2002 CANON INC. 2001 2001 2001 2001 CANON iR1600/iR2000 REV.1 JAN. 2002
v
INTRODUCTION
System Configuration
1. The machine may be configured as follows with its accessories (except the original/pa-
per feed device and boards):
F1 F2
[1] ADF-J1
[2] Finisher-L1 (if PDL output, requires hard disk.)
[3] Inner 2-Way Tray-B1
[4] 1-Cassette Unit-F1 (iR1600 only)
[5] 2-Cassette Unit-G1 (iR2000 only)
[6] 3-Cassette Unit-H1 (iR1600 only)
[7] Card Reader-E1
[2]
[1]
[6]
[5]
[3]
[4] [7]

COPYRIGHT © 2002 CANON INC. 2001 2001 2001 2001 CANON iR1600/iR2000 REV.1 JAN. 2002
vi
INTRODUCTION
2. The machine may be configured with the following accessory boards:
F3
[1] Printer Board-N1*
[2] Ethernet Network Interface Adapter iN-E5*
[3] Hard Disk HD-65
[4] Flash ROM Module FR-65
* : standard if printer model
Printer
Board
Ethernet
Board
Centronics interface
or USB interface
Hard
Disk
LAN interface
: Internal interface
: External interface
[3]
Flash ROM [2]
[1]
[4]

COPYRIGHT © 2002 CANON INC. 2001 2001 2001 2001 CANON iR1600/iR2000 REV.1 JAN. 2002
vii
INTRODUCTION
<Points to Note When Turning Off the Power Switch>
Be sure to turn off the power switch and disconnect the power plug before starting disas-
sembly/assembly work; further, keep the following in mind:
1. If you turn off the main power switch while a printer function is in use, the data being
processed can be lost. Check to be sure that the online LED in the control panel is OFF
before operating the power switch.
2. Do not turn off the power switch while downloading is taking place; otherwise, the ma-
chine may fail to operate.
3. Remember that not all power will be removed in response to the opening of the front
cover as long as the power switch remains ON.
4. Be sure to use SHUT DOWN MENU to shut down the printer if the Hard Disk HD-65
(accessory) has been installed.
[2]
[1]
F4
[1] Power switch
[2] Online LED

COPYRIGHT © 2002 CANON INC. 2001 2001 2001 2001 CANON iR1600/iR2000 REV.1 JAN. 2002
viii
CONTENTS
Contents
CHAPTER 1 INTRODUCTION
1 Features ............................................... 1-1
1.1 Features ...................................... 1-1
2 Specifications ...................................... 1-1
2.1 Copier ......................................... 1-3
2.1.1 Type ..................................... 1-3
2.1.2 System ................................. 1-3
2.1.3 Functions ............................. 1-4
2.1.4 Others .................................. 1-6
2.2 Cassette Unit .............................. 1-8
2.3 Inner 2-Way Tray ....................... 1-9
3 Names of Parts .................................. 1-10
3.1 External View ........................... 1-10
3.1.1 Copier ................................ 1-10
3.1.2 Cassette Unit ...................... 1-12
3.1.3 Inner 2-Way Tray ............... 1-13
3.2 Cross Section ........................... 1-14
3.2.1 Copier ................................ 1-14
3.2.2 Cassette Unit ...................... 1-16
3.2.3 Inner 2-Way Tray ............... 1-17
4 Control Panel .................................... 1-18
4.1 Control Panel ........................... 1-18
4.2 Basic Operation........................ 1-21
4.3 Extended Operation ................. 1-21
4.4 User Mode................................ 1-22
5 Cleaning by the User ........................ 1-30
5.1 Cleaning by the User ............... 1-30
5.1.1 Cleaning the
Fixing Roller ...................... 1-30
5.1.2 Cleaning the Copyboard Glass,
Reading Glass, and Copyboard
Cover White Plate ............. 1-32
6 Safety and Warnings ......................... 1-33
6.1 Safety of Laser Light ............... 1-33
6.2 CDRH Requirements ............... 1-33
6.3 Handling the Laser Unit ........... 1-34
6.4 Safety of the Toner ................... 1-35
7 Reproduction Processes .................... 1-36
7.1 Outline ..................................... 1-36
1 Basic Operation .................................. 2-1
1.1 Functional Construction ............. 2-1
1.2 Outline of Electrical Circuitry ... 2-2
1.2.1 Image Processor PCB .......... 2-2
1.2.2 DC Controller PCB.............. 2-3
1.2.3 Power Supply PCB .............. 2-5
1.2.4 Analog Processor PCB ........ 2-5
1.3 Inputs to and Outputs from
Electrical Components ................ 2-6
1.3.1 Wiring Diagram of the Major
PCBs .................................... 2-6
1.3.2 Wiring Diagram of the Electri-
cal Components (1/2) .......... 2-7
1.3.3 Wiring Diagram of Electrical
Components (2/2) ................ 2-8
1.4 Basic Sequence of Operation ..... 2-9
1.4.1 Outline ................................. 2-9
1.4.2 Basic Sequence of Operation
(power-on) ......................... 2-10
1.4.3 Basic Sequence of Operation
(printing) ............................ 2-11
1.5 Controlling the Main Motor
(M101) ..................................... 2-13
1.5.1 Outline ............................... 2-13
CHAPTER 2 BASIC OPERATION

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CONTENTS
1 Outline of Operation ........................... 3-1
1.1 Outline ....................................... 3-1
2 Reader Drive System .......................... 3-2
2.1 Outline ....................................... 3-2
2.2 Controlling the Reader Motor .... 3-3
2.2.1 Moving the Carriage in
Reverse After an
Image Scan .......................... 3-3
3 Detecting the Size of Originals........... 3-4
3.1 Outline ....................................... 3-4
3.2 Detection by the
Original Size Sensors ................. 3-4
3.3 Detecting the Size of
Originals..................................... 3-6
3.4 Detection by the ADF ................ 3-7
4 Image Processing ................................ 3-8
4.1 Outline ....................................... 3-8
4.2 Contact Sensor ........................... 3-9
4.2.1 Outline of the Contact
Sensor .................................. 3-9
4.2.2 Construction of the Contact
Sensor (CS) ........................ 3-10
4.3 A/D Conversion ....................... 3-11
4.4 Shading Correction .................. 3-11
4.4.1 Black Shading
Correction .......................... 3-12
4.4.2 White Shading
Correction .......................... 3-12
4.5 Re-Ordering ............................. 3-12
4.6 ABC
(auto background control) ........ 3-13
4.7 LED Intensity Adjustment ....... 3-14
4.8 Enlargement/Reduction............ 3-14
4.8.1 Enlargement/Reduction in Main
Scanning Direction ............ 3-14
4.8.2 Changing the Reproduction
Ratio in Sub Scanning
Direction ............................ 3-16
CHAPTER 3 IMAGE READING/PROCESSING SYSTEM
4.9 Edge Emphasis ......................... 3-17
4.10 Editing ...................................... 3-17
4.11 Density Conversion (LUT, i.e.,
look-up table processing) ......... 3-17
4.11.1 Density Adjustment
(F-value conversion) .......... 3-17
4.11.2 Density Correction
(g correction) ..................... 3-17
4.12 Binary Processing .................... 3-18
4.12.1 Error Diffusion .................. 3-18
4.13 Image Memory Control ........... 3-18
4.13.1 Compression/Expansion,
Rotation, and Enlargement/
Reduction ........................... 3-18
4.13.2 SDRAM ............................. 3-18
4.14 Output Image Processing ......... 3-19
4.14.1 Smoothing.......................... 3-19
5 Disassembly and Assembly .............. 3-20
5.1 Copyboard Glass ...................... 3-21
5.1.1 Removing the
Copyboard Glass................ 3-21
5.1.2 After Replacing the
Copyboard Glass................ 3-23
5.2 CS Unit .................................... 3-23
5.2.1 Removing the CS Unit ....... 3-23
5.2.2 Points to Note When
Mounting the CS Unit ....... 3-26
5.2.3 After Replacing the
CS Unit .............................. 3-28
5.2.4 Points to Note When
Handling the CS Unit ........ 3-29
5.3 Reader Motor ........................... 3-30
5.3.1 Removing the Reader
Motor ................................. 3-30
5.3.2 Points to Note When Mounting
the Reader Motor ............... 3-31

COPYRIGHT © 2002 CANON INC. 2001 2001 2001 2001 CANON iR1600/iR2000 REV.1 JAN. 2002
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CONTENTS
1 Outline of Operation ........................... 4-1
1.1 Outline ....................................... 4-1
1.2 Basic Sequence of Operation
(laser exposure system) .............. 4-3
2 Generating the Horizontal Signal ....... 4-4
2.1 Outline ....................................... 4-4
2.2 Signals Used .............................. 4-4
3 Laser Driver Circuit ............................ 4-6
3.1 Laser Control ............................. 4-6
CHAPTER 4 LASER EXPOSURE SYSTEM
4 Controlling the Scanner Motor ........... 4-8
4.1 Outline ....................................... 4-8
4.2 Controlling the Scanner
Motor ......................................... 4-8
4.3 Scanner Pre-Rotation ................. 4-9
5 Disassembly and Assembly .............. 4-10
5.1 Removing the Laser/
Scanner Unit ............................ 4-11
1 Outline of Processes ........................... 5-1
1.2 Sequence of Operation
(image formation system) .......... 5-3
2 1 Controlling the Primary Charging
Roller Bias .......................................... 5-4
2.1 Outline ....................................... 5-4
2.2 Turning On and Off the Bias...... 5-5
2.2.1 DC Bias ............................... 5-5
2.2.2 AC Bias ................................ 5-5
2.3 Bias Constant Voltage/
Constant Current Control ........... 5-5
2.3.1 DC Bias Constant Voltage
Control ................................. 5-5
2.3.2 AC Bias Constant Current
Control ................................. 5-5
3 Controlling the Developing Bias ........ 5-6
3.1 Outline ....................................... 5-6
3.2 Turning On/Off the Bias ............ 5-7
3.2.1 DC Bias ............................... 5-7
3.2.2 AC Bias ................................ 5-7
3.3 Controlling the Bias to a
Constant Voltage Level .............. 5-7
3.3.1 Controlling the Developing
DC Bias to a Constant
Level .................................... 5-7
3.3.2 Controlling the Developing
AC Bias to a Constant
Voltage Level ....................... 5-7
CHAPTER 5 IMAGE FORMATION SYSTEM
3.4 Controlling the Voltage Level of the
Developing DC Bias .................. 5-7
4 Controlling the Transfer
Charging Roller Bias .......................... 5-8
4.1 Outline ....................................... 5-8
4.2 Turning On and Off the Bias...... 5-9
4.2.1 Turning On and Off the
Positive DC Bias .................. 5-9
4.2.2 Turning On and Off the
Negative DC Bias ................ 5-9
4.3 Controlling the Bias to a Constant
Current /Voltage Level ............... 5-9
4.3.1 Controlling the DC Bias to a
Constant Current Level ........ 5-9
4.3.2 Controlling the DC Bias to a
Constant Level ..................... 5-9
4.4 Correcting the Voltage Level
(ATVC control) ........................ 5-10
4.5 Controlling the Output According to
Operation Mode ....................... 5-10
4.5.1 Type of Mode ..................... 5-10
5 Detecting the Presence/Absence of a Car-
tridge and the Level of Toner ............ 5-11
5.1 Outline ..................................... 5-11
5.2 Sequence of Detection
(level of toner) .......................... 5-12
6 Monitoring the Waste Toner Case ..... 5-14
6.1 Outline ..................................... 5-14

COPYRIGHT © 2002 CANON INC. 2001 2001 2001 2001 CANON iR1600/iR2000 REV.1 JAN. 2002
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CONTENTS
1 Outline ................................................ 6-1
1.1 Specifications and Constructions
................................................... 6-1
1.2 Arrangement of Major Rollers and
Sensors ....................................... 6-2
2 Controlling the Pickup Assembly ....... 6-3
2.1 Controlling the Pickup from the
Cassette ...................................... 6-3
2.1.1 Outline ................................. 6-3
2.1.2 Pickup form the Cassette ..... 6-4
2.1.3 Pickup Retry ........................ 6-6
2.1.4 Detecting the Size of Paper in
the Cassette .......................... 6-7
2.2 Controlling the Pickup from the
Multifeeder Tray ........................ 6-8
2.2.1 Outline ................................. 6-8
2.2.2 Pickup from the Multifeeder
Tray ...................................... 6-9
2.2.3 Multifeeder Retry
Operation ........................... 6-11
2.2.4 Setting the Paper Size for the
Multifeeder Tray
(user mode) ........................ 6-11
3 Controlling the Registration
Roller ................................................. 6-12
3.1 Detecting the Leading Edge of
Paper ........................................ 6-12
4 Detecting Jams .................................. 6-13
4.1 Outline ..................................... 6-13
4.2 Sequence of Jam Detection ...... 6-14
4.2.1 Delay Jam .......................... 6-14
4.2.2 Stationary Jams .................. 6-16
4.2.3 Cover Open Jam ................ 6-17
CHAPTER 6 PICKUP/FEEDING SYSTEM
4.2.4 Jam History ........................ 6-17
5 Disassembly and Assembly .............. 6-18
5.1 Cassette Pickup Assembly ....... 6-19
5.1.1 Remove the Cassette Pickup
Assembly ........................... 6-19
5.1.2 Removing the Cassette
Pickup Roller ..................... 6-21
5.1.3 Removing the Feeding/
Separation Roller ............... 6-22
5.1.4 Removing the Cassette
Pickup Solenoid ................. 6-22
5.1.5 Removing the Paper Size
Detecting Switch ............... 6-22
5.1.6 Removing the Cassette
Paper Sensor ...................... 6-23
5.1.7 Removing the Retry
Sensor ................................ 6-23
5.1.8 Removing the Pickup Motor
(iR2000 only)..................... 6-23
5.2 Multifeeder Tray Assembly ..... 6-24
5.2.1 Removing the Multifeeder
Tray .................................... 6-24
5.2.2 Removing the Manual feed
Pickup Roller ..................... 6-25
5.2.3 Removing the Separation
Pad ..................................... 6-26
5.2.4 Removing the Multifeeder
Paper Sensor ...................... 6-26
5.2.5 Removing the Multifeeder
Pickup Solenoid ................. 6-27
5.3 Drive Assembly ........................ 6-27
5.3.1 Removing the Drive
Assembly ........................... 6-27
6.2 Sequence of Operation ............. 5-15
7 Disassembly and Assembly .............. 5-16
7.1 Photosensitive Drum ................ 5-17
7.1.1 Removing the Drum
Unit .................................... 5-17
7.1.2 Cleaning the
Photosensitive Drum .......... 5-17
7.2 Developing Assembly .............. 5-18
7.2.1 Removing the Developing
Assembly ........................... 5-18
7.3 Transfer Roller ......................... 5-20
7.3.1 Removing the Transfer
Roller ................................. 5-20

COPYRIGHT © 2002 CANON INC. 2001 2001 2001 2001 CANON iR1600/iR2000 REV.1 JAN. 2002
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CONTENTS
1 Outline of Operation ........................... 7-1
1.1 Outline ....................................... 7-1
2 Controlling the Fixing Temperature ... 7-3
2.1 Outline ....................................... 7-3
2.2 Controlling the Temperature ...... 7-4
2.2.1 Control at Time of Power-On
............................................. 7-5
2.2.2 Control According to the
Type of Paper ....................... 7-6
2.2.3 Control at Time of Down
Sequence .............................. 7-6
2.2.4 Control in ESS
(energy save mode) .............. 7-7
2.3 Detecting an Error ...................... 7-8
2.3.1 Outline ................................. 7-8
2.3.2 Control in Response to an
Error ..................................... 7-8
CHAPTER 7 FIXING SYSTEM
2.3.3 Conditions for Error
Detection.............................. 7-8
2.4 Protective Mechanism .............. 7-10
3 Disassembly and Assembly .............. 7-11
3.1 Removing the Fixing
Assembly ................................. 7-12
3.2 Cleaning the Inside of the
Fixing Assembly or Replacing
Its Parts .................................... 7-15
3.3 Removing the Delivery Sensor 7-15
3.4 Removing the Pressure Roller . 7-16
3.5 Removing the Fixing Roller/
Fixing Heater/Separation
Claw ......................................... 7-22
3.6 Mounting the Fixing Roller/
Fixing Heater/Separation
Claw ......................................... 7-24
5.4 Registration Roller
Assembly ................................. 6-31
5.4.1 Removing the Registration
Roller ................................. 6-31
5.4.2 Removing the Registration
Paper Sensor ...................... 6-32
5.4.3 Removing the Registration
Clutch ................................ 6-33
1 Control Panel ...................................... 8-1
1.1 The machine’s control panel
has the following construction .... 8-1
2 Power supply ...................................... 8-2
2.1 Power Supply ............................. 8-2
2.1.1 Outline ................................. 8-2
2.1.2 Rated Outputs from the Power
Supply PCB ......................... 8-4
2.2 Protective Mechanisms .............. 8-5
2.3 High-Voltage Power Supply
Circuit ........................................ 8-5
CHAPTER 8 EXTERNALS AND AUXILIARY
CONTROL SYSTEM
3 Control at Time of Energy
Save Mode .............................................. 8-6
3.1 Outline ....................................... 8-6
3.2 Control ....................................... 8-6
3.3 Operation ............................. 8-8
4 Fan ....................................... 8-9
4.1 Outline ................................. 8-9
4.2 Control ............................... 8-10
4.2.1 Controlling the Speed ........ 8-10
4.2.2 Error Detection .................. 8-11
4.2.3 Sequence of Operation
(fan drive) .......................... 8-11

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CONTENTS
1 Outline ................................................ 9-1
1.1 Outline ....................................... 9-1
1.2 Specifications and
Construction ............................... 9-1
1.3 Arrangement of Major Rollers
and Sensors ................................ 9-2
2 Pickup Assembly ................................ 9-4
2.1 Pickup Control System .............. 9-4
2.2 Pickup Control ........................... 9-7
2.3 Cassette Pickup Operation ......... 9-7
2.4 Pickup Re-Try Operation ........... 9-7
2.5 Cassette Paper Size Detection.... 9-7
3 Detecting Jams .................................... 9-8
3.1 Outline ....................................... 9-8
3.2 Sequence of Jam Detection ........ 9-8
3.1.1 Delay Jam ............................ 9-8
3.1.2 Stationary Jam ..................... 9-8
3.1.3 Jam History .......................... 9-8
4 Disassembly and Assembly ................ 9-9
4.1 Removing the Cassette Unit ..... 9-10
CHAPTER 9 CASSETTE UNIT
4.2 Cassette Pickup
Assembly ........................... 9-12
4.2.1 Removing the Cassette
Pickup Assembly ............... 9-12
4.2.2 Removing the Cassette
Pickup Roller ..................... 9-12
4.2.3 Removing the Cassette
Pickup Solenoid ................. 9-12
4.2.4 Removing the Paper Size
Switch ................................ 9-12
4.2.5 Removing the Cassette
Paper Sensor ...................... 9-12
4.2.6 Removing the Re-Try
Sensor ................................ 9-12
4.3 PCBs ........................................ 9-13
4.3.1 Removing the Cassette Unit
Controller PCB .................. 9-13
4.4 Drive-Related Parts .................. 9-13
4.4.1 Removing the Pickup
Motor ................................. 9-13
5 Back-Up Battery ................................ 8-12
5.1 Back-Up Mechanism ............... 8-12
5.1.1 Outline ............................... 8-12
5.1.2 Lithium Battery (BAT1) .... 8-13
5.2 Back-Up Data .......................... 8-15
5.2.1 Types of Data ..................... 8-15
5.2.2 Printing Out the Back-Up
Data List ............................ 8-16
6 Disassembly and Assembly .............. 8-17
6.1 External Covers ........................ 8-18
6.1.1 Removing the Front
Cover ................................. 8-20
6.1.2 Removing the Control
Panel Lower Cover ............ 8-20
6.2 Control Panel ........................... 8-21
6.2.1 Removing the Control
Panel .................................. 8-21
6.3 Main Motor .............................. 8-22
6.3.1 Removing the Main
Motor ................................. 8-22
6.4 Fan ........................................... 8-23

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CONTENTS
1 Selecting the Site of Installation ....... 11-1
2 Unpacking and Installing the
Machine ............................................ 11-3
2.1 Points to Note Before Starting
the Work ................................... 11-3
2.2 Installing the Machine ............. 11-4
2.3 Unpacking and Removing the
Fixing Members ....................... 11-5
2.4 Removing the Dummy
Drum ........................................ 11-7
2.5 Mounting the Drum Unit ......... 11-9
2.6 Mounting the Toner
Cartridge ................................. 11-11
2.7 Putting Paper in the
Cassette .................................. 11-14
2.8 Placing Paper in the
Multifeeder Tray .................... 11-18
2.9 Checking the Copy Images ..... 11-20
CHAPTER 11 INSTALLATION
2.10 Data Initialization through
Service Operation .................. 11-21
2.11 Setting the Date/Time
(user mode) ............................ 11-22
2.12 Storing the Specifications
Report..................................... 11-23
2.13 Checking the Printer Functions
(if equipped with printer
functions) ............................... 11-24
3 Relocating the Machine .................. 11-25
4 Installing the Card Readere-E1
(accessory) ...................................... 11-26
4.1 Points to Note for
Installation .............................. 11-26
4.2 Installation ............................. 11-27
5 Installing the Image RAM
(accessory) ...................................... 11-31
5.1 Installation ............................. 11-31
1 Specifications .................................... 10-1
1.1 System ...................................... 10-1
1.2 Arrangement of Rollers and
Sensors ..................................... 10-2
2 Controlling Delivery Operation ........ 10-3
2.1 Controlling Delivery Operation
................................................. 10-3
2.2 Selecting a Delivery Slot
(user mode) .............................. 10-3
CHAPTER 10 INNER 2-WAY TRAY
3 Detecting Jams .................................. 10-4
3.1 Outline ..................................... 10-4
3.2 Sequence of Jam Detection ...... 10-4
3.2.1 Delay Jam .......................... 10-4
3.2.2 Stationary Jam ................... 10-4
3.2.3 Jam History ........................ 10-4
4 Disassembly and Assembly .............. 10-5
4.1 Removing the Inner 2-Way
Unit .......................................... 10-6

COPYRIGHT © 2002 CANON INC. 2001 2001 2001 2001 CANON iR1600/iR2000 REV.1 JAN. 2002
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CONTENTS
1 ImageAdjustment Basic
Procedure .......................................... 13-1
1.1 Image Adjustment Basic
Procedure ................................. 13-1
2 Standards and Adjustments ............... 13-3
2.1 Image Adjustments .................. 13-3
2.1.1 Standards for Image
Position .............................. 13-3
2.1.2 Adjusting the Image
Position .............................. 13-4
2.1.3 Adjusting the Leading Edge
Margin for the Printer Unit
(if equipped printer
functions) ........................... 13-5
2.1.4 Adjusting the Image
Position for Copying.......... 13-7
2.2 Fixing System .......................... 13-9
2.2.1 Checking the Fixing Roller
Pressure (nip) ..................... 13-9
2.3 Electrical Parts ....................... 13-10
2.3.1 When Replacing the
Major Parts ...................... 13-10
2.3.2 Gain Auto Adjustment ..... 13-10
2.3.3 When Replacing the
Contact Sensor ................. 13-10
2.3.4 When Replacing the
Image Processor PCB ...... 13-11
CHAPTER 13 TROUBLESHOOTING
2.3.5 When Replacing the DC
Controller PCB ................ 13-12
2.3.6 When Replacing the Analog
Processor PCB ................. 13-12
2.4 Checking the Sensors ............. 13-13
2.4.1 Checking the Sensors ...... 13-13
3 Troubleshooting Image/Operation
Faults............................................... 13-16
3.1 Making Initial Checks on
Image Faults ........................... 13-16
3.1.1 Site of Installation............ 13-16
3.1.2 Checking the Originals .... 13-16
3.1.3 Copyboard Cover and
Copyboard Glass (standard
white plate) ...................... 13-16
3.1.4 Checking the Transfer
Charging Roller/Static
Eliminator ......................... 13-17
3.1.5 Checking the Drum Unit . 13-17
3.1.6 Checking the Paper .......... 13-17
3.1.7 Image Adjustment Basic
Procedure ......................... 13-17
3.1.8 Others .............................. 13-17
3.2 Image Fault Samples .............. 13-20
3.3 Troubleshooting Image
Faults ...................................... 13-21
1 Periodically Replaced Parts .............. 12-1
1.1 Copier ....................................... 12-1
1.2 Cassette Unit ............................ 12-1
1.3 Inner 2-Way Tray ..................... 12-1
2 Guide to Durables ............................. 12-2
2.1 Checking the Timing of Replace-
ment ......................................... 12-2
2.2 Copier ....................................... 12-2
2.3 Cassette Unit ............................ 12-2
2.4 Inner 2-Way Tray ..................... 12-2
3 Basic Service Work ........................... 12-3
CHAPTER 12 MAINTENANCE AND INSPECTION
3.1 Basic Service Work .................. 12-3
4 Cleaning During a Visit .................... 12-4
5 Points to Note When Storing/Handling
the Drum Unit ................................... 12-7
5.1 Outline ..................................... 12-7
5.2 Storage and Handing After Remov-
ing the Packaging Seal ............. 12-7
5.2.1 Storage After Removing the
Packaging Seal ................... 12-7
5.2.2 Points to Note When Handling
the Drum Unit .................... 12-8

COPYRIGHT © 2002 CANON INC. 2001 2001 2001 2001 CANON iR1600/iR2000 REV.1 JAN. 2002
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CONTENTS
3.3.1 The copy is too light.
(halftone only) ................. 13-21
3.3.2 The copy is too light.
(both halftone and solid
black) ............................... 13-21
3.3.3 The copy is too light.
(entire copy,
appreciably) ...................... 13-21
3.3.4 The copy has uneven density.
(darker along front).......... 13-24
3.3.5 The copy has uneven density.
(lighter along front) ......... 13-24
3.3.6 The copy is foggy.
(entire copy) ..................... 13-25
3.3.7 The copy is foggy.
(feeding direction). .......... 13-26
3.3.8 The copy has black lines.
(feeding direction,
fuzzy, thick) ...................... 13-26
3.3.9 The copy has black lines.
(feeding direction, fine) .... 13-26
3.3.10 The copy has white strips.
(feeding direction) ........... 13-27
3.3.11 The copy has white lines.
(feeding direction) ............ 13-27
3.3.12 The output has white strips.
(cross-feeding
direction) .......................... 13-28
3.3.13 The back of the copy
is soiled. ........................... 13-29
3.3.14 The copy has a poor
fixing. ............................... 13-30
3.3.15 The copy has displaced
registration. (leading
edge extremely excessive
margin). ............................ 13-31
3.3.16 The copy has displaced
registration. (leading edge,
excessive margin) ............ 13-31
3.3.17 The copy has displaced
registration. (leading edge,
no margin)........................ 13-31
3.3.18 The copy has blurred
images. ............................. 13-32
3.3.19 The copy is foggy. (cross-
feeding direction) ............. 13-33
3.3.20 The copy has poor
sharpness. ........................ 13-34
3.3.21 The copy is blank............. 13-35
3.3.22 The copy is solid black. ... 13-36
3.4 Troubleshooting
Malfunctions .......................... 13-37
3.4.1 AC power is absent. ......... 13-37
3.4.2 DC power is absent. ......... 13-38
3.4.3 Pickup operation fails.
(cassette) .......................... 13-39
3.4.4 Pickup operation fails.
(multifeeder tray) ............. 13-40
3.4.5 Pickup operation fails.
(cassette unit) ................... 13-41
3.4.6 The vertical path roller
fails to rotate. .................... 13-42
3.4.7 The registration roller
fails to rotate. .................... 13-42
3.4.8 The contact sensor fails
to go ON. ......................... 13-43
3.4.9 The speaker fails to
operate. ............................. 13-43
3.4.10 The ‘Add Toner’ message
fails to go OFF. ................ 13-44
3.4.11 The ‘Add Paper’ message
fails to go OFF. (machine
and cassette unit) ............. 13-45
3.4.12 The ‘Add Paper’ message
fails to go OFF.
(multifeeder tray) .............. 13-46
3.4.13 The ‘Jam’ message fails
to go OFF. ........................ 13-46
3.4.14 The ‘Waste Toner Full’
message does not go
OFF. ................................. 13-47
3.4.15 The ‘Controller Card Set’
message does not
go ON. ............................. 13-47
3.4.16 The ‘Control Card Set’
message does not go
OFF. ................................. 13-47
3.5 Troubleshooting Feeding
Faults ...................................... 13-48

COPYRIGHT © 2002 CANON INC. 2001 2001 2001 2001 CANON iR1600/iR2000 REV.1 JAN. 2002
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CONTENTS
3.5.1 Outline ............................. 13-48
3.5.2 Pickup Assembly ............. 13-49
3.5.3 Transfer/Feeding
Assembly ......................... 13-50
3.5.4 Fixing/Delivery
Assembly ......................... 13-51
3.5.5 Feeding Fault
(double feeding) ............... 13-52
3.5.6 Feeding Faults
(wrinkling) ....................... 13-53
4 Arrangement and Functions
of Electrical Parts ............................ 13-54
4.1 Outline ................................... 13-54
4.1.1 Outline ............................. 13-54
4.1.2 Checking the Sensors ...... 13-54
4.2 Clutches, Solenoids, Motors,
and Fans ................................. 13-55
4.3 Sensors ................................... 13-56
4.4 PCBs ...................................... 13-57
4.5 Switches, Others .................... 13-59
4.6 Cassette Unit .......................... 13-61
4.7 Inner 2-Way Tray ................... 13-63
4.8 Variable Resistors (VR),
Light-Emitting Diodes
(LED), and Check Pins .......... 13-64
4.8.1 Image Processor PCB ...... 13-65
4.8.2 DC Controller PCB.......... 13-66
4.8.3 Power Supply PCB .......... 13-67
4.8.4 Analog Processor PCB .... 13-68
4.8.5 1-Cassette Unit Controller
PCB.................................. 13-69
4.8.6 2/3-Cassette Unit
Controller PCB ................ 13-69
5 Service Mode .................................. 13-70
5.1 Outline ................................... 13-70
5.2 Using the Mode ...................... 13-72
5.3 Service Mode Menus ............. 13-73
5.4 Setting the parameters ............ 13-77
5.4.1 Registering the Bit Switch
(#1 SSSW) ....................... 13-77
5.4.2 Setting Numeric Parameters
(#3 NUMERIC Param.) ... 13-79
5.4.3 Selecting the Country/Region of
Installation (#5 TYPE)..... 13-82
5.4.4 Setting Original Read Functions
(#6 SCANNER) ............... 13-83
5.4.5 Setting the Printer Parameters
(#7 PRINTER) ................. 13-86
5.4.6 PDL (#8 PDL) ................. 13-86
5.4.7 Counters
(#9 COUNTER) .............. 13-87
5.4.8 Generating a Report
(#10 REPORT) ................ 13-90
5.4.9 Downloading
(#11 DOWNLOAD) ........ 13-91
5.4.10 Clear (#12 CLEAR) ......... 13-92
5.4.11 ROM Indication
(#13 ROM) ...................... 13-93
5.4.12 Resetting the CS Unit
Position (#14 CS SET) .... 13-93
5.5 Test Mode (TEST MODE) .... 13-94
5.5.1 Outline ............................. 13-94
5.5.2 Test Mode Menu .............. 13-95
5.5.3 D-RAM Test
(1: D-RAM) ..................... 13-98
5.5.4 CCD Test
(2: CCD TEST) .............. 13-100
5.5.5 PRINT Test (3: PRINT) . 13-101
5.5.7 Faculty Test (6: FACULTY
TEST) ............................ 13-102
5.5.8 Book Read Test
(8: BOOK TEST) .......... 13-108
5.6 Report ................................... 13-109
5.6.1 User report ..................... 13-109
5.6.2 Service Report ............... 13-110
6 Self Diagnosis ............................... 13-117
6.1 Outline ................................. 13-117
6.2 Error Codes .......................... 13-118
6.2.1 Error Codes Used for
the Machine .................... 13-118
6.2.2 Finisher Error Codes...... 13-123

COPYRIGHT © 2002 CANON INC. 2001 2001 2001 2001 CANON iR1600/iR2000 REV.1 JAN. 2002
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CONTENTS
1 Upgrading ......................................... 14-1
1.1 Outline ..................................... 14-1
2 Upgrading by Downloading ............. 14-3
2.1 Before Starting the Work ......... 14-3
2.2 Installing the USB Driver
(only if Windows 98 or
Windows 98SE) ....................... 14-4
CHAPTER 14 VERSION UP
2.3 Installing the Firmware ............ 14-7
2.4 Downloading the System
Software ................................. 14-10
2.5 Downloading for the
Finisher-L1 ............................. 14-17
2.5.1 Outline ............................. 14-17
2.5.2 Downloading ................... 14-18
A General Timing Charts ....................... A-1
B General Circuit Diagram ................... A-3
C 1-cassette unit .................................... A-5
D 2/3-cassette unit ................................. A-6
APPENDIX
E Inner 2-way tray................................. A-7
F Special Tools ...................................... A-9
G Solvents and Oils ............................. A-11