Canon GP160F User manual

SERVICE
MANUAL
REVISION 0
FY8-13G2-000
FEB. 1999
COPYRIGHT © 1999 CANON INC. CANON GP160 REV.0 FEB. 1999 PRINTED IN JAPAN (IMPRIME AU JAPON)
GP160F/160DF/160

IMPORTANT
THIS DOCUMENTATION IS PUBLISHED BY CANON INC., JAPAN, TO SERVE AS A SOURCE OF
REFERENCE FOR WORK IN THE FIELD.
SPECIFICATIONS AND OTHER INFORMATION CONTAINED HEREIN MAY VARY SLIGHTLY
FROM ACTUAL MACHINE VALUES OR THOSE FOUND IN ADVERTISING AND OTHER PRINTED
MATTER.
ANY QUESTIONS REGARDING INFORMATION CONTAINED HEREIN SHOULD BE DIRECTED
TO THE COPIER SERVICE DEPARTMENT OF THE SALES COMPANY.
THIS DOCUMENTATION IS INTENDED FOR ALL SALES AREAS, AND MAY CONTAIN INFORMA-
TION NOT APPLICABLE TO CERTAIN AREAS.
COPYRIGHT © 1999 CANON INC.
Printed in Japan
Imprimé au Japon
Use of this manual should
be strictly supervised to
avoid disclosure of confiden-
tial information.
Prepared by
OFFICE IMAGING PRODUCTS TECHNICAL SUPPORT DEPARTMENT 3
OFFICE IMAGING PRODUCTS TECHNICAL SUPPORT DIVISION
CANON INC.
5-1, Hakusan 7-chome, Toride-shi, Ibaraki 302-8501 Japan
COPYRIGHT © 1999 CANON INC. CANON GP160 REV.0 FEB. 1999 PRINTED IN JAPAN (IMPRIME AU JAPON)

COPYRIGHT © 1999 CANON INC. CANON GP160 REV.0 FEB. 1999 PRINTED IN JAPAN (IMPRIME AU JAPON)
This service manual provides basic information required for performing field service
to maintain the product quality and functions of the this machine. The structure of the
manual is as described below.
Each chapter consists of the following sections.
Chapter 1, “Introduction,” : Features, specifications, operation methods, copying
process.
Chapter 2, “Basic operation,” : Explanation of the machine’s basic operations
Chapter 3, “Exposure system,” : Explanation of the exposure system’s mechanical /
electrical system operating principles, timing, disassembly, assembly and adjustment
methods.
Chapter 4, “Image processing system,” : Explanation of the CCD, analogue / digital
image processing, disassembly, assembly and adjustment methods.
Chapter 5, “Laser exposure system,” : Explanation of the laser exposure system’s
mechanical / electrical system operating principles, timing, disassembly, assembly and
adjustment methods.
Chapter 6, “Image formation system,” : Explanation of the image formation system’
mechanical / electrical system operating principles, timing, disassembly, assembly and
adjustment methods.
Chapter 7, “Pick-up / Feed system,” : Explanation of the pick-up / feed system’
mechanical / electrical system operating principles, timing, disassembly, assembly and
adjustment methods.
Chapter 8, “Fixing system,” : Explanation of the fixing system’s mechanical / electri
cal system operating principles, timing, disassembly, assembly and adjustment meth
ods.
Chapter 9, “Outer cover / auxiliary control system,” : Explanation of the outer cover
auxiliary control system’s mechanical / electrical system operating principles, timing
disassembly, assembly and adjustment methods.
Chapter 10, “Cassette feeder,” : Explanation of the cassette feeder’s mechanical
electrical system operating principles, timing, disassembly, assembly and adjustmen
methods.
Chapter 11, “Installation,” : Conditions relating to the place of installation, and the
installation procedures.
INTRODUCTION
Material Name
Main unit service manual
G3 FAX manual
ADF
Content
The main unit and cassette feeder’s; functions, mechanism,
disassembly, assembly, adjustment methods, etc.
The main unit’s G3 facsimile functions.
The functions, mechanism, disassembly, assembly, adjust-
ment method, etc. of the main unit’s ADF.
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COPYRIGHT © 1999 CANON INC. CANON GP160 REV.0 FEB. 1999 PRINTED IN JAPAN (IMPRIME AU JAPON)
Chapter 12, “Maintenance and Inspection,” :Table of periodic replacement parts and
consumables replacement targets, periodic service list and parts to be cleaned during a
customer service call.
Chapter 13, “Troubleshooting,” : Standards / adjustments, operation failure counter-
measures and delivery failure countermeasures
Appendix : General timing chart, general circuit diagram, etc..
The explanations in this manual are based on the following principles.
1. Each chapter gives an overview of each function’s purpose, role and the connection
between the electrical and mechanical systems as well as the operation timing of
each part.
In the outline diagram, the signal shows the mechanical drive transmission.
When the signal is shown with a signal name, it indicates the electric signal
flow.
In the explanation of this units digital circuit, “1” is indicated when the signal’s volt-
age level is high, and “0” is indicated when it is low. However, the voltage value will
differ depending on the electrical circuit. Furthermore, the * in the signal value
[DRMD*] shows the DRMD signal is “0” and ON.
In each chapter, [Power supply ON] indicates the power supply SW has been turned
“ON”, the front door, etc., has been shut, and power is being supplied to the copier.
2. This unit utilizes micro processors, however, due to the impossibility of checking the
micro processor’s internal operation, an explanation of the micro processor’s opera-
tion has been omitted. Furthermore, assuming that internal repair of the print circuit
board will not take place on the customer’s premises, the explanation of the circuit in
the print circuit board’s circuit is limited to an outline explanation using a block dia-
gram. Consequently, the electrical circuit explanations consist of 2 types, from the
sensors to the main circuit board’s input section, and from the main circuit board’s
output section to the load, and block diagrams by function.
Changes of the contents made for the sake of product improvements will be notified
in Service Information (Technical Information).
Gaining a sound and thorough understanding of the copier through careful reading
of this service manual and the subsequently issued Service Information (Technical
Information) bulletins is the only way to develop the technical skill necessary to prolong
product quality and functionality and the practical ability to be able to determine the
cause of breakdowns.
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System configuration
999 PRINTED IN JAPAN (IMPRIME AU JAPON)
Main unit configuration
ADF-H1
Cassette Unit D1
Cassette unit E1
Modem board NCU board Modular
board
Super G3 FAX board
8MB expanded memory
Digital black and white copier and facsimile
Digital black and white copier (with ADF)
Digital black and white copier
(Copy board cover model)
Installation options
Standard equipment Standard equipment Option
Option Option Option Option Option Option Option Option
Option Option
Standard equipment
Option
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GP160F GP160DF GP160

C ED IN JAPAN (IMPRIME AU JAPON)
iv

CONTENTS
CHAPTER 1 INTRODUCTION
CHAPTER 2 BASIC OPERATION
I. FEATURES..............................................1-1
II. SPECIFICATIONS...................................1-2
III. NAMES OF PARTS .................................1-6
A. External view......................................1-6
B. Cross sectional diagram ....................1-8
IV. OPERATION EXPLANATION................1-10
A. Control panel....................................1-10
B. Basic operation ................................1-13
C. Advanced features...........................1-13
D. User mode .......................................1-14
V. ROUTINE MAINTENANCE TO BE
CARRIED OUT BY THE USER .............1-32
VI. SAFETY.................................................1-33
A. Laser beam safety.......................1-33
B. Toner safety.....................................1-36
VII. COPYING PROCESS............................1-37
A. Outline..............................................1-37
I. BASIC OPERATION................................2-1
A. Function configuration........................2-1
B. Copy operation overview ...................2-2
II. ELECTRICAL CIRCUIT OVERVIEW.......2-3
III. BASIC SEQUENCES...............................2-4
IV. MAIN MOTOR..........................................2-5
V. PRINCIPAL CIRCUIT PCB
INPUT/OUTPUT.......................................2-6
CHAPTER 3 EXPOSURE SYSTEM
CHAPTER 4 IMAGE PROCESSING SYSTEM
I. OPERATION OVERVIEW........................3-1
A. Overview............................................3-1
B. Exposure system sequence...............3-2
II. SCANNER DRIVE SYSTEM....................3-3
A. Document scanner motor...................3-3
B. Charging the magnification ratio ........3-4
C. Scanning lamp control .......................3-4
III. DISASSEMBLY, ASSEMBLY ..................3-5
A. Scanning lamp ...................................3-6
B. Document scanning motor.................3-8
I. OVERVIEW..............................................4-1
II. ANALOG IMAGE PROCESSING.............4-2
A. Overview............................................4-2
B. CCD/CCD drive circuit .......................4-2
C. A-D conversion circuit /
ABC circuit .........................................4-3
III. DIGITAL IMAGE PROCESSING..............4-4
A. Overview............................................4-4
B. Shading correction.............................4-5
C. Magnification ratio process ................4-7
D. Edge emphasis / smoothing
process ..............................................4-7
E. Logarithmic correction........................4-8
F. Half tone density processing..............4-9
G. Binarisation ........................................4-9
IV. DISASSEMBLY, ASSEMBLY ................4-10
A. CCD unit ..........................................4-11
0 FEB. 1999 PRINTED IN JAPAN (IMPRIME AU JAPON)
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COPYRIGHT © 1999 CANON INC. CANON GP160 REV.0 FEB. 1999 PRINTED IN JAPAN (IMPRIME AU JAPON)
CHAPTER 5 LASER EXPOSURE SYSTEM
OVERVIEW..............................................5-1
. BD SIGNAL GENERATION.....................5-3
A. Overview............................................5-3
B. BD generation / detection ..................5-3
I. LASER DRIVER CIRCUIT.......................5-4
A. Operation ...........................................5-4
B. Laser light intensity control ................5-4
IV. LASER SCANNER MOTOR
CONTROL................................................5-6
A. Operation outline................................5-6
V. DISASSEMBLY, ASSEMBLY ..................5-7
A. Laser scanner unit .............................5-8
CHAPTER 6 IMAGE FORMATION SYSTEM
CHAPTER 7 PICK-UP / FEEDING SYSTEM
CHAPTER 8 FIXING SYSTEM
OVERVIEW..............................................6-1
A. Construction.......................................6-1
. PRIMARY CHARGING ROLLER BIAS
CONTROL................................................6-3
A. Outline ...............................................6-3
B. Control operation ...............................6-3
I. TRANSFER CHARGING ROLLER BIAS
CONTROL................................................6-4
A. Overview............................................6-4
B. Bias control ........................................6-5
IV. SEPARATION STATIC CHARGE
ELIMINATOR BIAS CONTROL ...............6-6
A. Operation ...........................................6-6
V. DEVELOPING BIAS CONTROL..............6-7
A. Outline ...............................................6-7
B. Operation ...........................................6-7
VI. RE-CHARGE BIAS CONTROL................6-8
A. Operation ...........................................6-8
VII. CARTRIDGE DETECTION......................6-9
A. Operation ...........................................6-9
I. OVERVIEW..............................................7-1
A. Construction Overveiw.......................7-1
II. PICK-UP FEEDING OPERATION ...........7-2
A. Overveiw............................................7-2
III. CASSETTE PICK-UP MECHANISM........7-3
A. Pick-up oparation...............................7-3
B. Retry pick-up......................................7-5
C. Paper size detection ..........................7-6
IV. MULTI-FEEDER PICK-UP.......................7-7
A. Overview............................................7-7
B. Multi-feeder pick-up mechanism........7-8
C. Multi-feeder retry pick-up ...................7-9
D. Multi-feeder paper size setting.........7-10
V. PAPER FEEDING OPERATION............7-12
A. Paper leading edge detection ..........7-12
B. Paper width detection ......................7-12
VI. JAM DETECTION..................................7-13
A. Overview..........................................7-13
B. Types of Jam ...................................7-14
C. Jam sequence..................................7-14
VII. DISASSEMBLY, ASSEMBLY ................7-23
A. Cassette feeding assembly..............7-24
B. Multi-feeder assembly......................7-30
C. Registration roller assembly.............7-33
D. Feeder assembly .............................7-35
I. OPERATIONAL OVERVIEW...................8-1
A. Overview............................................8-1
B. Fixing pressure roller cleaning...........8-1
II. FIXING CONTROL...................................8-3
A. Fixing temperature control .................8-3
B. Fixing heater safety mechanism ........8-5
C. Fixing assembly malfunction
detector..............................................8-5
III. DISASSEMBLY, ASSEMBLY ..................8-6
A. Removing the fixing assembly ...........8-7
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COPYRIGHT © 1999 CANON INC. CANON GP160 REV.0 FEB. 1999 PRINTED IN JAPAN (IMPRIME AU JAPON)
CHAPTER 9 EXTERNAL / AUXILIARY MECHANISM
CHAPTER 10 CASSETTE FEEDER
CHAPTER 11 INSTALLATION
CHAPTER 12 MAINTENANCE AND INSPECTION
I. CONTROL PANEL...................................9-1
A. Overview............................................9-1
II. POWER SUPPLY ....................................9-2
A. Low-voltage power supply circuit.......9-2
B. High voltage power supply circuit ......9-4
C. Energy save function control..............9-5
III. FAN..........................................................9-7
A. Rotation control mechanism ..............9-7
IV. BACK-UP BATTERY................................9-8
A. Back-up function ................................9-8
B. Back-up Data ...................................9-12
V. DISASSEMBLY, ASSEMBLY ................9-16
A. Control panel....................................9-1
B. Main Motor.......................................9-19
C. DC controller PCB............................9-25
D. Image processor PCB......................9-26
E. DC power supply PCB .....................9-2
I. OVERVIEW............................................10-1
II. OVERVIEW OF THE ELECTRICAL
CIRCUITS..............................................10-3
A. Overview..........................................10-3
III. FEEDER CONTROLLER PCB
INPUT AND OUTPUT.............................10-4
IV. OPERATION OVERVIEW......................10-5
A. Overview..........................................10-5
B. Basic Sequence..............................10-6
V. FEEDER MOTOR CONTROL................10-7
A. Operation .........................................10-
VI. JAM DETECTION..................................10-8
A. Overview..........................................10-8
B. Jam Sensing ....................................10-9
VII. DISASSEMBLY, ASSEMBLY ..............10-11
A. Removing the feeder motor ...........10-12
B. Removing the pick-up/feeder/
separation motor............................10-12
C. Removing the pick-up unit .............10-14
I. CHOOSING AN SUITABLE INSTALLATION
LOCATION.............................................11-1
II. UNPACKING AND INSTALLATION.......11-3
A. Opening the package and removing
the packing materials.......................11-4
B. Installing the cartridge......................11-5
C. Loading paper into the cassette.......11-8
D. Loading paper into the
multi-feeder....................................11-11
E. Attaching the tray/Power cord........11-12
F. Checking the Copy image..............11-13
G. Setting the Fax machine function....11-13
I. PERIODIC REPLACEMENT PARTS.....12-1
II. ESTIMATED LIFESPAN OF CONSUMABLE
PARTS ...................................................12-1
III. BASIC SERVICING PROCEDURES.....12-2
IV. CARTRIDGE STORAGE AND
HANDLING.............................................12-3
A. Storage when the packing seal is
intact ................................................12-3
B. Storage and handling when the
packing seal has been opened ........12-4
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COPYRIGHT © 1999 CANON INC. CANON GP160
APPENDIX
CHAPTER 13 TROUBLESHOOTING
I. STANDARDS AND ADJUSTMENTS.....13-2
A. Machanical system ..........................13-2
B. Electrical System .............................13-9
II. IMAGE AND MACHINE MALFUNCTION
COUNTERMEASURES.......................13-15
A. Initial check ....................................13-15
B. Treatment procedures by faulty
image type .....................................13-17
C. Operation malfunction
countermeasures ...........................13-26
III. FAULTY FEEDING
COUNTERMEASURES.......................13-34
A. Overview........................................13-34
B. Copy paper jam..............................13-35
C. Faulty feeding ................................13-38
IV. ELECTRICAL PARTS POSITIONS/
FUNCTIONS........................................13-39
A. Clutches, solenoids........................13-40
B. Motor, fan.......................................13-42
C. Sensors..........................................13-44
D. Switches, lamps, miscellaneous ....13-46
E. PCBs..............................................13-48
F. Variable resistor(VR)/LED/check
pin listed by PCB plate...................13-50
V. SERVICE MODE..................................13-55
A. Overview........................................13-55
B. Operating Procedures....................13-56
C. Service mode menu list..................13-57
D. SSSW Default Setting....................13-63
E. Parameter settings.........................13-78
F. Test Mode (TEST MODE)............13-111
VI. REPORTS..........................................13-142
A. User reports .................................13-142
B. Service report...............................13-145
VII. USER ERRORS.................................13-163
VIII. SERVICE ERRORS...........................13-170
A. GENERAL TIMING CHART.....................A-1
B. SIGNALS AND ABBREVIATIONS...........A-3
C. GENERAL CIRCUIT DIAGRAM..............A-5
D. LIST OF SPECIAL TOOLS....................A-11
E. SOLVENTS AND OILS..........................A-12
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