Canon CLC5100 Series User manual

Jul 7 2004
Portable Manual
CLC5100 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 informa
tion 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 reference 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, however, 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 sen
sors 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 pur
poses, and major changes will be communicated in the form of Service Information bulletins.
All service persons are expected to have a good understanding of the contents of this Service Manual and all relevant
Service Information bulletins and be able to identify and isolate faults in the machine."

Contents
Contents
Chapter 1 Maintenance and Inspection
1.1 Periodically Replaced Parts ............................................................................................................................. 11
1.1.1 Periodically Replaced Parts..................................................................................................................... 11
1.1.2 Periodically Replaced Parts..................................................................................................................... 14
1.1.3 Periodically Replaced Parts(Ref for heavy paper) .................................................................................. 18
1.2 Durables and Consumables............................................................................................................................ 112
1.2.1 Consumables and Durables ................................................................................................................... 112
1.2.2 Consumables and Durables(Ref for heavy paper)................................................................................. 116
1.3 Scheduled Servicing Basic Procedure ........................................................................................................... 119
1.3.1 Scheduled Servicing Procedure............................................................................................................. 119
1.3.2 Scheduled Maintenance Chart............................................................................................................... 121
1.4 Cleaning......................................................................................................................................................... 128
1.4.1 Cleaning the Shutter.............................................................................................................................. 128
1.4.2 Cleaning the Developing Assembly Upper Cover ................................................................................ 129
1.4.3 Cleaning the LED.................................................................................................................................. 130
1.4.4 Cleaning the Transfer Blade.................................................................................................................. 131
1.4.5 Cleaning the Grounding Roller ............................................................................................................. 131
1.4.6 Cleaning the Developing Assembly Bottom Cover and the Bearing ................................................... 131
1.4.7 How to Clean the SALT Sensor............................................................................................................ 132
1.4.8 How to Disassemble and Clean the SALT Sensor Unit........................................................................ 133
Chapter 2 Standards and Adjustments
2.1 Image Adjustment Basic Procedure................................................................................................................. 21
2.1.1 Image Adjustment Basic Procedure ........................................................................................................ 21
2.1.2 Checking the Transfer System ................................................................................................................ 25
2.1.3 Checking the Latent Static Image Formation System............................................................................. 26
2.1.4 Checking the Developing System ........................................................................................................... 27
2.2 Image Adjustments .......................................................................................................................................... 28
2.2.1 NonImage Width.................................................................................................................................... 28
2.2.2 Image Margin .......................................................................................................................................... 28
2.2.3 Checking and Adjusting the NonImage Width and Margin .................................................................. 29
2.2.4 Adjusting the Image Reading Start Position (ADJXY) ....................................................................... 210
2.2.5 Adjusting the PickUp Timing (paper deck) ......................................................................................... 211
2.2.6 Image Positioning Correction................................................................................................................ 211
2.3 Scanning System............................................................................................................................................ 212
2.3.1 When Replacing the Scanning Lamp, Standard White Plate, Lamp Regulator, Reflecting Lamp
Cover, Reader Controller PCB, Flash memory on Reader controller PCB, or Analog Processor PCB
CCD Unit............................................................................................................................................... 212
2.3.2 Routing the Scanner Cable.................................................................................................................... 212
2.4 Laser Exposure System.................................................................................................................................. 215
2.4.1 When Replacing the Laser Unit ............................................................................................................ 215
2.4.2 When Replacing the Video Controller PCB.......................................................................................... 215
2.4.3 When Replacing the BD Unit................................................................................................................ 215
2.4.4 Adjusting the Laser Power .................................................................................................................... 215
2.4.5 Adjusting the Laser Intensity ................................................................................................................ 217
2.4.6 Laser Focus Adjustment........................................................................................................................ 218

Contents
2.5 Image Formation System ...............................................................................................................................220
2.5.1 Adjusting the Tension on the Drive Belt of the Transfer Belt Motor....................................................220
2.5.2 Adjusting the Position of the Transfer BeltRelated Solenoid ..............................................................220
2.5.3 Adjusting the Height of the Charging Wire...........................................................................................220
2.5.4 Replacing the Developer........................................................................................................................221
2.6 Fixing System.................................................................................................................................................224
2.6.1 Adjusting the Nip (fixing pressure adjusting nut) .................................................................................224
2.6.2 Adjusting the Mounting Position of the External Paper Delivery Unit Guide Plate.............................224
2.7 Electrical Components ...................................................................................................................................226
2.7.1 When Replacing the ROM on the DC Controller PCB or the Reader Controller PCB.........................226
2.7.2 When Replacing the Reader Controller PCB ........................................................................................226
2.7.3 When Replacing the DC Controller PCB ..............................................................................................226
2.7.4 Initializing the RAM on the DC controller PCB ...................................................................................227
2.7.5 Initializing the RAM on the Reader Controller PCB.............................................................................228
2.7.6 When Replacing the Image Position Correction CCD Unit ..................................................................228
2.7.7 When Replacing the Paper Thickness Sensor .......................................................................................228
2.7.8 After Replacing the PickUp Motor/PickUp Unit................................................................................229
2.7.9 Checking the Environment Measurement PCB.....................................................................................229
2.7.10 Checking the High Voltage Control System .........................................................................................230
2.7.11 Checking the Photointerrupters .............................................................................................................231
2.8 Pickup/Feeding System..................................................................................................................................237
2.8.1 Registering the Cassette/Multifeeder Paper Width Basic Setting (under 'FUNC') ...............................237
2.8.2 Adding the Pressure of the Cassette Separation Roller .........................................................................238
2.8.3 Adjusting the Position of the Cassette PickUp Roller Releasing Solenoid (SL9, SL10).....................238
2.8.4 Adding the Pressure of the Cassette Separation Roller .........................................................................239
2.8.5 Adjusting the Position of the Multifeeder PickUp Roller Releasing Solenoid (SL5)..........................239
2.8.6 Adjusting the Position of the Delivery Paper Deflecting Plate Solenoid (SL14)..................................239
2.8.7 Adjusting the Position of the Duplexing Unit Paper Deflecting Plate Solenoid (SL11).......................240
2.8.8 Adjusting the Position of the Duplexing Unit Stacking Assembly Paper Guide Plate .........................240
2.8.9 Adjusting the Position of the Duplexing Unit Feeding Roller Solenoid (L13) .....................................240
2.8.10 Attaching the Timing Belt for the Duplexing Unit Stacking Assembly Paper Guide Plate..................241
2.8.11 Adjusting the Position of the Separation Claw Solenoid (SL15) ..........................................................241
2.8.12 Adjusting the Position of the Upper Fixing Web TakeUp Solenoid (SL3)..........................................241
2.8.13 When Replacing the Registration Roller Unit.......................................................................................242
2.8.14 Correcting Skew Movement..................................................................................................................242
Chapter 3 Error Code
3.1 Error Code Details............................................................................................................................................31
3.1.1 Error Code Details ...................................................................................................................................31
Chapter 4 User Mode Items
4.1 List of User Modes...........................................................................................................................................41

Contents
Chapter 5 Service Mode
5.1 DISPLAY㧔Status Display Mode㧕................................................................................................................. 51
5.1.1 DISPLAY Table...................................................................................................................................... 51
5.2 ADJUST㧔Adjustment Mode㧕...................................................................................................................... 530
5.2.1 ADJUST Table...................................................................................................................................... 530
5.3 FUNCTION 㧔Operation/Inspection Mode㧕................................................................................................ 546
5.3.1 FUNCTION Table................................................................................................................................. 546
5.4 OPTION 㧔Machine Settings Mode㧕............................................................................................................ 569
5.4.1 OPTION Table ...................................................................................................................................... 569
5.5 TEST 㧔Test Print Mode㧕............................................................................................................................. 582
5.5.1 TEST㧔Test Printing Mode㧕................................................................................................................ 582
5.6 COUNTER 㧔Counter Mode㧕...................................................................................................................... 586
5.6.1 COUNTER Table.................................................................................................................................. 586
Chapter 6 Outline of Components
6.1 Clutch/Solenoid ............................................................................................................................................... 61
6.1.1 Clutches................................................................................................................................................... 61
6.1.2 Solenoids ................................................................................................................................................. 63
6.2 Motor ............................................................................................................................................................... 66
6.2.1 Motors ..................................................................................................................................................... 66
6.3 Fan ................................................................................................................................................................. 613
6.3.1 Fans ....................................................................................................................................................... 613
6.4 Sensor............................................................................................................................................................. 618
6.4.1 Sensors, Others...................................................................................................................................... 618
6.5 Switch ............................................................................................................................................................ 626
6.5.1 Switches................................................................................................................................................. 626
6.6 Lamps, Heaters, and Others........................................................................................................................... 628
6.6.1 Lamps,Thermistors, and Heaters........................................................................................................... 628
6.7 PCBs .............................................................................................................................................................. 634
6.7.1 PCBs...................................................................................................................................................... 634

Contents
Chapter 7 System Construction
7.1 Construction .....................................................................................................................................................71
7.1.1 Functional Construction...........................................................................................................................71
7.1.2 Outline of Electrical Circuitry .................................................................................................................72
7.2 System Construction ........................................................................................................................................73
7.2.1 System Configuration ..............................................................................................................................73
7.3 Product Specifications......................................................................................................................................74
7.3.1 Specifications...........................................................................................................................................74
7.3.2 Specifications...........................................................................................................................................77
7.4 Function List ..................................................................................................................................................711
7.4.1 Dimensions ............................................................................................................................................711
7.4.2 Default Ratios ........................................................................................................................................712
7.4.3 Copy Speed............................................................................................................................................713
Chapter 8 Upgrading
8.1 Outline of the Version Upgrade .......................................................................................................................81

Chapter 1 Maintenance and
Inspection

Contents
Contents
1.1 Periodically Replaced Parts................................................................................................................................ 11
1.1.1 Periodically Replaced Parts......................................................................................................................... 11
1.1.2 Periodically Replaced Parts......................................................................................................................... 14
1.1.3 Periodically Replaced Parts(Ref for heavy paper) ...................................................................................... 18
1.2 Durables and Consumables .............................................................................................................................. 112
1.2.1 Consumables and Durables ....................................................................................................................... 112
1.2.2 Consumables and Durables(Ref for heavy paper)..................................................................................... 116
1.3 Scheduled Servicing Basic Procedure.............................................................................................................. 119
1.3.1 Scheduled Servicing Procedure................................................................................................................. 119
1.3.2 Scheduled Maintenance Chart................................................................................................................... 121
1.4 Cleaning............................................................................................................................................................ 128
1.4.1 Cleaning the Shutter .................................................................................................................................. 128
1.4.2 Cleaning the Developing Assembly Upper Cover .................................................................................... 129
1.4.3 Cleaning the LED...................................................................................................................................... 130
1.4.4 Cleaning the Transfer Blade...................................................................................................................... 131
1.4.5 Cleaning the Grounding Roller ................................................................................................................. 131
1.4.6 Cleaning the Developing Assembly Bottom Cover and the Bearing ....................................................... 131
1.4.7 How to Clean the SALT Sensor ................................................................................................................ 132
1.4.8 How to Disassemble and Clean the SALT Sensor Unit............................................................................ 133

Chapter 1
1-1
1.1 Periodically Replaced Parts
1.1.1 Periodically Replaced Parts 0002-1292
CLC5100
ޓޓޓޓޓޓޓޓޓޓޓޓޓޓޓޓޓޓޓޓޓޓޓޓޓޓޓޓAs of Jul 2003
T-1-1
No Parts name Parts
number Q'ty Life Remarks
1
Ozone filter 1
(primary charging
assembly)
FB23702 1 100,000 Or 1 yr. (FM6: primary
charging assembly fan)
2
Ozone filter 2
(delivery assembly,
general exhaust)
FB58775 2 100,000
Or 1 yr. (FM1/2/3: delivery
assembly exhaust fan FM21/
22/23: general exhaust)
3
Ozone filter 3 (power
supply assembly,
prefixing, exhaust)
FB23704 4 100,000
Or 1 yr. (FM17/18: power
supply assembly exhaust fan;
FM35/36: prefixing exhaust
fan)
4
Ozone filter 4
(reversing assembly
exhaust)
FB58428 2 100,000
Or 1 yr. (FM28/29/30/
33:reversing assembly
exhaust
fan,FM9002,9003:Reversing
twin fan)
5
Dustproofing filter 1
(laser unit,power
supply assembly
suction filter)
FA64538 8 100,000 Or 1 yr. (FM14/15/16:digital
unit cooling fan)
6
Dustproofing filter 3
(digital unit suction
filter)
FB23955 2 100,000 Or 1 yr. (FM14/15/16:digital
unit cooling fan)
7
Dustproofing filter 4
(primary suction
filter)
FB35608 2 100,000
Or 1 yr. (FM8/9: primary
charging assembly suction
fan)
8
Dustproofing filter 6
(delivery assembly,
general exhaust)
FB36320 2 100,000
Or 1 yr. (FM1/2/3: delivery
assembly exhaust fan; FM21/
22/23: general exhaust)

Chapter 1
1-2
Memo
The above values are estimates only and are subject to change based on future data.
The parts numbers are subject to change according to engineering revisions.
F-1-1
A: Dustproofing filter
B: Ozone filter
C: Toner filter
9
Dustproofing filter 7
(Laser scanner
cooling)
FB56264 1 100,000 Or 1 yr. (FM24: laser scanner
motor cooling fan)
10 Toner filter FB24383 1 100,000 Or 1 yr. (FM6: primary
exhaust fan)
11 Prefixing duct filter
(Prefixing duct) FF61117 1 50,000 Or 1 yr. (FM35/36: prefixing exhaust fan)
No Parts name Parts
number Q'ty Life Remarks
[6]
[5]
[5]
[5]
[8]
[5]
[2]
[7]
[3]
[5] [1]
[3]
[10]
[5]
[2]
[4]
[8]
[11]
[9]
A
B
C

Chapter 1
1-3
ޓޓޓޓޓޓޓޓޓޓޓޓޓޓޓޓޓޓޓޓޓޓޓޓޓޓޓޓAs of Jul 2003
T-1-2
No Parts name Parts
number Q'ty Life Remarks
12 Transfer blade FF60542 4 100,000
13 Primary grid FB22958 4 50,000
14 Primary/pretransfer
charging wire
FY30030 AR 50,000 200V
FY30040 AR 50,000 230/240V
15
Primary charging wire
cleaning pad (lower) FF23551 4 50,000
Primary charging wire
cleaning pad (upper) FF23552 4 50,000
16 Separation/prefixing
charging wire
FY30030 AR 100,000 200V
FY30040 AR 100,000 230/240V
17
Separation/prefixing
charging wire cleaning
pad
FF55517 2 100,000
18
Separation/prefixing
charging assembly gut
wire
RY11502 AR 100,000
19
Cleaning blade
(photosensitive drum
cleaner)
FB65717 4 80,000
20
Scoop up sheet
(photosensitive drum
cleaner)
FF61601 4 80,000 When replacing the
cleaning blade
21 No. 2 scoopup sheet
(SALT sensor) FB22924 4 80,000 When replacing the cleaning blade
22
Cleaner side seal
(front; photosensitive
drum cleaner)
FF54166 4 80,000 When replacing the
cleaning blade

Chapter 1
1-4
Memo
The above values are estimates only and subject to change based on future
data. Likewise, the parts numbers are subject to change to accommodate engineering revisions.
1.1.2 Periodically Replaced Parts 0003-2601
CLC4000
ޓޓޓޓޓޓޓޓޓޓޓޓޓޓޓޓޓޓޓޓޓޓޓޓޓޓޓޓAs of Jul 2003
T-1-3
23
Cleaner side seal (rear;
photosensitive drum
cleaner)
FF61585 4 80,000 When replacing the
cleaning blade
24
Cleaner end seal(front;
photosensitive drum
cleaner)
FF61600 4 80,000 When replacing the
cleaning blade
25
Cleaner end seal (rear;
photosensitive drum
cleaner)
FF62630 4 80,000 When replacing the
cleaning blade
26 Transfer web plate FF62629 1 100,000
27 Polishing roller backup FF61348 1 100,000
28 54T gear FU30551 1500,000
No Parts name Parts
number Q'ty Life Remarks
1
Ozone filter 1
(primary charging
assembly)
FB23702 1 100,000 Or 1 yr. (FM6: primary
charging assembly fan)
2
Ozone filter 2
(delivery assembly,
general exhaust)
FB58775 2 100,000
Or 1 yr. (FM1/2/3: delivery
assembly exhaust fan FM21/
22/23: general exhaust)
3
Ozone filter 3 (power
supply assembly,
prefixing, exhaust)
FB23704 4 100,000
Or 1 yr. (FM17/18: power
supply assembly exhaust fan;
FM35/36: prefixing exhaust
fan)
No Parts name Parts
number Q'ty Life Remarks

Chapter 1
1-5
Memo
The above values are estimates only and are subject to change based on future data.
The parts numbers are subject to change according to engineering revisions.
4
Ozone filter 4
(reversing assembly
exhaust)
FB58428 2 100,000
Or 1 yr. (FM28/29/30/
33:reversing assembly
exhaust
fan,FM9002,9003:Reversing
twin fan)
5
Dustproofing filter 1
(laser unit,power
supply assembly
suction filter)
FA64538 8 100,000 Or 1 yr. (FM14/15/16:digital
unit cooling fan)
6
Dustproofing filter 3
(digital unit suction
filter)
FB23955 2 100,000 Or 1 yr. (FM14/15/16:digital
unit cooling fan)
7
Dustproofing filter 4
(primary suction
filter)
FB35608 2 100,000
Or 1 yr. (FM8/9: primary
charging assembly suction
fan)
8
Dustproofing filter 6
(delivery assembly,
general exhaust)
FB36320 2 100,000
Or 1 yr. (FM1/2/3: delivery
assembly exhaust fan; FM21/
22/23: general exhaust)
9
Dustproofing filter 7
(Laser scanner
cooling)
FB56264 1 100,000 Or 1 yr. (FM24: laser scanner
motor cooling fan)
10 Toner filter FB24383 1 100,000 Or 1 yr. (FM6: primary
exhaust fan)
11 Prefixing duct filter
(Prefixing duct) FF61117 1 50,000 Or 1 yr. (FM35/36: prefixing exhaust fan)
No Parts name Parts
number Q'ty Life Remarks

Chapter 1
1-6
F-1-2
A: Dustproofing filter
B: Ozone filter
C: Toner filter
ޓޓޓޓޓޓޓޓޓޓޓޓޓޓޓޓޓޓޓޓޓޓޓޓޓޓޓޓAs of Jul 2003
T-1-4
No Parts name Parts
number Q'ty Life Remarks
12 Transfer blade FF60542 4 100,000
13 Primary grid FB22958 4 50,000
14 Primary/pretransfer
charging wire
FY30030 AR 50,000 200V
FY30040 AR 50,000 230/240V
[6]
[5]
[5]
[5]
[8]
[5]
[2]
[7]
[3]
[5] [1]
[3]
[10]
[5]
[2]
[4]
[8]
[11]
[9]
A
B
C