Canon GP405 How to use

FY8-23AZ-000
JAN. 1999
COPYRIGHT © 1999 CANON INC. CANON 405/335 REV.0 JAN. 1999 PRINTED IN JAPAN (IMPRIME AU JAPON)
SERVICE
HANDBOOK
REVISION 0

IMPORTANT
THE INFORMATION CONTAINED HEREIN IS PUBLISHED BY CANON, INC., JAPAN, AND IS
FOR REFERENCE USE ONLY. SPECIFICATIONS AND OTHER INFORMATION CONTAINED
HEREIN MAY VARY SLIGHTLY FROM ACTUAL MACHINE VALUES OR THOSE FOUND IN
ADVERTISING AND OTHER PRINTED MATTER.
ANYQUESTIONSREGARDINGINFORMATIONCONTAINEDHEREINSHOULDBEDIRECTED
TO THE COPIER SERVICE DEPARTMENT OF THE SALES COMPANY.
COPYRIGHT © 1999 CANON INC.
Printed in Japan
Imprimé au Japon
Use of this manual should be
strictly supervised to avoid
disclosure of confidential
information.
Prepared by
OFFICE IMAGING PRODUCTS TECHNICAL SUPPORT DEPARTMENT 1
OFFICE IMAGING PRODUCTS TECHNICAL SUPPORT DIVISION
CANON INC.
5-1, Hakusan 7-chome, Toride-shi Ibaraki, 302-8501 Japan
COPYRIGHT © 1999 CANON INC. CANON 405/335 REV.0 JAN. 1999 PRINTED IN JAPAN (IMPRIME AU JAPON)

i
CONTENTS
CHAPTER 1 MAINTENANCE AND INSPECTION
A. Scheduled Servicing Table........................1-1
1. Copier ..................................................1-1
2. Paper Deck..........................................1-2
B. Periodically Replaced Parts.......................1-3
C. Consumables and Durables ......................1-3
1. Copier ..................................................1-3
2. Side Paper Deck..................................1-4
D. Image Basic Adjustment Procedure ..........1-5
E. Points of Scheduled Servicing...................1-6
1
2
3
4
5
CHAPTER 2 STANDARDS AND ADJUSTMENTS
A. Image Adjustment......................................2-1
B. Exposure System ......................................2-6
C. Image Formation System ..........................2-9
D. Pick-Up/Feeding System .........................2-11
E. Fixing System ..........................................2-16
F. Electrical System .....................................2-18
CHAPTER 3 ARRANGEMENT AND FUNCTIONS OF
ELECTRICAL PARTS
A. Clutches and Solenoids.............................3-2
B. Motors........................................................3-4
C. Fan.............................................................3-6
D. Sensors......................................................3-8
E. Switches and Counters............................3-10
F. PCBs........................................................3-12
G. Side Paper Deck......................................3-14
1. Sensors and Switches.......................3-14
2. Motors, Solenoids, and PCBs ...........3-16
H. Variable Resisters, Light-Emitting Diodes,
and Check Pins by PCB ..........................3-18
1. Image Processor PCBs
(main controller).................................3-19
2. DC Controller PCB (DC driver)..........3-21
3. Composite Power Supply CPB .........3-23
4. Deck Driver (side paper deck)...........3-24
I. Upgrading ................................................3-25
1. Removing the DIMM..........................3-26
2. Mounting the DIMM ...........................3-27
3. Downloading......................................3-28

ii
CHAPTER 4 SERVICE MODE
3. FEEDER ............................................4-31
4. SORTER (Finisher C1, Saddle
Finisher C2, Finisher E1)...................4-34
D. ADJUST Adjustment Mode......................4-45
E. FUNCTION Operation Check Mode........4-53
F. OPTION Settings Mode...........................4-65
G. PG test Print ............................................4-73
H. COUNTER Mode.....................................4-78
I. FEEDER ..................................................4-81
J. SORTER (finisher, saddle stitcher) .........4-85
A. Outline .......................................................4-1
1. Starting Service Mode and Making
Selections ............................................4-1
2. Ending Service Mode ..........................4-2
3. Backing Up the RAM ...........................4-2
4. Basic Operation ...................................4-4
B. DISPLAY Control Display Mode................4-7
C. I/O Operation Check Mode......................4-22
1. DC-CON ............................................4-23
2. IP .......................................................4-30
CHAPTER 5 SELF DIAGNOSIS
F. Saddle Finisher-C2..................................5-14
G. Finisher-E1 ..............................................5-18
H. Paper Deck-B1 ........................................5-20
I. SCSI Interface Board-D1.........................5-21
A. Copier ........................................................5-3
B. DADF .......................................................5-10
C. Cassette Feeding Unit-R1/S1..................5-11
D. Multi Output Tray-D1 ...............................5-11
E. Finisher-C1 ..............................................5-12
A. General Timing Chart ............................... A-1
B. Signal name/abbreviation list.................... A-3
C. General Circuit Diagram ........................... A-7
D. General Circuit Diagram Paper Deck ..... A-13
APPENDIX
E. Specifications .......................................... A-15
1. Copier ............................................... A-15
2. Paper Deck....................................... A-21

1-1
CHAPTER 1 MAINTENANCE AND INSPECTION
CHAPTER 1 MAINTENANCE AND INSPECTION
A. Scheduled Servicing Table
Caution:
Do not use solvents/oils not indicated here.
1. Copier
Unit
Scanner drive
assembly
Optical assembly
Developing
assembly
Feeding assembly
Fixing
assembly
Part
Scanner rail
No. 1 through No. 3
mirrors
Dust-proofing glass
Lens
Reflecting plate
Original size sensor
Developing assembly
roll
Transfer guide
Feeding belt
Feeding assembly base
Fixing assembly
inlet guide
Upper separation claw
Lower separation claw
Remarks
Use lubricant.
Note
During a visit.
Clean as necessary.
During a visit.
Clean as necessary.
During a visit.
Clean as necessary.
Installation
every
60,000 every 120,000 every 240,000
Note: For cleaning intervals, use the hardware counter reading as a reference.
: Clean : Replace : Lubricate : Adjust : Inspect
1

CHAPTER 1 MAINTENANCE AND INSPECTION
1-2
2. Paper Deck
Unit
Pick-up
assembly
Part
Pick-up roller
Pick-up/feeding
roller
Separation roller
Feeding roller, roll
Remarks
Installation
every
250,000 every 500,000 every 750,000
Maintenance intervals
every
1,000,000
: Clean : Replace : Lubricate : Adjust : Inspect

1-3
CHAPTER 1 MAINTENANCE AND INSPECTION
B. Periodically Replaced Parts
The machine does not have parts that need to be replaced on a periodical basis.
C. Consumables and Durables
1. Copier
Some parts of the machine may require replacement once or more over the period of warranty
because of wear or damage. Replace them as necessary. As of Dec. 1998
No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
Remarks
Actual copies made.
Actual copies made.
Actual copies made.
Actual copies made.
Actual copies made.
Parts name
Pick-up roller
Feeding roller
Separation roller
Pick-up roller (multifeeder)
Separation pad (multifeeder)
Transfer roller
Separation static eliminator
Scanning lamp
Pre-exposure lamp
Developing cylinder
Upper fixing roller
Lower fixing roller
Upper fixing separation claw
Lower fixing separation claw
Fixing cleaning belt
Heat insulating bush
Fixing heater (main)
Fixing heater (sub)
Thermistor
Internal delivery roller
Internal delivery sensor
Q'ty
2
2
2
1
1
1
1
1
1
1
1
1
5
2
1
2
1
1
1
1
1
Life (copies)
120,000
120,000
120,000
240,000
240,000
240,000
240,000
240,000
240,000
480,000
240,000
240,000
240,000
240,000
160,000
240,000
360,000
360,000
240,000
240,000
500,000
Parts No.
FF5-4552-020
FF5-4552-020
FF5-4634-020
FB1-8581-000
FC1-9022-030
FF5-6980-000
FF5-7246-000
FH7-3314-000
FG5-6297-000
FG6-0626-000
FB5-0289-000
FB4-2867-000
FB1-7075-000
FA2-9037-000
FA3-8908-000
FB1-6823-000
FH7-4570-000
FH7-4573-000
FG6-3881-000
FB4-2901-000
FH7-7394-000

CHAPTER 1 MAINTENANCE AND INSPECTION
1-4
No.
1
2
3
Remarks
Actual copies made.
Actual copies made.
Actual copies made.
Parts name
Side paper deck pick-up roller
Side paper deck feeding roller
Side paper deck separation roller
Q'ty
2
2
1
Life (copies)
250,000
250,000
250,000
Parts No.
FB4-2033-000
FB4-2034-000
FB2-7777-000
2. Side Paper Deck As of Dec. 1998

1-5
D. Image Basic Adjustment Procedure
Service Mode
FUNCTION>CCD>CCD-ADJ
Service Mode
Density Auto Adjustment
5 items under FUNCTION>DENS.
WHITE-ME, PD-DENS, PD-ME,
DZ-DENS, DZ-ME
Service Mode
ADJUST>DENS>DENS-ADJ
Service Mode
ADJUST/DENS/DENS-ADJ
Clean the primary charging roller
/transfer charging roller.
¥ To clean the primary/transfer
charging roller, use ’roller clean’
under ’adjustment/clean’ in user mode.
Clean the separation static
eliminator.
Is the
setting of ’density
correction’ under ’adjust/clean’
in user mode the medium
value?
YES
NO Set it to the
medium value.
It the
setting of
’ADJUST’ in service
mode the value indicated on the
label attached to the
front door?
Enter the value
indicated on the
label.
Make 2 to 3 copies in non-AE
at copy density 5.
YES
NO
NO
NO
Are there vertical
lines (white, black)?
YES
YES
YES
YES
Clean the separation static
eliminator, dust-proofing glass,
mirrors (No. 1, No. 2, No. 3),
standard white plate, and lens.
Are the vertical lines gone?
Is the white
background foggy?
NO
End.
Set DENS-ADJ to 5.
Execute auto correction.
Open the copyboard cover or the
feeder, and make 2 solid black
copies.
Is the fogging in the white
background gone?
NO
Set DENS-ADJ lower than 5.

1-6
E. Points of Scheduled Servicing
Copyboard/Scanner
Item Tool/solvent Work/remarks
Copyboard glass
Original size sensor
Scanning lamp
Reflecting plate
No.1 through No.3 mirrors
Standard white plate
Scanner rail
Alcohol
Blower brush
Lint-free paper
Blower brush
Alcohol
Alcohol,
Lubricant
Clean.
Clean.
Dry-wipe.
As necessary, dry-wipe
with lint-free paper.
Clean
Clean, and lubricate.
Fixing/Delivery Assembly
Item Tool/solvent Work/remarks
Separation
Inlet guide Solvent
Solvent Clean.
Clean.
Optical Assembly
Item Tool/solvent Work/remarks
Lens
Dust-proofing glass Blower brush
Blower brush Clean.
Clean.
Item Tool/solvent Work/remarks
Developing Assembly
Developing roll Alcohol Clean.
Item Tool/solvent Work/remarks
Transfer/Feeding/Pick-Up Assembly
Static eliminator
Feeding assembly
base/Feeding belt
Pick-up/feeding/
separator roller
Moist cloth*
Special brush
Moist cloth*
Alcohol
Clean.
Clean.
Clean.
Clean.
*Take care not to leave droplets of water.
Do not turn on the power before it is
completely dry.
Transfer guide

2-1
CHAPTER 2 STANDARDS AND ADJUSTMENTS
CHAPTER 2 STANDARDS
AND ADJUSTMENTS
A. Image Adjustment
Adjust the image margin, and then the
non-image width.
Adjusting the Image Leading Edge
Margin and the Non-Image Width
a. Change the following settings in service
mode so that they are as indicated on the
service label.
• ADJUST>ADJ-XY>ADJ-X, ADJ-Y
• ADJUST>FEED-ADJ>REGIST
b. Adjusting the Image Margin
1) Put A4 or A3 paper in the cassette, and
select the cassette.
2) Select '6' in service mode (TEST>PG>
TYPE), and generate a solid black copy.
3) Make adjustments so that the margin is
2.5 ±1.5 mm.
<Main Scanning Direction>
Use the horizontal registration mount.
(See A-2.)
<Sub Scanning Direction>
Use service mode (ADJUST>FEED-
ADJ>REGIST; see A-1).
c. Adjusting the Non-Image Width
1) Select the cassette used for adjusting the
image margin, and make a copy of the
NA-3 Chart.
Caution:
Be sure that the NA-3 is placed on the
copyboard glass correctly.
2) Make adjustments so that the leading edge
and left/right non-image widths are 2.5
mm.
<Main Scanning Direction>
ADJUST>ADJ-XY>ADJ-Y
<Sub Scanning Direction>
ADJUST>ADJ-XY>ADJ-X 2

CHAPTER 2 STANDARDS AND ADJUSTMENTS
2-2
1Image Leading Edge Margin
(REGIST; registration roller
activation timing)
Standard: 2.5 ±1.5 mm
For steps see the previous page.
nCOPIER>ADJUST>FEED-ADJ>
REGIST
Figure 2-1
<Making Adjustments>
• To increase the leading edge margin,
increase the setting of REGIST (thereby
delaying the activation of the registration
roller).
• To decrease the leading edge margin,
decrease the setting of REGIST.
nAfter adjusting the image leading edge
margin, be sure to make adjustments
under ADJUST>ADJ-XY>ADJ-X. (See
the descriptions for service mode.)
2.5 ±1.5mm
2Adjusting the Left/Right
Registration (front)
a. Pick-Up from the Cassette
Check to see if the margin on the image
front is 2.5 ±1.5 mm for each cassette.
Figure 2-2
If it is not as indicated, perform the following:
1) Slide out the cassette in question.
2) Remove the two screws [1], and detach
the horizontal registration mount.
Figure 2-3
( ) ( + )
2.5 1.5mm
0
2
4
6
8
10
[1]
Horizontal registration mount

2-3
CHAPTER 2 STANDARDS AND ADJUSTMENTS
3) Loosen the hex screw, and move the
horizontal registration plate to the front/
rear to make adjustments.
Figure 2-4
Caution:
When making adjustments, match the
inside of the L angle of the horizontal
registration plate with the appropriate
graduation of the scale.
Figure 2-5
b. Pick-Up from the Multifeeder
Loosen the screw, and move the tray so
that it is 2.5 ±1.5 mm in Direct mode.
4mm
Hex screw diameter
(front) (rear)
Horizontal
registration plate Hex screw
+-
3
Left/Right Registration for the 2nd
Side of a Double-Sided/Overlay
Copy (rear/front direction)
Check to see if the image on the 2nd side
of a double-sided/overlay copy is as indicated.
• Standard: 2.5 mm ±2.0 mm
Figure 2-6
If it is not as indicated, make adjustments
using the following in service mode:
COPIER>ADJUST>FEED-ADJ
>ADJ-REFE
2.5mm ±2.0
Decrease ADJ-REFE.
(A decrease of 23
causes a change of
1 mm.)
Increase ADJ-REFE.
(An increase of 23
causes a change of
1 mm.)

CHAPTER 2 STANDARDS AND ADJUSTMENTS
2-4
4 Left/Right Registration (side paper deck)
1) Make a copy of the Test Sheet, and check to see if the left/right registration is 0 ±1.5 mm.
2) If it is not as indicated, slide out the compartment, and turn the two screws to adjust the position
of the latch plate of the deck open solenoid. (At this time, refer to the scale on the latch plate.)
Figure 2-7 (rear left of the compartment)
Latch plate Scale Screws

2-5
CHAPTER 2 STANDARDS AND ADJUSTMENTS
5 AE Adjustment
The machine's AE (auto density adjustment) based on "priority on speed," and its method and
concept are as follows:
1. Adjusting Priority on Speed AE Mode
ADJUST>AE>AE-TBL (1 through 9; 3 at time of shipment)
Adjust the density correction curve (text) for priority on speed AE mode.
• A higher setting makes text lighter.
• A lower setting makes text darker.
Figure 2-8
Copy density
White
White
Black
Black
Higher
setting Lower setting
Original density

CHAPTER 2 STANDARDS AND ADJUSTMENTS
2-6
B. Exposure System
1 Routing the Scanner Drive Cable
Route the cable from [1] through [9]; then, go to the next item, "Adjusting the Mirror Position."
Figure 2-9
38Å`39mm
Fit the mirror
positioning tool
Loosen the set screws
to free the pulley.
Put the steel ball into the
hole in the pulley.
Wind the cable 3.5
times inwardly and
4.5 times outwardly;
then, fit the
pulley clip.
Pulley clip
Steel ball
Set
screws
[2]
[7]
[1]
[4]
[2][3]
[6]
[9] [5]
[8]

2-7
CHAPTER 2 STANDARDS AND ADJUSTMENTS
2 Adjusting the Mirror Position
(optical length between No. 1 mirror and No. 2/No. 3 mirror)
Caution:
Use the mirror position tool FY9-3009-040. Be sure to relocate the pins before use.
Figure 2-10
[C]
[C][B]
[B]
[3]
[2]
[1]
[3]
[2]
[1]
[A]
FY9-3009-040 Before Repositioning the Pins After repositioning the Pins

CHAPTER 2 STANDARDS AND ADJUSTMENTS
2-8
1) Loosen the screws on the metal fixings used to secure the cable.
2) Fit the mirror positioning tools (after repositioning its pins) to the No. 1 mirror mount and the
No. 2 mirror mount.
Figure 2-11
3) Tighten the screws on the metal fixings.
4) Detach the mirror positioning tools.
Figure 2-12
Rear tab
Front tab
Metal fixing

2-9
CHAPTER 2 STANDARDS AND ADJUSTMENTS
3 Mounting the Scanning Lamp
Keep the following in mind when
mounting the scanning lamp:
1. Orient it so that the side (terminal) with
the manufacturer's name is toward the
rear.
2. Orient it so that its transparent side is
toward the reflecting plate.
3. Do not touch the transparent side.
Figure 2-13
Make the following adjustments when
replacing the scanning lamp:
1) Shading correction 2
FUNCTION>CCD>MAN-ADJ
2) Auto density correction
FUNCTION>DENS>WHITE-ME
PD-DENS
PD-ME
DZ-DENS
DZ-ME
For details, see the description for
FUCNTION in service mode (VIII. of Chapter
14).
Transparent side
Reflecting plate
C. Image Formation System
1 When Replacing the Drum Unit
• Record the date and the counter reading
on the label, and attach it to the front cover
of the new drum unit.
• Clean the fixing separation claw (upper,
lower).
date
date Datum notes note Notiz
counter
compteur Zähler

CHAPTER 2 STANDARDS AND ADJUSTMENTS
2-10
2Positioning the Developing
Assembly Magnetic Seal
Mount the magnetic seal by butting it
against the opening as shown.
Check to make sure that the magnetic seal
is in firm contact with the housing.
Figure 2-14
Figure 2-15
Opening (butted)
Magnetic seal
Magnetic seal
(rear) (front)
3Mounting the Developing
Assembly Blade
The blade is adjusted to a high accuracy
when it is mounted to the blade mount. Avoid
detaching it from its mount.
• If you must replace the blade on its own,
be sure to adjust the position of the blade
so that the gap between the blade and the
developing cylinder is 0.21 ±0.03 mm
when measured with a gap gauge (CK-
0057-000).
Figure 2-16
The surface of the developing cylinder
can easily be damaged. Be sure to slide the gap
gauge along its both ends.
Blade
Developing cylinder
0.21± 0.03mm