Canon imageRUNNER 1019j User manual

SERVICE
MANUAL
imageR NER
1019J/ 3/
1023N/ 3iF
COPYRIGHT 2006 CANON INC. CANON imageRUNNER 1019J/1023/1023N/1023iF REV. 0 PRINTED IN U.S.A.
NOVEMBER 2006
REV. 0
DU7-1207-000

Application
This manual has been issued by Canon Inc for qualified persons to learn technical theory, installation,
maintenance, and repair of products This manual covers all localities where the products are sold For this reason,
there may be information in this manual that does not apply to your locality
Corrections
This manual may contain technical inaccuracies or typographical errors due to improvements or changes in
products When changes occur in applicable products or in the contents of this manual, Canon will release technical
information as the need arises In the event of major changes in the contents of this manual over a long or short
period, Canon will issue a new edition of this manual
The following paragraph does not apply to any countries where such provisions are inconsistent with local law
Trademarks
The product names and company names used in this manual are the registered trademarks of the individual
companies
Copyright
This manual is copyrighted with all rights reserved Under the copyright laws, this manual may not be copied,
eproduced 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 elec-
ical and mechanical systems with reference to the timing of operation.
the diagrams, represents the path of mechanical drive; where a signal name accompanies the
mbol, the arrow indicates the direction of the electric signal.
he expression "turn on the power" means flipping on the power switch, closing the front door, and closing
e delivery unit door, which results in supplying the machine with power.
the digital circuits, '1'is used to indicate that the voltage level of a given signal is "High", while '0' is used
indicate "Low".(The voltage value, however, differs from circuit to circuit.) In addition, the asterisk (*) as
n "DRMD*" indicates that the DRMD signal goes on when '0'.
practically all cases, the internal mechanisms of a microprocessor cannot be checked in the field.
herefore, the operations of the microprocessors used in the machines are not discussed: they are explained
terms of from sensors to the input of the DC controller PCB and from the output of the DC controller PCB
the loads.
descriptions in this Service Manual are subject to change without notice for product improvement or other
oses, and major changes will be communicated in the form of Service Information bulletins.
ervice persons are expected to have a good understanding of the contents of this Service Manual and all
ant Service Information bulletins and be able to identify and isolate faults in the machine."

Contents
Contents
Chapter 1 Introduction
1.1 System Construction......................................................................................... 1-1
1.1.1 System Configuration................................................................................................ 1-1
1.2 Product Specifications...................................................................................... 1-3
1.2.1 Names of Parts ...........................................................................................................1-3
1.2.1.1 External View (Front)........................................................................................................... 1-3
1.2.1.2 External View (Rear)............................................................................................................ 1-4
1.2.1.3 Cross-Section (Main body)................................................................................................. 1-5
1.2.1.4 Cross Section (ADF)............................................................................................................ 1-6
1.2.2 Using the Machine .....................................................................................................1-7
1.2.2.1 Turning On the Power Switch............................................................................................. 1-7
1.2.2.2 When Turning Off the Main Power Switch ....................................................................... 1-8
1.2.2.3 Control Panel ...................................................................................................................... 1-10
1.2.3 User Mode Items ......................................................................................................1-12
1.2.3.1 COMMON SETTINGS....................................................................................................... 1-12
1.2.3.2 COPY SETTINGS.............................................................................................................. 1-13
1.2.3.3 TX/RX SETTINGS.............................................................................................................. 1-14
1.2.3.4 ADDRESS BOOK SET...................................................................................................... 1-15
1.2.3.5 PRINTER SETTINGS........................................................................................................ 1-17
1.2.3.6 TIMER SETTINGS............................................................................................................. 1-18
1.2.3.7 ADJUST./CLEANING ........................................................................................................ 1-18
1.2.3.8 REPORT SETTINGS......................................................................................................... 1-18
1.2.3.9 SYSTEM SETTINGS......................................................................................................... 1-19
1.2.4 Maintenance by the User ........................................................................................1-21
1.2.4.1 User Maintenance Items ................................................................................................... 1-21
1.2.4.2 Cleaning............................................................................................................................... 1-21
1.2.5 Safety .........................................................................................................................1-24
1.2.5.1 Safety of Toner................................................................................................................... 1-24
1.2.5.2 Safety of the Laser Light................................................................................................... 1-24
1.2.5.3 CDRH Regulations............................................................................................................. 1-24
1.2.5.4 Handling the Laser Unit..................................................................................................... 1-25
1.2.5.5 Point to Note about Fire .................................................................................................... 1-26
1.2.5.6 Cautions as to the replacement and disposal of lithium battery................................. 1-26
1.2.6 Product Specifications .............................................................................................1-27
1.2.6.1 Product Specifications....................................................................................................... 1-27
1.2.6.2 ADF Specifications............................................................................................................. 1-29
1.2.6.3 Fax Specifications.............................................................................................................. 1-30
1.2.7 Function List ..............................................................................................................1-31

Contents
1.2.7.1 Print Speed (iR1019J))...................................................................................................... 1-31
1.2.7.2 Print Speed (iR1023/1023N/1023iF)............................................................................... 1-32
1.2.7.3 Types of Paper................................................................................................................... 1-33
Chapter 2 Installation
2.1 Installing the Card Reader................................................................................ 2-1
2.1.1 Points to Note............................................................................................................ 2-1
2.1.2 Checking the Contents............................................................................................. 2-1
2.1.3 Installation Procedure............................................................................................... 2-3
2.2 Installing the PCL Printer Kit-M1................................................................................. 2-12
2.2.1 Checking the Contents........................................................................................... 2-12
2.2.2 Installation Procedure............................................................................................. 2-12
2.3 Installing the Network Interface Adapter iN-E11....................................................... 2-19
2.3.1 Checking the Contents........................................................................................... 2-19
2.3.2 Installation Procedure............................................................................................. 2-20
Chapter 3 Basic Operation
3.1 Construction........................................................................................................ 3-1
3.1.1 Functional Construction ........................................................................................... 3-1
3.1.2 Functional Block Diagram........................................................................................ 3-2
3.1.3 Image Processor PCB.............................................................................................. 3-2
3.1.4 DC Controller PCB.................................................................................................... 3-5
3.1.5 Analog Processor PCB............................................................................................. 3-6
3.1.6 Power Supply PCB ................................................................................................... 3-6
3.1.7 Relay PCB.................................................................................................................. 3-6
3.1.8 Control Panel PCB.................................................................................................... 3-6
3.1.9 NCU PCB (if equipped with fax functions) ............................................................ 3-6
3.1.10 Network PCB (if equipped with network functions)............................................ 3-6
3.1.11 Modular Jack PCB (if equipped with fax functions)........................................... 3-6
3.1.12 Modem PCB (if equipped with fax functions)...................................................... 3-7
3.2 Basic Sequence................................................................................................. 3-8
3.2.1 Basic Sequence......................................................................................................... 3-8
Chapter 4 Original Exposure System
4.1 Construction........................................................................................................ 4-1
4.1.1 Specifications, Control Methods, and Functions.................................................. 4-1
4.1.2 Major Components.................................................................................................... 4-2
4.2 Basic Sequence................................................................................................. 4-3
4.2.1 Basic Sequence at Power-on.................................................................................. 4-3

Contents
4.2.2 Basic Sequence after Depression of Start Key (Book mode, One Sheet of original)
4-4
4.2.3 Basic Sequence after Depression of Start Key (ADF Mode, One Sheet of Original)
4-5
.3 Various Control.................................................................................................. 4-6
4.3.1 Enlargement/Reduction ............................................................................................4-6
4.3.1.1 Magnification Change in Vertical Scan Direction............................................................ 4-6
4.3.1.2 Magnification Change in Horizontal Scan Direction........................................................ 4-6
4.3.2 Dirt Sensor Control ....................................................................................................4-6
4.3.2.1 Outline.................................................................................................................................... 4-6
4.4 Parts Replacement Procedure........................................................................ 4-8
4.4.1 Copyboard glass ........................................................................................................4-8
4.4.2 Reader Controller PCB .............................................................................................4-8
4.4.3 Scanner Motor ............................................................................................................4-9
4.4.4 Contact sensor ...........................................................................................................4-9
4.4.5 Contact Sensor HP Sensor ....................................................................................4-10
Chapter 5 Laser Exposure
5.1 Construction....................................................................................................... 5-1
5.1.1 Specifications and Control Mechanism.................................................................. 5-1
5.1.2 Main Components...................................................................................................... 5-2
5.2 Parts Replacement Procedure........................................................................ 5-3
5.2.1 Laser Scanner Unit ....................................................................................................5-3
Chapter 6 Image Formation
6.1 Construction....................................................................................................... 6-1
6.1.1 Specifications and Control Mechanism.................................................................. 6-1
6.1.2 Outline.......................................................................................................................... 6-2
6.2 Image Formation Process................................................................................ 6-3
6.2.1 Reproduction Processes........................................................................................... 6-3
6.3 Parts Replacement Procedure........................................................................ 6-5
6.3.1 Developing Assembly ................................................................................................6-5
6.3.2 Transfer Charging Roller ..........................................................................................6-5
6.3.3 Waste Toner Full Sensor ..........................................................................................6-6
Chapter 7 Pickup/Feeding System
7.1 Construction....................................................................................................... 7-1
7.1.1 Outline.......................................................................................................................... 7-1

Contents
7.2 Detecting Jams................................................................................................... 7-2
7.2.1 Jam Detection Outline .............................................................................................. 7-2
7.2.1.1 Outline.................................................................................................................................... 7-2
7.2.1.2 Types of Jams ...................................................................................................................... 7-3
7.3 Cassette Pick-Up Unit....................................................................................... 7-4
7.3.1 Outline......................................................................................................................... 7-4
7.3.2 Retry Pickup............................................................................................................... 7-4
7.3.3 Detecting the Size of Paper..................................................................................... 7-5
7.4 Manual Feed Pickup Unit ................................................................................. 7-5
7.4.1 Outline......................................................................................................................... 7-5
7.4.2 Retry Pickup............................................................................................................... 7-6
7.4.3 Detecting the Size of Paper..................................................................................... 7-6
7.5 Duplex Feeding Unit.......................................................................................... 7-6
7.5.1 Outline......................................................................................................................... 7-6
7.6 Parts Replacement Procedure......................................................................... 7-7
7.6.1 Pickup Roller .............................................................................................................. 7-7
7.6.2 Cassette Paper Sensor ............................................................................................ 7-7
7.6.3 Cassette Pickup Solenoid ........................................................................................ 7-8
7.6.4 Manual Pickup Roller ................................................................................................ 7-8
7.6.5 Manual Feed Tray paper sensor ............................................................................ 7-9
7.6.6 Manual Feed Pickup Solenoid ................................................................................ 7-9
7.6.7 Manual Separation Pad ............................................................................................ 7-9
7.6.8 Registration Roller .................................................................................................. 7-10
7.6.9 Registration Sensor ................................................................................................ 7-13
7.6.10 Registration Clutch ................................................................................................ 7-14
7.6.11 Feeding Roller ....................................................................................................... 7-14
7.6.12 Duplex Pickup Solenoid ....................................................................................... 7-15
7.6.13 Separation Roller .................................................................................................. 7-15
Chapter 8 Fixing System
8.1 Construction........................................................................................................ 8-1
8.1.1 Specifications, Control Mechanisms, and Functions........................................... 8-1
8.1.2 Outline......................................................................................................................... 8-2
8.2 Various Control Mechanisms........................................................................... 8-3
8.2.1 Controlling the Fixing Film Temperature ............................................................... 8-3
8.2.1.1 Outline.................................................................................................................................... 8-3
8.2.1.2 Controlling the Fixing Film Temperature.......................................................................... 8-3
8.2.1.3 Target Temperatures by Mode .......................................................................................... 8-4
8.3 Protective Functions.......................................................................................... 8-5
8.3.1 Outline......................................................................................................................... 8-5
8.3.2 Failure Detection....................................................................................................... 8-6

Contents
8.4 Parts Replacement Procedure........................................................................ 8-7
8.4.1 Fixing Unit ...................................................................................................................8-7
8.4.2 Pressure Roller .........................................................................................................8-10
8.4.3 Fixing Film .................................................................................................................8-11
8.4.4 Fixing Delivery Sensor ............................................................................................8-12
Chapter 9 External and Controls
9.1 Control Panel..................................................................................................... 9-1
9.1.1 Outline.......................................................................................................................... 9-1
9.2 Fans..................................................................................................................... 9-1
9.2.1 Outline.......................................................................................................................... 9-1
9.3 Power Supply System...................................................................................... 9-2
9.3.1 Power Supply ..............................................................................................................9-2
9.3.1.1 Outline.................................................................................................................................... 9-2
9.3.1.2 Rated Output of the Power Supply PCB........................................................................... 9-4
9.3.2 Protection Function ....................................................................................................9-4
9.3.2.1 Protective Functions ............................................................................................................ 9-4
9.4 Parts Replacement Procedure........................................................................ 9-5
9.4.1 External Covers ..........................................................................................................9-5
9.4.2 Drive Unit .....................................................................................................................9-9
9.4.3 Power Supply Unit ...................................................................................................9-10
9.4.4 Control Panel ............................................................................................................9-11
9.4.5 Image Processor PCB .............................................................................................9-11
9.4.6 NCU PCB ..................................................................................................................9-13
9.4.7 Modular Jack PCB ...................................................................................................9-13
9.4.8 Modem PCB ..............................................................................................................9-14
9.4.9 Network PCB ............................................................................................................9-14
9.4.10 Relay PCB ...............................................................................................................9-15
9.4.11 Interlock Switch ......................................................................................................9-15
9.4.12 Fans .........................................................................................................................9-16
9.4.13 Other ........................................................................................................................9-16
Chapter 10 Original Feeding System
10.1 Basic Construcion......................................................................................... 10-1
10.1.1 Outline...................................................................................................................... 10-1
10.1.2 Drive Mechanism ................................................................................................... 10-2
10.2 Basic Operation............................................................................................. 10-2
10.2.1 Outline of Operation Mode ................................................................................... 10-2
10.2.2 Document Size Detection..................................................................................... 10-5

ontents
0.2.3 Paper Pickup Operation....................................................................................... 10-6
0.2.4 Reversal Operation............................................................................................... 10-7
0.2.5 Delivery Operation ................................................................................................ 10-8
3 Detection Jams............................................................................................... 10-9
0.3.1 Outline..................................................................................................................... 10-9
Parts Replacement Procedure................................................................... 10-11
0.4.1 ADF ....................................................................................................................... 10-11
0.4.2 External Covers ................................................................................................... 10-11
0.4.3 ADF Drive Unit ..................................................................................................... 10-13
0.4.4 Feed Frame Unit ................................................................................................. 10-14
0.4.5 ADF Motor Unit .................................................................................................... 10-14
10.4.6 Pick-up/Feed Roller Unit .................................................................................... 10-15
10.4.7 Pickup Roller ........................................................................................................ 10-15
10.4.8 Original Separation Pad ..................................................................................... 10-16
10.4.9 Feed Roller ........................................................................................................... 10-16
10.4.10 Original Sensor .................................................................................................. 10-16
10.4.11 Separation Rear Sensor .................................................................................. 10-17
10.4.12 Registration Sensor .......................................................................................... 10-17
10.4.13 Document Edge Sensor ................................................................................... 10-17
10.4.14 Pick-up Solenoid ............................................................................................... 10-18
10.4.15 Registaration Solenoid ..................................................................................... 10-18
10.4.16 Roller Release Solenoid .................................................................................. 10-19
Chapter 11 Maintenance and Inspection
11.1 Periodically Replaced Parts......................................................................... 11-1
11.1.1 Periodically Replaced Parts................................................................................. 11-1
11.2 Durables and Consumables......................................................................... 11-1
11.2.1 Durables ................................................................................................................. 11-1
11.3 Scheduled Servicing Basic Procedure....................................................... 11-1
11.3.1 Periodeical Service Items.................................................................................... 11-1
Chapter 12 Standards and Adjustments
12.1 Image Adjustments........................................................................................ 12-1
12.1.1 Image parallelism adjustment ............................................................................. 12-1
12.2 Scanning System........................................................................................... 12-2
12.2.1 Procedure after Replacing the CS ..................................................................... 12-2
12.2.2 Procedure after Replacing the Copyboard Glass (if equipped with SEND
functions)....................................................................................................................... 12-2
12.3 Electrical Components.................................................................................. 12-3
12.3.1 Procedure after Replacing the Image Processor PCB.................................... 12-3