Canon iR6570 series User manual

Feb 22 2005
Portable Manual
iR6570/5570 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
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,
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
sensors 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
purposes, 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
1.1.1Outline ......................................................................................................................................................... 1- 1
1.1.2Reader Unit.................................................................................................................................................. 1- 1
1.1.3Printer Unit .................................................................................................................................................. 1- 1
1.2 Durables and Consumables ............................................................................................................................... 1- 3
1.2.1Outline ......................................................................................................................................................... 1- 3
1.2.2Reader Unit.................................................................................................................................................. 1- 3
1.2.3Printer Unit .................................................................................................................................................. 1- 3
1.3 Scheduled Servicing Basic Procedure............................................................................................................... 1- 6
1.3.1Scheduled Servicing Basic Procedure......................................................................................................... 1- 6
1.3.2Periodical Servicing Chart Reader Unit ...................................................................................................... 1- 7
1.3.3Periodical Servicing Chart Printer Unit....................................................................................................... 1- 8
1.3.4Points to Note for Periodical Servicing..................................................................................................... 1- 10
1.4 Cleaning........................................................................................................................................................... 1- 12
1.4.1Cleaning the Primary Anti-Stray Sheet ..................................................................................................... 1- 12
1.4.2Cleaning the Developing Anti-Stray Sheet ............................................................................................... 1- 12
1.4.3Cleaning the Cleaner Side Scraper............................................................................................................ 1- 12
1.4.4Cleaning the Photosensitive Drum ............................................................................................................ 1- 13
Chapter 2 Standards and Adjustments
2.1 Image Adjustment Basic Procedure .................................................................................................................. 2- 1
2.1.1Making Pre-Checks ..................................................................................................................................... 2- 1
2.1.2Making Checks on the Printer Unit (1/2) .................................................................................................... 2- 2
2.1.3Making Checks on the Printer Unit (2/2) .................................................................................................... 2- 4
2.1.4Making Checks on the Reader Unit ............................................................................................................ 2- 6
2.1.5Checking the Potential System.................................................................................................................... 2- 9
2.1.6Checking the Surface Potential Control System ....................................................................................... 2- 12
2.1.7Potential Control System Conversion Table ............................................................................................. 2- 16
2.1.8Emergency Measures for a Fault in the Potential Sensor.......................................................................... 2- 22
2.2 Image Adjustments.......................................................................................................................................... 2- 23
2.2.1Standards of Image Position...................................................................................................................... 2- 23
2.2.2Checking the Image Position..................................................................................................................... 2- 23
2.2.3Adjusting Side Registration....................................................................................................................... 2- 23
2.2.4Adjusting the Image Leading Edge Margin .............................................................................................. 2- 25
2.2.5Adjusting the Left/Right Non-Image Width ............................................................................................. 2- 26
2.2.6Adjusting the Leading Edge Non-Image Width........................................................................................ 2- 26
2.3 Scanning System ............................................................................................................................................. 2- 27
2.3.1After Replacing the Reader Controller PCB ............................................................................................. 2- 27
2.3.2When Replacing the CCD Unit ................................................................................................................. 2- 27
2.3.3Adjusting the Position of the No. 1/No. 2 Mirror Base............................................................................. 2- 28
2.3.4When Replacing the Platen Board Glass................................................................................................... 2- 29

Contents
2.3.5When Replacing the Reading Glass ..........................................................................................................2- 29
2.3.6When Replacing the Scanning Lamp ........................................................................................................2- 29
2.3.7When Replacing the Inverter PCB ............................................................................................................2- 29
2.4 Laser Exposure System....................................................................................................................................2- 31
2.4.1When Replacing the Scanner Unit.............................................................................................................2- 31
2.5 Image Formation System.................................................................................................................................2- 32
2.5.1Outline of the Charging Wire ....................................................................................................................2- 32
2.5.2Routing the Charging Wire........................................................................................................................2- 32
2.5.3Routing the Grid for the Primary Charging Assembly..............................................................................2- 33
2.5.4Adjusting the Height of the Charging Wire...............................................................................................2- 34
2.5.5Mounting the Cleaning Blade....................................................................................................................2- 35
2.5.6Mounting the Side Seal..............................................................................................................................2- 35
2.6 Fixing System ..................................................................................................................................................2- 36
2.6.1Applying Grease After Replacing the Fixing Roller .................................................................................2- 36
2.6.2Adjusting the Nip Width............................................................................................................................2- 36
2.6.3Adjusting the Position of the Fixing Web Solenoid (SL9)........................................................................2- 36
2.6.4After Replacing the Fixing Web................................................................................................................2- 37
2.6.5Adjusting the Position of he Fixing Inlet Guide Solenoid (SL1) ..............................................................2- 37
2.6.6Adjusting the Position of the Fixing Inlet Guide.......................................................................................2- 37
2.7 Electrical Components.....................................................................................................................................2- 39
2.7.1When Replacing the DC Controller PCB ..................................................................................................2- 39
2.7.2When Replacing the HVT PCB.................................................................................................................2- 39
2.7.3After Replacing the HDD ..........................................................................................................................2- 39
2.7.4When Replacing the Main Controller PCB ...............................................................................................2- 39
2.8 Pickup/Feeding System ...................................................................................................................................2- 41
2.8.1Orientation of the Deck/Cassette Pickup Roller ........................................................................................2- 41
2.8.2Orientation of the Separation Roller..........................................................................................................2- 41
2.8.3Orientation of the Feeding Roller of the Deck/Cassette Pickup Assembly...............................................2- 41
2.8.4Adjusting the Pressure of the Separation Roller of the Deck/Cassette......................................................2- 42
2.8.5Adjusting the Pressure of the Separation Roller of the Manual Feed Tray ...............................................2- 42
2.8.6Adjusting the Position of the Pickup Solenoid (SL3, SL4) of the Cassette 3/4 ........................................2- 43
2.8.7Adjusting the Position of the Delivery Flapper Solenoid (SL5)................................................................2- 43
2.8.8Adjusting the Position of the Right Deck Pickup Solenoid (SL6) ............................................................2- 43
2.8.9Adjusting the Position of the Left Deck Pickup Solenoid (SL7)...............................................................2- 44
2.8.10Adjusting the Position of the Reversing Flapper Solenoid(SL8) ............................................................2- 44
2.8.11Attaching the Side Guide Timing Belt in the Manual Feed Tray Assembly...........................................2- 44
2.8.12Adjusting the Position of the Lifter Motor M20 (M21) of the Cassette 3 (cassette 4)............................2- 44
Chapter 3 Error Code
3.1 Error Code Details .............................................................................................................................................3- 1
3.1.1Detail Error Code.........................................................................................................................................3- 1
3.1.2E602 in Detail ............................................................................................................................................3- 23
3.2 Error Code (SEND) .........................................................................................................................................3- 28
3.2.1Results of Self-Diagnosis ..........................................................................................................................3- 28
3.2.2Error Codes................................................................................................................................................3- 30
Chapter 4 User Mode Items

Contents
4.1 Common Settings .............................................................................................................................................. 4-1
4.2 Timer Settings ................................................................................................................................................... 4-4
4.3 Adjustment/Cleaning......................................................................................................................................... 4-5
4.4 Report Output .................................................................................................................................................... 4-6
4.5 System Control Settings .................................................................................................................................... 4-7
4.6 Copier Specifications ...................................................................................................................................... 4-10
4.7 Transmission/Reception Settings .................................................................................................................... 4-11
4.8 Box Settings .................................................................................................................................................... 4-14
4.9 Printer Settings ................................................................................................................................................ 4-15
4.10 Address Book Settings .................................................................................................................................. 4-17
4.11 Voice Guide Settings..................................................................................................................................... 4-19
Chapter 5 Service Mode
5.1 DISPLAY (Status Display Mode)..................................................................................................................... 5- 1
5.1.1 COPIER ...................................................................................................................................................... 5- 1
5.1.1.1 COPIER List........................................................................................................................................ 5- 1
5.1.2 FEEDER ................................................................................................................................................... 5- 10
5.1.2.1 FEEDER List..................................................................................................................................... 5- 10
5.2 I/O (I/O Display Mode)................................................................................................................................... 5- 12
5.2.1Outline ....................................................................................................................................................... 5- 12
5.2.2<R-CON> .................................................................................................................................................. 5- 13
5.2.3<FEEDER> ............................................................................................................................................... 5- 15
5.2.4<SORTER> ............................................................................................................................................... 5- 17
5.2.5<MN-CON> .............................................................................................................................................. 5- 27
5.2.6<P-CON>................................................................................................................................................... 5- 28
5.3 ADJUST (Adjustment Mode) ......................................................................................................................... 5- 37
5.3.1 COPIER .................................................................................................................................................... 5- 37
5.3.1.1 COPIER List...................................................................................................................................... 5- 37
5.3.2 FEEDER ................................................................................................................................................... 5- 43
5.3.2.1 FEEDER List..................................................................................................................................... 5- 43
5.3.3 SORTER ................................................................................................................................................... 5- 44
5.3.3.1 SORTER List..................................................................................................................................... 5- 44
5.4 FUNCTION (Operation/Inspection Mode)..................................................................................................... 5- 45
5.4.1 COPIER .................................................................................................................................................... 5- 45
5.4.1.1 COPIER List...................................................................................................................................... 5- 45
5.4.2 FEEDER ................................................................................................................................................... 5- 60
5.4.2.1 FEEDER List..................................................................................................................................... 5- 60
5.5 OPTION (Machine Settings Mode) ................................................................................................................ 5- 63
5.5.1 COPIER .................................................................................................................................................... 5- 63
5.5.1.1 COPIER List...................................................................................................................................... 5- 63
5.5.2 FEEDER ................................................................................................................................................... 5- 97
5.5.2.1 FEEDER List..................................................................................................................................... 5- 97
5.5.3 SORTER ................................................................................................................................................... 5- 98
5.5.3.1 SORTER List..................................................................................................................................... 5- 98
5.5.4 BOARD..................................................................................................................................................... 5- 99
5.5.4.1 BOARD List...................................................................................................................................... 5- 99
5.6 TEST (Test Print Mode)................................................................................................................................ 5- 100
5.6.1 COPIER .................................................................................................................................................. 5- 100

Contents
5.6.1.1 COPIER List ....................................................................................................................................5- 100
5.7 COUNTER (Counter Mode)..........................................................................................................................5- 103
5.7.1 COPIER...................................................................................................................................................5- 103
5.7.1.1 COPIER List ....................................................................................................................................5- 103
Chapter 6 Outline of Components
6.1 Clutch/Solenoid .................................................................................................................................................6- 1
6.1.1Clutches and Solenoids................................................................................................................................6- 1
6.2 Motor .................................................................................................................................................................6- 4
6.2.1Motors..........................................................................................................................................................6- 4
6.3 Fan ...................................................................................................................................................................6- 10
6.3.1Fans............................................................................................................................................................6- 10
6.4 Sensor ..............................................................................................................................................................6- 13
6.4.1Sensors.......................................................................................................................................................6- 13
6.5 Switch ..............................................................................................................................................................6- 20
6.5.1Switches.....................................................................................................................................................6- 20
6.6 Lamps, Heaters, and Others.............................................................................................................................6- 22
6.6.1Lamps, Heaters, and Others.......................................................................................................................6- 22
6.7 PCBs ................................................................................................................................................................6- 25
6.7.1PCBs ..........................................................................................................................................................6- 25
Chapter 7 System Construction
7.1 Construction.......................................................................................................................................................7- 1
7.1.1Functional Construction...............................................................................................................................7- 1
7.1.2Wiring Diagram of the Major PCBs............................................................................................................7- 1
7.1.3Controlling the Main Motor (M2) ...............................................................................................................7- 2
7.2 System Construction..........................................................................................................................................7- 4
7.2.1System Configuration with Input/Output Accessories ................................................................................7- 4
7.2.2System Configuration with Printing/Transmission Accessories (230V).....................................................7- 5
7.2.3Functions and Printing/Transmission Accessories (230V)..........................................................................7- 6
7.3 Product Specifications .......................................................................................................................................7- 7
7.3.1Product Specifications .................................................................................................................................7- 7
7.4 Function List....................................................................................................................................................7- 10
7.4.1Paper Types ...............................................................................................................................................7- 10
7.4.2Printing Speed............................................................................................................................................7- 10
Chapter 8 Upgrading
8.1 Outline of Upgrading the Machine .................................................................................................................... 8-1
8.2 Outline of the Service Support Tool.................................................................................................................. 8-2

Chapter 1 Maintenance
and Inspection

Contents
Contents
1.1 Periodically Replaced Parts................................................................................................................................ 1-1
1.1.1 Outline ......................................................................................................................................................... 1-1
1.1.2 Reader Unit.................................................................................................................................................. 1-1
1.1.3 Printer Unit .................................................................................................................................................. 1-1
1.2 Durables and Consumables ................................................................................................................................ 1-3
1.2.1 Outline ......................................................................................................................................................... 1-3
1.2.2 Reader Unit.................................................................................................................................................. 1-3
1.2.3 Printer Unit .................................................................................................................................................. 1-3
1.3 Scheduled Servicing Basic Procedure................................................................................................................ 1-6
1.3.1 Scheduled Servicing Basic Procedure ......................................................................................................... 1-6
1.3.2 Periodical Servicing Chart Reader Unit ...................................................................................................... 1-7
1.3.3 Periodical Servicing Chart Printer Unit....................................................................................................... 1-8
1.3.4 Points to Note for Periodical Servicing..................................................................................................... 1-10
1.4 Cleaning............................................................................................................................................................ 1-12
1.4.1 Cleaning the Primary Anti-Stray Sheet..................................................................................................... 1-12
1.4.2 Cleaning the Developing Anti-Stray Sheet ............................................................................................... 1-12
1.4.3 Cleaning the Cleaner Side Scraper............................................................................................................ 1-12
1.4.4 Cleaning the Photosensitive Drum ............................................................................................................ 1-13

Chapter 1
1-1
1.1 Periodically Replaced Parts
1.1.1 Outline 0009-5822
iR5570 / iR6570
Some parts of the machine must be replaced on a periodical basis for the machine to maintain a specific level of
performance. They must be replaced regardless of the presence/absence of external changes or damage, as the
performance of the machine will be considerably affected once they fail.
If possible, plan any replacement to coincide with a scheduled visit.
The intervals indicated may vary depending on the site environment and user habit.
- Checking the Timing of Replacement
The timing of replacement may be checked using the following service mode items:
COPIER > COUNTER > PRDC-1
1.1.2 Reader Unit 0009-5823
iR5570 / iR6570
The reader unit does not have parts that require periodical replacement.
1.1.3 Printer Unit 0009-5824
iR5570 / iR6570
T-1-1
As of December 2004
N
o. Part name Part No. Q'ty Life Remarks
1 Primary, pre-transfer,
transfer, separation
charging wire
FB4-3687-000 AR 500,000 (*)
2 Primary grid wire FY1-0883-000 AR 500,000

3 thermistor unit FK2-0809-000 1 500,000 Main thermister +
shutter thermister
4 Sub thermistor FM2-4161-000 1 500,000
5 Primary charging wire
cleaner 1
FF5-6883-000 2 500,000 Strengthened polish
type (blue)
6 Primary charging wire
cleaner 2
FF5-6884-000 2 500,000 Strengthened polish
type (blue)
7 Transfer charging wire
cleaner 1
FF5-6883-000 1 500,000 Strengthened polish
type (blue)
8 Transfer charging wire
cleaner 2
FF5-6884-000 1 500,000 Strengthened polish
type (blue)
9 Separation charging wire
cleaner
FF5-3090-000 2 500,000
10 Pre-transfer charging wire
cleaner
FF5-3090-000 1 500,000
11 Air filter 1 FC6-3482-000 1 500,000
12 Air filter 2 FC6-3483-000 1 500,000
13 Ozone filter FC6-3693-000 1 500,000
*: Do not use the old type (gold plated). After replacement of the charge wire, be sure to execute
wire cleaning in service mode. (COPIER > FUNCTION > CLEANING > WIRECLN)
As of December 2004
N
o. Part name Part No. Q'ty Life Remarks

Chapter 1
1-3
1.2 Durables and Consumables
1.2.1 Outline 0009-5829
iR5570 / iR6570
Some parts of the machine may have to be replaced once or more over the period of machine warranty because of
wear or damage. Replace them as needed by referring to the table of estimated lives (expressed in terms of the
number of prints they make).
The intervals indicated may vary depending on the site environment and user habit.
Making Checks When Replacing Durables
Use the following service mode items to find out when to replace parts:
- Machine
COPIER > COUNTER > DRBL-1
- Accessory
COPIER > COUNTER > DRBL-2
1.2.2 Reader Unit 0009-5830
iR5570 / iR6570
The reader unit does not have parts that are classified as "consumables" or "durables."
1.2.3 Printer Unit 0009-5831
iR5570 / iR6570
T-1-2
As of December 2004
No
.Part name Part No. Q't yLife Remarks
1 Developing cylinder FM2-3082-000 1 1,000,00
0

2 Developing assembly roll FB6-6569-000 2 1,000,00
0
3 Cleaner separation claw FB2-6899-000 3 500,000
4 Cleaning blade FA9-3995-000 1 1,000,00
0
Both edges are used;
each for 500,000;
apply toner upon
replacement
5 Primary corona assembly FM2-3069-000 1 1,000,00
0
6 Transfer/separation corona
assembly
FG6-5911-000 1 1,000,00
0
7 Pre-transfer corona
assembly
FM2-4217-000 1 1,000,00
0
8 Pre-separation charging
assembly scraper
FA4-1867-000 1 500,000
9 Fixing roller FC6-3566-000 1 500,000 *1
10 Pressure roller FC6-3838-000 1 500,000 *2
11 Fixing web FY1-1157-000 1 500,000
12 Insulating bushing FC6-3502-000 2 500,000 *3
13 Delivery upper separation
claw
FB5-3625-000 6 500,000
14 Delivery lower separation
claw
FA2-9037-000 2 1,000,00
0
15 Pickup roller rear FF5-1220-000 4 250,000 Real use number of
sheets (Each holder
uses 1 pc.)
16 Pickup roller front FF5-1221-000 4 250,000 Real use number of
sheets (Each holder
uses 1 pc.)
17 Pickup/feeding roller (deck,
cassette)
FF5-9779-000 4 250,000 Real use number of
sheets (Each holder
uses 1 pc.)
18 Separation roller (deck,
cassette)
FB2-7777-020 4 250,000 Real use number of
sheets (Each holder
uses 1 pc.)
As of December 2004
No
.Part name Part No. Q't yLife Remarks

19 Pickup/feeding roller
(manual feed roller)
FB1-8581-000 1 120,000 Real use number of
sheets
20 Separation roller (manual
feed tray)
FB5-0873-000 1 120,000 Real use number of
sheets
*1 As the fixing roller is used more and more, its surface tends to become discolored because of
heat. The change, however, will not affect the performance of the roller. Also, note that the roller
surface varies in color among manufacturers and the fact will not affect the roller performance.
*2 As the pressure roller is used more and more, its rubber surface can start to discolor. The change,
however, will not affect its performance or output images. Further, the physical properties of the
roller can permit its surface to start to wrinkle. The roller, however, is free of wrinkles when it is
heated and its performance will not be affected, thus not requiring replacement.
*3 Replace simultaneously with fixing roller. When you replace bushings, apply about 20 mg of
grease (Molykote HP-300; CK-8012) on the inner and outer surfaces of the bushing until there is a
white coating covering the entire sources.
As of December 2004
No
.Part name Part No. Q't yLife Remarks

Chapter 1
1-6
1.3 Scheduled Servicing Basic Procedure
1.3.1 Scheduled Servicing Basic Procedure 0009-5839
iR5570 / iR6570
- As a rule, provide scheduled servicing every 250,000 prints.
- Check with the Service Book before setting out for a scheduled service visit, and take parts for which replacement
is expected.
- If the power plug is left connected for a long time in a place subject to dust, humidity, or oil smoke, a fire hazard
is a possibility (i.e., the dust collecting around the plug can absorb moisture, resulting in insulating failure). Be
sure to disconnect the power plug on a periodical basis, and wipe off the dust and dirt collecting around it.
<Work Procedure>
1) Report to the person in charge, and check the general condition.
2) Record the counter reading, and check the faulty prints.
3) Make the following checks, and clean/adjust the items that are indicated:
T-1-3
4) Check the waste toner case.
If half full or more, dispose of the waste toner in a vinyl bag or the like for collection; or, replace the waste toner case.
Items
Test copy against image density standard
for soiling of back of paper
for clarity of characters
for margin
for fixing misplaced registration, soiled
back of paper
for margin standards (single-
sided print)
leading edge: 4.0+1.5/-1.0mm
left edge: 2.5+/- 1.5mm
(double-sided print) leading edge: 4.0+1.5/-1.0mm
left edge: 2.5+/- 2.0mm