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Canon iR8500 Service Manual
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Canon iR8500 Service Manual

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Service Manual

iR8500 Series
Apr 5 2005
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Summary of Contents for Canon iR8500

  • Page 1: Service Manual

    Service Manual iR8500 Series Apr 5 2005...
  • Page 2 Contents Contents Chapter 1 Introduction 1.1 System Construction ..........................1- 1 1.1.1 System Configuration .............................. 1- 1 1.1.2 System Configuration .............................. 1- 1 1.1.3 System Configuration .............................. 1- 2 1.1.4 Printing/Transmitting Accessories System Configuration..................1- 3 1.1.5 Printing/Transmitting Accessories System Configuration..................1- 4 1.1.6 Printing/Transmitting Accessories System Configuration..................
  • Page 3 Contents 1.2.4.10 System Settings ................................... 1- 37 1.2.4.11 System Settings ................................... 1- 38 1.2.4.12 Network Settings (in "System Settings") ..........................1- 39 1.2.4.13 Copy Settings..................................1- 42 1.2.4.14 Copy Settings..................................1- 43 1.2.4.15 Communications Settings ..............................1- 43 1.2.4.16 Mail Box Settings ................................. 1- 44 1.2.4.17 Address Book Settings.................................
  • Page 4 Contents 2.2.15 Mounting the Charging Assembly........................2- 29 2.2.16 Mounting the Pickup Assembly..........................2- 31 2.2.17 Checking the Developing Assembly ........................2- 32 2.2.18 Checking the Developing Assembly ........................2- 32 2.2.19 Mounting the Control Panel ..........................2- 33 2.2.20 Mounting the Pickup Assembly..........................2- 35 2.2.21 Mounting the Pickup Assembly..........................
  • Page 5 Contents 2.5.1 Checking the Contents............................2- 56 2.5.2 Checking the Contents............................2- 56 2.5.3 Checking the Contents............................2- 57 2.5.4 Installing the Card Reader-D1 ..........................2- 57 2.5.5 Installing the Card Reader-D1 ..........................2- 61 2.5.6 Installing the Card Reader-D1 ..........................2- 64 2.5.7 Installing the Card Reader-D1 ..........................2- 67 2.6 Installing the NE Controller........................
  • Page 6 Contents 4.3.6 Construction of the System Software(iR105) ......................4- 11 4.3.7 E602 in Detaill ............................... 4- 11 4.4 Shut-Down Sequence..........................4- 17 4.4.1 Overview................................4- 17 4.4.2 Flow of Operation ..............................4- 17 4.5 Image Processing .............................4- 18 4.5.1 Outline(iR105) ............................... 4- 18 4.5.2 Overview of the Image Flow ..........................
  • Page 7 Contents 4.7.5.9 When Replacing the HDD..............................4- 33 4.7.6 Controller Fan ................................4- 33 4.7.6.1 Removing the Rear Cover ..............................4- 33 4.7.6.2 Removing the Rear Cover ..............................4- 34 4.7.6.3 Removing the Rear Cover ..............................4- 34 4.7.6.4 Removing the System Connector Cover..........................4- 34 4.7.6.5 Removing the Main Controller Box Cover..........................
  • Page 8 Contents 5.4.1.1 Removing the Reader Unit..............................5- 27 5.4.1.2 Sliding the Reader Unit ................................5- 27 5.4.2 CCD Unit ................................5- 27 5.4.2.1 Removing the CCD Unit................................. 5- 27 5.4.2.2 Removing the CCD Unit................................. 5- 28 5.4.2.3 Removing the CCD Unit................................. 5- 28 5.4.2.4 When Replacing the CCD Unit ..............................
  • Page 9 Contents 5.4.13.2 Removing the Original Size Sensor 1/2 ..........................5- 44 5.4.13.3 Removing the Original Size Sensor ............................. 5- 44 5.4.13.4 Removing the Original Size Sensor 3/4 ..........................5- 44 5.4.13.5 Removing the Original Size Sensor 3/4 ..........................5- 45 5.4.14 Scanner Home Position Sensor ...........................5- 45 5.4.14.1 Removing the HP Sensor..............................
  • Page 10 Contents 7.3.3 Controlling the Laser Scanner Motor........................7- 7 7.3.3.1 Outline...................................... 7- 7 7.4 Parts Replacement Procedure ........................7- 9 7.4.1 Laser Scanner Unit..............................7- 9 7.4.1.1 Removing the Laser Unit ................................. 7- 9 7.4.1.2 Removing the Laser Unit ................................. 7- 9 7.4.1.3 Removing the Laser Unit .................................
  • Page 11 Contents 8.6.1 Outline..................................8- 25 8.6.2 Controlling the Developing Assembly ........................8- 25 8.6.3 Controlling the Toner Cartridge Drive Mechanism....................8- 26 8.6.4 Controlling the Developing Bias..........................8- 27 8.6.5 Detecting the Toner Level and Controlling the Toner Supply Mechanism.............8- 28 8.7 Transfer Mechanism..........................8- 31 8.7.1 Transfer Guide Bias ...............................8- 31 8.7.1.1 Outline....................................
  • Page 12 Contents 8.9.12 Developing Cylinder Clutch ..........................8- 50 8.9.12.1 Remove the Developing Cylinder Clutch ..........................8- 50 8.9.12.2 Remove the Developing Cylinder Clutch ..........................8- 51 8.9.13 Transfer/Separation Charging Assembly......................8- 51 8.9.13.1 Removing the Transfer/Separation Charging Assembly ...................... 8- 51 8.9.14 Pre-Transfer Exposure LED ..........................
  • Page 13 Contents 9.4.2 Detecting the Presence/Absence of Paper ......................9- 21 9.4.3 Detecting the Level of Paper..........................9- 22 9.4.4 Cassette 3/4................................9- 23 9.4.5 Markings on the Width Guide Rail .........................9- 24 9.4.6 Paper Size ................................9- 24 9.5 Manual Feed Pickup Unit ......................... 9- 27 9.5.1 Pickup Operation ..............................9- 27 9.5.2 Detecting the Paper Size ............................9- 27 9.6 Deck .................................
  • Page 14 Contents 9.10.8.1 Removing the Feeding Roller............................... 9- 61 9.10.8.2 Orientation of the Feeding Roller ............................9- 61 9.10.8.3 Removing the Manual Feed Roller............................9- 61 9.10.8.4 Mounting the Manual Feed Roller ............................9- 62 9.10.9 Manual Separation Roller ............................ 9- 62 9.10.9.1 Removing the Separation Roller ............................
  • Page 15 Contents 10.1.4 Outline..................................10- 2 10.1.5 Major Components...............................10- 2 10.1.6 Fixing Drive System Outline..........................10- 3 10.1.7 Controlling the Fixing Roller Drive Mechanism ....................10- 4 10.1.8 Controlling the Cleaning Belt Drive Mechanism....................10- 5 10.1.9 Controlling the Thermistor Reciprocating Mechanism ..................10- 5 10.1.10 Controlling the Upper Separation Claw Reciprocating Mechanism..............10- 6 10.2 Basic Sequence............................
  • Page 16 Contents 10.5.8.2 Removing the Thermal Switch Unit............................ 10- 29 10.5.8.3 Mounting the Thermal Switch Unit ............................. 10- 29 10.5.8.4 Mounting the Thermal Switch Unit ............................. 10- 29 10.5.9 Fixing Heater ..............................10- 30 10.5.9.1 Removing the Main/Sub Heater ............................10- 30 10.5.9.2 Removing the Main/Sub Heater ............................
  • Page 17 Contents 11.4.3.1 Backup Battery................................... 11- 16 11.4.4 Energy-Saving Function.............................11- 16 11.4.4.1 Outline....................................11- 16 11.4.4.2 Outline....................................11- 17 11.4.4.3 Outline....................................11- 17 11.4.4.4 Outline....................................11- 18 11.4.4.5 Power Supply Mode ................................11- 18 11.4.4.6 Standby Mode (normal operation)............................11- 19 11.4.4.7 Power Save Mode................................
  • Page 18 Contents 11.5.18.2 Removing the DC Controller PCB ............................ 11- 36 11.5.18.3 When Replacing the DC Controller PCB.......................... 11- 36 11.5.18.4 When Replacing the DC Controller PCB.......................... 11- 36 11.5.19 Control Panel Controller PCB .......................... 11- 36 11.5.19.1 Removing the Control Panel Controller (CPU) PCB ......................11- 36 11.5.19.2 Removing the Control Panel Controller (CPU) PCB ......................
  • Page 19 Contents 11.5.38.1 Removing the Separation Fan (FM13) ..........................11- 48 11.5.38.2 Removing the Separation Fan (FM13) ..........................11- 49 11.5.39 Developing Fan ..............................11- 49 11.5.39.1 Removing the Developing Fan (FM15) ..........................11- 49 11.5.39.2 Removing the Developing Fan (FM15) ..........................11- 50 11.5.40 Delivery Anti-Adhesion Fan..........................11- 50 11.5.40.1 Removing the Delivery Anti-Adhesion Fan (FM17) ......................
  • Page 20 Contents Chapter 14 Standards and Adjustments 14.1 Image Adjustment Basic Procedure......................14- 1 14.1.1 Making Pre-Checks ............................. 14- 1 14.1.2 Making Pre-Checks ............................. 14- 1 14.1.3 Making Checks on the Printer Side (Checking the Images) ................14- 2 14.1.4 Making Checks on the Printer Side (Checking the Density Slope)..............14- 2 14.1.5 Making Checks on the Printer Side (Checking the Solid Black Density) .............
  • Page 21 Contents 14.7.2 Electrical Components Requiring Work After Replacement................14- 33 14.7.3 Electrical Parts Requiring Work After Replacement...................14- 33 14.7.4 When Replacing the HDD ..........................14- 33 14.7.5 When Replacing the Main Controller PCB ......................14- 33 14.7.6 Replacing the Main Controller PCB ........................14- 34 14.7.7 When Replacing the Main Controller PCB ......................14- 34 14.7.8 When Replacing the HV-DC PCB ........................14- 34 14.7.9 When Replacing the DC Controller PCB......................14- 35...
  • Page 22 Contents 14.8.33 Position of the Side Paper Deck Pickup Roller Releasing Solenoid ..............14- 67 14.8.34 Position of the Side Paper Deck Pickup Roller Releasing Solenoid ..............14- 67 14.8.35 Fitting the Side Guide Timing Belt of the Manual Feed Tray Assembly............14- 67 14.8.36 Attaching the Timing Belt for the Manual Feed Tray Assembly Side Guide ............
  • Page 23 Contents 15.3.1.1 Clutches ..................................... 15- 19 15.3.1.2 Clutches ..................................... 15- 20 15.3.1.3 Clutches ..................................... 15- 20 15.3.1.4 Solenoids ................................... 15- 21 15.3.1.5 Solenoids ................................... 15- 22 15.3.1.6 Solenoids ................................... 15- 23 15.3.2 Motor ..................................15- 24 15.3.2.1 Motors ....................................15- 24 15.3.2.2 Motors ....................................
  • Page 24 Contents 16.1.4 Error Code List..............................16- 3 16.1.5 Error Code List..............................16- 4 16.2 Error Code Details ..........................16- 6 16.2.1 Error Code Detail ..............................16- 6 16.2.2 Error Code Detail ............................... 16- 15 16.2.3 Error Code Detail ............................... 16- 24 16.2.4 E602 in Detaill..............................
  • Page 25 Contents 17.3.8 FEEDER................................17- 49 17.3.9 SORTER ................................17- 51 17.3.10 MN-CON(iR105)...............................17- 58 17.4 ADJUST (Adjustment Mode) ........................ 17- 60 17.4.1 COPIER ................................17- 60 17.4.1.1 Copier List ..................................17- 60 17.4.1.2 Copier List ..................................17- 68 17.4.1.3 Copier List ..................................17- 75 17.4.1.4 Copier List ..................................
  • Page 26 Contents 17.8.1.4 Copier List ..................................17- 227 Chapter 18 Upgrading 18.1 Outline ..............................18- 1 18.1.1 Outline of Version upgrade ..........................18- 1 18.1.2 Outline of Version upgrade ..........................18- 1 18.1.3 Outline of the Service Support Tool........................18- 1 18.2 Making Preparations ..........................18- 5 18.2.1 Registering the Firmware.............................
  • Page 27 REVISION 1 FY8-13H3-010 AUG. 2001 COPYRIGHT© 2001 CANON INC. CANON iR8500/7200 REV.1 AUG. 2001 PRINTED IN JAPAN (IMPRIME AU JAPON)
  • Page 28 INTRODUCTION 2 Outline of the Manual This Service Manual provides basic facts and figures about the iR8500 series and the side paper deck designed as an option to the copier; use the information for servicing the ma- chine in the field, thus ensuring the initial product quality.
  • Page 29 2.2 Side Paper Deck-M1 ....1-13 1.3 High-Performance Controller, 3 Names of Parts ........1-14 Large-Capacity Hard Disk for 3.1 External View (iR8500) ... 1-14 High-Level Processing ....1-1 3.2 External View (iR7200) ... 1-16 1.4 Ease of Use ........ 1-1 3.3 Cross Section (iR8500) ....
  • Page 30 Gain Correction and Offset the Scanning Lamp .... 2-61 Correction of the CCD 3.9.5 Removing the Scanner Output ........ 2-88 Motor ......... 2-61 5.2.4 A/D Conversion of the CCD Output ....2-88 xiii COPYRIGHT© 2001 CANON INC. CANON iR8500/7200 REV.1 AUG. 2001...
  • Page 31 10.4.5 Switches ......2-209 System (iR8500) ....2-132 10.4.6 PCBs ........ 2-211 8.3 List of Changes Made to 10.4.7 Others ......2-223 the Pickup/Feeding System 11 Side Paper Deck ......2-227 (iR7200) ......... 2-133 11.1 Outline ......2-227 CANON iR8500/7200 REV.1 AUG. 2001...
  • Page 32 Rotation, and Enlargement/ 4.7.3 Return to Standby Mode (off mode → standby) ..3-16 Reduction ......3-10 2.3.2 SDRAM ......3-10 4.8 Power Supply Off Mode ..3-16 2.3.3 HDD ........3-10 COPYRIGHT© 2001 CANON INC. CANON iR8500/7200 REV.1 AUG. 2001...
  • Page 33 7 Installing the Network LIPS Printer the Work ........4-37 Kit -B1 ..........4-69 3.1.1 Attachments ....... 4-37 7.1 Installing the Network LIPS 3.2 Unpacking ........ 4-39 Printer Kit-B1 ......4-69 COPYRIGHT© 2001 CANON INC. CANON iR8500/7200 REV.1 AUG. 2001...
  • Page 34 Printer Side (2/2) ... 6-5 Cassette Pickup Roller ..6-20 1.1.4 Making Checks on 2.4.2 Orientation of the Deck/ the Scanner Side (iR8500) ... 6-6 Cassette Separation 1.1.5 Making Checks on Roller ......... 6-21 the Reader Unit (iR7200) ..6-7 2.4.3...
  • Page 35 3.1.8 Others ........ 6-73 2.7.3 When Replacing the Reader 3.2 Sample Faulty Images ....6-76 Controller PCB 3.3 Troubleshooting Faulty (iR8500) ......6-45 Images ........6-77 3.3.1 The copy is too light (halftone area) ....6-77 xviii REV.1 AUG. 2001...
  • Page 36 (no margin) ... 6-88 4.1.30 E215 ......... 6-110 3.3.18 The copy is wobbly ... 6-89 4.1.31 E218 3.3.19 The copy is foggy (Indicated if iR8500) ..6-110 horizontally ......6-90 4.1.32 E219 3.3.20 The copy has poor (Indicated if iR8500) ..6-111 sharpness ......
  • Page 37 CONTENTS 4.1.38 E240 ......... 6-112 4.1.65 E732 ......... 6-125 4.1.39 E241 (iR8500) ....6-112 4.1.66 E733 ......... 6-126 4.1.40 E243 ......... 6-113 4.1.67 E737 ......... 6-126 4.1.41 E248 (iR7200) ....6-113 4.1.68 E740 ......... 6-126 4.1.42 E251 4.1.69 E741 ......... 6-127 (Indicated if iR8500) ..
  • Page 38 OFF .. 6-146 6.10.1 Main Controller PCB ..6-180 4.1.96 The “Add Paper” message 6.10.2 Reader Controller PCB fails to go OFF (iR8500) ......6-181 (deck right/left) ....6-147 6.10.3 Reader Controller PCB 4.1.97 The “Add Paper Message” (iR7200) ......6-181 fails to go OFF 6.10.4 DC Controller PCB ..
  • Page 39 CONTENTS APPENDIX 1 GENERAL TIMING CHART ... A-1 3 GENERAL CIRCUIT DIAGRAM ..A-7 2 LIST OF SIGNALS/ 4 Special Tools Table ......A-13 ABBREVIATIONS ......A-3 5 Solvents/Oils ........A-16 SERVICE MODE 1 Construction of Service Mode .... S-1 2.4 FUNCTION ......
  • Page 40 REVISION 0 FY8-13H3-000 MAR. 2001 COPYRIGHT© 2001 CANON INC. CANON iR8500 REV.0 MAR. 2001 PRINTED IN JAPAN (IMPRIME AU JAPON)
  • Page 41 Exposure System ....2-25 closed) of the DADF ..2-10 2.4 Image Formation System ..2-27 2.1.8 Detecting Dust in Stream 2.4.1 Changes in the Image Reading Mode ....2-12 formation System ....2-27 COPYRIGHT© 2001 CANON INC. CANON iR8500 REV.0 MAR. 2001...
  • Page 42 2.1 Outline ........3-8 2.3.3 HDD ........3-10 2.2 Input Image Processing ....3-9 2.4 Processing Output Image ..3-10 2.2.1 Image Data from the Reader 2.4.1 Smoothing ......3-10 Unit ........3-9 COPYRIGHT© 2001 CANON INC. CANON iR8500 REV.1 MAR. 2001...
  • Page 43 2.2 Side Paper Deck ......5-8 4.2.2 Work Procedure 2 ....5-19 3 Scheduled Servicing Work ....5-9 5 Mechanical System ......5-23 4 Scheduled Service Chart ....5-13 5.1 No. 1 Mirror Base ....5-23 COPYRIGHT© 2001 CANON INC. CANON iR8500 REV.0 MAR. 2001...
  • Page 44 5.13.1 Removing the Registration 5.7.1 Removing the BD Unit ..5-50 Clutch ........ 5-70 5.8 Components Around 5.13.2 Removing the Registration the Process Unit ....... 5-51 Brake Clutch ...... 5-71 xiii COPYRIGHT© 2001 CANON INC. CANON iR8500 REV.1 MAR. 2001...
  • Page 45 5.18.3 Removing the Fixing/ 5.22.2 After Replacing the DC Feeding Unit Cover ... 5-91 Controller PCB ....5-113 5.18.4 Removing the Rear 5.22.3 Removing the Differential Cover ......... 5-91 PCB ........5-113 COPYRIGHT© 2001 CANON INC. CANON iR8500 REV.0 MAR. 2001...
  • Page 46 Roller ......... 6-21 (ADF mode) ....... 6-17 2.4.3 Orientation of the Feeding 2.2 Scanner System ......6-18 Roller of the Deck/Cassette 2.2.1 Replacing the Scanner Pickup Assembly ....6-21 Drive Cable ......6-18 COPYRIGHT© 2001 CANON INC. CANON iR8500 REV.1 MAR. 2001...
  • Page 47 2.5 Fixing System ......6-37 Sensor ........6-67 2.5.1 Points to Note When 2.10 Checking Mounting the Fixing the Photointerrupters ....6-68 Heater ......... 6-37 3 Troubleshooting Image Faults ..6-74 COPYRIGHT© 2001 CANON INC. CANON iR8500 REV.0 MAR. 2001...
  • Page 48 3.3.11 The copy has white lines 4.1.19 E067 ......... 6-106 (vertical) ......6-86 4.1.20 E068 ......... 6-107 3.3.12 The copy has white spots 4.1.21 E069 ......... 6-108 (horizontal) ......6-88 4.1.22 E100 ......... 6-109 xvii COPYRIGHT© 2001 CANON INC. CANON iR8500 REV.1 MAR. 2001...
  • Page 49 4.1.85 The drum heater fails to (DC controller PCB), E711- operate ......6-146 0003 (Main controller 4.1.86 The “Add Toner” message PCB) ........ 6-124 fails to go OFF ....6-146 xviii COPYRIGHT© 2001 CANON INC. CANON iR8500 REV.0 MAR. 2001...
  • Page 50 Backing Up Data ..... 6-211 6.4 Fans ........6-166 8.2.4 Downloading Backup 6.5 Sensor 1 ......... 6-168 Data ........6-216 6.6 Sensor 2 ......... 6-170 8.2.5 Managing Backup Data ... 6-220 COPYRIGHT© 2001 CANON INC. CANON iR8500 REV.1 MAR. 2001...
  • Page 51 2.1 DISPLAY ........S-6 5 BOARD .......... S-122 2.2 I/O ..........S-23 5.1 OPTION ......... S-122 2.3 ADJUST ........S-49 ERROR CODE 1 Error Codes ........E-1 1.1 Introduction ....... E-1 COPYRIGHT© 2001 CANON INC. CANON iR8500 REV.0 MAR. 2001...
  • Page 52 PARTS CATALOG iR8500/85/85+/7200/8070 Jan 18 2005...
  • Page 53 Contents Parts List Index iR8500/85/85+/7200/8070 ..............1-1 iR8500/85/85+/7200/8070 ASSEMBLY LOCATION DIAGRAM ........2-1 SPECIAL TOOLS ..............2-7 EXTERNAL COVERS, PANELS, ETC. (IR8500/7200/8570/8070 TYPE) EXTERNAL COVERS, PANELS, ETC. (IR8500B/85/85+ TYPE) 2-14 100A MACHINE FRONT PLATE ...........2-18 INTERNAL COMPONENTS 1 ..........2-22 INTERNAL COMPONENTS 2 ..........2-26 INTERNAL COMPONENTS 3 ..........2-29...
  • Page 54 CONTROL PANEL CPU PCB ASSEMBLY ......2-205 CONTROL PANEL INVERTER PCB ASSEMBLY ....2-206 DC CONTROLLER PCB ASSEMBLY ........2-207 READER CONTROLLER PCB ASSEMBLY (IR8500/8570N TYPE) 2- READER CONTROLLER PCB ASSEMBLY (IR7200/8070 TYPE) 2- POTENTIAL MEASURING PCB ASSEMBLY .....2-210 INVERTER PCB ASSEMBLY ..........2-212 AC DRIVER PCB ASSEMBLY ..........2-213...
  • Page 55 Contents H.V. DC TRANSFORMER PCB ASSEMBLY .......2-216 LIST OF CONNECTORS .............2-218...

  • Page 56: Parts Catalog

    PARTS CATALOG REVISION 1 FY8-31F7-010 OCT. 2001 I - 1 00/8500P/7200/7200P REV.1 OCT. 2001 PRINTED IN U.S.A. [IMPRIME AU U.S.A.
  • Page 57 EXTERNAL COVERS, PANELS, ETC. 360. DUPLEXING FEEDER ASSEMBLY 101. MACHINE FRONT PLATE 102. INTERNAL COMPONENTS 1 420. MIRROR ASSEMBLY 1 (iR8500/8500P TYPE) 103. INTERNAL COMPONENTS 2 421. MIRROR ASSEMBLY 1 (iR7200/7200P TYPE) 104. INTERNAL COMPONENTS 3 430. MIRROR ASSEMBLY 2 (iR8500/8500P TYPE) 105.
  • Page 58 − Ethernet Network Interface Adapter iN-E3 − ASSEMBLY LOCATION DIAGRAM G10. NETWORK MULTI PDL PRINTER KIT ASSEMBLY LIST OF STANDARD FASTENERS NUMERICAL INDEX (iR8500/8500P/7200/7200P) NUMERICAL INDEX NUMERICAL INDEX (Ethernet Network Interface Adapter iN-E3) Ⅰ-6 COPYRIGHT © 2001 CANON INC. CANON iR8500/8500P/7200/7200P REV.1 OCT. 2001...