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  • Brand:   Canon
  • Models included:
    • Canon GP-160

File Information:

  • Type:   Factory Service Manual (FSM)
  • Language:   English
  • Number of pages:   797
  • File size:  ∼ 8.09  MB
  • File Format:   PDF only
  • SME Watermarks:   None
  • Password lock:   No
  • Edit/copy/modify:   Yes
  • SKU:   BMCN-1009

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SERVICE
MANUAL
REVISION 0
FY8-13G2-000 FEB. 1999
GP160F/160DF/160
IMPORTANT
THIS DOCUMENTATION IS PUBLISHED BY CANON INC., JAPAN, TO SERVE AS A SOURCE OF
REFERENCE FOR WORK IN THE FIELD.
SPECIFICATIONS AND OTHER INFORMATION CONTAINED HEREIN MAY VARY SLIGHTLY
FROM ACTUAL MACHINE VALUES OR THOSE FOUND IN ADVERTISING AND OTHER PRINTED
MATTER.
ANY QUESTIONS REGARDING INFORMATION CONTAINED HEREIN SHOULD BE DIRECTED
TO THE COPIER SERVICE DEPARTMENT OF THE SALES COMPANY.
THIS DOCUMENTATION IS INTENDED FOR ALL SALES AREAS, AND MAY CONTAIN INFORMA-
TION NOT APPLICABLE TO CERTAIN AREAS.
Printed in Japan
Imprimé au Japon
Use of this manual should
be strictly supervised to
tial information.
Prepared by
OFFICE IMAGING PRODUCTS TECHNICAL SUPPORT DEPARTMENT 3
OFFICE IMAGING PRODUCTS TECHNICAL SUPPORT DIVISION
CANON INC.
5-1, Hakusan 7-chome, Toride-shi, Ibaraki 302-8501 Japan
This service manual provides basic information required for performing field service
to maintain the product quality and functions of the this machine. The structure of the
manual is as described below.
Each chapter consists of the following sections.
Chapter 1, “Introduction,” : Features, specifications, operation methods, copying
process.
Chapter 2, “Basic operation,” : Explanation of the machine’s basic operations
Chapter 3, “Exposure system,” : Explanation of the exposure system’s mechanical /
electrical system operating principles, timing, disassembly, assembly and adjustment
methods.
Chapter 4, “Image processing system,” : Explanation of the CCD, analogue / digital
image processing, disassembly, assembly and adjustment methods.
Chapter 5, “Laser exposure system,” : Explanation of the laser exposure system’s
mechanical / electrical system operating principles, timing, disassembly, assembly and
adjustment methods.
Chapter 6, “Image formation system,” : Explanation of the image formation system’s
mechanical / electrical system operating principles, timing, disassembly, assembly and
adjustment methods.
Chapter 7, “Pick-up / Feed system,” : Explanation of the pick-up / feed system’s
mechanical / electrical system operating principles, timing, disassembly, assembly and
adjustment methods.
Chapter 8, “Fixing system,” : Explanation of the fixing system’s mechanical / electri-
cal system operating principles, timing, disassembly, assembly and adjustment meth-
Chapter 9, “Outer cover / auxiliary control system,” : Explanation of the outer cover /
auxiliary control system’s mechanical / electrical system operating principles, timing,
disassembly, assembly and adjustment methods.
Chapter 10, “Cassette feeder,” : Explanation of the cassette feeder’s mechanical /
electrical system operating principles, timing, disassembly, assembly and adjustment
methods.
Chapter 11, “Installation,” : Conditions relating to the place of installation, and the
installation procedures.
INTRODUCTION
Material Name
Main unit service manual
G3 FAX manual
Content
The main unit and cassette feeder’s; functions, mechanism,
disassembly, assembly, adjustment methods, etc.
The main unit’s G3 facsimile functions.
The functions, mechanism, disassembly, assembly, adjust-
ment method, etc. of the main unit’s ADF.
Chapter 12, “Maintenance and Inspection,” : Table of periodic replacement parts and
consumables replacement targets, periodic service list and parts to be cleaned during a
customer service call.
Chapter 13, “Troubleshooting,” : Standards / adjustments, operation failure counter-
measures and delivery failure countermeasures
Appendix : General timing chart, general circuit diagram, etc..
The explanations in this manual are based on the following principles.
1. Each chapter gives an overview of each function’s purpose, role and the connection
between the electrical and mechanical systems as well as the operation timing of
each part.
In the outline diagram, the signal shows the mechanical drive transmission.
When the signal is shown with a signal name, it indicates the electric signal
In the explanation of this units digital circuit, “1” is indicated when the signal’s volt-
age level is high, and “0” is indicated when it is low. However, the voltage value will
differ depending on the electrical circuit. Furthermore, the * in the signal v alue
[DRMD*] shows the DRMD signal is “0” and ON.
In each chapter, [Power supply ON] indicates the power supply SW has been turned
“ON”, the front door, etc., has been shut, and power is being supplied to the copier.
2. This unit utilizes micro processors, however, due to the impossibility of checking the
micro processor’s internal operation, an explanation of the micro processor’s opera-
tion has been omitted. Furthermore, assuming that internal repair of the print circuit
board will not take place on the customer’s premises, the explanation of the circuit in
the print circuit board’s circuit is limited to an outline explanation using a block dia-
gram. Consequently, the electrical circuit explanations consist of 2 types, from the
sensors to the main circuit board’s input section, and from the main circuit board’s
output section to the load, and block diagrams by function.
Changes of the contents made for the sake of product improvements will be notified
in Service Information (Technical Information).
Gaining a sound and thorough understanding of the copier through careful reading
of this service manual and the subsequently issued Service Information (Technical
Information) bulletins is the only way to develop the technical skill necessary to prolong
product quality and functionality and the practical ability to be able to determine the
cause of breakdowns.
System
configuration
Main unit configuration
ADF-H1
Cassette Unit D1 Cassette unit E1
Modem board NCU board Modular
board Super G3 FAX board 8MB expanded memory
Digital black and white copier and facsimile
Digital black and white copier (with ADF)
Digital black and white copier
(Copy board cover model)
Installation options
Standard equipment Standard equipment Option
Option Option
Option Option
Option Option
Option Option
Standard equipment
Option
GP160F
GP160DF
CONTENTS
CHAPTER 1 INTRODUCTION
CHAPTER 2 BASIC OPERATION
I. FEATURES
II. SPECIFICATIONS
III. NAMES OF PARTS
A. External view
B. Cross sectional diagram
IV. OPERATION EXPLANATION
A. Control panel
B. Basic operation
C. Advanced features
D. User mode
V. ROUTINE MAINTENANCE TO BE
CARRIED OUT BY THE USER
VI. SAFETY
A. Laser beam safety
B. Toner safety
VII. COPYING PROCESS
A. Outline
I. BASIC OPERATION
A. Function configuration
B. Copy operation overview
II. ELECTRICAL CIRCUIT OVERVIEW
III. BASIC SEQUENCES
IV. MAIN MOTOR
V. PRINCIPAL CIRCUIT PCB
INPUT/OUTPUT
CHAPTER 3 EXPOSURE SYSTEM
CHAPTER 4 IMAGE PROCESSING SYSTEM
I. OPERATION OVERVIEW
A. Overview
B. Exposure system sequence
II. SCANNER DRIVE SYSTEM
A. Document scanner motor
B. Charging the magnification ratio
C. Scanning lamp control
III. DISASSEMBLY, ASSEMBLY
A. Scanning lamp
B. Document scanning motor
I. OVERVIEW
II. ANALOG IMAGE PROCESSING
A. Overview
B. CCD/CCD drive circuit
C. A-D conversion circuit /
ABC circuit
III. DIGITAL IMAGE PROCESSING
A. Overview
B. Shading correction
C. Magnification ratio process
D. Edge emphasis / smoothing
process
E. Logarithmic correction
F. Half tone density processing
G. Binarisation
IV. DISASSEMBLY, ASSEMBLY
A. CCD unit
CHAPTER 5 LASER EXPOSURE SYSTEM
I. OVERVIEW
II. BD SIGNAL GENERATION
A. Overview
B. BD generation / detection
III. LASER DRIVER CIRCUIT
A. Operation
B. Laser light intensity control
IV. LASER SCANNER MOTOR
CONTROL
A. Operation outline
V. DISASSEMBLY, ASSEMBLY
A. Laser scanner unit
CHAPTER 6 IMAGE FORMATION SYSTEM
CHAPTER 7 PICK-UP / FEEDING SYSTEM
CHAPTER 8 FIXING SYSTEM
I. OVERVIEW
A. Construction
II. PRIMARY CHARGING ROLLER BIAS
CONTROL
A. Outline
B. Control operation
III. TRANSFER CHARGING ROLLER BIAS
CONTROL
A. Overview
B. Bias control
IV. SEPARATION STATIC CHARGE
ELIMINATOR BIAS CONTROL
A. Operation
V. DEVELOPING BIAS CONTROL
A. Outline
B. Operation
VI. RE-CHARGE BIAS CONTROL
A. Operation
VII. CARTRIDGE DETECTION
A. Operation
I. OVERVIEW
A. Construction Overveiw
II. PICK-UP FEEDING OPERATION
A. Overveiw
III. CASSETTE PICK-UP MECHANISM
A. Pick-up oparation
B. Retry pick-up
C. Paper size detection
IV. MULTI-FEEDER PICK-UP
A. Overview
B. Multi-feeder pick-up mechanism
C. Multi-feeder retry pick-up
D. Multi-feeder paper size setting
V. PAPER FEEDING OPERATION
A. Paper leading edge detection
B. Paper width detection
VI. JAM DETECTION
A. Overview
B. Types of Jam
C. Jam sequence
VII. DISASSEMBLY, ASSEMBLY
A. Cassette feeding assembly
B. Multi-feeder assembly
C. Registration roller assembly
D. Feeder assembly
I. OPERATIONAL OVERVIEW
A. Overview
B. Fixing pressure roller cleaning
II. FIXING CONTROL
A. Fixing temperature control
B. Fixing heater safety mechanism
C. Fixing assembly malfunction
detector
III. DISASSEMBLY, ASSEMBLY
A. Removing the fixing assembly
CHAPTER 9 EXTERNAL / AUXILIARY MECHANISM
CHAPTER 10 CASSETTE FEEDER
CHAPTER 11 INSTALLATION
CHAPTER 12 MAINTENANCE AND INSPECTION
I. CONTROL PANEL
A. Overview
II. POWER SUPPLY
A. Low-voltage power supply circuit
B. High voltage power supply circuit
C. Energy save function control
III. FAN
A. Rotation control mechanism
IV. BACK-UP BATTERY
A. Back-up function
B. Back-up Data
V. DISASSEMBLY, ASSEMBLY
A. Control panel
B. Main Motor
C. DC controller PCB
D. Image processor PCB
E. DC power supply PCB
I. OVERVIEW
II. OVERVIEW OF THE ELECTRICAL
CIRCUITS
A. Overview
III. FEEDER CONTROLLER PCB
INPUT AND OUTPUT
IV. OPERATION OVERVIEW
A. Overview
B. Basic Sequence
V. FEEDER MOTOR CONTROL
A. Operation
VI. JAM DETECTION
A. Overview
B. Jam Sensing
VII. DISASSEMBLY, ASSEMBLY
A. Removing the feeder motor
B. Removing the pick-up/feeder/
separation motor
C. Removing the pick-up unit
I. CHOOSING AN SUITABLE INSTALLATION
LOCATION
II. UNPACKING AND INSTALLATION
A. Opening the package and removing
the packing materials
B. Installing the cartridge
C. Loading paper into the cassette
D. Loading paper into the
multi-feeder
E. Attaching the tray/Power cord
F. Checking the Copy image
G. Setting the Fax machine function
I. PERIODIC REPLACEMENT PARTS
II. ESTIMATED LIFESPAN OF CONSUMABLE
III. BASIC SERVICING PROCEDURES
IV. CARTRIDGE STORAGE AND
HANDLING
A. Storage when the packing seal is
intact
B. Storage and handling when the
packing seal has been opened
APPENDIX
CHAPTER 13 TROUBLESHOOTING
I. STANDARDS AND ADJUSTMENTS
A. Machanical system
B. Electrical System
II. IMAGE AND MACHINE MALFUNCTION
COUNTERMEASURES
A. Initial check
B. Treatment procedures by faulty
image type
C. Operation malfunction
countermeasures
III. FAULTY FEEDING
COUNTERMEASURES
A. Overview
B. Copy paper jam
C. Faulty feeding
IV. ELECTRICAL PARTS POSITIONS/
FUNCTIONS
A. Clutches, solenoids
B. Motor, fan
C. Sensors
D. Switches, lamps, miscellaneous
E. PCBs
F. Variable resistor(VR)/LED/check
pin listed by PCB plate
V. SERVICE MODE
A. Overview
B. Operating Procedures
C. Service mode menu list
D. SSSW Default Setting
E. Parameter settings
F. Test Mode (TEST MODE)
VI. REPORTS
A. User reports
B. Service report
VII. USER ERRORS
VIII. SERVICE ERRORS
A. GENERAL TIMING CHART
B. SIGNALS AND ABBREVIATIONS
C. GENERAL CIRCUIT DIAGRAM
D. LIST OF SPECIAL TOOLS
E. SOLVENTS AND OILS
CHAPTER 1
INTRODUCTION
I. FEATURES
II. SPECIFICATIONS
III. NAMES OF PARTS
A. External view
B. Cross sectional diagram
IV. OPERATION EXPLANATION
A. Control panel
B. Basic operation
C. Advanced features
D. User mode
V. ROUTINE MAINTENANCE TO BE
CARRIED OUT BY THE USER
VI. SAFETY
A. Laser beam safety
B. Toner safety
VII. COPYING PROCESS
A. Outline
This chapter provides an overview of the unit’s specifications, operating method and
copying process.
REVISION 0
FEB. 1999 FY8-23B3-000
GP160F/160DF/160
Printed in Japan
Imprimé au Japon
Use of this manual should be strictly
supervised to avoid disclosure of confi-
dential information.
IMPORTANT
THIS DOCUMENTATION IS PUBLISHED BY CANON INC., JAPAN, TO SERVE AS A SOURCE OF
REFERENCE FOR WORK IN THE FIELD.
SPECIFICATIONS AND OTHER INFORMATION CONTAINED HEREIN MAY VARY SLIGHTLY FROM
ACTUAL MACHINE VALUES OR THOSE FOUND IN ADVERTISING AND OTHER PRINTED MAT-
ANY QUESTIONS REGARDING INFORMATION CONTAINED HEREIN SHOULD BE DIRECTED TO
THE COPIER SERVICE DEPARTMENT OF THE SALES COMPANY.
THIS DOCUMENTATION IS INTENDED FOR ALL SALES AREAS, AND MAY CONTAIN
INFORMATION NOT APPLICABLE TO CERTAIN AREAS.
Prepared by
OFFICE IMAGING PRODUCTS TECHNICAL SUPPORT DEPARTMENT 3
OFFICE IMAGING PRODUCTS TECHNICAL SUPPORT DIVISION
CANON INC.
5-1, Hakusan 7-chome, Toride-shi, Ibaraki 302-8501 Japan
CONTENTS
CHAPTER 1 MAINTENANCE AND SERVICING
A. Main Unit
1. Periodic replacement parts
2. Estimated lifespan of
consumable parts
B. ADF
1. Periodic replacement parts
2. Consumables replacement
targets
C. Basic servicing procedures
D. Cartridge storage and handling
1. Storage when the packing
seal is intact
2. Storage and handling when
the packing seal has been
opened
CHAPTER 2 STANDARDS AND ADJUSTMENTS
A. Mechanical system
1. Right and left registration
adjustment
2. Image leading edge margin
adjustment
3. Attaching the scanner wire
4. Mirror positioning adjustment..2-3
5. Printer unit receptacle
connector mount positioning
adjustment
6. Check the pressure (nip width)
of the fixing pressure roller
B. Electrical System
1. Automatic shading
adjustment
2. Image positioning
adjustment
3. Sensor check
4. Image processor PCB
replacement procedures
C. ADF height adjustment
1. Height check
2. Height adjustment
D. Skew feed adjustment
1. Checking ADF skew feed
2. Adjusting skew feed
E. Adjusting image position
1. Checking image position
2. Adjusting image position
CHAPTER 3 ARRANGEMENT AND FUNCTIONS
OF ELECTRICAL PARTS
A. Clutches, solenoids
B. Motor, fan
C. Sensors
D. Switches, lamps, miscellaneous
E. PCBs
F. Variable resistor (VR)/LED/check
pin listed by PCB plate
1. Image processor PCB
2. DC controller PCB/Sensor
3. Feeder controller PCB
(Cassette feeder)
4. Modem board
5. NCU board
6. ADF
A. User errors
CHAPTER 4 SERVICE MODE
A. Overview
B. Operating Procedures
C. Service mode menu list
D. SSSW Default Setting
E. Parameter settings
1. SSSW settings
2. Menu switch settings
(#2 MENU)
3. Numeric settings by type
(#3 NUMERIC Param.)
4. Special settings
(#4A SPECIAL)
5. Country type setting
(#5 TYPE)
6. Document scanning function
setting (#6 SCANNER)
7. Printer parameter settings
(#7 PRINTER)
8. Initialization of setting values
(#8 CLEAR)
9. ROM information display
(#9 ROM)
10.CS SET (mirror mount
initialization setting)
E. Test Mode (TEST MODE)
1. Overview
2. Test Mode menu
3. D-RAM test <1:DRAM>
4. CCD test <2:CCD TEST>
5. PRINT test <3:PRINT>
6. MODEM NCU test
<4:MODEM NCU>
7. AGING test
<5:AGING TEST>
8. FACULTY test
<6:FACULTY TEST>
9. BOOK scanning test
<8:BOOK TEST>
CHAPTER 5 SELF DIAGNOSIS
APPENDIX
A. GENERAL TIMING CHART
B. SIGNALS AND
ABBREVIATIONS
C. GENERAL CIRCUIT DIAGRAM ..A-5
1. Image processor PCB
2. DC controller PCB
3. Cassette Feader
D. SPECIFICATIONS
1. Type
2. Method
3. Functions
4. Other
5. Copy speed
6. Communication section
7. Scanning system
8. Recording system
9. Memory
10.Transmission functions
11.Dialing
12.Reception functions
13.Activity management
function
CATALOG
REVISION 1
FEB. 1999 FY8-31E3-010
PREFACE
This Parts Catalog contains listings of parts used in the Canon GP160PF/GP160F/
GP160DF/GP160/LP3000/LP3010. Diagrams are provided with the listings to aid the
service technician in identifying clearly, the item to be orderd.
Whenever ordering parts, consult this Parts Catalog for all of the information per-
taining to each item. Be sure to include, in the Parts Request, the full item
description, the item part number, and the quantity.
Canon Inc.
Office Imaging Products Technical Support Dept.3
Office Imaging Products Technical Support Div.
5-1, Hakusan 7-chome,
Toride-shi, Ibaraki 302-8501, Japan
Use of this manual should be
strictly supervised to avoid dis-
mation.
CONTENTS
ASSEMBLY LOCATION DIAGRAM
EXTERNAL COVERS, PANELS, ETC.
INTERNAL COMPONENTS
SEPARATION ASSEMBLY
UPPER GUIDE ASSEMBLY
FEEDING ASSEMBLY
STAMP ASSEMBLY
ADF CONNECTING PCB ASSEMBLY
SENSOR PCB ASSEMBLY
LIST OF CONNECTORS
-CASSETTE FEEDING MODULE - D1-
-CASSETTE FEEDING MODULE - E1-
ASSEMBLY LOCATION DIAGRAM
INTERNAL COMPONENTS 1
INTERNAL COMPONENTS 2 (E1 TYPE)
CASSETTE
PICK-UP ROLLER ASSEMBLY
FEEDER CONTROLLER PCB ASSEMBLY
LIST OF CONNECTORS
-SUPER G3 FAX BOARD-
ASSEMBLY LOCATION DIAGRAM
FAX KIT
-GP160PF/GP160F/GP160DF/GP160//LP3000/LP3010-
ASSEMBLY LOCATION DIAGRAM
EXTERNAL COVERS, PANELS, ETC.
INTERNAL COMPONENTS 1
INTERNAL COMPONENTS 2
INTERNAL COMPONENTS 3
INTERNAL COMPONENTS 4 (100V)
PRINTER INTERNAL COMPONENTS 1
PRINTER INTERNAL COMPONENTS 2
PRINTER INTERNAL COMPONENTS 3
COPYBOARD COVER ASSEMBLY
(GP160/LP3010/120V)
SCANNER DRIVE ASSEMBLY
MAIN DRIVE ASSEMBLY
MULTI DRIVE ASSEMBLY
CASSETTE
PAPER PICK-UP ASSEMBLY
MANUAL FEED TRAY ASSEMBLY
REGISTRATION ROLLER ASSEMBLY
PAPER FEED BELT ASSEMBLY
MIRROR ASSEMBLY 1
MIRROR ASSEMBLY 2
MIRROR ASSEMBLY 4
CCD LENS MOUNT ASSEMBLY
FIXING ASSEMBLY (100V)
FIXING ASSEMBLY (120/230V)
DC CONTROLLER ASSEMBLY
FLASH ROM PCB ASSEMBLY
IMAGE PROCESSOR PCB ASSEMBLY
SENSOR PCB ASSEMBLY
LIST OF CONNECTORS
-ADF - H1-
CONTENTS
MODEM CONTROLLER PCB ASSEMBLY (LP3000)
MODEM CONTROLLER PCB ASSEMBLY
(120V/GP160F/GP160PF)
NCU BOARD PCB ASSEMBLY (LP3000/120V)
NCU BOARD PCB ASSEMBLY (GP160F/GP160PF)
MODULAR PCB ASSEMBLY
LIST OF CONNECTORS
LIST OF STANDARD FASTENERS
NUMERICAL INDEX
(GP160PF/GP160F/GP160DF/GP160/LP3000/LP3010)
NUMERICAL INDEX (ADF - H1)
NUMERICAL INDEX
(CASSETTE FEEDING MODULE - D1)
(CASSETTE FEEDING MODULE - E1)
NUMERICAL INDEX (SUPER G3 FAX BOARD)


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