Canon iR1600/iR2000 Copier Service Manual, 2002–2009 (P/N FY8-13HJ-000)

Canon factory service manual for the iR1600 and iR2000, P/N FY8-13HJ-000, Revision 0 (September 2001), covering technical theory, installation, maintenance, troubleshooting, and repair.

PDF Search, Bookmarks, and Circuit Detail

Text search and diagram detail: Searchable text and embedded bookmarks provide access to chapters and major sections. Small pin numbers and signal labels in the large General Circuit Diagram require zooming.

The ZIP download contains one printable, 488-page English PDF. This total includes the cover, 19 preliminary pages, 15 chapter and appendix divider pages, 29 blank or “Blank Page” pages, and two closing publication pages.

Reader, Paper-Feed, and Fixing-System Service

The following selected service topics illustrate the manual’s coverage. Further material includes control-panel functions and user-mode settings.

• Reader and laser exposure: Copyboard glass, CS unit, reader motor, and laser/scanner unit removal, with gain adjustment, ADF-related CS-position adjustment, laser APC, and BD synchronization.

• Image formation: Drum-unit, developing-assembly, and transfer-roller removal, with explanations of charging, developing, transfer-bias control, and toner detection.

• Fixing-system repair: Step-by-step procedures for fixing-assembly removal, pressure-roller service, and fixing roller, heater, and separation-claw removal and installation.

• Paper pickup and feeding: Cassette and multifeeder retry, registration, and jam-detection logic, plus removal procedures for rollers, sensors, solenoids, registration clutch, and drive assembly.

• Cassette and delivery options: 1-Cassette Unit-F1 and 3-Cassette Unit-H1 coverage for the iR1600, 2-Cassette Unit-G1 for the iR2000, and Inner 2-Way Tray-B1 service.

• Installation and relocation: Site selection, unpacking, drum and toner setup, image checks, data initialization, printer testing, Card Reader-E1 installation, and Image RAM installation.

• Service diagnostics: D-RAM, CCD, PRINT, FACULTY, and BOOK tests, image and feeding fault charts, self-diagnostic error tables, firmware updating, wiring diagrams, and timing charts.

Canon issued this manual for qualified service personnel; its electrical test points, service-mode settings, and special-tool requirements assume trained copier technicians.

System Operation and Accessory Differences

The six functional blocks are pickup/feeding, original reading/processing, laser exposure, image formation, communication, and control. Circuit descriptions connect the DC controller, image processor, analog processor, power supply, and high-voltage control to power-on and printing sequences, main-motor operation, sensors, and loads.

The F1 cassette unit takes its drive from the host’s main motor. Lower cassettes in G1/H1 configurations use the 2/3-cassette controller and cassette pickup motor; the host’s additional pickup-motor removal reference applies to the iR2000. B1 tray coverage explains delivery selection, flapper and solenoid control, sensors, jam detection, and complete unit removal.

Accessory scope: Dedicated accessory service chapters cover the cassette units and B1 tray. The ADF-J1 and other accessories require their own service manuals, although this publication includes the installation and Finisher-L1 diagnostic and firmware references described here.

Image Faults, Service Mode, and Electrical References

The image-adjustment workflow uses the NA-3 test sheet and internal print patterns to distinguish reader-side faults from printer-side faults before following the troubleshooting tables. Those tables address density, fogging, lines, blank or black output, blur, registration, fixing, power, pickup, toner messages, double feeding, and wrinkling.

Adjustment coverage includes image position, gain auto adjustment after CS or analog-processor replacement, fixing-nip inspection, sensor checks, PCB replacement setup, and jam/error reports. Test Mode explains BLACK and ENDURANCE patterns, control-panel and energy-save tests, and BOOK tests; self-diagnosis supplies machine and Finisher-L1 error causes and connector or assembly checks.

Electrical references include Wiring Diagram of the Major PCBs, the paired Wiring Diagram of Electrical Components sheets, General Timing Chart, General Circuit Diagram, cassette-unit circuit sheets, and the Inner 2-way tray circuit sheet.

The special-tools appendix identifies digital multimeter FY9-2002, door switch TKN-0093, NA-3 Test Sheet FY9-9196, meter extension pins FY9-3038 and FY9-3039, and downloader PCB FY9-2034.

Firmware, Maintenance, and Repair Cautions

Firmware coverage explains system-software loading over USB and Finisher-L1 updating. The documented Service Support Tool procedure uses the iR1600 selection for either copier and specifies Windows 98, 98SE, or 2000.

The maintenance chapter lists no periodically replaced parts for the copier, cassette units, or B1 tray. The copier’s durable-parts table instead provides part numbers and reference life data for wear-based replacement, supported by service counters.

The laser/scanner is removable as an assembly and has no internal field adjustment. The drum unit is not intended for disassembly, and PCB coverage supports board diagnosis and replacement rather than component repair.

Disturbing the CS rail guide’s factory-set screws can upset alignment, while powering up with the CS at the left edge can put the reader motor out of sync. Image-processor PCB replacement also requires preservation of control data and transfer of JP201.

The fuser thermistor and thermal switch are excluded from field cleaning or disassembly because deformation or incorrect adjustment can create a fire hazard.

Disconnect the power plug before disassembly and follow the manual’s laser, high-voltage, hot-fuser, toner, and lithium-battery precautions.

Examples of Fixing-Nip and Image-Margin Specifications

For fixing-nip inspection using an A3 or 11 × 17 solid-black test sheet, the center contact width is specified as 2.9–4.6 mm. The allowable left-to-right width difference is no more than 0.5 mm; the nip is inspected rather than adjusted.

Image-position standards for prints made in Direct mode specify a leading-edge margin of 3.0 ± 1.5 mm. Separate procedures distinguish printer-unit margin adjustment from copy image-position adjustment.