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

• Canon factory service manual with document code FY8-13HJ-000, Revision 0 (September 2001); a 488-page PDF covering the iR1600 and iR2000.
• Matches feed options to host models: 1-Cassette Unit-F1 and 3-Cassette Unit-H1 for the iR1600, 2-Cassette Unit-G1 for the iR2000, plus Inner 2-Way Tray-B1 service coverage.
• Covers copyboard glass, CS unit, reader motor, and laser/scanner unit removal, with gain auto adjustment, ADF-related CS-position auto adjustment, laser APC, BD synchronization, and image-position setup.
• Details drum-unit, developing-assembly, transfer-roller, and fixing-assembly repair, including fuser removal, pressure-roller service, fixing roller/heater/separation-claw removal and installation, and nip inspection.
• Traces cassette and multifeeder pickup/feeding faults through retry, registration, delay-jam, stationary-jam, and cover-open logic, with removal procedures for rollers, sensors, solenoids, clutch, drive assembly, and the iR2000-only pickup motor.
• Covers site selection, installation, and relocation, from unpacking and drum/toner setup through image checks, data initialization, printer testing, Card Reader-E1 installation, and Image RAM installation.
• Provides service-mode diagnostics and electrical references: sensor checks, D-RAM/CCD/PRINT/FACULTY/BOOK tests, image and feeding fault charts, self-diagnostic error tables, firmware updating, wiring diagrams, timing charts, and accessory circuit sheets.

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

Six-System Architecture and Workshop Procedures

Six functional blocks are covered: pickup/feeding, original reading/processing, laser exposure, image formation, communication, and control. The manual maps the DC controller, image processor, analog processor, power supply, and high-voltage control to power-on and printing sequences, main-motor control, sensors, and loads. Reader coverage extends to CS handling and calibration, while the image-formation material follows charging, developing, and transfer-bias control along with toner and waste-toner detection.

Pickup coverage separates the built-in cassette, multifeeder, and accessory cassette operation. The F1 is driven from the host's main motor; lower cassettes in G1/H1 configurations use the 2/3-cassette controller and cassette pickup motor. The B1 chapter covers delivery selection, flapper/solenoid control, sensors, jam detection, and complete unit removal.

Serial-prefix coverage is explicit. iR1600 entries are UHR, UJJ, SDM, SED, TDW, TEN, QSK, RSM, QEN, QFB, QSL, RSN, REN, RFJ, RSP, and RSQ; iR2000 entries are UHS, UJK, SDP, SEE, TDY, TEP, QSM, RSS, QEQ, QFC, QSN, REV, REP, RFK, and RST.

Service Mode, Fault Isolation, and Electrical References

Troubleshooting begins with an image-adjustment workflow using the NA-3 test sheet and internal print patterns to separate reader-side faults from printer-side faults. It then covers image position, gain auto adjustment after CS or analog-processor replacement, fixing-nip inspection, sensor checks, PCB replacement setup, and jam/error reports. Fault tables address density, fogging, lines, blank or black output, blur, registration, fixing, power, pickup, toner messages, double feeds, and wrinkles.

Test Mode documents D-RAM and CCD checks, BLACK and ENDURANCE print patterns, sensor/control-panel/energy-save tests, and BOOK tests. Self-diagnosis adds machine and Finisher-L1 error-code tables with possible 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 coverage explains system-software loading over USB and Finisher-L1 updating. This period procedure instructs technicians to select iR1600 for either copier in Canon's Service Support Tool and specifies Windows 98, 98SE, or 2000.

Accessory Scope and Repair Cautions

Dedicated accessory service chapters are limited to the cassette units and B1 tray. The ADF-J1 and other accessories require their own manuals, although this publication does include Card Reader-E1 and Image RAM installation, plus Finisher-L1 error-code and firmware references. The laser/scanner is removable only as an assembly and is not field-adjustable internally; PCB coverage likewise supports board-level diagnosis and replacement rather than component repair.

The maintenance chapter states that the copier, cassette units, and B1 have no periodically replaced parts; it instead supplies service-counter guidance, part numbers, and life data for wear-based durables. Two easy-to-miss repair traps are called out: disturbing the CS rail guide's factory-set screws can ruin alignment, while powering up with the CS at the left edge can put the reader motor out of sync. During image-processor PCB replacement, failing to preserve control data and transfer JP201 resets user and service settings; the fuser thermistor and thermal switch are also 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.