1999 Canon GP405/335 Copier Service Manual (P/N FY8-13FV-000)

Canon’s GP405/335 Service Manual (P/N FY8-13FV-000), January 1999 Revision 0, covers field service for the GP405 and GP335 multifunction copiers.

Searchable Text, Bookmarks and Circuit Detail

Finding text and reading diagrams: The main text is searchable, with embedded bookmarks for chapters and major sections. The Image Fault Samples sheet on PDF p. 454 has no searchable text. Small connector, pin and signal labels in the circuit diagrams require zooming for comfortable reading.

One printable PDF contains 682 pages, including the original cover, preliminary pages, appendix, production/back-cover pages and 22 blank pages.

Imaging, Paper Transport and Fixing Service

The following is a selection of the manual’s contents; other topics include installation of the Control Card V and Copy Data Controller-A1.

• Exposure and scanning: Step-by-step removal procedures for the scanning lamp, CCD unit and laser scanner assembly, plus scanner cable routing and mirror adjustment.

• Image formation: Drum unit removal, cleaning and replacement; developing assembly disassembly, toner sensor replacement, transfer roller service and image adjustment.

• Paper transport: Cassette pick-up, multifeeder, registration, duplexing and delivery mechanisms, with jam detection, roller replacement and Paper Deck-B1 service.

• Fixing assembly: Heater and roller removal, thermistor and thermal switch mounting, cleaning belt replacement and lower fixing roller pressure adjustment.

• Fault diagnosis: Image-fault tables, malfunction troubleshooting, error histories, sensor I/O checks, load tests, service modes and test-pattern printing.

• Electrical reference: PCB pinouts, wiring diagrams, timing charts, cross-section and exploded component views, with scheduled servicing charts and replacement-part references.

Written for field service personnel, this manual assumes familiarity with copier operation and electrical fault isolation.

Core System Architecture and Fault Tracing

This manual maps out the copier’s seven functional systems and the interaction between its scanner and printer components. It explains the image processor PCB, composite power supply and DC controller PCB, including the different sequences used for direct and memory copying.

The “Inputs to and Outputs from the Major PCBs,” “General Timing Chart” and “General Circuit Diagram” let technicians relate sensor states and control signals to the operating sequence when tracing faults on the workbench. The “Cross Section” and “Side Paper Deck General Circuit Diagram” provide mechanical and accessory-circuit references.

Image Quality, Drum Service and Fixing Repair

AE processing, shading correction and copy-density adjustment are covered alongside symptom-specific checks for light, foggy, streaked or blank copies. Component replacement instructions identify the follow-up adjustments needed after work on the scanning lamp, image processor PCB or drum unit.

The drum section covers unit removal, cleaning and replacement. Fixing repair goes further into individual components, including upper and lower rollers, heaters, separation claws and the cleaning belt, with nip checks and lubrication instructions.

Accessory Coverage and Service Equipment

Paper Deck-B1 procedures cover its lifter cable, drive motors, feeding rollers and registration adjustment. The system integration chapter covers the SCSI Interface Board-D1 and Expansion Board Base Unit-C1; detailed service for the Handset-C1, Super G3 FAX Board-F1 and Printer Board requires separate manuals. Canon also specifies the separately available Copier Basic Series for shared technical fundamentals.

Scanner alignment calls for the Mirror Positioning Tool FY9-3009-040. Electrical checks specify probe extensions FY9-3038-000 and FY9-3039-000; the PCB connectors do not accept ordinary meter probes directly.

Connector and Memory Precautions

Connecting the paper deck to the cassette pedestal connector and powering on can blow the deck PCB fuse and may require PCB replacement. For fax-equipped machines, the manual specifies a one-hour power-off work limit because stored fax images depend on the backup battery.

Working on commercial copiers involves high voltage and complex moving parts, so always ensure you have the proper technical qualifications and follow standard shop safety practices before diving into the machine.

A Preview of Memory and Operating Conditions

The standard image memory is 32 MB, expandable to 96 MB. For memory copying, the print-start conditions include image data in page memory and an upper fixing roller surface temperature of at least 170°C.

Installation specifications give an operating temperature range of 7.5–32.5°C. These conditions accompany the site checks used when assessing image and feeding problems.