2000 Canon iR5000 / iR6000 Copier Service Manual (P/N FY8-13GS-000)

• Covers Canon iR5000 and iR6000 console copiers, including regional power-supply configurations and model-specific serial-prefix tables. Canon publication code FY8-13GS-000, Revision 0, July 2000; an 803-page PDF.
• Documents the main controller PCB, DC controller PCB, reader controller PCB, HDD, SDRAM startup sequence, power modes, digital image-processing path, and major PCB inputs and outputs.
• Reader repair procedures cover scanning-lamp and scanner-motor removal, scanner drive-cable routing, No. 1/No. 2 mirror-base positioning, CCD/AP PCB and reader-controller service, shading adjustment, and auto-density correction.
• Printer repair sections address the drum and process unit, potential-control system, charging assemblies and wire routing, developing and toner-supply assemblies, pickup/feed and duplex mechanisms, and fixing-roller, web, heater, thermistor, and separation-claw work.
• Installation coverage includes site selection, unpacking, scanner/fixing/developing/pickup setup, deck paper-size configuration, image checks, relocation, Control Card IV, and NE Controller-A1 installation.
• Diagnostic material includes image-adjustment routines, surface-potential and photointerrupter checks, jam and feeding-fault diagnosis, service-mode DISPLAY/I/O/ADJUST/FUNCTION/OPTION/TEST/COUNTER functions, and error-code self-diagnosis.
• Accessory scope is specific: Paper Deck-G1 and Shift Tray-B1 receive theory, circuit, adjustment, and disassembly coverage. Finisher-F1, Saddle Finisher-F2, Puncher Unit-B1/C1/D1, and DADF-D1 appear in the system configuration; selected host diagnostics are provided, but detailed mechanical repair requires the appropriate separate manual.

System Structure and Electrical Theory

The manual divides the machine into control, original-exposure, image-processing, laser-exposure, image-formation, and pickup/feed systems. Electrical theory follows sensor inputs, PCB communications, and outputs to electromechanical loads and high-voltage circuits. Serial-prefix tables distinguish 100/120/220/230 V regional builds.

The main-controller chapter traces startup from the boot-ROM self-check through loading system software from the hard drive into SDRAM. It then follows image data through enlargement/reduction, edge emphasis, LUT density conversion, T-BIC and dither processing, compression, rotation, and smoothing. Board and storage repair covers counter-memory/EEPROM transfer, service-setting backup, and HDD formatting plus software installation with Canon’s Service Support Tool.

Repair, Adjustment, and Troubleshooting Depth

Reader-unit procedures cover the xenon scanning lamp, scanner motor and drive cable, mirror bases, original-size and home-position sensors, inverter and fuse PCBs, CCD/AP PCB, and reader controller. Factory adjustment coverage includes mirror positioning, scanner image-leading-edge and CCD read-start settings, shading auto adjustment after component replacement, edge-gain correction, and auto-density adjustment.

Printer repair reaches the laser scanner, drum/process unit, potential sensor, and the primary, pre-transfer, transfer, and separation charging systems. Separate procedures cover the developing cylinder and blade, magnetic seal, hopper, drum cleaner, pickup and registration assemblies, feeding belt, and duplex unit. The fixing chapters address the fixing/feeding unit, cleaning web, heaters, thermal switch, thermistors, upper and lower rollers, separation claws, delivery rollers, inlet guide, solenoid positions, and nip adjustment. Paper-path procedures add roller orientation and pressure, deck/cassette registration, jam-sensor checks, and reversal/duplex timing.

Troubleshooting follows symptoms and system failures. It covers density and fogging faults, black or white lines and spots, fixing and image-position errors, blank or solid-black pages, pickup and lifter failures, heater faults, jams, double feeds, and wrinkles. Service mode adds I/O monitoring, test prints, adjustments, counters, and settings backup; self-diagnosis supplies error causes, detection conditions, and fault-isolation checks.

Accessory Scope, Diagrams, and Safety

Paper Deck-G1 coverage includes deck-driver I/O, pickup and lifter control, paper-level and size detection, and jam diagnosis. Repair procedures cover compartment removal, paper-size configuration, registration adjustment, lifter-cable routing, roller orientation and pressure, and PCB service. Shift Tray-B1 sections cover its driver PCB, shifting and stacking, paper detection, limit-sensor adjustment, and tray-drive removal. The host-machine documentation also provides finisher and saddle-stitcher I/O, counters, and self-diagnosis, but their mechanical repair chapters are not part of this volume.

Representative drawings include the system functional-construction map, major-PCB wiring and controller I/O sheets, the digital image-processing block diagram, simplex and duplex timing charts, the machine General Circuit Diagram, and dedicated Paper Deck-G1 and Shift Tray circuit diagrams. Listed factory aids include the NA-3 Test Sheet FY9-9196, potential-sensor electrode FY9-3012, environment-sensor checker FY9-3014, and tester extension pins FY9-3038/FY9-3039.

Maintenance tables identify periodically replaced parts, consumables, scheduled service points, cleaning materials, and related service counters. Two repair cautions are especially useful: an angled pre-transfer charging assembly can damage the drum surface, while uncontrolled counterclockwise drum movement during process-unit work can disturb cleaning-blade contact and cause cleaning faults.

Before internal repair, verify that the Execution/Memory lamp is off, disconnect the power plug, and remember that the cassette and drum heaters can remain energized with the main switch off. Do not interrupt a software download; the manual warns that doing so can disable the machine.