ADF-H1

COPYRIGHT © 1999 CANON INC. CANON GP160 REV.0 FEB. 1999 PRINTED IN JAPAN (IMPRIME AU JAPON)
 INTRODUCTION

This service manual provides basic information required in performing field service to
maintain the product quality and functions of the ADF.

Each chapter consists of the following sections:

Chapter 1, “Introduction,” : Features, Specifications, Operation procedure features,

Specifications , Operation procedures.

Chapter 2, “Operation overview,” : Description of the mechanical and electrical oper-

ating principles and timing by function, Description and overview of electric circuit con-
figuration.

Chapter 3, “Mechanical system,” : Description of mechanical structure, and disas-

sembly, assembly and adjustment methods.

Chapter 4, “Maintenance and Inspection,” : Table of periodic replacement parts and

consumables replacement targets, periodic service list.

Chapter 5, “Troubleshooting,” : Standards/adjustments, operation failure countermea-

sures.

Appendix : General circuit diagram, printed circuit board diagrams.

For information regarding installation, refer to the instruction manual packed with the
ADF.
Changes of the contents made for the sake of product improvements will be notified
in Service Information (Technical Information) whenever such changes are made.
Gaining a sound and thorough understanding of the unit 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.

COPYRIGHT © 1999 CANON INC. CANON GP160 REV.0 FEB. 1999 PRINTED IN JAPAN (IMPRIME AU JAPON) i
ii COPYRIGHT © 1999 CANON INC. CANON GP160 REV.0 FEB. 1999 PRINTED IN JAPAN (IMPRIME AU JAPON)
 CONTENTS
CHAPTER 1 INTRODUCTION
I. FEATURES ..............................................1-1 IV. OPERATION DESCRIPTION...................1-4
II. SPECIFICATIONS....................................1-2 A. Basic procedures ...............................1-4
III. NAMES OF PARTS..................................1-3 B. Warning indications and remedies.......1-4
A. External view......................................1-3 C. User routine inspections ....................1-5

CHAPTER 2 OPERATION OVERVIEW

I. BASIC CONFIGURATION........................2-1 B. Document detection ...........................2-4
A. Overview of electric circuits ...............2-1 C. Pick-up and feed operations ..............2-8
B. ADF relay controller PCB I/O.............2-2 D. Stamp function .................................2-13
II. BASIC OPERATION.................................2-3 E. ADF motor (M801) control ...............2-14
A. Overview ............................................2-3 F. Document jam detection ..................2-15

CHAPTER 3 MECHANICAL SYSTEM

I. EXTERNAL CONTROL ITEMS ...............3-1 B. Removing the separation bar.............3-7
A. External covers ..................................3-1 C. Removing the document feed
B. Removing ADF...................................3-1 roller ...................................................3-9
C. Removing the document contact D. Removing the document delivery
plate ...................................................3-2 roller .................................................3-10
D. Removing the hinge unit ....................3-3 IV. ELECTRICAL COMPONENTS ..............3-13
II. DOCUMENT FEED SYSTEM..................3-3 A. Removing the ADF relay PCB .........3-13
A. Removing the ADF motor ..................3-3 B. Removing the paper detection sensor
III. ROLLERS ................................................3-6 PCB..................................................3-13
A. Removing the separation roller unit......3-6

CHAPTER 4 MAINTENANCE AND INSPECTIONS

I. PERIODIC REPLACEMENT PARTS .......4-1 II. CONSUMABLES REPLACEMENT
TARGETS.................................................4-1

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iii
 CHAPTER 5 TROUBLESHOOTING
I. STANDARDS AND ADJUSTMENTS .......5-1 A. Operation failure countermeasure
A. ADF height adjustment ......................5-1 procedures .......................................5-11
B. Skew feed adjustment........................5-3 III. DIAGRAM SHOWING LOCATION OF
C. Adjusting image position ....................5-5 ELECTRIC PARTS.................................5-13
II. OPERATION FAILURE COUNTERMEA- IV. LIST OF VARIABLE RESISTORS (VR),
SURES...................................................5-11 LEDS AND CHECK PINS BY PRINTED
CIRCUIT BOARD...................................5-14

APPENDIX
A. GENERAL TIMING CHART.....................A-1 D. LIST OF SPECIAL TOOLS......................A-7
B. LIST OF SIGNAL NAMES .......................A-3 E. SOLVENTS AND OILS ............................A-8
C. GENERAL CIRCUIT DIAGRAM ..............A-5

iv COPYRIGHT © 1999 CANON INC. CANON GP160 REV.0 FEB. 1999 PRINTED IN JAPAN (IMPRIME AU JAPON)
 CHAPTER 1
INTRODUCTION

I. FEATURES ..............................................1-1 IV. OPERATION DESCRIPTION...................1-4

II. SPECIFICATIONS....................................1-2 A. Basic procedures ...............................1-4
III. NAMES OF PARTS..................................1-3 B. Warning indications and remedies.......1-4
A. External view......................................1-3 C. User routine inspections ....................1-5

COPYRIGHT © 1999 CANON INC. CANON GP160 REV.0 FEB. 1999 PRINTED IN JAPAN (IMPRIME AU JAPON)
 CHAPTER 1 INTRODUCTION

I. FEATURES
1. Document size recognition

When a document is set, the ADF automatically senses a regular document size and
sends information on the document size to the unit.

2. Stamp function

A completion stamp can be stamped on the surface of the document when the
stamp function is selected on the unit.

3. Single document pick-up and separation mechanism

Document pick-up roller, separation roller and drive mechanism have been integrat-
ed into one unit to simplify replacement work.

4. Hinge unit for thick documents

Hinge unit modifications have made it possible to lower the pressure applied to the
copyboard glass by the lifting mechanism of the hinge unit when thick documents are
copied in pressure plate mode.

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 CHAPTER 1 INTRODUCTION

II. SPECIFICATIONS
Item Specifications
Document pick-up system Omatic pick-up/delivery system
Document types One-sided sheet documents (50 to 200 g/m2)
Document size A3, B4, A4, A4R, B5, B5R, A5, A5R, 11 × 17, LGL, LTR, LTRR
(paper feed up to 1 m is possible during fax transmission)
Document set orientation • Place documents face down.
• Place the first document page at the bottom.
Document set position Center reference.
Document processing One-sided original → one-sided scanning.
mode
AutNumber of stackable • A3, B4, 11 × 17, LGL: 20 pages or less.
documents • A4, A4R, B5, B5R, A5, A5R, LTR, LTRR: 50 pages or less.
Mix originals No
Document size recognition Yes (regular size only)
Stamp function Yes (yellow)
Power supply Supplied by unit (5 or 24 V DC)
Serial number Eur: ZSSxxxxx Asia: ZSXxxxxx
Operating environment As per copier specifications.
Ambient temperature
Ambient humidity range

The following type of documents will not provide guaranteed operation

• OHP film
• Documents with holes for file storage
• Stapled documents, documents containing paper clips or with glue on them
• Documents to which paper clippings have been attached.
• Documents with carbon paper attached on the back
• Excessively curled, folded or wrinkled documents
Tell users that if they have to use curled documents to make them as straight as pos-
sible and to place the most deformed part of the document to the rear.

Specifications are subject to change for the sake of product improvements.

1-2 COPYRIGHT © 1999 CANON INC. CANON GP160 REV.0 FEB. 1999 PRINTED IN JAPAN (IMPRIME AU JAPON)
 CHAPTER 1 INTRODUCTION

III. NAMES OF PARTS

A. External view

[3]

[1] [2] [4]

[5]
[6]

[1] ADF upper cover [4] Document length sensor

[2] Document tray [5] Opening grip
[3] Slide guide [6] Document delivery tray

Figure 1-301

[5]
[3] [4]
[2]

[6] [7]

[1]

[9] [8]

[10]
[12] [11]

[1] Upper delivery roller [7] Document length sensor 2

[2] Feed roller [8] Document stopper
[3] Friction bar [9] Separation roller
[4] Paper pressing plate [10] Delivery roller
[5] Paper detection sensor lever [11] Document contact plate
[6] Document length sensor 1 [12] Stamp
Figure 1-302

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 CHAPTER 1 INTRODUCTION

IV. OPERATION DESCRIPTION

A. Basic procedures
1) Align the leading edges of the document and insert the document with the first page
facing down as far as it will go.
2) Adjust the slide guide to suit the width of the document.
3) Make the required copy or fax settings on the operation panel of the unit.
4) Press the unit Start key.

Caution:
Advice the user not to touch the upper ADF cover during document feeding. Touching
the upper ADF cover could cause the document to shake during feeding, resulting in
poor images.

B. Warning indications and remedies

When a document becomes jammed, the message “Document jam” appears on the
display of the unit operation panel and a red alarm lamp starts to flash. Use the follow-
ing procedure to clear the paper jam.
1) Press the Stop key on the unit operation panel. This deletes the partly scanned doc-
ument image from memory.
2) Gently open the upper ADF cover and remove the document.
3) Close the feeder cover.
4) Return the documents to their original order.

Caution:
This unit is not provided with a mix original function. Thus loading documents of dif-
ferent sizes will result in a paper jam.

1-4 COPYRIGHT © 1999 CANON INC. CANON GP160 REV.0 FEB. 1999 PRINTED IN JAPAN (IMPRIME AU JAPON)
 CHAPTER 1 INTRODUCTION

C. User routine inspections

Advise the user to perform the maintenance operations described below.

1. Replenishing stamp ink

Replenish stamp ink according to the following procedure.

1) After making sure that the green alarm lamp on the operation panel of the unit is not
on or flashing, power down the unit and open the ADF.
2) Fill one drop of stamp ink at the location shown in the figure.

Caution:
• Since it takes time for the replenished ink to take effect, wait 1 hour to after replen-
ishing the ink before using the stamp function.
• Take care not to add too much ink.
• Turn on the power switch on the main unit as soon as ink has been replenished.

Add ink here

Figure 1-401

Caution:
Do not touch the stamp surface. Should you by accident get ink on your hands or
other parts of the body, immediately wash it off.

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 CHAPTER 1 INTRODUCTION

2. Areas to clean and cleaning methods

• Copyboard glass cleaning

Clean with a cloth moistened in water, alcohol or ??• C-17, and wipe it dry. It is
essential that the copyboard glass is kept clean, as dirt adhering to the glass of the
scanning assembly glass will appear as dark stripes, especially on images scanned
in stream reading mode.
• Cleaning the document pressure sheet
Clean using a cloth with a cloth moistened in water or alcohol.
• Cleaning the document contact plate
Clean using a cloth with a cloth moistened in water or alcohol.
• Cleaning document length sensor cover
Wipe it with a dry cloth.

1-6 COPYRIGHT © 1999 CANON INC. CANON GP160 REV.0 FEB. 1999 PRINTED IN JAPAN (IMPRIME AU JAPON)
 CHAPTER 2
OPERATION OVERVIEW

1. This chapter describes the objective and role of each function, the relationship
between the electrical and mechanical systems and also gives an overview of the
operation timing of each part by function.
The symbol in the outline diagram indicates the transmission of mechanical
drive, and the symbol together with a signal name indicates the flow of
electric signals.
2. In the descriptions of the digital circuits of the cassette feeding unit, “1” indicates a
high electric signal level and “0” indicates a low electric signal level. The voltage dif-
fers with the circuit.
Since it is assumed that service engineers will not repair printed circuit boards on the
customer’s premises, descriptions of printed circuit boards are limited to overviews
illustrated with block diagrams. Consequently, circuit descriptions cover from sensors
to the input sections of the ADF connector printed circuit and the image processor
and from the output sections of the image processor and the ADF printed circuit out-
put sections to the loads, as well as block diagrams of each function.

I. BASIC CONFIGURATION........................2-1 B. Document detection ...........................2-4

A. Overview of electric circuits ...............2-1 C. Pick-up and feed operations ..............2-8
B. ADF relay controller PCB I/O.............2-2 D. Stamp function .................................2-13
II. BASIC OPERATION.................................2-3 E. ADF motor (M801) control ...............2-14
A. Overview ............................................2-3 F. Document jam detection ..................2-15

COPYRIGHT © 1999 CANON INC. CANON GP160 REV.0 FEB. 1999 PRINTED IN JAPAN (IMPRIME AU JAPON)
 CHAPTER 2 OPERATION OVERVIEW

I. BASIC CONFIGURATION

A. Overview of electric circuits

ADF electric control is performed by IC15 on the unit image processor circuit board
running a program stored in the program ROM (IC1, IC2).
ADF operation control signals transmitted from the image processor PCB and sig-
nals relaying ADF load operation states are all transferred via the ADF relay PCB.
The unit supplies 5 V DC and 24 V DC power.

ADF relay Main unit image

PCB processor PCB

Control IC
(IC15)
Sensor

Program
Motor ROM
(IC1, IC2)

Figure 2-101

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 CHAPTER 2 OPERATION OVERVIEW

B. ADF relay controller PCB I/O

ADF relay PCB Main unit image processor PCB
+5V

J813-1 J801-1 J205-A16

-3 -12 -A5 “0” when document is detected
PS801S* (when the light shield is not at sensor
PS801 -2
position)
Document sensor

J810-1
-3 J802-7 J205-B10 “1” when the ADF is closed
PS806S (when the light shield obstructs
PS806 -2
the sensor)
ADF closed sensor

+5V

J812-9 J801-4 J205-A13

-8 J802-3 -B14
PS802S “1” when the document is detected
PS802 -7
Document length sensor 1

J812-6
-5 J802-6 J205-B11
PS803S “1” when the document is detected
PS803 -4

Document length sensor 2

J811-1
-3 J802-4 J205-B13
PS805S* “0” when the document is detected
PS805 -2
Document leading
edge sensor

J813-4
-8
PS851 J801-14 J205-A3
-7 PS851S In combination, these two sensors
-5 J801-13 -A4 detect the paper width
PS852S
-6 ??????
PS802

Document width sensor

circuit board
J814-1
TH801 -2

ADF motor thermoswitch

J815-1
-2 See page 2-14.
-3
M801 -4
-5
-6
ADF motor

Figure 2-102

2-2 COPYRIGHT © 1999 CANON INC. CANON GP160 REV.0 FEB. 1999 PRINTED IN JAPAN (IMPRIME AU JAPON)
 CHAPTER 2 OPERATION OVERVIEW

II. BASIC OPERATION

A. Overview
This is a dedicated stream reading document feeder.
The document pick-up, feed and delivery sequence of the unit is performed using
drive provided by the ADF motor (M801).
Documents on the document tray are picked up in order from the bottom of the docu-
ment sheaf (the first page of the document) in response to commands from the copier
and moved (streamed) across the copyboard glass.
The stamp is located on the upper left cover of the unit in which the ADF has been
installed. When the stamp function is set to ON in the unit, the surface of fax documents
that have been transmitted will be stamped.

Main unit image processor PCB

ADF relay PCB

ADF closed signal (PS806S)

Document length detection
Document length detection
Document detection signal
Document leading edge

ADF motor drive signal

Paper detection signal
Paper detection signal
signal (PS805S)

signal (PS803S)
signal (PS802S)
(PS852S)
(PS851S)
(PS801S)

Document width sensor PCB

M801
Stamp solenoid
(controlled by the unit image processor PCB)
ADF motor

Figure 2-201

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 CHAPTER 2 OPERATION OVERVIEW

B. Document detection

1. Overview

This unit incorporates three types of document sensors.

• Document detection sensor
• Document size sensor
• Document leading edge sensor

2. Document detection

The document sensor (PS801) detects documents in the document tray. When docu-
ments are inserted in the document tray, the light shield is separated from the document
sensor (PS801) resulting in the generation of a paper detection signal (PS801S*).
The signal output by the sensor is transmitted to the unit image processor PCB
where paper detection is confirmed.

Light shield Document

OFF

ON

Document sensor (PS801)

Figure 2-202

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 CHAPTER 2 OPERATION OVERVIEW

3. Document size detection

Regular size document sizes are detected through a combination of ON and OFF
states of the paper detection sensors (PS851, PS852) and document length sensors
(PS802, PS803).
Sensor ON and OFF states are transferred to the unit image processor PCB, which
identifies the document sizes.

a. Paper detection
The light shields interlocked with the slide guides obstruct (sensor ON) or do not
obstruct (sensor OFF) the two paper detection sensors (PS851, PS852) on the paper
width sensor PCB and it is a combination of these two states that allow the unit to detect
document width.

Slide guide Slide guide

PS852

PS851

Document width sensor PCB

Figure 2-203

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 CHAPTER 2 OPERATION OVERVIEW

b. Document length detection

When a document is placed on the document tray, the combination of ON states of
the reflective document length sensors (PS802, PS803) generated by the document
length makes it possible to detect the length of the document.

c. List of document size detection

To detect document size, first document width detection is used to determine which
regular size before identifying document length.
Consequently, unless the slide guides of the document tray are correctly set, the
document will be detected as the closest regular document size.
The combination of paper sensor and document length sensor ON and OFF states
for each regular document size are listed below.

Paper width detector *1 Paper length detector *2

Paper size
PS851 PS852 PS802 PS803
A3 ON ON ON ON
A4 ON ON ON OFF
B4 ON OFF ON ON
B5 ON OFF ON OFF
A4R OFF OFF ON ON
A5 OFF OFF OFF OFF
A5R OFF ON ON OFF
B5R OFF ON ON ON

*1 The paper detectors (PS851, PS852) are ON when the light shield does not obstruct
the sensor, and are OFF when the light shield obstructs it.
* 2 The document length detectors (PS802, PS803) are ON when a document is above
the sensor and OFF when one is not.

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 CHAPTER 2 OPERATION OVERVIEW

4. Document leading edge detection

The role of the document leading edge sensor (PS805S) is to synchronize the timing
of the document scanning operation and the main unit print operation during stream
reading, and thereby detect the position of the document.
When the Start key is pressed, the document pick-up operation starts. If the docu-
ment was fed directly to the scanning glass for stream reading, the timing of image
scanning and the print operation would be out of phase. To prevent this from happening,
a document leading edge sensor (PS805S) has been installed in the feeding path.
When this sensor detects the leading edge of the document, it causes the document to
stop for a short while. The document pick-up operation is resumed when a pick-up con-
trol signal is received from the unit image processor PCB. (This delay in document feed)
makes it possible to synchronize scanning with the print operation.

Main unit image processor PCB

Leading edge and trailing Feed operation start control

edge detector signals and feed operation finish control

ADF relay PCB

Leading edge and trailing edge detector signals (PS805S)

Document leading
edge sensor
(PS805)

Figure 2-204

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 CHAPTER 2 OPERATION OVERVIEW

C. Pick-up and feed operations

1. Overview of pick-up operation

When a document is placed in the document tray and the Start key is pressed, the
ADF motor starts turning and document pick-up starts. The picked up document is fed to
the stream reading position on the copyboard glass by (the drive of) the feed rollers.
The stream scanned document is delivered to the document delivery tray by the doc-
ument delivery rollers.
The document pick-up and separation mechanism is shown below.

Document feed roller Friction bar Copyboard cover

Document

Pick-up roller

Document stopper

Cam
Document separation roller
Feed roller
Document delivery roller

Figure 2-205

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 CHAPTER 2 OPERATION OVERVIEW

2. Document pick-up operation

The structure of the document pick-up assembly is shown below. The document
pick-up operations described below are performed when the Start key is pressed and
there is a document on the document tray.

a. Pick-up operation
When the ADF motor (M801) rotates forward, the document pick-up roller and the
document separation roller start to turn. At the same time, the operation of the spring
clutch and the rotation of the timing belt cause the document stopper to descend and
the pick-up roller to ascend.

Friction bar
Document separation roller

Document sheaf

Pick-up roller ascends

Cam starts to rotate Document stopper descends

Figure 2-206

b. Document separation operation

After pick-up, the document is fed between the friction bar and the separation roller
to prevent double feed.

Friction bar
Document separation roller

Document sheaf

Pick-up roller

Figure 2-207

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 CHAPTER 2 OPERATION OVERVIEW

c. Document feed operation

The document is fed by the drive of the feed rollers. The separation roller rotates
together with the feed roller through the operation of the spring clutch.

Document sheaf

Document separation roller

Figure 2-208

d. Document feed operation

When the leading edge of the first document reaches the document leading edge
sensor (PS805), the document feed operation stops momentarily. This delay synchro-
nizes the paper pick-up and feed operations.

Document leading edge sensor (PS805) Document sheaf

First page

Figure 2-209

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 CHAPTER 2 OPERATION OVERVIEW

e. Document feed operation 3

As the first page leaves the document separation roller, the second page is picked
up and fed to the document leading edge sensor (PS805).

Document leading edge sensor (PS805) Document sheaf

Document separation roller

Second page

First page Document feed roller

Figure 2-210

f. Post operation
When all documents have been picked up, the ADF motor (M801) rotates in reverse,
the pick-up roller descends and the document stopper rises. The unit is now ready to
receive the next document sheaf.

Document stopper (ascending)

The cam turns to raise
document stopper Pick-up roller (descending)

Figure 2-211

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 CHAPTER 2 OPERATION OVERVIEW

3. Document stopper descend and pick-up roller ascends

The pick-up roller is held at the lowered position, in standby, to provide enough clear-
ance to load a document sheaf. The document stopper is held at the raised position by
the cam at standby; this position prevents a document from being inserted too far into
the copier when documents are set.
When the ADF motor (M801) turns, the document pick-up operation starts transmit-
ting drive to the cam and the timing belt, causing the document stopper to descend and
the pick-up roller to ascend. This series of actions causes the picked up document to be
fed into the copier.

Document Document
Torque limiter feed roller separation roller Timing belt

Document feed direction

Document pick-up roller

Document stopper
Cam
Clutch

Figure 2-212

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 CHAPTER 2 OPERATION OVERVIEW

D. Stamp function

1. Overview

When the stamp function is selected in the fax mode of the unit, a 3 mm diameter
round stamp is imprinted on the surface of the document to indicate that document
scanning has been completed, or that the document has been transmitted.

Reference:
Although the stamp unit of the unit is located on the upper left cover of the main unit,
it is here described as an ADF function.

2. Operation

Stamp operation is controlled by the image processor PCB on the unit. The CPU in
the image processor PCB turns on the stamp solenoid at the prescribed time to imprint
a stamp at the location shown in the figure below.

Document feed direction Document surface

Completion stamp

Figure 2-213

Caution:
Since the speed of document feed differs in the fax scanning mode, the position of
the stamp imprint position (the imprint position in sub-scanning direction) also differs.

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 CHAPTER 2 OPERATION OVERVIEW

E. ADF motor (M801) control

1. Overview

The circuits shown below, which control the ADF motor (M801), have the following
functions.
• ADF motor forward rotation/reverse rotation control
• ADF motor rotation speed control
The ADF motor is equipped with a thermoswitch that is triggered when the surface
temperature of the motor exceeds the prescribed value and forcibly shuts down the
power supply to the motor.

Reference:
When a paper jam error code #001 or #003 occurs, the thermoswitch has probably
been triggered. Although the thermoswitch returns to normal when the temperature
drops, it is essential that the cause of the temperature rise is determined.

2. Operation

The unit ADF motor (M801) drive is controlled by signals from the unit image proces-
sor PCB.
The unit image processor PCB outputs the ADF motor drive pulse and controls drive
depending on the magnification of document scanning, operation mode, etc.
The ADF motor is a stepping motor that controls rotation direction and rotation
speed by changing the order of drive pulse (A, A*, B, B*) output and frequency.
The operating temperature and return temperature of the thermoswitch (TH801)
used for detecting motor surface temperature are shown below.

■ Operating temperature: 70°C Return temperature: 55°C

ADF relay PCB

+24V
J814-1
Thermoswitch
(TH801)
IC801 -2
A J815-1
Motor drive signal
-3
M801 ADF motor
Main unit image Rotation direction A* -5
processor PCB switch signal Motor
drive IC
B -2
Clock signal
-4

B* -6

Figure 2-214

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 CHAPTER 2 OPERATION OVERVIEW

F. Document jam detection

PS851
PS805
PS806
PS801 PS802 PS803
PS852

PS801: Paper detection sensor PS805: Document leading edge sensor

PS802: Document length detection sen- PS806: ADF closed sensor
sor 1 PS851: Paper detection sensor 1
PS803: Document length detection sen- PS852: Paper detection sensor 2
sor 2

Figure 2-215

Document jam detection is performed by the unit image processor PCB, according
to a programmed check timing.
The conditions of document jam detection are as shown below.
The unit differentiates between two types of document jams.
• Defective pick-up jam: When the document leading edge sensor (PS805) does not
go on (the light shield does not leave the sensor) 15 sec-
onds or more after start of document pick-up operation. In a
continuous pick-up operation involving two or more pages,
when the document leading edge sensor (PS805) does not
go on (the light shield does not leave the sensor) 15 sec-
onds or more after the trailing edge of the previous page
has left the document leading edge sensor (PS805).
• Defective feed jam: When the document leading edge sensor (PS805) detects
the leading edge of the document after the start of docu-
ment pick-up, the ADF momentarily stops the document
feed operation to synchronize it with the main unit operation
(leading pick-up operation). When the document leading
edge sensor (PS805) does not go OFF within a 9 second
period after the ADF motor (M801) goes on again, the sys-
tem assumes that a defective feed jam has occurred.

In both conditions, the message “Check document” appears on the operation panel
and ADF operation stops.
When a document jam occurs, correct document position and do the operation over
from the beginning.

COPYRIGHT © 1999 CANON INC. CANON GP160 REV.0 FEB. 1999 PRINTED IN JAPAN (IMPRIME AU JAPON) 2-15
 CHAPTER 2 OPERATION OVERVIEW

Jam detection sequence

■ Defective pick-up jam

Condition: feed of two A4 size documents

Start key on

Feed operation for first page

Second page leading pick-up operation
ADF motor (M801)
15 seconds
Jam check
Document leading Normal Abnormal
edge sensor (PS805)

Figure 2-216

■ Defective feed jam

Condition: feed of two A4 size documents

Start key on

Feed operation for first page

Second page leading pick-up operation
ADF motor (M801)
9 seconds
Jam check
Document leading Normal Abnormal
edge sensor (PS805)

Figure 2-217

2-16 COPYRIGHT © 1999 CANON INC. CANON GP160 REV.0 FEB. 1999 PRINTED IN JAPAN (IMPRIME AU JAPON)
 CHAPTER 3
MECHANICAL SYSTEM

This chapter describes mechanical features and operations as well as disassembly

and assembly procedures.
The following precautions must be observed during disassembly and assembly work.
1. For the sake of safety, disconnect the power plug before performing any disas-
sembly or assembly work.
2. Unless otherwise specified, assembly work is performed in the reverse order of the
disassembly operations.
3. An inner-clip washer is used with one securing screw in the metal cover to prevent
buildup of static electricity. Make sure to use this washer during assembly work.
4. An inner-clip washer is used with the securing screws of the earth wire to ensure
electric conductivity. Make sure to use this washer during assembly work.
5. In principal, the copier must not be operated when parts have been removed.

I. EXTERNAL CONTROL ITEMS ...............3-1 B. Removing the separation bar.............3-7

A. External covers ..................................3-1 C. Removing the document feed
B. Removing ADF...................................3-1 roller ...................................................3-9
C. Removing the document contact D. Removing the document delivery
plate ...................................................3-2 roller .................................................3-10
D. Removing the hinge unit ....................3-3 IV. ELECTRICAL COMPONENTS ..............3-13
II. DOCUMENT FEED SYSTEM..................3-3 A. Removing the ADF relay PCB .........3-13
A. Removing the ADF motor ..................3-3 B. Removing the paper detection sensor
III. ROLLERS ................................................3-6 PCB..................................................3-13
A. Removing the separation roller unit......3-6

COPYRIGHT © 1999 CANON INC. CANON GP160 REV.0 FEB. 1999 PRINTED IN JAPAN (IMPRIME AU JAPON)
 CHAPTER 3 MECHANICAL SYSTEM

I. EXTERNAL CONTROL
ITEMS

A. External covers
Remove the covers according to the
[1]
following procedure to perform cleaning,
inspection or repair of internal mechani-
cal components. Procedures for remov-
ing covers that can be removed indepen-
dently and easily by removing a few
securing screws have been omitted.

[2]

Figure 3-101

[1] Lower front cover (4)

[2] Rear cover (4)
The number of screws is indicated
within brackets ( ).

B. Removing ADF
1) Remove four securing screws and [2] [3]
remove the rear unit cover.

2) Disconnect connector J205 [1] on the

image processor PCB.

3) Remove one securing screw [2] and

the cable assembly [3].

[1]

Figure 3-102

COPYRIGHT © 1999 CANON INC. CANON GP160 REV.0 FEB. 1999 PRINTED IN JAPAN (IMPRIME AU JAPON) 3-1
 CHAPTER 3 MECHANICAL SYSTEM

4) Remove one securing screw [4] and [4]

the grounding wire.

Figure 3-103
5) Go to the front of the unit and remove [5]
the two securing screws [6] in the
right and left front hinges. Note that
the two screws are different.

6) Remove the bracket at the rear of the

hinges and remove the ADF.

[6]

Figure 3-104
C. Removing the document
contact plate
1) Remove the lower front cover (4
screws) and the lower rear cover (4
screws).

2) Remove the grounding wire (one [2]

securing screw [1]), two securing
screws [2] and the document contact
plate [3].

[3] [1]

Figure 3-105

3-2 COPYRIGHT © 1999 CANON INC. CANON GP160 REV.0 FEB. 1999 PRINTED IN JAPAN (IMPRIME AU JAPON)
 CHAPTER 3 MECHANICAL SYSTEM

D. Removing the hinge unit [3] [4 ] [2] [1]

1) Remove the ADF from the main unit.

2) Remove the lower rear cover (four

screws).

3) Remove the two securing screws [1]

and the right hinge unit [2], and
remove two securing screws [3] and
the left hinge unit [4].
[3] [1]

Figure 3-106

II. DOCUMENT FEED

SYSTEM

A. Removing the ADF motor

1) Remove the stay at the rear of the
upper cover unit and open the upper
cover unit.

2) Remove one securing screw and the

separation roller unit cover (see page
3-6).

3) Remove the ADF from the main unit

(see page 3-1).

4) Remove the document contact plate

(see page 3-2).

COPYRIGHT © 1999 CANON INC. CANON GP160 REV.0 FEB. 1999 PRINTED IN JAPAN (IMPRIME AU JAPON) 3-3
 CHAPTER 3 MECHANICAL SYSTEM

5) Remove all ADF relay PCB assembly [2] [3]

[1] connectors.

6) Remove the relay connector [2].

7) Remove one securing screw [3] and

the grounding wire.

[1]

Figure 3-201
8) Remove the six securing screws [4] [4]
and the right hinge [5].

[5]

Figure 3-202
9) Remove one securing screw [6] and [9]
the grounding wire [7].

10) Remove the relay connector [8] and

the three securing screws [9].

[8]

[6] [7]

Figure 3-203

3-4 COPYRIGHT © 1999 CANON INC. CANON GP160 REV.0 FEB. 1999 PRINTED IN JAPAN (IMPRIME AU JAPON)
 CHAPTER 3 MECHANICAL SYSTEM

11) Remove nine securing screws [10]

and the drive unit stay [11].

[11]

[10]

Figure 3-204
12) Remove the two tension springs [12]. [14]
[12]
13) Remove the three securing screws
[13] and the ADF motor [14] with its
stay.

14) Remove the two securing screws to

separate the ADF motor from its stay.

[13] Stay

Figure 3-205

COPYRIGHT © 1999 CANON INC. CANON GP160 REV.0 FEB. 1999 PRINTED IN JAPAN (IMPRIME AU JAPON) 3-5
 CHAPTER 3 MECHANICAL SYSTEM

III. ROLLERS

A. Removing the separation

roller unit [2] [1]

1) Remove the stay [1] at the rear and

open the upper cover unit [2].

Figure 3-301
2) Remove one securing screw [3] and [4] [3]
the separation roller unit cover [4].

Figure 3-302
3) Remove the three securing screws [5] [6] [5]
[5] and the separation roller unit [6].

Figure 3-303

3-6 COPYRIGHT © 1999 CANON INC. CANON GP160 REV.0 FEB. 1999 PRINTED IN JAPAN (IMPRIME AU JAPON)
 CHAPTER 3 MECHANICAL SYSTEM

B. Removing the separation

bar
1) Remove the stay at the rear and [1]
open the upper cover. [2]

2) Remove the two securing screws [1]

and the upper cover unit cover [2].

Figure 3-304
3) Remove the tension spring [3], the [3] [5] [4]
two securing screws [4] and the fric-
tion bar [5].

Figure 3-305

COPYRIGHT © 1999 CANON INC. CANON GP160 REV.0 FEB. 1999 PRINTED IN JAPAN (IMPRIME AU JAPON) 3-7
 CHAPTER 3 MECHANICAL SYSTEM

Reference:
An exploded view of the separation roller is shown in the diagram below.

Pulley

Belt

E-ring

Document separation roller

Clutch spring

Shaft
Mold B

Gear

E-ring Document pick-up roller

Bearing

Shaft

Plate A

Bearing

E-ring

Figure 3-306

3-8 COPYRIGHT © 1999 CANON INC. CANON GP160 REV.0 FEB. 1999 PRINTED IN JAPAN (IMPRIME AU JAPON)
 CHAPTER 3 MECHANICAL SYSTEM

C. Removing the document

feed roller
1) Remove the ADF motor and its stay
(see page 3-3).

2) Hold the front pawl [1] at the front [2]

open to remove the document feed
roller shaft [2]. Be sure not to open
the gear pawl too wide, as this could [1]
damage it.

Figure 3-307
3) Remove the belt [4] from the docu- [3] [5] [4]
ment feed roller shaft gear [3], and
remove the E-ring [5].

4) Remove the gear [3] from the docu-

ment feed roller shaft.

5) Remove the front and rear bearings

and the document feed roller [6].
Figure 3-308

COPYRIGHT © 1999 CANON INC. CANON GP160 REV.0 FEB. 1999 PRINTED IN JAPAN (IMPRIME AU JAPON) 3-9
 CHAPTER 3 MECHANICAL SYSTEM

D. Removing the document

delivery roller
1) Remove the drive unit stay according
to the instructions given in steps 1 to
12 in Section A, “Removing the ADF
motor” on page 3-3.

2) Remove one securing screw [1] and [2]

the cable guide [2].

[1]

Figure 3-309
3) Place the ADF with its front side up
[3]
and remove the upper cover unit [3],
threading the cable through the open-
ing.

Figure 3-310

3-10 COPYRIGHT © 1999 CANON INC. CANON GP160 REV.0 FEB. 1999 PRINTED IN JAPAN (IMPRIME AU JAPON)
 CHAPTER 3 MECHANICAL SYSTEM

4) Remove the two securing screws and [4] [5]

the upper cover unit.

5) Remove one securing screw [4] and

the document leading edge sensor
[5] from its holder.

6) Remove one securing screw [6] and

the static charge grounding spring [7]
from the projection.

[7] [6]

Figure 3-311
7) Remove the E-ring [9] and the gear [8]
[10] in the drive assembly at the rear
of the document delivery roller [8].

[9] [10]

Figure 3-312
8) Remove the bearings on both sides [11]
of the document delivery roller shaft
and avoid the static charge grounding [12]
spring while removing the document
delivery roller [12]
Take care not to excessively bend the
static charge grounding spring.

Figure 3-313

COPYRIGHT © 1999 CANON INC. CANON GP160 REV.0 FEB. 1999 PRINTED IN JAPAN (IMPRIME AU JAPON) 3-11
 CHAPTER 3 MECHANICAL SYSTEM

Caution:
When the document delivery roller is installed, make sure that there is a clearance
between the roller shaft and the static charge grounding spring. If the leaf spring is in
contact with the roller shaft, the document delivery roller will be exposed to excessive
electric charges which could lead to a document jam.
Also, check that the front document roller grounding spring is in contact with the doc-
ument delivery roller shaft.

Static charge
Delivery roller grounding spring
grounding spring
Roller shaft
Roller shaft

Make sure Clearance to be maintained

there is contact

Figure 3-314

3-12 COPYRIGHT © 1999 CANON INC. CANON GP160 REV.0 FEB. 1999 PRINTED IN JAPAN (IMPRIME AU JAPON)
 CHAPTER 3 MECHANICAL SYSTEM

IV. ELECTRICAL COMPO-

NENTS

A. Removing the ADF relay

PCB
[4] [2] [1]
1) Remove the ADF from the main unit.

2) Remove the lower rear cover.

3) Remove one securing screw [1] and

the grounding wire [2].

4) Remove all connectors on the ADF

relay PCB [3].

5) Remove the four securing screws [4]

and the ADF relay PCB.
[3]

Figure 3-401

B. Removing the paper detec-

tion sensor PCB
[1]
1) Remove the drive unit stay according
to the instructions given in steps 1 to
12 in the Section A., “Removing the
ADF motor” on page 3-3.

2) Remove the connector (J85) on the

paper detection sensor PCB [1], one
securing screw [2] and take out the
PCB.

[2]

Figure 3-402

COPYRIGHT © 1999 CANON INC. CANON GP160 REV.0 FEB. 1999 PRINTED IN JAPAN (IMPRIME AU JAPON) 3-13
 CHAPTER 4
MAINTENANCE AND INSPECTIONS

I. PERIODIC REPLACEMENT PARTS .......4-1 II. CONSUMABLES REPLACEMENT

TARGETS.................................................4-1

COPYRIGHT © 1999 CANON INC. CANON GP160 REV.0 FEB. 1999 PRINTED IN JAPAN (IMPRIME AU JAPON)
 CHAPTER 4 MAINTENANCE AND INSPECTIONS

I. PERIODIC REPLACEMENT PARTS

There are no parts in the unit that need to be periodically replaced.

II. CONSUMABLES REPLACEMENT TARGETS

These parts may require replacement once or more during the warranty period due
to deterioration or damage. The expected life (number of pages) of parts that do not
need to be replaced until they fail is indicated below.

As of January, 1999

No. Part Name Part No. Quantity Expected life span Remarks
1 Pick-up roller/ HG5-1652-000 1 50,000 sheets
separation roller
2 Friction bar FG6-1303-000 1 50,000 sheets
3 Stamp unit HH7-2206-000 1 100,000 sheets

Caution:
The information in the table above is not unit counter data but the actual number of
sheets. It is only an estimate, and may be revised in the light of empirical data.

COPYRIGHT © 1999 CANON INC. CANON GP160 REV.0 FEB. 1999 PRINTED IN JAPAN (IMPRIME AU JAPON) 4-1
 CHAPTER 5
TROUBLESHOOTING

I. STANDARDS AND ADJUSTMENTS .......5-1 A. Operation failure countermeasure

A. ADF height adjustment ......................5-1 procedures .......................................5-11
B. Skew feed adjustment........................5-3 III. DIAGRAM SHOWING LOCATION OF
C. Adjusting image position ....................5-5 ELECTRIC PARTS.................................5-13
II. OPERATION FAILURE COUNTERMEA- IV. LIST OF VARIABLE RESISTORS (VR),
SURES...................................................5-11 LEDS AND CHECK PINS BY PRINTED
CIRCUIT BOARD...................................5-14

COPYRIGHT © 1999 CANON INC. CANON GP160 REV.0 FEB. 1999 PRINTED IN JAPAN (IMPRIME AU JAPON)
 CHAPTER 5 TROUBLESHOOTING

I. STANDARDS AND ADJUSTMENTS

A. ADF height adjustment

1. Height check

Measure the clearance at the locations indicated in the diagram to check that they
meet the standard value. If the clearance length is outside the standard value, adjust the
height.

2.0mm or more
Less than 2.5mm

1.6mm or more
Less than 2.0mm

Clearance A standard: 1.6 mm or more to less than 2.0 mm.

Clearance B standard: 2.0 mm or more to less than 2.5 mm.
Figure 5-101

COPYRIGHT © 1999 CANON INC. CANON GP160 REV.0 FEB. 1999 PRINTED IN JAPAN (IMPRIME AU JAPON) 5-1
 CHAPTER 5 TROUBLESHOOTING

2. Height adjustment

If the clearance is outside the standard, loosen the nut on the ADF hinge unit and
adjust with the adjusting screw.
When clearance A is outside the standard value, turn the adjusting screw on the left
hinge unit.
When clearance B is outside the standard value, turn the adjusting screw on the
right hinge unit.

Adjusting screw

Nut

Adjusting screw

Nut
Hinge unit

Hinge unit

Figure 5-102

5-2 COPYRIGHT © 1999 CANON INC. CANON GP160 REV.0 FEB. 1999 PRINTED IN JAPAN (IMPRIME AU JAPON)
 CHAPTER 5 TROUBLESHOOTING

B. Skew feed adjustment

1. Checking ADF skew feed

Compare the surface position of the DF cover and DF delivery cover to make sure
that the surface positions are correctly aligned.

Align the surface

positions of the DF
cover and the unit.

Figure 5-103

COPYRIGHT © 1999 CANON INC. CANON GP160 REV.0 FEB. 1999 PRINTED IN JAPAN (IMPRIME AU JAPON) 5-3
 CHAPTER 5 TROUBLESHOOTING

2. Adjusting skew feed

1) Loosen the right ADF hinge nut.
2) Use an Allen wrench to turn the adjusting screw and adjust ADF position.
3) After adjusting skew feed, tighten the nut to secure the adjusting screw.

Stay
Allen wrench

Right hinge
Nut

Adjusting screw

Figure 5-104

5-4 COPYRIGHT © 1999 CANON INC. CANON GP160 REV.0 FEB. 1999 PRINTED IN JAPAN (IMPRIME AU JAPON)
 CHAPTER 5 TROUBLESHOOTING

C. Adjusting image position

1. Checking image position

Check for image displacement of ADF copy and pressure plate mode copy.
1) Use A3 (297 × 420 mm) size plain paper (64 to 80 g/m2) and draw a straight line 10
mm from the paper edge on three sides of the paper to create a simple chart.

A3 size paper

10mm 10mm

10mm

Figure 5-105

2) Place the chart on the copyboard glass and make a direct copy to A3 (297 × 420 mm)
size paper. The delivered copy is sample A.

ÉnÉKÉL A4
A5 B5 A5 B5 A4 B4 A3

ÉnÉKÉL

Document
A5 (rear side of document)
B5

A5
A4

B5
B4

A4
A3

Figure 5-106

COPYRIGHT © 1999 CANON INC. CANON GP160 REV.0 FEB. 1999 PRINTED IN JAPAN (IMPRIME AU JAPON) 5-5
 CHAPTER 5 TROUBLESHOOTING

3) Place the chart in the ADF and make a direct copy to A3 (297 × 420 mm) size paper.
The delivered copy is sample B. Make sure that the chart is correctly oriented.

Chart
(the surface with the lines is
to be placed on the back side)
ADF

Figure 5-107

5-6 COPYRIGHT © 1999 CANON INC. CANON GP160 REV.0 FEB. 1999 PRINTED IN JAPAN (IMPRIME AU JAPON)
 CHAPTER 5 TROUBLESHOOTING

4) Measure the distance from the ruled line on sample A and sample B to the edge of
the paper. The distances to be measured are a1, a2, a3, b1, b2 and b3.

Sample A

a2 a3

a1

Sample B

b2 b3

b1

Figure 5-108

5) Make sure that the following values conform to the standard. If the values are out-
side the standard values, adjust the image position.

Right and left registration: a1- b1 = 0 ± 1 mm

Leading edge registration: a2 - b2 = 0 ± 1 mm
Sub-scanning direction magnification: (a2 + a3) - (b2 + B3) = 0 ± 1 mm

COPYRIGHT © 1999 CANON INC. CANON GP160 REV.0 FEB. 1999 PRINTED IN JAPAN (IMPRIME AU JAPON) 5-7
 CHAPTER 5 TROUBLESHOOTING

2. Adjusting image position

Image position displacement can be corrected in the service mode.

a) Adjusting right-left registration
Determine the difference between a1 and b1 in sample A and sample B to adjust dis-
placement.
1) Press the Data Registration/Set key, then press the # key to enter the service mode.
2) Use the ▲ ▼ shift keys to select #6 SCANNER and press the Set key.
3) Use the ▲ ▼ shift keys to select 8.CCD.
4) Use the ▲ ▼ shift keys to select 014.
The 014 parameter is now displayed.
5) If a1 > b1,
Decrease the 014 parameter value.
If a1 < b1,
Increase the 014 parameter value.
(Use the numeric keys for input.)
An increase (decrease) of 16 in the parameter value yields a displacement of
approximately 1 mm.

Reference:
An increase (decrease) of 1 in the parameter value yields a displacement of approxi-
mately 0.0635 mm.

6) Press the Set key.

5-8 COPYRIGHT © 1999 CANON INC. CANON GP160 REV.0 FEB. 1999 PRINTED IN JAPAN (IMPRIME AU JAPON)
 CHAPTER 5 TROUBLESHOOTING

b) Adjusting leading edge registration

Determine the difference between a2 and b2 in sample A and sample B to adjust dis-
placement.
1) Press the Register/Set key, then press the # key to enter the service mode.
2) Use the ▲ ▼ shift keys to select #6 SCANNER and press the Set key.
3) Use the ▲ ▼ shift keys to select 8.CCD.
4) Use the ▲ ▼ shift keys to select 015.
The 015 parameter is now displayed.
5) If a2 > b2,
Decrease the 015 parameter value.
If a2 < b2,
Increase the 015 parameter value.
(Use the numeric keys for input.)
An increase (decrease) of 10 in the parameter value yields a displacement of
approximately 1 mm.

Reference:
An increase (decrease) of 1 in the parameter value yields a displacement of approxi-
mately 0.1 mm.

6) Press the Set key.

COPYRIGHT © 1999 CANON INC. CANON GP160 REV.0 FEB. 1999 PRINTED IN JAPAN (IMPRIME AU JAPON) 5-9
 CHAPTER 5 TROUBLESHOOTING

c) Adjusting sub-scanning direction magnification

Determine the difference between a2 + a3 and b2 + b3 in sample A and sample B to
adjust displacement.
1) Press the Register/Set key, then press the # key to enter the service mode.
2) Use the ▲ ▼ shift keys to select #6 SCANNER and press the Set key.
3) Use the ▲ ▼ shift keys to select 8.CCD.
4) Use the ▲ ▼ shift keys to select 016.
The 016 parameter is now displayed.
5) If a2 + a3 > b2 + b3,
Decrease the 016 parameter value.
If a2 + a3 < b2 + b3,
Increase the 016 parameter value.
(Use the numeric keys for input.)
An increase (decrease) of 3 in the parameter value yields a displacement of approxi-
mately 1 mm.

Reference:
An increase (decrease) of 1 in the parameter value yields a displacement of approxi-
mately 0.33 mm.

6) Press the Set key.

After the message “Registered” has appeared on the display, the value of parameter
017 is shown.
7) Add (subtract) 1/3 of the value added (subtracted) in step 5) to the 017 parameter
value.
If a2 + a3 > b2 + b3,
Subtract from the 017 parameter value.
If a2 + a3 < b2 + b3,
Add to the 017 parameter value.
(Use the numeric keys for input.)
8) Press the Set key.
Example:
When a2 = 10 mm a3 = 11 mm b2 = 12 mm b3 = 12 mm,
a2 + a3 = 21 b2 + b3 = 24
Since the difference is 3 mm, add 9 to the 016 parameter value and add to the 017
parameter value.

5-10 COPYRIGHT © 1999 CANON INC. CANON GP160 REV.0 FEB. 1999 PRINTED IN JAPAN (IMPRIME AU JAPON)
 CHAPTER 5 TROUBLESHOOTING

II. OPERATION FAILURE COUNTERMEASURES

A. Operation failure countermeasure procedures

1 No document pick-up

Cause/location Proce Check item Result Measure

of error dure
1 Check ADF motor (M801) operation NO Perform check in step
in Test Mode [5] Aging Test. Is the 5.
motor rotating normally?
2 Is the document pick-up roller rotat- NO Check the gears and
ing? timing belt that transmit
drive to the ADF motor
(M801).
Document pick- 3 Does the surface of the document YES Replace the document
up roller pick-up roller exhibit cuts, wear or pick-up roller.
other defects?
Document 4 Does the document stopper plate of NO Check the spring clutch
stopper plate the document separation roller unit of the document sepa-
lowering mech- descend during document pick-up? ration roller unit. If the
anism spring is extended or
damaged, replace the
document separation
roller unit.
ADF motor 5 Is the ADF motor surface tempera- YES Shut down unit until
thermoswitch ture detection thermoswitch operate temperature drops
(TH801) (operating temperature: 70°C, (Identify cause of ther-
recovery temperature: 55°C)? moswitch operation.)
Cable connec- 6 Is the J815 connector properly con- NO Correct connection.
tion check nected to the ADF connector PCB?
ADF motor 7 Can the error condition be remedied YES End
(M801) by replacing the ADF motor (M801)?
ADF connector 8 Can the error condition be remedied YES End
PCB by replacing the ADF connector
Main unit PCB? NO Replace the unit image
image proces- processor PCB.
sor PCB

COPYRIGHT © 1999 CANON INC. CANON GP160 REV.0 FEB. 1999 PRINTED IN JAPAN (IMPRIME AU JAPON) 5-11
 CHAPTER 5 TROUBLESHOOTING

2 Double feed

Cause/location Proce Check item Result Measure

of error dure
Document 1 Is the document sheaf curled or YES Tell the user that the
does it exhibit “clinging” due to static document is the cause
electricity? of the problem. Tell him
to remove curls and rif-
fle the document pages
before loading.
2 Does the user use force when load- YES Advise the user not to
ing documents? use force in loading
documents.
Installation 3 Does the installation environment NO Tell the user that this is
environment meet the operating conditions? a defect resulting from
the installation environ-
ment and that the
installation location
should, if possible, be
changed.
Friction bar, 4 Can the error condition be remedied YES End
document roller by cleaning the friction bar and doc- NO Replace worn rollers in
unit rollers ument separation roller unit? the friction bar and the
document separation
roller unit.

3 Skew feed

Cause/location Proce Check item Result Measure

of error dure
Slide guide 1 Have the slide guides been properly NO Adjust the guides prop-
adjusted to the document? erly.
Document 2 Have documents of different sizes YES Load documents of the
been loaded? same size only.
Friction bar, 3 Can the error condition be remedied YES End
document roller by cleaning the friction bar and doc- NO Replace the friction bar
unit rollers ument separation roller unit? and worn rollers.

5-12 COPYRIGHT © 1999 CANON INC. CANON GP160 REV.0 FEB. 1999 PRINTED IN JAPAN (IMPRIME AU JAPON)
 CHAPTER 5 TROUBLESHOOTING

III. DIAGRAM SHOWING LOCATION OF ELECTRIC

PARTS

M801

PS806
TH801
PS805 [1]

PS801 [2]

PS802
PS803

Figure 5-301

Electric load

Symbol Name Code Role

Photo-interrupter PS801 Paper detection
PS805 Document leading edge sensor
Reflective sensor PS802 Document length sensor 1
PS803 Document length sensor 2
Motor M801 ADF motor
Thermoswitch TH801 ADF motor thermoswitch

PCBs

Symbol Name Role

[1] ADF relay PCB Communication signal interface between
ADF and main unit
[2] Document width sensor PCB Document width detection

COPYRIGHT © 1999 CANON INC. CANON GP160 REV.0 FEB. 1999 PRINTED IN JAPAN (IMPRIME AU JAPON) 5-13
 CHAPTER 5 TROUBLESHOOTING

IV. LIST OF VARIABLE RESISTORS (VR), LEDS AND

CHECK PINS BY PRINTED CIRCUIT BOARD
Only the variable resistors, LEDs and check pins in the unit that need to be checked
during field service are listed below.

Caution:
1. Some LEDs leak a small amount of current even when normal, and therefore glow
faintly even when they are off. Do not mistake this phenomenon for their being ON.
2. Variable resistors to be checked during field service:
Variable resistors not to be checked during field service:

Caution:
Variable resistors and check pins not listed are only for factory use, and their adjust-
ment and check requires special tools and measurement instruments. Their adjust-
ments require a greater degree of accuracy and must not be touched during field ser-
vice.

J813 J812 J811

J815 J810
J814

J801 J802

ADF relay PCB

Figure 5-401

5-14 COPYRIGHT © 1999 CANON INC. CANON GP160 REV.0 FEB. 1999 PRINTED IN JAPAN (IMPRIME AU JAPON)
 APPENDIX

A. GENERAL TIMING CHART.....................A-1 D. LIST OF SPECIAL TOOLS......................A-7

B. LIST OF SIGNAL NAMES .......................A-3 E. SOLVENTS AND OILS ............................A-8
C. GENERAL CIRCUIT DIAGRAM ..............A-5

COPYRIGHT © 1999 CANON INC. CANON GP160 REV.0 FEB. 1999 PRINTED IN JAPAN (IMPRIME AU JAPON)
 A. GENERAL TIMING CHART

• Conditions: ADF mode direct copy, pick-up from main unit cassette, A4 document 2 sheets, A4 paper 1 copy

Power ON Document set Start key ON

STBY STBY

2nd page fed as far as the document leading edge sensor

ADF motor (M801)

Document sensor (PS801) High speed rotation

Document width sensor (PS805S)

Differs according to document length

Main motor (M601)

Document scanning motor (M701)

Scanning assembly HPsensor
(PS101)

Document scanning lamp

Cassette pick-up solenoid (SL301)
Paper pick-up vertical path clutch
(CL301)
Paper pick-up sensor (PS303)

Registration clutch (CL302)

Registration sensor (PS302)

Paper leading edge sensor (PS301)

Paper width sensor (PS304)

Image formation

Transfer operation

Paper delivery sensor (PS306)

COPYRIGHT © 1999 CANON INC. CANON GP160 REV.0 JAN. 1999 PRINTED IN JAPAN (IMPRIME AU JAPON) A-1
 APPENDIX

B. LIST OF SIGNAL NAMES

PS801S PAPER DETECTION Signal
PS802S DOCUMENT LENGTH DETECTION 1 Signal
PS803S DOCUMENT LENGTH DETECTION 2 Signal
PS804S DOCUMENT LENGTH DETECTION 3 Signal
PS805S DOCUMENT TOP Signal
PS806S ADF CLOSED Signal
PS851S PAPER DETECTION 1 Signal
PS852S PAPER DETECTION 2 Signal

COPYRIGHT © 1999 CANON INC. CANON GP160 REV.0 FEB. 1999 PRINTED IN JAPAN (IMPRIME AU JAPON) A-3
 C. GENERAL CIRCUIT DIAGRAM

Document width sensor

PCB
PS851 PS852
ADF motor Document Document
Document thermoswitch length length Document leading ADF
TH801
sensor sensor 1 sensor 2 edge sensor closed sensor

PS851S

PS852S
LEDON

LEDON
D-GND
ADF motor
M801 PS802 PS803 PS805 PS806
M P S P S
1 2 3 4 5 J851
1 2 3 1 2 3 1 2 3 1 2 3 1 2 3
J852 J853 J857 J858 J861 J865
1 2 3 4 5 1 2 3 1 2 3 1 2 3 1 2 3 1 2 3

9 8 7 6 5 4 3 2 1 3 2 1
J860 J862

J867 J863
1 2 3 4 5 6 7 8 9 1 2 3

8 7 6 5 4 3 2 1 6 5 4 3 2 1 2 1 9 8 7 6 5 4 3 2 1 4 3 2 1 3 2 1
J854 J855 J856 J868 J864 J866
8 7 6 5 4 3 2 1 J813 J815 6 5 4 3 2 1 2 1 J814 9 8 7 6 5 4 3 2 1 J812 4 3 2 1 J811 3 2 1 J810
PS851S

PS852S

PS801S

PS802S

PS803S

PS805S

PS805S
LEDON

LEDON

LEDON

LEDON

LEDON

LEDON

LEDON

LEDON
COM-B
COM-A
D-GND

D-GND

D-GND

D-GND

D-GND

D-GND

D-GND
+24U
COM

DLS1

N.C
B*
A*

B
A
ADF relay PCB

I-DOWN
PS801S
PS852S
PS851S

PS802S
PS805S

PS803S
PS806S
MOT-I0

MOT-I2
MOT-I1
SEN5V
D-GND
D-GND

R-GND
R-GND
R-GND
OFF5V

MOD3
MOD2
MOD1
RTRN
DLS1
+24U
+24U
+24U

RST*
CCW
ENB

CLK
+5U

N.C

J801 J802
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
J873 J874
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
B16

B15

B14

B13

B12

B11

B10

A10

A11

A12

A13

A14

A15

A16
A1

A2

A3

A4

A5

A6

A7

A8
B9
A9
B8

B7

B6

B5

B4

B3

B2

B1

J251

for Image processor PCB

COPYRIGHT © 1999 CANON INC. CANON GP160 REV.0 JAN. 1999 PRINTED IN JAPAN (IMPRIME AU JAPON) A-5
 APPENDIX

D LIST OF SPECIAL TOOLS

Special tools other than the standard tools used in servicing the unit are listed below.

No. Tool Name Tool No. Configuration Rank Use/Remarks

1 Stop ring pliers CK-0246 B Grip ring
replacement removal
blades 4 to 9 mm

Reference:
Ranks
A: Tools of which there should be one for each service engineer.
B: Tools of which there should be one for a group of five service engineers
C: Tools of which there should be one for each workshop

COPYRIGHT © 1999 CANON INC. CANON GP160 REV.0 FEB. 1999 PRINTED IN JAPAN (IMPRIME AU JAPON) A-7
 APPENDIX

E. SOLVENTS AND OILS

No. Name Purpose Composition Remarks
1 Alcohol Cleaning Fluoride carbon • Must not be used near naked flame.
Example: hydride • Procure locally
glass, Alcohol • C1, IPA (isopropylene alcohol)
plastics Surface active
rubber, agent
external covers Water
2 Lubricati ADF drive gear Silicon oil • Permalube SHV-2 (oil made in
on oil assembly Japan)
• Tool no.: CK8005
3 Lubricant Lubrication Petroleum jelly • Uniway 68 (CK0451)
(paraffin based) • Substitutes
Cosmo Dynaway 68 (Cosmo Sekiyu
product)
Mobil Pactora Oil (Mobil Oil product)
4 Cleaning Cleaning Cleaning tissue TKN-0454
tissue Example:
copyboard
cover,
copyboard glass

A-8 COPYRIGHT © 1999 CANON INC. CANON GP160 REV.0 FEB. 1999 PRINTED IN JAPAN (IMPRIME AU JAPON)