e-Support Filename: TP07 216.

pdf
Date: 08-02-07

PRODUCTS AFFECTED / SERIAL NUMBERS AFFECTED:

Color imageRUNNER C3100 / C3170 Series / All Serial Numbers

SUBJECT:
Performing a Total Service Call

GENERAL:
This Technical Publication is to inform the field of the recommended criteria for a Total Service Call on the
Color imageRUNNER C3100 / C3170. This procedure is intended to help minimize E020-0081 Error
Codes, Toner Scatter and Developing Unit Lock Ups.

DETAILS:
To reduce the number of service calls, regarding various error codes and copy quality issues such as E020-
0081, toner scatter and developing unit lock ups, this document gives recommendations on criteria for a
“Total Service Call”. Please reference the imageRUNNER C3100 / C3170 Series Service Manual for
details pertaining to disassembly and re-assembly of the equipment and its various assemblies. The
information and procedures contained herein can be lengthy and take from 1.5 ~ 2 hours, depending on the
technical experience of the individual performing them.

As with any service call, ensure you use the proper tools. Lint-free cloths should be standard issue for all
tool bags. If your tool bag is equipped with “oil impregnated” cloths, do not use them on the interior of this
equipment. Typically these oil impregnated type cloths are yellow in color. If the oil from these cloths gets
into the interior of the engine, stray toner will more likely be attracted to those areas, possibly causing some
of the issues listed below.
NOTE:
Due to the technological nature of the iRC3100 / iRC3170 Series, this equipment needs to be serviced as
a color device. At no time should this equipment be equated with the older Black and White devices (i.e.
imageRUNNER 3300 or imageRUNNER 3570). Although less color percentage is utilized on this
equipment, the servicing is much more involved than the Black and White devices. As an example, a
typical service call on an imageRUNNER C type device can take between 1~3 hours, depending on the
condition of the equipment, due to its color capabilities.

Examples of Possible Issues:

Specific items that may cause E020-0081, Toner Scatter and Developing Unit Lock Ups can be stated as
follows:
1. Drum Assembly at or above maximum life
When a drum assembly is at, or above, maximum life the D-PRINT will only indicate 100% as
its lifetime value. When this occurs, the OPC properties of the drum assembly may no longer
be strong enough to hold toner to it thereby causing a light patch to reproduce on the drum. If

THIS TECHNICAL PUBLICATION IS THE PROPERTY OF CANON U.S.A. INC. AND CONTAINS CONFIDENTIAL INFORMATION OWNED BY OR LICENSED TO,
CANON U.S.A., AUTHORIZED CANON U.S.A., DEALERS MAY USE THIS TECHNICAL PUBLICATION FOR REFERENCE PURPOSES ONLY. ANY OTHER USE
BY AN AUTHORIZED CANON USA DEALER, OR USE BY ANY THIRD PARTY, IS PROHIBITED.
For additional technical information, please visit the Canon Systems and Technical Support Division website at:
www.support.cusa.canon.com. You can also call the Technical Support Center at 1-800-528-2830 or contact your Regional Support Office.
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there is a light patch, the Patch Image Read sensor tells the DC Controller to add toner until the
criteria is satisfied. If not satisfied an E020-0081 Error Code, toner scattering or developing
unit lock ups may occur.
2. Dirty Patch Image Read Sensor
If a Patch Image Read Sensor becomes dirty, it can no longer read the patch on the drum. This
results in an increase in P-LED-DA readings. If the Patch Image Read Sensor cannot read the
patch properly, the result is the DC Controller will add more toner. If logic and control is still
not satisfied an E020-0081, toner scatter or developing unit lock up may occur.
3. Faulty clutch CL7
If clutch CL7 becomes faulty, the ‘D’ cut shaft which is attached to the clutch will continue to
rotate continuously. If this failure occurs, toner is continually added to the developing
assembly. If this continues, E020-xxxx, toner scatter or developing unit lock ups may occur.
4. ITB Cleaning Assembly Fault
When the ITB Cleaning Assembly becomes faulty, whether due to age or other extenuating
circumstances, toner builds up inside the assembly. This toner build up may cause toner
scatter which can lead to a dirty ITB, dirty Patch Image Read Sensor or contamination of the
developing unit assemblies. If this occurs, E020-xxxx, toner scatter or developing unit lock
ups may occur.

The first step in the “Total Service Call” is to observe the engines current situation. To accomplish this,
first generate a P-PRINT, D-PRINT, HISTORY PRINT and ENVIRONMENT PRINT and physically write
“Before” on each set of prints. The DCON firmware should be version 48.01 or higher for iRC3100
(DCON version 17.01 or higher for iRC3170) on the problem engine. If it is not, be sure to upgrade all
firmware to the latest versions as stated on e-Support. Once this is completed, proceed to “Understanding D-
PRINT Values”.

Understanding D-PRINT Values:

There are several values on the D-PRINT which when combined can give an entire picture of the current
situation. These values include the following:

• DENS-“X”-H (“X” = Y, M, C, K)
• DS-S-“X”-H (“X” = Y, M, C, K)
• DENS-“X” (“X” = Y, M, C, K)
• P-LED-DA
• P-SENS-P
• DRM-LIFE

Most of the above-mentioned readings have value ranges. Only DS-S-“X”-H has a distinct value. The
other five (5) readings have value ranges. The explanation and value ranges are detailed on the following
page in Chart 1.

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D-Print Definition Value Comments

Reading (Range)
DENS-"X"-H Actual reading of how much toner is FFD8 ~ 0028 DENS-"X"-H and DS-S-"X"-H are
inside the hopper portion of the compared to form a percentage expressed
developing assembly in DENS-"X"
DS-S-"X"-H Actual reading of how much starter Y, M, C =
compared to toner is inside the 0119
Developing Assembly Bk = 0138
DENS-"X" Average percentage of how much toner -25 ~ +25 The more negative the value, the less
is inside the developing assembly. toner inside the developing assembly.

The more positive the value, the more

P-LED-DA Actual reading of the LED portion of
the Patch Image Read Sensor. This
reading leads to the normalizing of P-
SENS-P.
P-SENS-P Actual reading which measures the
reflectivity value of the LED against the
drum surface. No patches are read for
this reading.
DRM-LIFE This is the percentage of drum life used
toner inside the developing assembly.
55 ~ 90 As the value increases, the Patch Image
Read Sensor LED intensifies in order to
read the patch properly. If this does not
normalize, toner will be added to the
developing assembly.
0 ~ 1023 If the value read by the Patch Image Read
Sensor is less than 255, an E020-0081
Optimum may occur.
Range 400 ~
600
0 ~ 100% At 100%, the drum needs to be replaced.

Chart 1
NOTE:
DS-S-“X”-H does not have a range but a set value. This value is hexadecimal in nature. The higher the
value, the more toner there is in the developing assembly. The lesser the value, the less toner there is in
the developing assembly.

Items to Note When Executing the “Total Service Call”:

1. Depending on the end user needs, items like color developing units may need to be replaced. An
example of this can be:
• If an end user produces less than 5% color prints / copies and Counter 101 indicates more than
100,000. There should be consideration to replace the color developing units even though the
DRBL-1 Counters indicate less than 100% used. The reasoning for this is due to the amount of
Image Stabilization Control processes occurring during the copy / print process. Image
Stabilization Control occurs at the beginning and end of every copy / print job. It also occurs
throughout the copy / print process at specific intervals. When an end user produces less than 5%
color prints / copies, at approximately 100,000 prints, the color developing units have processed
approximately 50,000 prints. This equals the amount of prints for the life of the developer.

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2. Waste toner bottles should be replaced at the proper intervals.

• Waste toner bottles are rated at 60,000 images. This should be changed around the same time the
drum assembly is changed.

Executing the “Total Service Call”:

When a service call is placed on the iRC3100 / C3170 Series, there are several items that need to be
cleaned or replaced. Please be sure the following items are cleaned at every service call:
1. Patch Image Read Sensor
• Blower brush the Patch Image Read Sensor.
• If this sensor is cleaned with a rag, lint may form on the window. In addition if there is excess
toner on the PIR sensor and it is cleaned with a rag, the toner may “scratch” the optical window
thus not allowing the Patch Image Read Sensor to read the patches on the drum properly. This
may result in the P-SENS-P reading to be outside the acceptable range.
2. Patch Image Read Sensor Protection Plate
• This is a black plastic plate below the Patch Image Read Sensor. To remove it, remove the drum
unit and then remove the plate by moving the plastic tab down and moving the plate back.
Patch Image Read
Sensor

As seen in the picture above, once the plastic tab is released, the plate can then be removed.
When placing the plate back into position, be sure the tab is secured as seen in the above picture.
If it does not, the black plastic plate may fall out of position and cause damage to the drum or
surrounding areas.

Once removed, clean both sides with a damp lint free cloth (water or alcohol may be used). Do
not use a dry cloth or vacuum as static may build up on the plate causing toner to adhere to the
plate more frequently, which results in a dirty Patch Image Read Sensor.

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The picture above shows areas where toner build-up may occur and needs to be cleaned.
Be sure to clean both sides of this guide to ensure stray toner does not adhere to the Patch Image
Read Sensor.

3. Filters
• There are not many filters within the iRC3100/C3170 Series. One filter specifically to be aware
of is the exhaust filter on the rear left side of the engine. This filter can become filled with stray
toner and cause poor ventilation. Once this occurs, the excess toner can attach itself to other
components possibly causing other issues. As a rule, be sure to inspect and / or replace all filters
at the time of the service call.

4. ATR Sensor
• Blower brush the ATR Sensor. Do not use a vacuum to clean this sensor! If a vacuum is used,
static build up will occur from any excess starter material or toner thus causing the ATR sensor to
fail.

5. Rotary
• The rotary should be cleaned at every service call due to its rotation and location of the
developing assemblies. Remove the developing assemblies before cleaning. Using a vacuum for
rotary cleaning is acceptable.

6. ITB Cleaning Assembly

• The ITB Cleaning Assembly should be cleaned and inspected at every service call. Using a
vacuum with a conductive rubberized hose is acceptable for this area. If a conductive rubberized
hose is not used, it may be possible for the technician to get shocked due to a static build up from
vacuuming developer material possibly inside the cleaning assembly. Also be sure to lubricate
the ITB Cleaning Blade when installing a new one as stated in the Service Manual. The part
number for the ITB Cleaning Blade Lubricant is TKN-0480-000.

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Clean Toner Build

Up at the Base of
the Cleaning Blade

7. Inspection of clutch CL7

• Remove the left rear cover.

Cover

• Locate CL7 by flashing a light by the fan duct.

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• In Service Mode go to COPIER>TEST>PG>

• TYPE = 5
• DENS-“X” = set to “0” (Default = 128)
• “X” = Y, M, C, Bk
• PG-PICK
• Choose the cassette which has letter sized paper
• PG-QTY = 10
• Press OK
• Observe the D-Cut shaft attached to CL7 and observe its movement

• The only time the D-Cut shaft moves is during rotary rotation (1-2 rotations) or toner supply.
As the pages printed are blank, there should be no toner supply movement. If the D-Cut shaft
is moving, replace CL7 with a new clutch. For the iRC3100 / C3170 series only, the clutch part
number for CL7 was changed from FH6-5005-020 to FK2-6000-000. If toner is compacted
inside the old clutch, be sure to clean the surrounding areas to prevent stray toner compacting
inside of the new clutch.

8. ITB
• Clean all components of the ITB assembly as per the procedures stated in the Service Manual.
Be sure all excess toner is removed from the ITB and it’s components including the tension
rollers. Toner build up on these rollers may cause bowing in the ITB which can lead to poor
cleaning of the ITB.
• Specifically check for ground plate connectivity and cleanliness. If the ground plates look
“shiny” there may have been toner build up which can cause intermittent grounding issues
causing a possible E070.

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• The ground plate at the rear of the engine that comes into contact with the ITB assembly should
look rounded. If there seems to be a “dip” or “divot”, replace the ground plate with a new one.

This Ground Contact

should be “rounded”.

• Also be sure to clean all other grounding contacts around the ITB area. If necessary replace the
grounding contacts as needed. The below picture shows one of the contacts in the ITB area
which needs to be regularly cleaned.

Drum

If the drum life is 90% or higher, replacement is recommended. When replacing the drum, be sure to execute
COPIER>FUNCTION>CLEAR>DRM-LFE. If this function is not executed, the references for the Primary
Roller will not be corrected for the new drum, possibly causing the drum to attract more toner than it can
handle. This may contribute to toner scatter inside the engine. Executing this will limit recalls (call backs) and

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ensure all items around the drum do not incur any stray toner whether due to the lack of the drum OPC material
charge holding properties or Primary Roller charge properties.

The amount of time this procedure may take is between 1.5 to 3 hours per engine. This procedure may take
longer depending on the accessories attached. Be sure to clear any counter of any item replaced. This will
allow less confusion between technicians on part replacement during the servicing of the equipment.

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