Canon iR5000dN - failing hard drive (HDD)

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  • tech_under_siege
    • May 2025

    #1

    Canon iR5000dN - failing hard drive (HDD)

    Hi guys!

    I’m kinda new in the copier tech business and I really need someone wiser’s help.
    Otherwise, I’m pretty seasoned in the computers business.

    1. The problem
    I have to fix a Canon iR5000dN which has a failing hard drive: it starts after 10 - 15 power cycles.
    After it starts, copier works OK.
    I checked this hard drive on a computer and it behaves the same. Otherwise, the drive is perfect: no bad sectors, SMART is clean.

    The copier is in a very remote location, so I really need a one-time travel fix.

    2. The information I have so far
    2.1 Copy Service Report (partial)
    COPY SERVICE REPORT
    SERIAL NO XXXXXXXX
    DISPLAY
    SYSTEM NAME
    SYSTEM NAME iR5000dN
    VERSION
    DC-CON 22.01
    R-CON 08.01
    PANEL 00.02
    FEEDER 06.02
    SORTER --.--
    NIB 03.00
    PS/PCL 30.06
    LIPS --.--
    SDL-STCH --.-—
    MN-CONT 82.03
    RIP1 --.--
    BOOT-ROM 26.44N
    DIAG-DVC --.--
    RUI --.--
    ACC-STS
    FEEDER 1
    SORTER 0 0
    DECK 0
    CARD 1
    DATA-CON 0
    RAM 256MB
    NIB 1
    LIPS-RAM 0MB
    LIPS 0
    PS/PCL 1
    RIP1 0
    NETWARE 1

    2.2 Current hard drive (HDD) info - used a Linux distro and pulled this:
    #hdparm -I /dev/sda
    ATA device, with non-removable media
    Model Number: QUANTUM FIREBALLlct10 05
    Serial Number: 871005995409
    Firmware Revision: A03.0900
    Standards:
    Used: ATA/ATAPI-4 T13 1153D revision 15
    Supported: 4 3 2
    Configuration:
    Logical max current
    cylinders 10585 10585
    heads 15 15
    sectors/track 63 63
    --
    CHS current addressable sectors: 10002825
    LBA user addressable sectors: 10002825
    Logical/Physical Sector size: 512 bytes
    device size with M = 1024*1024: 4884 MBytes
    device size with M = 1000*1000: 5121 MBytes (5 GB)
    cache/buffer size = 418 KBytes (type=DualPortCache)


    3. What I’ve tried
    3.1 Checked partitions on the original drive (from Service Menu): partitions 1 to 4 = OK
    3.2 Cloned the data on the 5.1 GB HDD to a 40 GB HDD (Maxtor 6E040L0): didn’t work.
    At startup, the copier showed error E602-0004 and got stuck there.
    Checked partitions on clone drive: partitions 2 to 4 = OK, partition 1 got stuck to 100% (drive seemed to be idle).
    For cloning, I used dd and ddrescue (both Linux) - using this method I successfully cloned tens of HDDs for computers (PCs and Macs).

    4. The tools and parts I have
    - PC with parallel port (ECP capable) and Windows XP;
    - parallel cable;
    - Philips PH1 and PH2 screwdrivers;
    - Canon SST software, various versions (from 1.xx to 4.7x);
    - HDDs: Samsung SP0411N and Seagate ST340014A;
    - knowledge: gathered from the very nice and knowledgeable community on this forum (especially teckat)

    5. What (I think) I need

    System software, newer or same version as original.

    I met two very kind copier techs (not Canon specific though) who tried to help me on this issue.
    They gave me some system software:
    4.1 FY9-4155-009 - iR5020/6020 Series System Software v59.51, Ref No.: F1-T01-0K9-10163-01, date: September 9, 2008, size (unpacked): 216MB - I guess I don’t need this;
    4.2 FY9-4059-020 - iR5000/6000 System Software (ver.20.01), Ref No: F1-T01-0K9-10099-01, date: May 20, 2004, size (unpacked): 270MB - maybe this is too old;
    Contains: iR5000N\System\USen\iR5000N-USen2001-2DDD.PRG - I guess not what I want;
    4.3 FY9-4098-012, no PDF files. This contains 5000i and 5000iN directories, so I guess it’s not what I need.
    4.4 FY9-4091-014, no PDF files, size (unpacked): 382MB (attached files/directories listing).
    Contains (among others):
    - iR5000d\HDFORMAT\iR5000d-XXxx0014-HDFormat.ift
    - iR5000d\RUI\XXde\iR5000d-XXde8101-RUI.ift
    - iR5000dN\BOOT\iR5000dN-XXxx2644-4A54-BOOT.PRG
    - iR5000dN\SYSTEM\iR5000dN-USen\iR5000dN-USen8203-C7D3.PRG

    This might be it?

    So, guys, can anyone confirm 100% that FY9-4091-014 is all I need for this machine, in terms of system software?
    Attached Files
    Last edited by Guest; 10-02-2014, 04:13 AM. Reason: Darn, this editor blew my nicely formatted table!
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