Canon iR C6800 Series How to use

Feb 4 2004
SERVICE HANDBOOK(temp)
iR C6800 Series
iR C6800CN

Application
This manual has been issued by Canon Inc. for qualified persons to learn technical theory, installation, maintenance, and
repair of products. This manual covers all localities where the products are sold. For this reason, there may be
information in this manual that does not apply to your locality.
Corrections
This manual may contain technical inaccuracies or typographical errors due to improvements or changes in products.
When changes occur in applicable products or in the contents of this manual, Canon will release technical information
as the need arises. In the event of major changes in the contents of this manual over a long or short period, Canon will
issue a new edition of this manual.
The following paragraph does not apply to any countries where such provisions are inconsistent with local law.
Trademarks
The product names and company names used in this manual are the registered trademarks of the individual companies.
Copyright
This manual is copyrighted with all rights reserved. Under the copyright laws, this manual may not be copied,
reproduced or translated into another language, in whole or in part, without the written consent of Canon Inc.
COPYRIGHT © 2001 CANON INC.
Printed in Japan
Caution
Use of this manual should be strictly supervised to avoid disclosure of confidential information.

Introduction
Symbols Used
This documentation uses the following symbols to indicate special information:
Symbol Description
Indicates an item of a non-specific nature, possibly classified as Note, Caution, or Warning.
Indicates an item requiring care to avoid electric shocks.
Indicates an item requiring care to avoid combustion (fire).
Indicates an item prohibiting disassembly to avoid electric shocks or problems.
Indicates an item requiring disconnection of the power plug from the electric outlet.
Indicates an item intended to provide notes assisting the understanding of the topic in question.
Indicates an item of reference assisting the understanding of the topic in question.
Provides a description of a service mode.
Provides a description of the nature of an error indication.
Memo
REF.

Introduction
The following rules apply throughout this Service Manual:
1. Each chapter contains sections explaining the purpose of specific functions and the relationship between electrical
and mechanical systems with reference to the timing of operation.
In the diagrams, represents the path of mechanical drive; where a signal name accompanies the symbol ,
the arrow indicates the direction of the electric signal.
The expression "turn on the power" means flipping on the power switch, closing the front door, and closing the
delivery unit door, which results in supplying the machine with power.
2. In the digital circuits, '1'is used to indicate that the voltage level of a given signal is "High", while '0' is used to
indicate "Low".(The voltage value, however, differs from circuit to circuit.) In addition, the asterisk (*) as in
"DRMD*" indicates that the DRMD signal goes on when '0'.
In practically all cases, the internal mechanisms of a microprocessor cannot be checked in the field. Therefore, the
operations of the microprocessors used in the machines are not discussed: they are explained in terms of from
sensors to the input of the DC controller PCB and from the output of the DC controller PCB to the loads.
The descriptions in this Service Manual are subject to change without notice for product improvement or other
purposes, and major changes will be communicated in the form of Service Information bulletins.
All service persons are expected to have a good understanding of the contents of this Service Manual and all relevant
Service Information bulletins and be able to identify and isolate faults in the machine."

Contents
Contents
Chapter 1 Maintenance and Inspection
1.1 Periodically Replaced Parts............................................................................................................................... 1- 2
1.1.1Overview ..................................................................................................................................................... 1- 2
1.1.2Reader Unit.................................................................................................................................................. 1- 2
1.1.3Printer Unit .................................................................................................................................................. 1- 2
1.2 Durables and Consumables ............................................................................................................................... 1- 4
1.2.1Overview ..................................................................................................................................................... 1- 4
1.2.2Reader Unit.................................................................................................................................................. 1- 4
1.2.3Printer Unit .................................................................................................................................................. 1- 4
1.3 Scheduled Servicing Basic Procedure............................................................................................................... 1- 7
1.3.1Scheduled Servicing Basic Procedure......................................................................................................... 1- 7
1.3.2Scheduled Servicing (reader unit) ............................................................................................................... 1- 8
1.3.3Scheduled Servicing (printer unit) .............................................................................................................. 1- 9
1.4 Cleaning........................................................................................................................................................... 1- 17
1.4.1Cleaning the Photosensitive Drum ............................................................................................................ 1- 17
1.4.2Cleaning the Secondary Transfer Rear Guide ........................................................................................... 1- 18
1.4.3Cleaning the Registration Roller, Registration Guide, and Transparency Sensor .................................... 1- 19
1.5 Upgrading........................................................................................................................................................ 1- 22
1.5.1Outline of the Version Upgrade ................................................................................................................ 1- 22
1.5.2Outline of the Service Support Tool.......................................................................................................... 1- 22
1.5.3Network Interface of the Machine with the SST in Use ........................................................................... 1- 25
Chapter 2 Standards and Adjustments
2.1 Image Adjustments.......................................................................................................................................... 2- 30
2.1.1Image Position........................................................................................................................................... 2- 30
2.1.2Checking the Image Position..................................................................................................................... 2- 30
2.1.3Cassette...................................................................................................................................................... 2- 31
2.1.4Manual Feed Tray ..................................................................................................................................... 2- 31
2.1.5Front Deck................................................................................................................................................. 2- 32
2.2 Scanning System ............................................................................................................................................. 2- 35
2.2.1After Replacing the CCD Unit .................................................................................................................. 2- 35
2.2.2After Replacing the Copyboard Glass....................................................................................................... 2- 35
2.2.3After Replacing the Reader Controller PCB or Initializing the RAM ...................................................... 2- 35
2.3 Laser Exposure System ................................................................................................................................... 2- 38
2.3.1After Replacing the Laser Scanner............................................................................................................ 2- 38
2.4 Image Formation System................................................................................................................................. 2- 39
2.4.1After Replacing the Black Developing Unit ............................................................................................. 2- 39
2.4.2Replacing the Color Developing Unit ....................................................................................................... 2- 39
2.4.3Replacing the Starter of the Color Developing Unit ................................................................................. 2- 41
2.4.4After Replacing the Primary Charging Assembly..................................................................................... 2- 43
2.4.5After Replacing the Primary Charging Wire............................................................................................. 2- 43
2.4.6After Replacing the Pre-Transfer Charging Wire ..................................................................................... 2- 43

Contents
2.4.7After Replacing the Pre-Transfer Charging Wire......................................................................................2- 43
2.4.8After Replacing the Waste Toner Box.......................................................................................................2- 43
2.4.9After Replacing the ITB Cleaner Blade.....................................................................................................2- 43
2.4.10After Repacking the Photosensitive Drum Cleaning Blade ....................................................................2- 43
2.4.11After Replacing the Photosensitive Drum ...............................................................................................2- 44
2.4.12After Repacking the ITB ........................................................................................................................2- 44
2.4.13After Replacing the Primary Transfer Roller ..........................................................................................2- 44
2.4.14After Replacing the Primary Transfer Outside Roller .............................................................................2- 44
2.4.15After Replacing the Primary Transfer Static Eliminator .........................................................................2- 44
2.4.16After Replacing the ITB Unit ..................................................................................................................2- 44
2.5 Fixing System ..................................................................................................................................................2- 45
2.5.1Points to Note When Mounting the Fixing Assembly...............................................................................2- 45
2.5.2After Replacing the Fixing Roller .............................................................................................................2- 45
2.5.3After Replacing the Fixing Web................................................................................................................2- 45
2.5.4Position of the Fixing inlet Guide..............................................................................................................2- 45
2.5.5Points to Note When Mounting the Pressure Roller..................................................................................2- 45
2.5.6Adjusting the Position of the Feeding Web Solenoid (SL2) .....................................................................2- 46
2.5.7Points to Note About the Position of the Fixing Thermal Switch .............................................................2- 46
2.5.8Points to Note When Mounting the Shift Thermal Switch........................................................................2- 46
2.5.9Points to Note When Mounting the Outside Heating Roller Thermal Switch ..........................................2- 47
2.5.10Points to Note When Mounting the Fixing Upper Thermistor ................................................................ 2- 47
2.5.11Points to Note When Mounting the Fixing Lower Thermistor................................................................2- 47
2.5.12Points to Note When Mounting the External Heat Thermistor ...............................................................2- 48
2.6 Electrical Components.....................................................................................................................................2- 49
2.6.1When Replacing the Reader Controller PCB ............................................................................................2- 49
2.6.2After Replacing the DC Controller PCB ...................................................................................................2- 50
2.6.3Points to Note When Mounting the DC Controller PCB/ DC Controller Box..........................................2- 50
2.6.4After Replacing the Main Controller PCB (main).....................................................................................2- 51
2.6.5After Repacking the SRAM Board............................................................................................................2- 51
2.6.6After Replacing the HDD ..........................................................................................................................2- 52
2.6.7When Replacing the HV2 PCB .................................................................................................................2- 52
2.6.8When Replacing the ATR Sensor/Patch Image Read Sensor....................................................................2- 53
2.7 Pickup/Feeding System ...................................................................................................................................2- 54
2.7.1Adjusting the Horizontal Registration After Replacing the Pickup Cassette ............................................2- 54
2.7.2Adjusting the Manual Feed Pickup Horizontal Registration.....................................................................2- 54
2.7.3Adjusting the Front Deck Pickup Horizontal Registration........................................................................2- 54
2.7.4Registering the Paper Width Basic Value .................................................................................................2- 56
Chapter 3 User Mode Items
3.1 Common Settings............................................................................................................................................. 3-60
3.2 Setting the Timers............................................................................................................................................ 3-62
3.3 Adjustment, Cleaning ...................................................................................................................................... 3-63
3.4 Report .............................................................................................................................................................. 3-64
3.5 System Control Settings .................................................................................................................................. 3-65
3.6 Copier Settings................................................................................................................................................. 3-66
3.7 Common Transmission Settings ...................................................................................................................... 3-67
3.8 Box Settings..................................................................................................................................................... 3-69
3.9 Printer Settings................................................................................................................................................. 3-70

Contents
3.10 Address Book Settings .................................................................................................................................. 3-71
Chapter 4 Service Mode
4.1 Test Print ......................................................................................................................................................... 4- 74
4.1.1Overview ................................................................................................................................................... 4- 74
4.1.2Test Print TYPE ........................................................................................................................................ 4- 74
4.1.3Selecting Test Print TYPE ........................................................................................................................ 4- 74
4.1.416-Gradation (TYPE=4)............................................................................................................................ 4- 75
4.1.5Grid (TYPE=6).......................................................................................................................................... 4- 75
4.1.6MCYBk Horizontal Stripes (TYPE=10) ................................................................................................... 4- 76
4.1.764-Gradation (TYPE=12).......................................................................................................................... 4- 77
4.1.8Full Color 16-Gradation (TYPE=14) ........................................................................................................ 4- 77
Chapter 5 Outline of Components
5.1 Clutch/Solenoid ............................................................................................................................................... 5- 80
5.1.1Clutches and Solenoids ............................................................................................................................. 5- 80
5.2 Motor ............................................................................................................................................................... 5- 83
5.2.1Motors ....................................................................................................................................................... 5- 83
5.3 Fan ................................................................................................................................................................... 5- 89
5.3.1Fans ........................................................................................................................................................... 5- 89
5.4 Sensor .............................................................................................................................................................. 5- 93
5.4.1Sensors....................................................................................................................................................... 5- 93
5.5 Switch............................................................................................................................................................ 5- 103
5.5.1Switches................................................................................................................................................... 5- 103
5.6 Lamps, Heaters, and Others .......................................................................................................................... 5- 105
5.6.1Heaters, Lamps, and Others .................................................................................................................... 5- 105
5.7 PCBs.............................................................................................................................................................. 5- 108
5.7.1PCB ......................................................................................................................................................... 5- 108
Chapter 6 System Construction
6.1 System Construction...................................................................................................................................... 6- 114
6.1.1System Configuration with Pickup/Delivery Accessories ...................................................................... 6- 114
6.1.2System Configuration with Printing/Transmission Accessories ............................................................. 6- 114
6.2 Function List.................................................................................................................................................. 6- 116
6.2.1Print Speed .............................................................................................................................................. 6- 116
6.2.2Paper Type............................................................................................................................................... 6- 119
6.2.3Accessories .............................................................................................................................................. 6- 120

Chapter 1
1-1
Chapter 1 Maintenance
and Inspection

Chapter 1
1-2
1.1 Periodically Replaced Parts
1.1.1 Overview 0002-9397
Some parts of the machine must be replaced on a periodical basis for the machine to maintain a specific level of
performance. They must be replaced regardless of the presence/absence of external changes or damage, as the
performance of the machine will be considerably affected once they fail.
If possible, plan any replacement to coincide with a scheduled visit.
The intervals indicated may vary depending on the site environment and user habit.
- Checking the Timing of Replacement
The timing of replacement may be checked using the following service mode items:
- Copier
COPIER>COUNTER>PRDC-1
- Accessory
COPIER>COUNTER>PRDC-2
1.1.2 Reader Unit 0000-9633
The machine's reader unit does not have parts that must be replaced on a periodical basis.
1.1.3 Printer Unit 0002-9400
T-1-1
as of February 2004
Ref. Parts name Parts No. Q'ty Interval Remarks
1 Ozone filter FC5-2486-
000 1250,000 images* (*)
2 Toner filter FL2-0554-
000 1250,000 images* (*)
3 Primary charging wire FB4-3687-
000 AR 500,000 images* (*)
4 Charging wire cleaner 1 FL2-2427-
000 1500,000 images* (*)
5 Charging wire cleaner 2 FL2-2428-
000 1500,000 images*

Chapter 1
1-3
* In the case of a black mono color print, counted as 1; in the case of a full color print, counted as 4 images.
6Pre-transfer charging
assembly
FB4-3687-
000 AR 500,000 images*
7Pre-transfer charging
assembly wire cleaner 1
FL2-2427-
000 1500,000 images*
8Pre-transfer charging
assembly wire cleaner 2
FL2-2428-
000 1500,000 images*
9 Primary grid wire FY1-0883-
000 1500,000 images*
10 Fixing thermistor FK2-0013-
000 1 500,000 prints
11 Pressure thermistor FK2-0013-
000 1 500,000 prints
12 Outside heating roller
thermistor
FK2-0013-
000 1 500,000 prints
13 Primary charging assembly FM2-0429-
000 11,000,000 images (*)
14 Pre-transfer charging
assembly
FM2-0427-
000 11,000,000 images (*)
15 Fixing thermal switch FM2-0497-
000 11,000,000 prints
16 Pressure thermal switch FM2-0498-
000 11,000,000 prints
17 Outside heating thermal
switch
FM2-0499-
000 11,000,000 prints
as of February 2004
Ref. Parts name Parts No. Q'ty Interval Remarks

Chapter 1
1-4
1.2 Durables and Consumables
1.2.1 Overview 0005-8047
Some parts of the machine may have to be replaced once or more over the period of machine warranty because of
wear or damage. Replace them as needed by referring to the table of estimated lives (expressed in terms of the
number of prints they make).
Making Checks When Replacing Durables
Use the following service mode items to find out when to replace parts:
- Machine
COPIER>COUNTER>DRBL-1
- Accessory
COPIER>COUNTER>DRBL-2
1.2.2 Reader Unit 0000-9645
The machine's reader unit does not have parts that are classified as durables.
1.2.3 Printer Unit 0002-9470
T-1-2
2
as of February 2004
Ref. Parts name Parts No. Q't
yInterval Remarks
[1] Feed roller (manual feed) FB1-8581-
000 1 120,000 prints
[2] Separation roller (manual
feed)
FB5-0873-
000 1 120,000 prints
[3] ITB cleaner blade FC5-1662-
000 1 150,000 prints
[4] ITB cleaner scoop-up sheet FL2-0411-
000 1 150,000 prints
[5] Primary transfer outside
roller
FC5-2157-
000 1 150,000 prints
[6] Secondary transfer static
eliminator holder
FL2-0598-
000 1 150,000 prints

Chapter 1
1-5
[7] Fixing roller FC5-6298-
000 1150,000 prints*
[8] Pressure roller FC5-6299-
000 1150,000 prints*
[9] Outside heating roller FC5-2285-
000 1150,000 prints*
[10] Cleaner scoop-up sheet FL2-0422-
000 1250,000 images*2
[11] Cleaner blade FC5-1788-
000
1250,000
images*2
(one edge in
use)
[12] Pickup roller (left/right
paper deck)
FC5-2524-
000
2
eac
h250,000 prints
[13] Feed roller (left/right paper
deck)
FC5-2526-
000
2
eac
h
250,000 prints
[14] Separation roller (left/right
paper deck)
FC5-2528-
000
2
eac
h
250,000 prints
[15] Pickup roller (cassette 3/4) FC5-2524-
000
2
eac
h
250,000 prints
[16] Feed roller (cassette 3/4) FC5-2526-
000
2
eac
h
250,000 prints
[17] Separation roller (cassette 3/
4)
FC5-2528-
000
2
eac
h
250,000 prints
[18] Primary transfer roller FC5-1660-
000 1300,000 images*2
[19] Primary transfer static
eliminator
FM2-0420-
000 1300,000 images*2
[20] ITB FC5-1658-
000 1300,000 images*2
[21] Secondary transfer inside
roller
FC5-1661-
000 1 300,000 prints
as of February 2004
Ref. Parts name Parts No. Q't
yInterval Remarks

Chapter 1
1-6
*1: in the case of a color ratio of 10%; if 100%, 60,000 prints; if 0%, 180,000 prints.
*2: in the case of a black mono color print, counted as 1 image; in the case of a full color print, counted as 4 images.
[22] Edge scraper FC5-5136-
000 2500,000 images*2
[23] Color developing assembly FM2-0446-
000 3 500,000 prints
[24] Fixing web FC5-2286-
000 1 500,000 prints
[25] Fixing heat insulating bush FB5-3613-
000 2 500,000 prints
[26] Delivery upper separation
claw
FM2-1672-
000 4 500,000 prints
[27] Delivery lower separation
claw unit
FM2-0501-
000 6 500,000 prints
[28] Pressure insulating bush RB1-0325-
000 2 500,000 prints
[29] Outside heat insulating bush FC5-2582-
000 2 500,000 prints
[30] Fixing heat discharge ozone
filter
FC5-6370-
000 11,000,000 images
[31] Tner filter (inside) FL2-0554-
000 21,000,000 images
[32] Bk developing cylinder
(black developing assembly)
FM2-0434-
000 11,000,000 prints
[33] Developing roll (black
developing assembly)
FC5-1863-
000 21,000,000 prints
as of February 2004
Ref. Parts name Parts No. Q't
yInterval Remarks

Chapter 1
1-7
1.3 Scheduled Servicing Basic Procedure
1.3.1 Scheduled Servicing Basic Procedure 0003-4125
- As a rule, provide scheduled servicing every 150,000 prints.
- Check with the Service Book before setting out for a scheduled service visit, and take parts for which replacement
is expected.
- If the power plug is left connected for a long time in a place subject to dust, humidity, or oil smoke, a fire hazard
is a possibility (i.e., the dust collecting around the plug can absorb moisture, resulting in insulating failure). Be sure
to disconnect the power plug on a periodical basis, and wipe off the dust and dirt collecting around it.
<Work Procedure>
1) Report to the person in charge, and check the general condition.
2) Record the counter reading, and check the faulty prints.
3) Make the following checks, and clean/adjust the items that are indicated:
T-1-3
4) Check the waste toner case.
If half full or more, dispose of the waste toner in a vinyl bag or the like for collection; or, replace the waste toner case.
Items
Text copy against image density standard
for soiling of back of paper
for clarity of characters
for margin
for fixing misplaced registration, soiled
back of paper
for margin standards (single-
sided print)
leading edge: 4.0+1.5/-1.0mm
left edge: 2.5+/- 1.5mm
(double-sided print) leading edge: 4.0+1.5/-1.0mm
left edge: 2.5+/- 2.0mm
Feeding system registration upper/lower roller
for paper lint along front edge
of registration assembly

Chapter 1
1-8
- If you need to dispose of the waste toner, be sure to do so in strict accordance with the regulations imposed by the
local authorities.
- Do not dispose of waste toner in a fire. Doing so may cause an explosion.
5) Clean the copyboard glass and the reading glass.
6) Make test copies.
7) Make sample copies.
8) Check the operation of the leakage breaker.
With the power switch at ON, push the test switch of the leakage breaker to see that it operates normally (i.e., the
breaker switch shifts to the OFF side to cut off the power).
If the leakage beaker fails to operate normally, replace it, and run a check once again.
<Resetting the Breaker>
When you have made the check, turn off the main power switch, and turn on the breaker switch, and then turn the
main power switch back on.
9) Put the sample copies in order, and clean up the area around the machine.
10) Record the final counter reading; at this time, be sure to fill out the blanks for 'FX-UP-RL' and 'DV-UNT-K'
(service counters).
11) Fill out the Service Book, and report to the person in change. Be sure to update the history of checks on the
leakage breaker in the Service Book.
1.3.2 Scheduled Servicing (reader unit) 0003-4139
Do not use solvents or oils other than those indicated herein.
T-1-4
Unit Location Wo
rk
Interva
ls Remarks
Original
exposure
system
Copyboard glass clea
n
as
needed
clean the face, back, and the white plate on the
back.
Original
exposure
system
ADF reading
glass
clea
n
as
needed
clean the back and the face.

Chapter 1
1-9
The foreign values are estimates only, and are subject to change based on future data.
1.3.3 Scheduled Servicing (printer unit) 0003-4126
Do not use solvents or oils other than those permitted.
Original
exposure
system
Scanner rail clea
n/
lubr
icat
e
as
needed
Original
exposure
system
Scanner mirror
(No. 1 through
No. 3 mirrors)
clea
n
250,000
images
Original
exposure
system
Reflecting plate clea
n
250,000
images
Unit Location Wo
rk
Interva
ls Remarks

Chapter 1
1-10
T-1-5
Unit Location Item Interval Remarks
Externals
and controls
Ozone filter repla
ce
250,000
images
[1]Toner filter
[2]Ozone filter
Externals
and controls
Toner filter repla
ce
250,000
images
Externals
and controls
Dust-
collecting
filter (primary)
clean 250,000
prints
inside of the right upper cover
Laser
exposure
system
Dust-colleting
glass
clean 250,000
prints
Charging
assembly
Primary
charging
assembly
repla
ce
1,000,00
0 images
[1]
[1]
[2