Canon iR C6800 Series User manual

Jan 20 2005
Portable Manual
iR C6800 Series

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- 1
1.1.1Overview ..................................................................................................................................................... 1- 1
1.1.2Reader Unit.................................................................................................................................................. 1- 1
1.1.3Printer Unit .................................................................................................................................................. 1- 1
1.1.4Print Unit ..................................................................................................................................................... 1- 2
1.2 Durables and Consumables ............................................................................................................................... 1- 5
1.2.1Overview ..................................................................................................................................................... 1- 5
1.2.2Overview ..................................................................................................................................................... 1- 5
1.2.3Reader Unit.................................................................................................................................................. 1- 5
1.2.4Printer Unit .................................................................................................................................................. 1- 5
1.2.5Printer Unit ................................................................................................................................................ 1- 10
1.3 Scheduled Servicing Basic Procedure............................................................................................................. 1- 14
1.3.1Scheduled Servicing Basic Procedure....................................................................................................... 1- 14
1.3.2Scheduled Servicing (reader unit) ............................................................................................................. 1- 15
1.3.3Scheduled Servicing (printer unit) ............................................................................................................ 1- 16
1.3.4Shifting the Photosensitive Drum Phase ................................................................................................... 1- 24
1.4 Cleaning........................................................................................................................................................... 1- 32
1.4.1Cleaning the Secondary Transfer Rear Guide ........................................................................................... 1- 32
1.4.2Cleaning the Registration Roller, Registration Guide, and Transparency Sensor .................................... 1- 32
Chapter 2 Standards and Adjustments
2.1 Image Adjustment Basic Procedure .................................................................................................................. 2- 1
2.1.1Image Adjustment Basic Procedure 1 ......................................................................................................... 2- 1
2.1.2Image Adjustment Basic Procedure 2 ......................................................................................................... 2- 2
2.1.3Image Adjustment Basic Procedure 3 ......................................................................................................... 2- 3
2.1.4Image Adjustment Basic Procedure 4 ......................................................................................................... 2- 4
2.1.5Image Adjustment Basic Procedure 5 ......................................................................................................... 2- 5
2.1.6Image Adjustment Basic Procedure 6 ......................................................................................................... 2- 6
2.1.7Potential Control Conversion Table ............................................................................................................ 2- 7
2.2 Image Adjustments.......................................................................................................................................... 2- 18
2.2.1Image Position........................................................................................................................................... 2- 18
2.2.2Checking the Image Position..................................................................................................................... 2- 18
2.2.3Cassette...................................................................................................................................................... 2- 19
2.2.4Manual Feed Tray ..................................................................................................................................... 2- 19
2.2.5Front Deck................................................................................................................................................. 2- 20
2.3 Scanning System ............................................................................................................................................. 2- 23
2.3.1After Replacing the CCD Unit .................................................................................................................. 2- 23
2.3.2After Replacing the Copyboard Glass....................................................................................................... 2- 23
2.3.3After Replacing the Reader Controller PCB or Initializing the RAM ...................................................... 2- 23
2.4 Laser Exposure System ................................................................................................................................... 2- 26
2.4.1After Replacing the Laser Scanner............................................................................................................ 2- 26

Contents
2.5 Image Formation System.................................................................................................................................2- 27
2.5.1After Replacing the Black Developing Unit..............................................................................................2- 27
2.5.2Points to Note When Mounting the Polarity Positioning Plate .................................................................2- 27
2.5.3Replacing the Color Developing Unit .......................................................................................................2- 27
2.5.4Replacing the Starter of the Color Developing Unit .................................................................................2- 30
2.5.5After Replacing the Primary Charging Assembly .....................................................................................2- 32
2.5.6After Replacing the Primary Charging Wire .............................................................................................2- 32
2.5.7After Replacing the Pre-Transfer Charging Wire......................................................................................2- 32
2.5.8After Replacing the Pre-Transfer Charging Wire......................................................................................2- 32
2.5.9After Replacing the Waste Toner Box.......................................................................................................2- 32
2.5.10After Replacing the ITB Cleaning Blade.................................................................................................2- 33
2.5.11After Repacking the Photosensitive Drum Cleaning Blade ....................................................................2- 34
2.5.12Replacing the Photosensitive Drum.........................................................................................................2- 35
2.5.13Points to Note When Replacing the Drum Heater...................................................................................2- 36
2.5.14Points to Note When Replacing the Drum Heater PCB ..........................................................................2- 37
2.5.15After Repacking the ITB ........................................................................................................................2- 38
2.5.16After Replacing the Primary Transfer Roller ..........................................................................................2- 38
2.6 Fixing System ..................................................................................................................................................2- 41
2.6.1Points to Note When Mounting the Fixing Assembly...............................................................................2- 41
2.6.2After Replacing the Fixing Roller .............................................................................................................2- 41
2.6.3After Replacing the Fixing Web................................................................................................................2- 41
2.6.4Position of the Fixing inlet Guide..............................................................................................................2- 41
2.6.5Points to Note When Mounting the Pressure Roller..................................................................................2- 42
2.6.6Adjusting the Nip Pressure of the Pressure Roller ...................................................................................2- 42
2.6.7Adjusting the Position of the Feeding Web Solenoid (SL2) .....................................................................2- 42
2.6.8Points to Note About the Position of the Fixing Thermal Switch .............................................................2- 42
2.6.9Points to Note When Mounting the Shift Thermal Switch........................................................................2- 43
2.6.10Points to Note When Mounting the Outside Heating Roller Thermal Switch ........................................2- 43
2.6.11Points to Note When Mounting the Fixing Upper Thermistor ................................................................2- 44
2.6.12Points to Note When Mounting the Fixing Lower Thermistor................................................................2- 44
2.6.13Points to Note When Mounting the External Heat Thermistor ...............................................................2- 44
2.7 Electrical Components.....................................................................................................................................2- 46
2.7.1When Replacing the Reader Controller PCB ............................................................................................2- 46
2.7.2After Replacing the DC Controller PCB ...................................................................................................2- 47
2.7.3Points to Note When Mounting the DC Controller PCB/ DC Controller Box..........................................2- 48
2.7.4After Replacing the Main Controller PCB (main).....................................................................................2- 48
2.7.5After Repacking the SRAM Board............................................................................................................2- 49
2.7.6After Replacing the HDD ..........................................................................................................................2- 49
2.7.7When Replacing the HV2 PCB .................................................................................................................2- 50
2.7.8When Replacing the ATR Sensor/Patch Image Read Sensor....................................................................2- 50
2.8 Pickup/Feeding System ...................................................................................................................................2- 52
2.8.1Adjusting the Horizontal Registration After Replacing the Pickup Cassette............................................2- 52
2.8.2Adjusting the Manual Feed Pickup Horizontal Registration.....................................................................2- 52
2.8.3Adjusting the Front Deck Pickup Horizontal Registration........................................................................2- 52
2.8.4Registering the Paper Width Basic Value .................................................................................................2- 54
Chapter 3 Error Code
3.1 Error Code Details .............................................................................................................................................3- 1

Contents
3.1.1Error Code in Detail .................................................................................................................................... 3- 1
3.2 Error Code (SEND) ......................................................................................................................................... 3- 45
3.2.1Self-Diagnostic Display ............................................................................................................................ 3- 45
3.2.2List of Error Codes without Messages ...................................................................................................... 3- 48
Chapter 4 User Mode Items
4.1 Common Settings .............................................................................................................................................. 4-1
4.2 Setting the Timers ............................................................................................................................................. 4-3
4.3 Adjustment and Cleaning ................................................................................................................................. 4-4
4.4 Report ................................................................................................................................................................ 4-5
4.5 System Control Settings .................................................................................................................................... 4-6
4.6 Copier Settings .................................................................................................................................................. 4-7
4.7 Common Transmission Settings........................................................................................................................ 4-8
4.8 Box Settings .................................................................................................................................................... 4-10
4.9 Printer Settings ................................................................................................................................................ 4-11
4.10 Address Book Settings .................................................................................................................................. 4-13
Chapter 5 Service Mode
5.1 Test Print ........................................................................................................................................................... 5- 1
5.1.1Overview ..................................................................................................................................................... 5- 1
5.1.2Test Print TYPE .......................................................................................................................................... 5- 1
5.1.3Selecting Test Print TYPE .......................................................................................................................... 5- 1
5.1.416-Gradation (TYPE=4).............................................................................................................................. 5- 2
5.1.5Full Page Halftone (TYPE=5)..................................................................................................................... 5- 2
5.1.6Grid (TYPE=6)............................................................................................................................................ 5- 3
5.1.7MCYBk Horizontal Stripes (TYPE=10) ..................................................................................................... 5- 4
5.1.864-Gradation (TYPE=12)............................................................................................................................ 5- 5
5.1.9Full Color 16-Gradation (TYPE=14) .......................................................................................................... 5- 5
5.2 DISPLAY (Status Display Mode)..................................................................................................................... 5- 7
5.2.1 COPIER ...................................................................................................................................................... 5- 7
5.2.1.1 COPIER List........................................................................................................................................ 5- 7
5.2.2 FEEDER ................................................................................................................................................... 5- 24
5.2.2.1 FEEDER List..................................................................................................................................... 5- 24
5.3 I/O (I/O Display Mode)................................................................................................................................... 5- 26
5.3.1Overview ................................................................................................................................................... 5- 26
5.3.2<DC-CON> ............................................................................................................................................... 5- 27
5.3.3<R-CON> .................................................................................................................................................. 5- 34
5.3.4<FEEDER> ............................................................................................................................................... 5- 36
5.3.5<SORTER> ............................................................................................................................................... 5- 38
5.3.6<MN-CON> .............................................................................................................................................. 5- 47
5.4 ADJUST (Adjustment Mode) ......................................................................................................................... 5- 50
5.4.1 COPIER .................................................................................................................................................... 5- 50
5.4.1.1 COPIER List...................................................................................................................................... 5- 50
5.4.2 FEEDER ................................................................................................................................................... 5- 81
5.4.2.1 FEEDER List..................................................................................................................................... 5- 81
5.4.3 SORTER ................................................................................................................................................... 5- 82
5.4.3.1 SORTER List..................................................................................................................................... 5- 82

Contents
5.5 FUNCTION (Operation/Inspection Mode) .....................................................................................................5- 83
5.5.1 COPIER.....................................................................................................................................................5- 83
5.5.1.1 COPIER List ......................................................................................................................................5- 83
5.5.2 FEEDER..................................................................................................................................................5- 105
5.5.2.1 FEEDER List ...................................................................................................................................5- 105
5.6 OPTION (Machine Settings Mode)...............................................................................................................5- 110
5.6.1 COPIER...................................................................................................................................................5- 110
5.6.1.1 COPIER List ....................................................................................................................................5- 110
5.6.2 FEEDER..................................................................................................................................................5- 163
5.6.2.1 FEEDER List ...................................................................................................................................5- 163
5.6.3 SORTER..................................................................................................................................................5- 164
5.6.3.1 SORTER List...................................................................................................................................5- 164
5.6.4 BOARD...................................................................................................................................................5- 165
5.6.4.1 BOARD List ....................................................................................................................................5- 165
5.7 TEST (Test Print Mode) ................................................................................................................................5- 166
5.7.1 COPIER...................................................................................................................................................5- 166
5.7.1.1 COPIER List ....................................................................................................................................5- 166
5.8 COUNTER (Counter Mode)..........................................................................................................................5- 170
5.8.1 COPIER...................................................................................................................................................5- 170
5.8.1.1 COPIER List ....................................................................................................................................5- 170
Chapter 6 Outline of Components
6.1 Clutch/Solenoid .................................................................................................................................................6- 1
6.1.1Clutches and Solenoids................................................................................................................................6- 1
6.2 Motor .................................................................................................................................................................6- 4
6.2.1Motors..........................................................................................................................................................6- 4
6.3 Fan ...................................................................................................................................................................6- 10
6.3.1Fans............................................................................................................................................................6- 10
6.4 Sensor ..............................................................................................................................................................6- 14
6.4.1Sensors.......................................................................................................................................................6- 14
6.5 Switch ..............................................................................................................................................................6- 24
6.5.1Switches.....................................................................................................................................................6- 24
6.6 Lamps, Heaters, and Others.............................................................................................................................6- 26
6.6.1Heaters, Lamps, and Others.......................................................................................................................6- 26
6.7 PCBs ................................................................................................................................................................6- 30
6.7.1PCB............................................................................................................................................................6- 30
Chapter 7 System Construction
7.1 Construction.......................................................................................................................................................7- 1
7.1.1Functional Construction...............................................................................................................................7- 1
7.1.2Arrangement of the Major PCBs .................................................................................................................7- 2
7.1.3DC Controller ..............................................................................................................................................7- 3
7.2 System Construction..........................................................................................................................................7- 6
7.2.1System Configuration with Pickup/Delivery Accessories...........................................................................7- 6
7.2.2System Configuration with Printing/Transmission Accessories .................................................................7- 6
7.2.3Functions of Printing/Transmitting Accessories .........................................................................................7- 7
7.3 Product Specifications .......................................................................................................................................7- 9

Contents
7.3.1Specifications .............................................................................................................................................. 7- 9
7.4 Function List.................................................................................................................................................... 7- 13
7.4.1Print Speed ................................................................................................................................................ 7- 13
7.4.2Print Speed ................................................................................................................................................ 7- 15
7.4.3Paper Type................................................................................................................................................. 7- 18
7.4.4Accessories ................................................................................................................................................ 7- 19
Chapter 8 Upgrading
8.1 Outline of the Version Upgrade ........................................................................................................................ 8-1
8.2 Outline of the Service Support Tool.................................................................................................................. 8-2
8.3 Network Interface of the Machine with the SST in Use ................................................................................... 8-5

Chapter 1 Maintenance
and Inspection

Contents
Contents
1.1 Periodically Replaced Parts................................................................................................................................ 1-1
1.1.1 Overview ..................................................................................................................................................... 1-1
1.1.2 Reader Unit.................................................................................................................................................. 1-1
1.1.3 Printer Unit .................................................................................................................................................. 1-1
1.1.4 Print Unit ..................................................................................................................................................... 1-2
1.2 Durables and Consumables ................................................................................................................................ 1-5
1.2.1 Overview ..................................................................................................................................................... 1-5
1.2.2 Overview ..................................................................................................................................................... 1-5
1.2.3 Reader Unit.................................................................................................................................................. 1-5
1.2.4 Printer Unit .................................................................................................................................................. 1-5
1.2.5 Printer Unit ................................................................................................................................................ 1-10
1.3 Scheduled Servicing Basic Procedure.............................................................................................................. 1-14
1.3.1 Scheduled Servicing Basic Procedure ....................................................................................................... 1-14
1.3.2 Scheduled Servicing (reader unit) ............................................................................................................. 1-15
1.3.3 Scheduled Servicing (printer unit) ............................................................................................................ 1-16
1.3.4 Shifting the Photosensitive Drum Phase ................................................................................................... 1-24
1.4 Cleaning............................................................................................................................................................ 1-32
1.4.1 Cleaning the Secondary Transfer Rear Guide ........................................................................................... 1-32
1.4.2 Cleaning the Registration Roller, Registration Guide, and ...................................................................... 1-32

Chapter 1
1-1
1.1 Periodically Replaced Parts
1.1.1 Overview 0002-9397
iR C6800C / iR C6800CN
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
iR C6800C / iR C6800CN / iR 5800C / iR 5800CN
The machine's reader unit does not have parts that must be replaced on a periodical basis.
1.1.3 Printer Unit 0002-9400
iR C6800C / iR C6800CN
T-1-1
as of March 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*

Chapter 1
1-2
* In the case of a black mono color print, counted as 1; in the case of a full color print, counted as 4 images.
** Under high humidity and high temperature condition, 100,000 images
1.1.4 Print Unit 0008-7100
iR 5800C / iR 5800CN
4 Charging wire cleaner 1 FL2-2427-
000 1500,000 images* **
5 Charging wire cleaner 2 FL2-2428-
000 1500,000 images* **
6 Pre-transfer charging wire 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 March 2004
Ref. Parts name Parts No. Q'ty Interval Remarks

Chapter 1
1-3
T-1-2
* In the case of a black mono color print, counted as 1; in the case of a full color print, counted as 4 images.
as of March 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* **
6 Pre-transfer charging wire 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

Chapter 1
1-4
** Under high humidity and high temperature condition, 85,000 images