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Oki C9200 Service Manual

Color led page printer
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Download this manual See also: Maintenance Manual, Setup & Installation
C9000 Series
Color LED Page Printer

Service Manual

ODA
05-18-200 Based on Rev.2
1 / 157
41388601TH Rev.2A

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Table of Contents
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Summary of Contents for Oki C9200

  • Page 1: Service Manual

    C9000 Series Color LED Page Printer Service Manual 05-18-200 Based on Rev.2 1 / 157 41388601TH Rev.2A...
  • Page 2 Document Revision History Corrected items Person in Rev.No. Date charge Page Description of change 2000-12-05 ISSUE EM3 Murakami 2000-12-13 Correction of errors in K Yamazaki the parts list 05-18-2001 ODA Revisions ODA Training 41388601TH Rev.2A...
  • Page 3 Although reasonable efforts have been taken in the preparation of this manual to assure its accuracy, this manual may still contain some errors and omissions. OKI will not be liable for any damage caused or alleged to be caused, by the customer or any other person using this maintenance manual to repair, modify, or alter C9000 in any manner.

  • Page 4: Table Of Contents

    CONTENTS 1. SPECIFICATIONS .................... 7 Basic System Configuration ..................... 7 Printer Engine Specifications ................... 8 Option Configuration ......................9 Specifications ......................... 10 2. OPERATION DESCRIPTION ................. 12 Main Control Board (CRM-PWB) ................... 13 Engine Control Board (K73 PWB) .................. 15 Power Units ........................
  • Page 5 3.3.16 Registration roller Assy (B) ................66 3.3.17 Registration clutch, Registration motor Assy ............ 67 3.3.18 Cooling fan ....................... 68 3.3.19 Color registration sensor Assy................69 3.3.20 Duplex guide Assy .................... 70 3.3.21 Electrical chassis/ Electrical chassis cooling fan ..........71 3.3.22 Printer engine controller PWB ................

  • Page 6: Specifications

    SPECIFICATIONS Basic System Configuration The basic system configuration of C9000 is illustrated in Figure 1.1. 41388601TH Rev.2...

  • Page 7: Printer Engine Specifications

    Printer Engine Specifications The inside of the printer is composed of the followings: • Electrophotographic Processor • Paper Paths • Controller Block (CU and PU) • Operator Panel • Power Units (High-Voltage Unit and Low-Voltage Unit) Figure 1-2 shows the printer configuration. Figure 1.2 41388601TH Rev.2...

  • Page 8: Option Configuration

    Option Configuration The followings are available as options on C9000. 2nd Tray/ 3rd Tray Duplex Unit Large-Capacity Tray Expansion Memory 64/128/256MB Internal Hard Disk Ethernet Board 41388601TH Rev. 2...

  • Page 9: Specifications

    Monochrome: 26 pages per minute (Transparency: 15 pages per minute) Postal Card, Label, Thick Paper: 10 pages per minute Resolution 600 600 DPI / 600 x 1200 DPI (C9200 series) & 1200 x 1200 DPI (C9400 series) Power Input 100VAC 10% Power Consumption...
  • Page 10 (12) Temperatures and Relative Humidities Temperature Temperature (ºF) Temperature (ºC) Remark 17 to 27ºC (Temperatures to Operating 50 to 89.6 10 to 32 assure full color print quality) Non-Operating 32 to 109.4 0 to 43 Power-off Storage (Max. One Year) -14 to 109.4 -10 to 43 With drum and toner...

  • Page 11: Operation Description

    OPERATION DESCRIPTION C9000, a tandem color electrophotographic page printer, adopts technologies such as 4992-LED array, OPC, dry single-component non-magnetic developing, roller transfer and heat-compression fusing. The printing method is black writing by shedding light on print areas. Figure 2-1 provides the block diagram of this device. P18 Blue P18 Red P12 Yellow...

  • Page 12: Main Control Board (Crm-Pwb)

    Main Control Board (CRM-PWB) Figure 2-2 provides the block diagram of the main control board (CRM-PWB). Figure 2.2 12 / 41388601TH Rev.2...
  • Page 13 The IDE HDD is used for storing font data, spooling edited video data temporarily and registering form data. (10) PCI Bus Option Two PCI I/F slots are provided for option board use. The bus, which uses an Oki Data original connector, can accept an Ethernet board. (11) Host Interface...

  • Page 14: Engine Control Board (K73 Pwb)

    CPU (MSM66Q577), general LSI chip, flash ROM, EEPROM, pulse motor drivers, and video memory (see Figure 2.3). This, a 16-bit CPU with an AD converter (OKI MIM66Q577), controls the entire system. General LSI This LSI (MG63P011-001LA), which is contained in the printer engine control block,...

  • Page 15: Power Units

    Flash ROM 8 megabits of flash ROM (MBM29F800TA-70) which stores PU programs. EEPROM 4 kilobits of EEPROM (NM93C66N-NW) which is mounted on the board with an IC socket and stores correction values. Pulse Motor Driver The pulse motor driver (A2918, A2919, A3955) drives nine pulse motors to revolve the EP and carry media.

  • Page 16: Mechanical Processes

    Mechanical Processes Figure 2.4 shows the mechanical processes of the printer. Figure 2.4 16 / 41388601TH Rev.2...

  • Page 17: Electrophotographic Process

    2.4.1 Electrophotographic process Electrophotographic process The following is the outline of electrophotographic process: 1 Charging DC voltage is applied to the charging roller and the surface of the OPC drum is negatively and evenly charged. 2 Exposure The LED head, under image signals, emits light to the negatively charged surface of the OPC drum.
  • Page 18 Charging Negative DC voltage is applied to the charging roller contacting the surface of the OPC drum. Power Charging roller Unit OPC drum Exposure The negatively charged surface of the OPC drum is radiated with light from the LED head. The negative charge of the radiated portions of the drum surface attenuates in response to the intensity of the light and a latent electrostatic image responsive to the potentials of the surface is formed on the drum surface.
  • Page 19 Developing By the adhesion of toner to the latent electrostatic image on the drum surface, the image is changed to a toner image. The developing is processed at the contact part between the OPC drum and the developing roller. 1 The sponge roller causes toner to adhere to the developing roller. The toner becomes negatively charged.
  • Page 20 Fusing When passed between the heat roller and the backup roller, the toner image transferred to the paper is fused into place by the application of heat and pressure to it. The Teflon coated heat roller is heated by the built-in heat roller of 800W/backup roller of 500W (halogen lamp).

  • Page 21: Paper Running Process

    2.4.2 Paper running process Figure 2.5 shows how paper moves in the C9000. Fuser Registration roller Assy (B) Face-down stacker 4 x LED Units 4 x LED heads Heat roller Registration roller Assy (B) Eject roller Hopping roller Multipurpose tray Belt unit Eject roller Low-voltage power supply...
  • Page 22 Paper Loading from 1st Tray 1. The paper loading motor runs (CCW), the paper loading clutch is engaged and, until the entrance cassette sensor is turned on, paper is advanced (the on/off operations of the paper loading clutch control the pickup roller). 2.
  • Page 23 Paper Loading from Option Tray 1. The paper loading motor runs (CW), the paper loading clutch is engaged and, until the carrier sensor on a tray which sits atop a loading tray is turned on, paper is advanced. 2. After the paper turns the carrier sensor on, the paper is forwarded a further fixed length and touches the carrier roller (this corrects paper skew).
  • Page 24 Paper Loading from Multipurpose Tray (MT) 1. The release lever usually pushes down the hopping plate to a position to turn the micro SW on (Figure 2.8-a). 2. The running of the motor in the (a) direction drives the MT feed roller, causing the cam to turn.
  • Page 25 Carrier Belt 1. The running of the carrier belt motor in the direction of the arrow (a) drives the carrier belt. The belt unit sits with one carrier roller immediately below each color’s drum, and the carrier belt between them. By the application of a fixed voltage, the carrier belt and carrier roller feed paper on the carrier belt into the fuser unit, transferring a toner image from each color’s drum.
  • Page 26 Driving and Up-and-Down Movements of I/D Unit 1. The I/D unit driving and up-and-down movements are effected by a single-pulse motor. The running of the main motor in the direction of the arrow (a) turns the lever 1 to the left. Then, the lever 2 that was lifted by the lever 1 lowers to move down the I/D unit.
  • Page 27 Plate Spring Board Up-and-down Sensor Figure 2.10-c Figure 2.10-d Figure 2.10-e 27 / 41388601TH Rev.2...
  • Page 28 Fuser Unit and Paper Ejection 1. A single-pulse motor drives the fuser unit and the eject rollers. In response to the running of the heat motor in the direction of the arrow (a), the heat roller turns. This roller fuses a toner image to paper by heat and pressure. 2.
  • Page 29 Duplex Unit 1. When the duplex unit receives an instruction from the printer to print on both sides of a sheet of paper, the solenoid opens the separator after the completion of one side printing of a sheet of paper sent from the tray. The path is switched to that to the duplex unit. At this time, as the roller (1) turns in the direction of the arrow “a,”...

  • Page 30: Sensor

    Sensor 2.5.1 Paper related sensors Face-down paper eject sensor Paper eject roller Face-down sensor Stacker full sensor Entrance belt sensor C drum M drum Y drum K drum Heat roller MT feed roller Pinch roller 2 Paper eject sensor Driving roller Pinch roller 1 Driving roller Carrier belt...

  • Page 31: Other Sensors

    2.5.2 Other sensors Paper Empty sensor This sensor checks whether the paper cassette is empty. Paper Near sensor This sensor checks whether the paper cassette is near empty. MPF Paper Empty sensor This sensor checks whether the front feeder has paper. MPF Hopping switch This microswitch checks whether the front feeder table is in the up position or in the down position.

  • Page 32: Color Misalignment Correction

    Color Misalignment Correction C9000 is equipped with multiple LED heads, which can result in color misalignment. The mechanically induced color misalignment is automatically corrected as follows: Color alignment to be corrected 1 Color misalignment in X-axis direction (Positional error caused by LED head) 2 Color misalignment in slanting direction (Positional error caused by LED head) 3 Color misalignment in Y-axis direction (Positional error caused by I/D unit and LED head) Correcting...

  • Page 33: Paper Jam Detection

    Paper Jam Detection C9000 detects paper jams after power-on and during printing. When a paper jam occurs, the printer immediately suspends the printing operation. Opening the cover to remove the jammed paper and closing it resumes the printing. LCD Error Code Error Description Paper Size Error...

  • Page 34: Cover Opening

    Cover Opening When the top cover of the printer is open, the cover open microswitch turns opens to cut off the high- voltage power supply, and outputs which are not less than 32V. At the same time, the CPU receives CVOPN signals indicating the status of the microswitch and performs cover open operations.

  • Page 35: Toner Low Detection

    2.10 Toner Low Detection • Structure This device consists of the stirring gear which revolves at a constant speed, the stirring bar, and the magnet on the stirring bar. The stirring bar turns in synchronization with the protrusion of the stirring gear. Stirring gear Link Stirring bar...
  • Page 36 Toner Full Condition (At warming-up,A4 transverse:16ppm *1) t1 1.12 TNRSNS T=2.3 Toner Low Condition (At warming-up,A4 transverse:16ppm *1) t1 1.12 TNRSNS T=2.3 • When the toner low condition is detected 20 consecutive times, toner low is detected. (The toner low message is displayed when about 1000 A4 sheets at 5% density have been printed after toner low had been detected.) The detection is not performed until toner low occurs after the detection of toner low.

  • Page 37: Paper Size Detection

    2.11 Paper Size Detection Via the cam tied to the paper guide of the paper cassette, the four tab pieces are driven according to the set position of the paper guide. Upon installation of the paper cassette, the microswitch detects the condition of the tab pieces and the paper size is recognized.

  • Page 38: Operation At Power-On

    2.12 Operation at Power-on 2.12.1 Self-diagnostic test Initial test The following checks are automatically performed at power-on. (a) ROM check (b) RAM check (c) EEPROM check (d) Flash ROM check ROM check The ROM is checked by calculating a HASH value. RAM check (a) Checking is conducted by RAM type.

  • Page 39: Color Misalignment Detection

    2.13 Color Misalignment Detection Reflection-type optical sensors (Z71-PCB) are mounted at the right and left ends of the belt, respectively, in front of the toner scraping (cleaning) blade which is at the back of the belt unit. The color misalignment detection pattern is printed on the belt at the right and left ends each and, by reading the patterns by the reflection-type optical sensors, the misalignment amounts are measured with respect to Black to determine correction values.

  • Page 40: Version Read Of Periodically Replaced Units

    2.14 Version Read of Periodically Replaced Units The condition (new or used) of the I/D, fuser unit and belt unit are determined by an internal fuse within the units. When the unit is powered on or the upper cover is opened and closed, the printer scans for consumables fuses.

  • Page 41: Parts Replacement

    PARTS REPLACEMENT This section describes the procedure for replacing the parts, assemblies and units in the field. The replacing procedure is given for detachment. To attach, use the reverse procedure. Precautions in Replacing Parts (1) Before replacing the parts, be sure to remove the AC cable and the interface cable. (a) To remove the AC cable, always use the following procedure.
  • Page 42 [Maintenance Tools] Table 3-1 lists tools necessary to replace the units. Table 3-1 Maintenance Tools Service Tools Q' ty Place of use Remarks No. 1-100 Philips 2~2.5 mm screws screwdriver No. 2-200 Philips 3~5 mm screws screwdriver, Magnetized No. 3-100 screwdriver No.

  • Page 43: Parts Layout

    Parts Layout Figure 3.1 43 / 41388601TH Rev.2...
  • Page 44 [Top Cover Assy] Figure 3.2 44 / 41388601TH Rev.2...
  • Page 45 [Printer Unit-1/2] Figure 3.3 45 / 41388601TH Rev.2...
  • Page 46 [Printer Unit-2/2] Figure 3.4 46 / 41388601TH Rev.2...
  • Page 47 [Cassette Guide Assy (L), (R)] Figure 3.5 47 / 41388601TH Rev.2...
  • Page 48 48 / 41388601TH Rev.2...
  • Page 49 [Duplex Unit] Figure 3.6 49 / 41388601TH Rev.2...

  • Page 50: Replacing Parts

    Replacing Parts This section describes how to replace the parts and assemblies illustrated below. 41531301 41515110 Print Engine Controller PWB (3.3.22) 41502304 LED Assy (3.3.2) 40737401 Power-Unit AC-DC Switching (115V) (3.3.34) 40737501 Power-Unit AC-DC Switching (230V) (3.3.34) 40737601 HV Power Supply (3.3.35) 41531402, 41531404 Fuser Unit (3.3.37) 41531502...

  • Page 51: Top Cover

    3.3.1 Top cover Open the top cover Assy. Remove the nine screws 1 to detach the top cover 2. 51 / 41388601TH Rev.2...

  • Page 52: Led Assy/ Led Assy Spring

    3.3.2 LED Assy/ LED Assy spring Open the top cove 1. Remove the three cables, and unhook the LED Assy 2 at the two places to demount it (The two springs 3 become detached together with the LED Assy 2). Detach the LED connector 4.

  • Page 53: Top Cover Unit

    3.3.3 Top cover unit Remove the top cover (see section 3.3.1). Remove the rear cover (see section 3.3.12). Remove the front cover (see section 3.3.11). Remove the electrical chassis (see section 3.3.21). Unscrew the screws 1 and 2 to remove the limiters (F) 3 and (R) 4. Remove the inner shaft 5, then the top cover unit 8 (The inner springs 6 and 7 become detached).

  • Page 54: Control Panel Assy/ Control Panel Bezel/ Led Control Pwb/ Toner Sensor/Stack Full Sensor/ Control Panel Tape Harness/ Eject Roller

    3.3.4 Control panel Assy/ Control panel bezel/ LED control PWB/ Toner sensor/ Stack full sensor/ Control panel tape harness/ Eject roller Detach the control panel bezel 1. Remove the screws 2 to demount the control panel 3. Detach the control panel tape harness 4. Remove the screws 6, unhook the connector 7 and demount the LED control PWB 8.

  • Page 55: Top Cover Handle/ Tope Cover Latch/ Top Cover Latch Spring

    3.3.5 Top cover handle/ Top cover latch/ Top cover latch spring Remove the two screws 1 to detach the top cover handle 2 and disengage the top cover latch 3 (The two top cover latch springs 4 become detached). 55 / 41388601TH Rev.2...

  • Page 56: Eject Guide Assy

    3.3.6 Eject guide Assy Remove the seven screws 1 to detach the eject guide Assy 2. 56 / 41388601TH Rev.2...

  • Page 57: Cassette Assy/ Blind Cover/ Side Cover R Assy

    3.3.7 Cassette Assy/ Blind cover/ Side cover R Assy Detach the cassette Assy 1. Disengage the blind cover 2 at the two places to detach it. Unscrew the two screws to remove the stopper 4. Disengage the claw on the left support of the side cover R to detach the side cover R. 57 / 41388601TH Rev.2...

  • Page 58: Feed Rollers

    3.3.8 Feed rollers Remove the cassette. Unlatch and demount the feed rollers 1. 58 / 41388601TH Rev.2...

  • Page 59: Left Side Cover

    3.3.9 Left side cover Remove the four screws 1 to detach the left side cover 2. 59 / 41388601TH Rev.2...

  • Page 60: Face-Up Tray

    3.3.10 Face-up tray Open the face-up tray in the arrow direction and move the links 2 out of engagement (at two places each of the links) to detach the face-up tray 1. 60 / 41388601TH Rev.2...

  • Page 61: Front Cover

    3.3.11 Front cover Open the top cover 1. Disengage the claws and remove the blind cover 2. Unscrew the six screws 4 to detach the front cover 3. 61 / 41388601TH Rev.2...

  • Page 62: Rear Cover

    3.3.12 Rear cover Open the top cover 1, Remove the five screws 3 and 4 to detach the rear cover 2. 62 / 41388601TH Rev.2...

  • Page 63: Multipurpose Tray Assy/ Multipurpose Tray Cover Assy/ Links/Multipurpose Tray Top Cover/ Multipurpose Tray Drive Gear

    3.3.13 Multipurpose tray Assy/ Multipurpose tray cover Assy/ Links/ Multipurpose tray top cover/ Multipurpose tray drive gear Remove the rear cover (see section 3.3.12). Remove the front cover (see section 3.3.11). Unscrew the three screws 1 to detach the multipurpose tray top cover 2. Unscrew the two screws 3 and remove the connector to detach the multipurpose tray 4.

  • Page 64: Drum Contact Assys

    3.3.14 Drum contact Assys Insert a flatblade screwdriver between the printer case and the drum contact Assy 1 to demount the drum contact Assy. 64 / 41388601TH Rev.2...

  • Page 65: Registration Roller Assy (A)/ Registration Drive Gear (A)

    3.3.15 Registration roller Assy (A)/ Registration drive gear (A) Remove the front cover (see section 3.3.11). Remove the rear cover (see section 3.3.12). Remove the multipurpose tray (see section 3.3.13). Unscrew the four screws 1 to demount the registration roller Assy (A) 2. Remove the E ring 3 to detach the registration gear (A) 4.

  • Page 66: Registration Roller Assy (B)

    3.3.16 Registration roller Assy (B) Remove the cassette Assy. Remove the front cover (see section 3.3.11). Remove the rear cover (see section 3.3.12). Remove the electrical chassis (see section 3.3.21). Remove the registration clutch (see section 3.3.17). Remove the printer chassis (see section 3.3.23). Unscrew the four screws and pull out the registration Assy (B) 2 in the arrow direction.

  • Page 67: Registration Clutch, Registration Motor Assy

    3.3.17 Registration clutch, Registration motor Assy Remove the left side cover (see section 3.3.9). Remove the electrical chassis (see section 3.3.21). Remove the connector and the E ring 1, then screws 3 and 4, and then the earth plate 5. Remove the connector and unscrew the two screws 6 to demount the registration motor Assy 67 / 41388601TH Rev.2...

  • Page 68: Cooling Fan

    3.3.18 Cooling fan Unhook the connector 1, and remove the screws 2 and the cooling fan 3. air direction 68 / 41388601TH Rev.2...

  • Page 69: Color Registration Sensor Assy

    3.3.19 Color registration sensor Assy Remove the two screws 1 and the three connectors to demount the color registration sensor Assy 2. Remove the earth plate B 3. 69 / 41388601TH Rev.2...

  • Page 70: Duplex Guide Assy

    3.3.20 Duplex guide Assy Unlatch and demount the duplex guide Assy 1. Remove the springs 2. Main chassis (L side) 70 / 41388601TH Rev.2...

  • Page 71: Electrical Chassis/ Electrical Chassis Cooling Fan

    3.3.21 Electrical chassis/ Electrical chassis cooling fan Unscrew the five screws 1 and two screws 2 to remove the plate A 3. Unscrew the thirty-one screws 4 to remove the shield plate B 5. Remove the printer engine controller PWB (see section 3.3.22). Unscrew the eleven screws 6 to detach the electrical chassis 7.

  • Page 72: Printer Engine Controller Pwb

    3.3.22 Printer engine controller PWB Remove the rear cover (see section 3.3.12). Remove the electrical chassis and the electrical cooling fan (see section 3.3.21). Remove the five screws 1 and all the connectors to demount the printer engine controller PWB 2. 72 / 41388601TH Rev.2...

  • Page 73: Printer Unit Chassis

    3.3.23 Printer unit chassis Unscrew the screw 1 and remove the AC switch Assy 2. Remove the four black screws 3 and six screws 4 to detach the printer unit chassis 5. 73 / 41388601TH Rev.2...

  • Page 74: Entrance Cassette Sensor Actuator

    3.3.24 Entrance cassette sensor actuator Remove the printer unit chassis (see section 3.3.23). Turn over the main chassis. Remove the two clamps with tweezers to demount the entrance cassette sensor actuator 1. Main chassis 74 / 41388601TH Rev.2...

  • Page 75: Entrance Sensor Pwb

    3.3.25 Entrance sensor PWB Remove the registration roller Assy (B) (see section 3.3.16). Remove the two screws 1 to demount the entrance sensor PWB 2. 75 / 41388601TH Rev.2...

  • Page 76: Entrance Mt Sensor Actuator And Entrance Belt Sensor Actuator

    3.3.26 Entrance MT sensor actuator and Entrance belt sensor actuator Remove the entrance sensor PWB (R71) (see section 3.3.25). Unlatch and detach the entrance MT sensor actuator 1. Unlatch and detach the entrance belt actuator 2. 76 / 41388601TH Rev.2...

  • Page 77: Main Motor Fan/ Fuser Eject Roller

    3.3.27 Main motor fan/ Fuser eject roller Unscrew the two screws 1 to remove the fan Assy 2. Unscrew the fuser eject roller contact 4. Remove the fuser drive gear 5. Unscrew the fuser drive gear Assy 8. Remove the screws and washers 0 to demount the fan A. Unlatch and detach the fuser eject roller bearing (L) B and fuser eject roller C.

  • Page 78: Eject Sensor Assy

    3.3.28 Eject sensor Assy Remove the fuser eject roller (see section 3.3.27). Remove the screw 1 and connector 2 to demount the (red/blue) eject sensor Assy 2. 78 / 41388601TH Rev.2...

  • Page 79: Fuser Latching Handle (L)

    3.3.29 Fuser latching handle (L) Remove the latching handle spring 1. Unscrew the fuser latching handle (L) 3. 79 / 41388601TH Rev.2...

  • Page 80: Belt Motor Assy

    3.3.30 Belt motor Assy Remove the fuser latching handle (R) (see section 3.3.32). Unscrew the two screws 1 to detach the two connector 2. Demount the belt motor Assy 3. 80 / 41388601TH Rev.2...

  • Page 81: Fuser Latching Handle (R)

    3.3.31 Fuser latching handle (R) Remove the printer unit chassis (see section 3.3.23). Remove the E ring 1. Remove the fuser latching handle spring 2 to detach the fuser latching handle (R) 3. 81 / 41388601TH Rev.2...

  • Page 82: Main Motor Assy

    3.3.32 Main motor Assy Remove the belt motor Assy (see section 3.3.30). Remove all the connectors. Remove the two screws 1 to demount the main motor Assy 2. 82 / 41388601TH Rev.2...

  • Page 83: Contact Assy/ Side Plate Assy

    3.3.33 Contact Assy/ Side plate Assy Remove the printer unit chassis (see section 3.3.23). Remove the four screws 1 to detach the side plate Assy 2. Remove the three screws 3 to detach the contact Assy 4. 83 / 41388601TH Rev.2...

  • Page 84: Low Voltage Power Supply

    3.3.34 Low voltage power supply Remove the printer unit chassis (see section 3.3.23). Unhook the connector 1. Remove the eight screws 2 to demount the low voltage power supply 5. 84 / 41388601TH Rev.2...

  • Page 85: High Voltage Power Supply

    3.3.35 High voltage power supply Remove the contact Assy (see section 3.3.33). Unhook the connector of the high voltage power supply 2. Remove the two screws 1 to detach the high voltage power supply 2 and the tape harness 85 / 41388601TH Rev.2...

  • Page 86: Main Feed Assy

    3.3.36 Main feed Assy Remove the printer unit chassis (see section 3.3.23). Remove the low voltage power supply and high voltage power supply (see sections 3.3.34 and 3.3.35). Unscrew the five screws 1 to remove the lower plate 2. Unscrew the six screws 3 to demount the main feed Assy 4. Unscrew the screws 5 to detach the cable and then the PCB size board 6.

  • Page 87: Fuser Unit

    3.3.37 Fuser unit Open the top cover 1. Push the right and left fuser levers (blue) 2 in the arrow direction to detach the fuser unit 3. 87 / 41388601TH Rev.2...

  • Page 88: Belt Unit

    3.3.38 Belt unit Open the top cover 1. Remove the I/D unit. Push the lever (blue) 2 in the arrow direction, raise the handle (blue) and detach the belt unit 88 / 41388601TH Rev.2...

  • Page 89: Duplex Unit

    3.3.39 Duplex unit Remove the cassette Assy, the front cover and the front cover inner buffle. Unlatch the rear at the right and left and pull the duplex unit 1 toward the front. 89 / 41388601TH Rev.2...

  • Page 90: Cu Assy

    3.3.40 CU Assy Pulling out Control Board 1. Loosen the two screws 1. 2. Pull the control board 2 out. 3. Place the control board 2 on a flat table. Detaching Fan 1. Remove the connector 3. 2. Remove the two screws 4. 3.
  • Page 91 Demounting CRM Board 1. Remove the three screws 6 to detach the fan bracket 7. 2. Remove the four screws 8 to detach the plate support 9 and the guide rail 0. 3. Remove the two screws A to detach the guide rail B. 4.

  • Page 92: Adjustment

    ADJUSTMENT Adjustments are carried out by key operations on the operator panel. The maintenance menu is included in the general menu of this printer. Choose the maintenance menu for adjustment. Maintenance Menu and Its Functions The general menu has the category, MAINTENANCE MENU. The items adjustable in this menu are shown below.

  • Page 93: Short Plug Settings

    Short Plug Settings The CRM board has five short plugs that can be set as follows: Short Plug (WE1,3, 5 and 7) Sets flash ROM DIMM to connect WE signals. (1-2 Short: Disconnects WE signals; 2-3 Short: Connects WE signals.) The factory-shipped short plug is set to the 2-3 short: Re-programmable the Flash ROM DIMM.

  • Page 94: Adjustment After Part Replacement

    Adjustment after Part Replacement Adjustment to be implemented after each part replacement is described below. Adjustment and correction of color registration are always required for each part replacement. Adjustment Replaced Part LED Head Color balance adjustment Drum Cartridge (Y, M, C, K) Not required.

  • Page 95: Color Balance Adjustment

    Color Balance Adjustment Color balance has been adjusted appropriately when a printer is shipped from the plant. However, it may be out of the appropriate balance during use. In such a case, color balance should be modified. Note: Density of each color depends on each other. Therefore, adjustment must be repeated several times to reach the correct color balance.
  • Page 96 96 / 41388601TH Rev.2...

  • Page 97: Eeprom Replacement After Crm Board And K73 Board Replacement

    EEPROM Replacement after CRM Board and K73 Board Replacement When replacing the CRM Board or K73 Board, the EEPROM must be removed and re-mounted on the new board (to deliver the user setting and font installation information to the new board). If the EEPROM used by the user is broken and not suitable for further use, the EEPROM on the new board may be used.

  • Page 98: Regular Maintenance

    REGULAR MAINTENANCE Consumables to be Regulary Replaced It is recommended that a user should replace the consumables below according to the replacement standard. (If not replaced, print quality is not assured or it may result in a failure.) Part Name Time for Replacement Replacement Condition Adjustment after Replacement...

  • Page 99: Troubleshooting Procedures

    TROUBLESHOOTING PROCEDURES Tips for Troubleshooting Check the basic check points covered in the user’s manual. Gather as much information on the problem from the customer as possible. Perform inspections in conditions close to those in which the problem had occurred. Check Points before Correcting Image Problems Is the printer being run in proper ambient conditions? Have the consumables toner and image drum cartridges been replaced properly?

  • Page 100: Preparation For Troubleshooting

    Preparation for Troubleshooting Operator panel display The failure status of this printer is indicated on the LCD (liquid crystal display) of the Operator panel. Take the proper corrective action according to the message displayed on the LCD. Troubleshooting Flow If a problem should develop in this printer, troubleshoot in the following procedure. Problem Problem that results Troubleshoot based on the...

  • Page 101: Lcd Message List

    6.5.1 LCD Message List The printer indicates a Service Call Error message on the LCD as shown below, detecting an unrecoverable error. Service Call nnn : Error Note: nnn is an error code. When the Service Call message is displayed, the error information corresponding to the error code appears on the lower line of the LCD.
  • Page 102 Table 6-1-1 Operator Alarms (2/5) Message Cause Error Description Solutions CU EEPROM Error Service Call Can the printer recover from the error by Replace the EEPROM. (Settings of the 040: Error replacing the EEPROM on the CU board? user must be restored on the new.) Replace the CRM board.
  • Page 103 Table 6-1-1 Operator Alarms (3/5) Message Cause Error Description Solutions Service Call Error detected at the 1) Is the error message displayed? Turn off/on the printer. 125: Error MT home position. 2) Does the error repeat? Replace the MT. Service Call Temperature rise at 1) Is the error message displayed? Turn off the printer, leave it for 30 min and...
  • Page 104 Table 6-1-1 Operator Alarms (4/5) Message Cause Error Description Solutions End of the ID unit life. Install New Drum Is it displayed soon after the ID unit Confirm the life of the ID unit. 26,000 or more replacement? 350: Y Drum Life copies printed.
  • Page 105 Table 6-1-1 Operator Alarms (5/5) Message Cause Error Description Solutions Load *** Papers The specified cassette 1) No paper in MT? Load papers in MT. 490: No paper in has no paper or is the MP Tray removed. Or, the 2) Does the Paper out sensor operate Replace the Paper out sensor.

  • Page 106: Lcd Message Troubleshooting

    6.5.2 LCD message troubleshooting LCD Message The message on the LCD (liquid crystal display) tells the problem situation of the printer. Implement the appropriate troubleshooting base on the message. Problem Flowchart Number The printer does not work normally after being turned on. JAM Error Paper Input Jam (1st Tray) Paper Input Jam (MT)
  • Page 107 The printer does not work normally after turned on. • Turn off the printer, wait a few seconds, then turn it on again. • displayed on the LCD (for about 1 second)? • Is the AC cable connected correctly? Connect the AC cable correctly. •...
  • Page 108 2-1 Paper Input Jam (1st Tray) • Does the jam occur soon after the printer is turned on? • Yes Is the paper jammed at the entrance cassette sensor or the entrance MT sensor ? * MT : Multipurpose Tray Yes Remove the jammed paper.
  • Page 109 2-2 Paper Input Jam (Multipurpose Tray (MT)) • Does the paper jam occur immediately after the printer is powered on? • Yes Is the paper jammed at the entrance cassette sensor or the entrance MT sensor ? Yes Remove the paper jam. •...
  • Page 110 2-3 Paper Feed Jam • Does the paper jam occur immediately after the printer is powered on? • Yes Is the paper jammed at the entrance belt sensor? Yes Remove the jammed paper. • Does the lever of the write sensor work right? Replace the lever of the write sensor.
  • Page 111 2-4 Paper Eject Jam • Does the paper jam occur immediately after the printer is powered on? • Yes Is the paper jammed at the ejection sensor? Yes Remove the jammed paper. • Does the lever of the ejection sensor operate normally? Replace the ejection sensor lever.
  • Page 112 2-5 DUPLEX jam • Does the paper jam occur immediately after the printer is turned on? • Yes Is the paper jammed at the in sensor, rear sensor or front sensor in the DUPLEX unit? Yes Remove the jammed paper. •...
  • Page 113 Paper Size Error • Is paper in the specified size used? Use paper that complies with the specification. Yes Is the paper jammed at the entrance MT sensor or at the paper width sensor? Yes Remove the jammed paper. • Does the lever of the entrance MT sensor operate normally? Replace the defective sensor lever.
  • Page 114 Image Drum Unit (IDU) Up/Down Error • Turn off the printer, wait a few seconds, then turn it on again. • Does each drum unit rotate properly while printing? • Is the resistance of the IDU motor at the rated value (approx. 4.0 )? Replace the defective IDU motor.
  • Page 115 Fuser Unit Error • Does the fuser error occur immediately after the printer is turned on? • Yes Does the heat roller thermistor have a open or short circuit? (See Figure 6.1.) (at room temperature 0 C~ 43 C, approx. 190 ~ 980 ) Yes Replace the fuser unit.
  • Page 116 Fan Motor Error • Does the fan of the low-voltage power supply unit rotate after the printer is turned on? • Yes Does the error recur after the fan of the low-voltage power supply unit has been replaced? • Yes Replace the low-voltage power supply unit. •...

  • Page 117: Image Troubleshooting

    6.5.3 Image troubleshooting When the printout images are not satisfactory as shown below, follow the troubleshooting procedures given in this section. Printout problem Flowchart No. Light or blurred images, or images in inappropriate color tone (Figure 6.2- A ) Dark background (Figure 6.2- B ) No images on print output (Figure 6.2- C ) Band/stripes in black or color in the longitudinal direction (Figure 6.2- D ) Band/stripes in white or irregular color in the longitudinal direction (Figure 6.2- F )
  • Page 118 Light or blurred images or images in inappropriate color tone on the whole printout area (Figure 6.2- A ) • Is toner low? (Is the message "Toner Low" displayed?) Yes Supply toner. • Is the specified paper used? Use the specified paper. •...
  • Page 119 Dark background (Figure 6.2- B ) • Was each ID exposed to external light for a long time? Yes Replace the ID unit. Note: Reset the counter after replacement. • Are the rollers in the fuser unit contaminated? Yes Replace the fuser unit. •...
  • Page 120 Blank paper (Figure 6.2- C ) • Is each LED head assembly connected to the junction board (Y71 PWB) and Engine board (K73 PWB)correctly? Check the cable connection the LED assembly with the junction board (Y71 PWB) and engine board. •...
  • Page 121 Band/stripes in black or color in the longitudinal direction (Figure 6.2- D ) • Is each LED head assembly connected to the junction board (Y71 PWB) correctly? Connect the LED head assembly to the junction board correctly. • Check the cable connection, or replace the LED head assembly. Recovered? Yes End •...
  • Page 122 Band/stripes in white or irregular color in the longitudinal direction (Figure 6.2- F ) • Is each LED head lens contaminated? Yes Clean the LED head lens. • Is each LED head assembly connected to the junction board (Y71 PWB) correctly? Connect the LED head assembly to the junction board (Y71 PWB) correctly.
  • Page 123 Poor fusing (Images are blurred or peeled off when touched with a hand.) • Is the specified paper used? Use the proper paper. • Is the contact of the fuser unit connected correctly? Connect the contact of the fuser unit properly. •...
  • Page 124 Cyclical printout defects (Figure 6.2- E ) Cycle Defective Part Solution 3.71 in. Image Drum Replace the ID unit. 1.95 in. Developing Roller Replace the ID unit. 2.66in. Toner Supply Roller Replace the ID unit 1.73 in. Charge Roller Replace the ID unit. 4.45 in.
  • Page 125 Missing characters • Is the LED head lens contaminated? Yes Clean the lens of LED head. • Is each LED head assembly connected to the junction board (Y71 PWB) correctly? Check the cable connection, and connect the LED head to the junction board correctly. •...
  • Page 126 Color Misalignment • Are any of the following gears broken? (Gear assy of ID unit, Multipurpose Tray, belt unit and belt motor) Yes Replace the broken gear assembly. • Is each LED head unit connected to the junction board (Y71 PWB) correctly? Connect the LED head unit correctly with the junction board.
  • Page 127 Printout colors different from the original • Are the LED head lens contaminated? Yes Clean the LED head lens. • Is each LED head assembly connected to the junction board (Y73 PWB) correctly? Check the cable connection (between each LED head and the junction board) and connect the LED assy to the junction board correctly.
  • Page 128 Ground Charge Roller Developing Roller Toner Supply Roller Figure 6.3 128 / 41388601TH Rev.2...
  • Page 129 Unit Circuit Diagram Illustration Resistance Yellow Orange Between pins 1 and 2: 7.9 Transfer Belt Motor Between pins 3 and 4: 7.9 Black Black Between pins 1 and 2: 2.4 Main Motor (Y) Between pins 3 and 4: 2.4 Between pins 1 and 2: 2.4 Main Motor (M) Between pins 3 and 4: 2.4...
  • Page 130 Unit Circuit Diagram Illustration Resistance Between pins 1 and 2: 2.4 Main Motor (C) Between pins 3 and 4: 2.4 Between pins 1 and 2: 2.4 Main Motor (B) Between pins 3 and 4: 2.4 Between pins 1 and 2: 7.9 Between pins 3 and 4: 7.9 Resistration Motor...
  • Page 131 Unit Circuit Diagram Illustration Resistance Yellow Orange Between pins 1 and 2: 7.9 Fuser Motor Between pins 3 and 4: 7.9 Black Black Between pins 1 and 2: 7.9 or 8.4 Feeder Motor Between pins 3 and 4: 7.9 or 8.4 Yellow Orange Between pins 1 and 2: 23...
  • Page 132 Unit Circuit Diagram Illustration Resistance CN-1 Geared Motor CN-2 +32 V Yellow FANALM-N CU Low-voltage Ejection Fuser Fan Black +32 V Yellow FANALM-N Low-voltage Absorption Black...
  • Page 133 Unit Circuit Diagram Illustration Resistance +5 V White FANALM-N CU Board Black +5 V Yellow ID and Fuser Black 1 Upper roller 2 Lower roller Thermostat Thermostat Between pins a and b: Heater Heater Between pins c and d: 231.4k Between pins e and f: 231.4k (at 25 C) Thermistor Fuser Unit...

  • Page 134: Parts Layout On Boards

    Parts Layout on Boards Print Engine Controller PWB (K73) 134 / 41388601TH Rev.2...
  • Page 135 Main Controller PWB: CRM PUIF PCICU CENT 135 / 41388601TH Rev.2...
  • Page 136 LED Control PWB (Y71-2 PWB) (4) Duplex Control PWB (V73- PWB) SNS1 Control Panel PWB (X71- PWB) 136 / 41388601TH Rev.2...
  • Page 137 N71-PWB JODEN Entrance Sensor PWB (R71- PWB) INSNS2 INSNS1 WRSNS (8) Paper Size Sensing PWB PXC (B73- PWB) CN11 Sensor PWB (A73-PWB) LIFT (10) Option I/F PWB (C73-PWB) MAIN1 SAVIF 137 / 41388601TH Rev.2...

  • Page 138: Parts List

    PARTS LIST Figure 8-1-1/3 138 / 41388601TH Rev.2...
  • Page 139 Figure 8-1-2/3 139 / 41388601TH Rev.2...
  • Page 140 Figure 8-1-3/3 140 / 41388601TH Rev.2...

  • Page 141: Main Assembly

    Table 8-1-1/3 Main Assembly Recommended Q’ty/Year Patrs No. Name Q’ty Remarks /Unit 1000 2000 41481201 Cover Assy-R 41484905 Cassette Assy 41353701 Cover-Front-CS 41277901 Cover-Blank 41276401 Cover-Front 41277401 Cover-Side(L) 41484201 Stacker-Face-Up Assy 41276501 Cover-Rear 41484601 Cover-Assy MT 41493001 MPT Assy-703 41297101 Plate-Top 40325101 Gear-Z68...
  • Page 142 Table 8-1-2/3 Recommended Q’ty/Year Patrs No. Name Q’ty Remarks /Unit 1000 2000 ID-Y Type C3 ID-M Type C3 ID-C Type C3 ID-K Type C3 41515205 Toner-Cartridge_Type_C3_Y (15K) 41515206 Toner-Cartridge_Type_C3_M (15K) 41515207 Toner-Cartridge_Type_C3_C (15K) 41515208 Toner-Cartridge_Type_C3_K (15K) Toner-Cartridge_Type_C3_Y (15K) Toner-Cartridge_Type_C3_M (15K) Toner-Cartridge_Type_C3_C (15K) Toner-Cartridge_Type_C3_K (15K) Toner-Cartridge_Type_C3_Y (15K)
  • Page 143 Table 8-1-3/3 Recommended Q’ty/Year Patrs No. Name Q’ty Remarks /Unit 1000 2000 41437418 Board-Memory 64MB 600dpi-ODA Board-Memory 64MB 600dpi-OEL Board-Memory 64MB 600dpi-APS 41437419 Board-Memory 128MB 600dpi Duplex- ODA,1200dpi-ODA Board-Memory 128MB 600dpi Duplex- OEL,1200dpi-OEL Board-Memory 128MB 600dpi Duplex- APS,1200dpi-APS 41437420 Board-Memory 256MB 1200dpi Duplex-ODA Board-Memory 256MB 1200dpi Duplex-OEL...
  • Page 144 Figure 8-2 144 / 41388601TH Rev.2...

  • Page 145: Top Cover Assembly

    Table 8-2 Top Cover Assembly Recommended Q’ty/Year Parts No. Name Q’ty Remarks /Unit 1000 2000 41484401 Cover Assy-Stacker 41502301 LED Assy 1200dpi ODA/OEL/APS 41502302 LED Assy 600dpi ODA/OEL/APS 40861001 LED Assy Spring 41257902 LED control PWB 41349801 Lever Stacker Full 41487101 Cover Assy-Inn(Sub) 41514103...
  • Page 146 Figure 8-3-1/2 146 / 41388601TH Rev.2...
  • Page 147 Figure 8-3-2/2 147 / 41388601TH Rev.2...

  • Page 148: Printer Unit Chassis

    Table 8-3-1/2 Printer Unit Chassis Recommended Q’ty/Year Parts No. Name Q’ty Remarks /Unit 1000 2000 41189701 Drum contact Assy 41483201 Registration Roller Assy (A) 41483301 Registration Roller Assy (B) 40845401 Registration Drive Gear (A) 41187101 Registration Clutch 41483401 Registration Motor Assy 41483701 Motor-Assy-Fan 41491001...
  • Page 149 Table 8-3-2/2 Recommended Q’ty/Year Parts No. Name Q’ty Remarks /Unit 1000 2000 56732302 HV Tape Harness 41500101 Power Supply Insulation 4PB4013-3100P006 Screw (M3 6) PSW4-8C Screw (M4 8) 4PB4083-2500P008 Screw (T3 8) 41346301 Transfer Contact Assy 41589501 Power Supply Insulation(HV) 40197103 FAN-Power Supply (PUSH) 41431602...
  • Page 150 Figure 8-4-1/2 150 / 41388601TH Rev.2...
  • Page 151 Figure 8-4-2/2 151 / 41388601TH Rev.2...
  • Page 152 Table 8-4 Paper Tray Guide Recommended Q’ty/Year Parts No. Name Q’ty Remarks /Unit 1000 2000 41481301 Guide-Assy-R-1st 41481701 Roller-Feed 41488401 Roller-Feed-A3 41529101 Motor-Pulse(Hop) 41515701 Board-A73 41503001 Gear Assy-Clutch(2pin) 41502601 Rubber Foot 41515801 Paper Size Sensing PWB 56731640 Connector 4PB4013-3101P006 Screw (T4 6) 4PB4013-3101P008 Screw (T4 8) 4PB4013-3100P008...
  • Page 153 Figure 8-5 153 / 41388601TH Rev.2...
  • Page 154 Table 8-5 Duplex Unit Recommended Q’ty/Year Parts No. Name Q’ty Remarks /Unit 1000 2000 41178201 Duplex Assy 41178203 Duplex Assy 41178207 Duplex Assy 4PB4043-4718P001 Screw (SP3 10) 4PB4083-2500P008 Screw (T3 8) 4PB4013-3100P006 Screw (M3 6) 154 / 41388601TH Rev.2...
  • Page 155 Figure 8-6-1/2 155 / 41388601TH Rev.2...
  • Page 156 These parts are not attached to the lowest tray. Figure 8-6-2/2 156 / 41388601TH Rev.2...
  • Page 157 High Capacity Tray Unit, 2nd/3rd Tray Unit Recommended Q’ty/Year Parts No. Name Q’ty Remarks /Unit 1000 2000 41481301 Guide R Assy 41481701 Roller-Feed 41488401 Roller-Feed (A3) 41529101 Motor-Hopping 41515701 Board A73 41503001 Clutch Guide Assy (2 pin) 41502601 Rubber-Foot 2201000P140 Connector 4PB4013-3101P006 Screw (T4 6)

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C9000 series

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