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C9200
MAINTENANCE MANUAL
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Okidata C9200, C9400 MAINTENANCE MANUAL

Oki Data CONFIDENTIAL
C9400/C9200 Color LED Page Printer
MAINTENANCE MANUAL
ODA/OEL/INT
2002-12-10 Rev.6
41388601TH Rev.6 1 / 142

Document Revision History

Oki Data CONFIDENTIAL
Rev.No. Date
No.
Corrected items
Page Description of change
Person in
charge 1 2000-12-05 ISSUE EM3 Murakami 2 2000-12-13 8 Correction of errors in K Yamazaki
the parts list 3 2001-05-15 CN11 Kasuya 4 2001-10-12 K Yamazaki 5 2002-11-27 K Yamazaki 6 2002-12-10 NP34 Ueda
Oki Data CONFIDENTIAL

PREFACE

This maintenance manual provides procedures and techniques for the troubleshooting, maintenance, and repair of C9400/C9200.
This manual is written for maintenance personnel, but it should always be accompanied with the C9400/ C9200 User’s Manual for procedures for handling and operating C9400/C9200. For repairing each component of C9400/C9200, see the Troubleshooting manual.
[Notices] The contents of this manual are subject to change without prior notice. 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 C9400/C9200 in any manner.
[Warning] Many parts of C9400/C9200 are very sensitive and can be easily damaged by improper servicing. We strongly suggest that C9400/C9200 be serviced by OKI’s authorized technical service engineers.
Oki Data CONFIDENTIAL

CONTENTS

1. SPECIFICATIONS ............................................................................................ 6
1.1 Basic System Configuration............................................................................................. 6
1.2 Printer Engine Specifications ........................................................................................... 7
1.3 Option Configuration ........................................................................................................ 8
1.4 Specifications................................................................................................................... 9
2. PARTS REPLACEMENT................................................................................11
2.1 Precautions in Replacing Parts...................................................................................... 11
2.2 Parts Layout................................................................................................................... 13
2.3 Replacing Parts..............................................................................................................20
2.3.1 Top cover.......................................................................................................... 21
2.3.2 LED Assy/ LED Assy spring ............................................................................. 22
2.3.3 Top cover unit................................................................................................... 23
2.3.4 Control panel Assy/ Control panel bezel/ LED control PWB/ Toner sensor/
Stack full sensor/ Control panel tape harness/ Eject roller ............................... 24
2.3.5 Top cover handle/ Tope cover latch/ Top cover latch spring............................ 25
2.3.6 Eject guide Assy ............................................................................................... 26
2.3.7 Cassette Assy/ Blind cover/ Side cover R Assy ............................................... 27
2.3.8 Feed rollers....................................................................................................... 28
2.3.9 Left side cover .................................................................................................. 29
2.3.10 Face-up tray ..................................................................................................... 30
2.3.11 Front cover ....................................................................................................... 31
2.3.12 Rear cover........................................................................................................ 32
2.3.13 Multipurpose tray Assy/ Multipurpose tray cover Assy/ Links/
Multipurpose tray top cover/ Multipurpose tray drive gear................................ 33
2.3.14 Drum contact Assys.......................................................................................... 34
2.3.15 Registration roller Assy (A)/ Registration drive gear (A)................................... 35
2.3.16 Registration roller Assy (B)............................................................................... 36
2.3.17 Registration clutch, Registration motor Assy.................................................... 37
2.3.18 Cooling fan ....................................................................................................... 38
2.3.19 Color registration sensor Assy.......................................................................... 39
2.3.20 Duplex guide Assy............................................................................................ 40
2.3.21 Electrical chassis/ Electrical chassis cooling fan.............................................. 41
2.3.22 Printer engine controller PWB.......................................................................... 42
2.3.23 Printer unit chassis........................................................................................... 43
2.3.24 Entrance cassette sensor actuator................................................................... 44
2.3.25 Entrance sensor PWB...................................................................................... 45
2.3.26 Entrance MT sensor actuator and Entrance belt sensor actuator.................... 46
2.3.27 Main motor fan/ Fuser eject roller..................................................................... 47
2.3.28 Eject sensor Assy............................................................................................. 48
2.3.29 Fuser latching handle (L).................................................................................. 49
2.3.30 Belt motor Assy ................................................................................................ 50
2.3.31 Fuser latching handle (R)................................................................................. 51
2.3.32 Main motor Assy............................................................................................... 52
2.3.33 Contact Assy/ Side plate Assy.......................................................................... 53
2.3.34 Low voltage power supply................................................................................ 54
2.3.35 High voltage power supply ............................................................................... 55
2.3.36 Main feed Assy................................................................................................. 56
2.3.37 Fuser unit.......................................................................................................... 57
2.3.38 Belt unit............................................................................................................. 58
2.3.39 Duplex unit........................................................................................................ 59
2.3.40 CU Assy............................................................................................................ 60
Oki Data CONFIDENTIAL
3. Adjustment .................................................................................................... 62
3.1 Maintenance Menu and Its Functions ............................................................................ 62
3.2 Short Plug Settings ........................................................................................................ 63
3.3 Printing Singly Using Controller-Equipped Printer ......................................................... 63
3.4 Adjustment after Part Replacement ............................................................................... 64
3.5 Color Balance Adjustment ............................................................................................. 65
3.6 EEPROM Replacement after SWA Board and K73 Board Replacement ...................... 67
4. Regular Maintenance .................................................................................... 68
4.1 Parts to be Replaced Regularly ..................................................................................... 68
4.2 Cleaning......................................................................................................................... 68
4.3 Cleaning of LED Lens Array .......................................................................................... 68
4.4 Cleaning of Pick-up Roller ............................................................................................. 68
5. TROUBLESHOOTING PROCEDURES .........................................................69
5.1 Tips for Troubleshooting ................................................................................................ 69
5.2 Check Points before Correcting Image Problems.......................................................... 69
5.3 Tips for Correcting Image Problems .............................................................................. 69
5.4 Preparation for Troubleshooting .................................................................................... 70
5.5 Troubleshooting Flow..................................................................................................... 70
5.5.1 LCD Message List ............................................................................................ 71
5.5.2 LCD message troubleshooting ......................................................................... 79
5.5.3 Image troubleshooting...................................................................................... 90
6. WIRING DIAGRAM...................................................................................... 102
6.1 Resistance Check ........................................................................................................ 102
6.2 Parts Layout on Boards ............................................................................................... 107
7. Parts List...................................................................................................... 111
7.1 Printer Unit Parts List ................................................................................................... 111
7.2 C9400/C9200 Finisher for OEL/INT Parts Layout........................................................ 131
Job
offset
M
M
M
M
M
M
M
LED Head
Junction Board
Pulse Motors
Engine Controller
Low-Voltage
Power Unit
Fuser Unit
High-Voltage
Power Unit
2nd/3rd T r ay/
Large-Capacity
Tray
Duplex Unit
Belt Unit
<Sensors, Switches and Thermistors>
Paper carrier sensors
Paper size detection
Fuser temperature detection
Ambient temperature and humidity detection
Toner remaining detection
Color registration sensor
ID, belt and fuser checks
C-ID
Unit
M-ID
Unit
Y-ID
Unit
K-ID
Unit
C ID
M
Heater
M ID
Y ID
K ID
Belt
MT/
Registration
Hopping
Geared
motor
DC motor
Operator Panel
Centronics
USB
IDE
HDD
DC
FAN
Ethernet
ROM DIMM × 3
SDRAM DIMM
× 4
Controller
Block

1. SPECIFICATIONS

1.1 Basic System Configuration
The basic system configuration of C9400/C9200 is illustrated in Figure 1.1.
Oki Data CONFIDENTIAL
Figure 1.1
1.2 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.
Oki Data CONFIDENTIAL
Figure 1.2
1.3 Option Configuration
The followings are available as options on C9400/C9200. (1) 2nd Tray/ 3rd Tray
(2) Duplex Unit
Oki Data CONFIDENTIAL
(3) Large-Capacity Tray
(4) Expansion Memory 64/128/256MB
(5) Internal Hard Disk
(6) Ethernet Board
(7) Finisher Unit (for C9400/C9200 OEL/INT Version)
1.4 Specifications
Oki Data CONFIDENTIAL
(1) Dimensions Height: 460mm Width: 666mm Length: 626mm (2) Weight 72kg (3) Paper Type: Ordinary paper and transparencies (Recommended: ML OHP01)
Size: Postal card, Legal 13" or 14", Executive, A4, A5, B5, A6, A3 A3-Nobi, B4
(Only the 1st tray and the front feeder support A6 and postal card sizes.)
Weight: 1st tray 55 kg to 90 kg (64 to 105g/m2)
Front feeder 55 kg to 140 kg (64 to 163g/ m2)
(4) Print Speed Color: 21 pages per minute (Transparency: 5 pages per minute)
Monochrome: 26 pages per minute (Transparency: 15 pages per minute)
Postal Card, Label, Thick Paper: 10 pages per minute (5) Resolution 600 × 600 dots per inch (6) Power Input 100VAC ±10% (7) Power Consumption Peak: 1400W Normal Operation: 550W (5% duty)
Idle: 150W Power Saving Mode: 50W (8) Frequency 50Hz or 60Hz ± 2% (9) Noise Operating: 54 dB (without Second tray)
Standby: 45 dB Power Saving: 43 dB
(10) Consumable Life Toner Cartridge: 7,500 pages (5% duty)
Large-Capacity Toner Cartridge: 15,000 pages (5% duty)
(in each of Y, M, C and K)
Image Drum: 39,000 pages (5% duty, Continuous printing)
(in each of Y, M, C and K)
(11) Parts Replaced Periodically Fuser Unit Assy: Every 80,000 pages
Belt Cassette Assy: Equivalent of 80,000 pages (3P/J) Transfer Belt cartridge: 60,000 prints
(12) Temperatures and Relative Humidities Temperature
Temperature (ºF) RemarkTemperature (ºC)
Oki Data CONFIDENTIAL
Operating 50 to 89.6 10 to 32
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 Transport (Max. One Month) -20 to 122 -29 to 50 With drum and without toner Transport (Max. One Month) -20 to 122 -29 to 50 With drum and toner
17 to 27ºC (Temperatures to assure full color print quality)
Humidity
Relative Humidity (%) Max. Wet-Bulb Temperature (ºC) Remark
Operating 20 to 80 25 50 to 70%
(Humidities to assure full color print quality) Non-Operating 10 to 90 26.8 Power-off Storage 10 to 90 35 Transport 10 to 90 40
(13 Printer Life 1,000,000 pages (on a A4 basis) or five years
41388601TH Rev.6 10 /

2. 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.
2.1 Precautions in Replacing Parts
(1) Before replacing the parts, be sure to remove the CA cable and the interface cable.
(a) To remove the AC cable, always use the following procedure.
1 Flip the power switch of the printer off (to “O”). 2 Pull the AC inlet plug of the AC cable out of the AC receptable. 3 Remove the AC cable and the interface cable from the printer.
(b) To connect the printer again, always use the following procedure.
1 Connect the AC cable and the interface cable to the printer. 2 Insert the AC inlet plug into the AC receptacle. 3 Flip the power switch of the printer on (to “I”).
Oki Data CONFIDENTIAL
Disconnect
(2) Do not disassemble the printer so long as it operates properly. (3) Minimize the disassembly. Do not detach parts other than those shown in the replacing
(4) For maintenance applications, use designated tools. (5) Follow the order instructed to disassemble the printer. Incorrect order may damage the
(6) Small parts such as screws and collars tend to get lost, so temporarily place and fix them in (7) When handling ICs and circuit boards such as microprocessors, ROMs and RAMs, do not (8) Do not place the printed circuit boards directly on the printer or the floor.
Connect
procedure.
parts. their original positions. use gloves that likely to have static.
41388601TH Rev.6 11 /
[Maintenance Tools] Table 2-1 lists tools necessary to replace the units.
Table 2-1 Maintenance Tools
Oki Data CONFIDENTIAL
No.
1
2
3
4
5
6
7 1
8
9
No. 1-100 Philips screwdriver
No. 2-200 Philips screwdriver, Magnetized
No. 3-100 screwdriver
No. 5-200 screwdriver
Digital multimeter
Pliers
Handy cleaner
LED Head cleaner P/N 4PB4083-2248P001
High voltage probe
Q' ty Place of use RemarksService Tools
1
2~2.5 mm screws
1
3~5 mm screws
1
1
1
1
1
Cleans LED head
1
41388601TH Rev.6 12 /
2.2 Parts Layout
Oki Data CONFIDENTIAL
Figure 2.1
41388601TH Rev.6 13 /
[Top Cover Assy]
Oki Data CONFIDENTIAL
Figure 2.2
41388601TH Rev.6 14 /
[Printer Unit-1/2]
Oki Data CONFIDENTIAL
Figure 2.3
41388601TH Rev.6 15 /
[Printer Unit-2/2]
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Figure 2.4
41388601TH Rev.6 16 /
[Cassette Guide Assy (L), (R)]
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Figure 2.5
41388601TH Rev.6 17 /
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Figure 2.6
41388601TH Rev.6 18 /
[Duplex Unit]
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D
C
B
A
D
C
E
B
E
A
Figure 2.7
41388601TH Rev.6 19 /
2.3 Replacing Parts
This section describes how to replace the parts and assemblies illustrated below.
41531301 41515110
Print Engine Controller PWB (2.3.22) 41502304 × 4 LED Assy (2.3.2) 40737401 Power-Unit AC-DC Switching (115V) (2.3.34) 40737501 Power-Unit AC-DC Switching (230V) (2.3.34) 40737601 HV Power Supply (2.3.35) 41531402, 41531404 Fuser Unit (2.3.37) 41531502 Belt Unit (2.3.38) 41178202 Duplex Unit (2.3.39)
41480901 Printer NIP
41483001 Printer Unit
41481001 Unit-Lower-Frame (2.3.36)
41500101 Insurator 41483701 Main Cooling Fan Assy (2.3.18) 2381018P0001 HV Tape Harness
41484101 Electrical Chassis (2.3.21)
41483801 Main Motor Assy (2.3.32) 41483902 Belt Motor Assy (2.3.30)
41489001 Plate Assy-Side (2.3.33) 41493002 Multipurpose Tray (2.3.13) 41276502 Rear Cover (2.3.12) 41277402 Left Side Cover (2.3.9) 41481202 Right Side Cover (2.3.7) 41276402 Front Cover (2.3.11) 41277502 Face Up Tray (2.3.10) 41504401 Top Cover 41484402 Top cover (2.3.1) 40866212 Control panel Bezel (2.3.4)
41493002 Multipurpose Tray Assy (2.3.13)
41484902 Cassette Assy (2.3.7) 41277902 Cover-Blind (2.3.7) 41481701 Feed-Roller (2.3.8) 40863801 Plate-Side (2.3.21)
41483102 Printer Chassis (2.3.23) 41483202 Regist Roller Assy (A) (2.3.15) 41483301 Regist Roller Assy (B) (2.3.16) 41483401 Registration Motor Assy (2.3.17) 41187101 Registration Clutch (2.3.17) 41486601 Duplex Guide Assy (2.3.20)
41481301 Main Feed Assy (2.3.36) 41515801 PCE-Size Sence (2.3.36) 22011000P0140 IMSA-9714N-14A (2.3.36)
41490702 Electrical Chassis Cooling Fan
40841402 Fuser Latching Handle (R) (2.3.31) 41628301 Fuser Latching Handle Spring (2.3.31)
40850201 Contact Assy (2.3.33)
41045802 × 2 Link (2.3.13) 41486202 MT Tray Cover Assy (2.3.13) 41278002 MT Top Cover (2.3.13) 40325101 MT Drive Gear (2.3.13)
Oki Data CONFIDENTIAL
40841302 Fuser Latching Handle (L) (2.3.29) 41628301 Fuser Latching Handle Spring (2.3.29) 40841601 Entrance Sensor Actuator #1 (2.3.24) 41578501 Entrance Sensor Actuator #2 (2.3.26) 40841801 Entrance Sensor Actuator #3 (2.3.26) 41621801 Registration Shutter Solenoid Assy 41488801 Registration Shutter 41589401 Registration Shutter Spring 41641701 Fuser Driver Gear-A (2.3.27) 41095901 Fuser Exit Roller (2.3.27) 4PP4043-4489P001 Fuser Exit Roller Bushing (L) (2.3.27) 4PP4076-3949P001 Fuser Exit Roller Bushing (R) (2.3.27) 41189701 × 4 Drum Contact Assy (2.3.14) 41258301 Entrance Sensor PWB (2.3.25) 41491001 Color Registration Sensor Assy (2.3.19) 41073601 Exit Sensor Assy (2.3.28) 41483701 Main Motor FAN Assy (2.3.27)
40861001 × 8 LED Assy Spring (2.3.2) 41257902 LED Control PWB (Y71) (2.3.4) 41349801 Stack Full Sensor (2.3.4) 41349301 × 4 Eject Roller (2.3.4) 41484501 Control Panel Assy (2.3.4) 2381005P0015 Control Panel Tape Harness (2.3.4) 41514101 LED Harness K 41514102 LED Harness Y 41514103 LED Harness M 41514104 LED Harness C 41328402 Top Cover Handle (2.3.5) 41277602 Top Cover Latch (2.3.5) 40861401 × 2 Top Cover Latch Spring (2.3.5) 41484701 Eject Guide Assy (2.3.6)
41388601TH Rev.6 20 /
2.3.1 Top cover (1) Open the top cover Assy.
(2) Remove the nine screws 1 to detach the top cover 2.
Oki Data CONFIDENTIAL
2
1
1
1
41388601TH Rev.6 21 /
2.3.2 LED Assy/ LED Assy spring (1) Open the top cove 1.
(2) 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).
(3) Detach the LED connector 4.
When assembling, attach the LED connector 4 to the LED head and insert the flat cable.
Oki Data CONFIDENTIAL
1
3
3
4
4
2
41388601TH Rev.6 22 /
2.3.3 Top cover unit (1) Remove the top cover (see section 2.3.1).
(2) Remove the rear cover (see section 2.3.12). (3) Remove the front cover (see section 2.3.11). (4) Remove the electrical chassis (see section 2.3.21). (5) Unscrew the screws 1 and 2 to remove the limiters (F) 3 and (R) 4. (6) Remove the inner shaft 5, then the top cover unit 8 (The inner springs 6 and 7 become
detached).
Oki Data CONFIDENTIAL
8
1
6
2
3
7
5
2
1
4
41388601TH Rev.6 23 /
Oki Data CONFIDENTIAL
2.3.4 Control panel Assy/ Control panel bezel/ LED control PWB/ Toner sensor/ Stack full sensor/ Control panel tape harness/ Eject roller
(1) Detach the control panel bezel 1. (2) Remove the screws 2 to demount the control panel 3. (3) Detach the control panel tape harness 4. (4) Remove the screws 6, unhook the connector 7 and demount the LED control PWB 8. (5) Unscrew the screws 9 to remove the plate 0. (6) Disengage the claw to demount the toner sensor A. (7) Demount the stacker full sensor B. (8) Unscrew the eject sensor bracket C, D.
1
2
6
2
9
C
D
7
3
4
8
B
A
9
0
41388601TH Rev.6 24 /
2.3.5 Top cover handle/ Tope cover latch/ Top cover latch spring (1) 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).
Oki Data CONFIDENTIAL
1
1
4
3
2
4
41388601TH Rev.6 25 /
2.3.6 Eject guide Assy (1) Remove the seven screws 1 to detach the eject guide Assy 2.
Oki Data CONFIDENTIAL
1
2
1
1
1
41388601TH Rev.6 26 /
2.3.7 Cassette Assy/ Blind cover/ Side cover R Assy (1) Detach the cassette Assy 1.
(2) Disengage the blind cover 2 at the two places to detach it. (3) Unscrew the two screws to remove the stopper 4. (4) Disengage the claw on the left support of the side cover R to detach the side cover R.
Oki Data CONFIDENTIAL
2
1
5
4
5
5
3
5
41388601TH Rev.6 27 /
2.3.8 Feed rollers (1) Remove the cassette.
(2) Unlatch and demount the feed rollers 1.
Oki Data CONFIDENTIAL
1
1
1
41388601TH Rev.6 28 /
2.3.9 Left side cover (1) Remove the four screws 1 to detach the left side cover 2.
Oki Data CONFIDENTIAL
2
1
1
41388601TH Rev.6 29 /
2.3.10 Face-up tray (1) 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.
Oki Data CONFIDENTIAL
2
2
1
41388601TH Rev.6 30 /
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