Oki MC860 MFP User manual

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MC860/CX2633MFP
Maintenance Manual
032007A
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*All instances that mention MC860MFP also apply to the CX2633 unless otherwise noted.

Copyright Information
Copyright © 2009by Oki Data. All Rights Reserved
Disclaimer
Every effort has been made to ensure that the information in this document is complete, accurate, and up-to-
date. The manufacturer assumes no responsibility for the results of errors beyond its control. The
manufacturer also cannot guarantee that changes in software and equipment made by other manufacturers and
referred to in this guide will not affect the applicability of the information in it. Mention of software products
manufactured by other companies does not necessarily constitute endorsement by the manufacturer.
While all reasonable efforts have been made to make this document as accurate and helpful as possible, we
make no warranty of any kind, expressed or implied, as to the accuracy or completeness of the information
contained herein.
The most up-to-date drivers and manuals are available from the web site:
http://www.okiprintingsolutions.com

43967002TH Rev.1 3 /
Oki Data CONFIDENTIAL
This is the Maintenance Manual for the Oki Data Color LED MFP MC860series MC860dn/
MC860dtn describing the maintenance procedures. This manual is intended to be used by
the experienced maintenance engineer. For the operating procedure of the Oki Data Color
LED MFP MC860 series MC860dn/MC860dtn, refer to the User’s Manual.
The Oki Data Color LED MFP MC860series MC860dn/MC860dtn is sometimes abbreviated
simply as MC860 or MFP in this manual.
Note! * Contents of this manual can be changed without prior notice.
* There can be errors in this manual even though Oki Data has made
best efforts to create the accurate manual. Oki Data is not liable for
any loss and/or damage that are asserted by user to have been
caused by the repair/adjustment/change which are implemented to
the MFP by using this manual.
* The parts/components that are used in the MFP are delicate and
can be easily damaged if they are not handled in appropriate
method. Oki Data recommends strongly that maintenance of the
MFP should be made by the maintenance engineers who are the
registered member of Oki Data.
* Before starting any work, remove static electricity beforehand.
PREFACE
PREFACE

43967002TH Rev.1 4 /
Oki Data CONFIDENTIAL
Contents
CONTENTS
1. Configuration .............................................................................7
1.1 System configuration ............................................................................................8
1.2 MFP configuration ...............................................................................................10
1.2.1 Name and function of each part ....................................................................11
1.3 Options configuration...........................................................................................16
1.4 Specifications ......................................................................................................18
1.5 Interface specifications.........................................................................................28
1.5.1 USB interface specifications..........................................................................28
1.5.2 Network interface specifications....................................................................28
1.5.3 Parallel interface specifications .....................................................................29
2.Theory of Operation ................................................................30
2.1 Electro-photographic process system..................................................................31
2.2 Print process .......................................................................................................34
2.3 Image scanning process .....................................................................................44
2.3.1 Structure and process of RADF.....................................................................44
2.3.1.1 Cross-section view ................................................................................44
2.3.1.2 Electrical configuration ..........................................................................44
2.3.1.3 Fundamental operations .......................................................................45
2.3.1.4 Document detection ..............................................................................47
2.3.1.5 Jam detection ........................................................................................49
2.3.1.6 Power supply..........................................................................................49
2.3.2 Document table structure .............................................................................50
2.3.2.1 Overview ...............................................................................................50
2.3.2.2 Exposure block ......................................................................................50
2.3.2.3 Mirror carriage drive mechanism............................................................51
2.3.2.4 Document size detection .......................................................................52
3. Installation...............................................................................53
3.1 Warnings and prohibited items.............................................................................54
3.2 Installation of MFP...............................................................................................55
3.2.1 Unpacking......................................................................................................55
3.2.2 Main unit and list of accessories....................................................................56
3.2.3 Installation method ........................................................................................58
3.3 Installation of add-on tray unit..............................................................................64
3.3.1 Unpacking......................................................................................................64
3.3.2 Main unit and list of accessories ...................................................................65
3.3.3 Installation method ........................................................................................66
3.4 Preparation before use.........................................................................................77
3.4.1. Preparation of paper.....................................................................................77
3.4.2 Power cable connection.................................................................................79
3.4.3 Add-on memory replacement........................................................................81
3.4.4 Internal hard disk replacement......................................................................83
3.4.5 Duplex unit installation and removal..............................................................85
3.5 Report print..........................................................................................................88
3.6 Control panel........................................................................................................89
3.7 Menu list...............................................................................................................90
3.8 MFP information print.........................................................................................133
3.9 Network information print...................................................................................134
3.10 Connection method..........................................................................................135
3.10.1 Connect the interface cable.......................................................................135
3.10.1.1 Connect the network cable.................................................................135
3.10.1.2 Connect the USB cable. ....................................................................135
3.10.1.3 Connect the telephone line cable.......................................................136
3.10.2 Turn ON the power.....................................................................................139
3.10.2.1 Required conditions for power supply................................................139
3.10.2.2 Power switch......................................................................................139
3.11 Checking papers used by user.........................................................................140
4. Parts Replacement...............................................................141
4.1 Precautions when replacing part .......................................................................142
4.2 Part replacement method ..................................................................................144
4.2.1 How to separate scanner and printer .........................................................144
4.2.2 Scanner ......................................................................................................147
4.2.2.1 Separation pad ....................................................................................147
4.2.2.2 Operator panel Assy ...........................................................................148
4.2.2.3 RADF Assy ..........................................................................................149
4.2.3 Printer..........................................................................................................152
4.2.3.1 Belt unit ...............................................................................................152
4.2.3.2 Fuser unit ............................................................................................153
4.2.3.3 Cover-Side-L........................................................................................154
4.2.3.4 Cover-Side-R........................................................................................155
4.2.3.5 Rear cover ...........................................................................................156
4.2.3.6 LED Assy .............................................................................................157
4.2.3.7 MZA PCB/CU PCB...............................................................................158
4.2.3.8 ID motor/paper feed motor/ID lift-up motor ........................................161
4.2.3.9 PU PCB ...............................................................................................163
4.2.3.10 Top cover Assy...................................................................................165
4.2.3.11 Top cover/Extension transport Assy...................................................167
4.2.3.12 Shaft eject Assy (FU)/Shaft eject Assy (FD)......................................168
4.2.3.13 Guide eject Assy lower/Color regist Assy/Relay PCB (P6Y)..............169
4.2.3.14 FAN (Fuser)/High voltage PCB/Contact Assy/Fuser sensor Assy ....173
4.2.3.15 MPT Assy/MPT hopping roller/Separator/Pickup roller .....................175
4.2.3.16 Regist roller Assy...............................................................................176
4.2.3.17 Gear box/Regist/Hopping roller Assy/Solenoid .................................177
4.2.3.18 Holder switch Assy/Fan for low voltage power supply/Low
voltage power supply ........................................................................180

43967002TH Rev.1 5 /
Oki Data CONFIDENTIAL CONTENTS
4.2.3.19 Belt motor Assy/Fuser motor Assy.....................................................182
4.2.3.20 Side R Assy/Side L Assy....................................................................184
4.2.3.21 Paper feed roller (tray 1) ...................................................................186
4.2.3.22 Feed paper roller (Tray 2 and 3 (option)) ...........................................188
4.2.3.23 Add-on tray unit (option) ....................................................................190
4.2.3.24 Feed paper roller (Multipurpose tray) ................................................192
4.3 Lubricating points...............................................................................................193
5.Maintenance Menu ................................................................212
5.1 Service function.................................................................................................213
5.1.1 How enter the service menu........................................................................213
5.1.1.1 Special operation of the hardware keys...............................................213
5.1.1.2 Password entry screen ........................................................................213
5.1.2 Operation required upon completion of the service menu operation .........213
5.2 Service Maintenance menu ...............................................................................214
5.2.1 Service Maintenance menu structure..........................................................214
5.3 System maintenance ........................................................................................215
5.3.1 OKIUSER ....................................................................................................215
5.3.2 Format HDD ................................................................................................215
5.3.3 Format Flash ROM......................................................................................216
5.3.4 Menu Reset(Administrator password reset) ................................................216
5.3.5 All Reset......................................................................................................217
5.3.6 Test Print Menu............................................................................................217
5.3.7 Change Password........................................................................................218
5.4 Panel maintenance ...........................................................................................219
5.4.1 LED test ......................................................................................................219
5.4.1.1 Operating procedure ...........................................................................219
5.4.2 LCD test ......................................................................................................220
5.4.2.1 Operating procedure ...........................................................................220
5.4.3 Control panel key test..................................................................................220
5.4.3.1 Operating procedure ...........................................................................220
5.5 Copy maintenance ............................................................................................222
5.5.1 Color copy ...................................................................................................222
5.6 Scanner maintenance .......................................................................................223
5.6.1 Shading data loading ..................................................................................223
5.6.2 Operating procedure ...................................................................................223
5.6.3 Scanning roller cleaning .............................................................................223
5.6.3.1 Operating procedure ...........................................................................223
5.6.4 Scan position adjustment ............................................................................224
5.6.4.1 Side registration adjustment ................................................................224
5.6.4.2 Top end position adjustment ................................................................224
5.6.4.3 Back end position adjustment .............................................................225
5.7 Mirror carriage mode..........................................................................................226
5.7.1 How to enter the mirror carriage communication mode ..............................226
5.7.2 How to release the mirror carriage mode ...................................................226
5.8 Fax maintenance................................................................................................227
5.8.1 Country code...............................................................................................227
5.8.2 Tone For Echo .............................................................................................228
5.8.2.1 TX(During send) ..................................................................................228
5.8.2.2 RX(During receive)...............................................................................229
5.8.3 H/Modem Rate ...........................................................................................229
5.8.3.1 TX(During send)...................................................................................229
5.8.3.2 RX(During receive) ..............................................................................229
5.8.4 Pulse Make Ratio .......................................................................................230
5.8.5 MF(Tome) Duration .....................................................................................230
5.8.5.1 ON period.............................................................................................230
5.8.5.2 OFF period...........................................................................................230
5.8.6 Colling Timer................................................................................................230
5.8.7 Attenuator....................................................................................................230
5.8.8 FM Attenuator..............................................................................................230
5.8.9 Fax maintenance items – Default value list .................................................231
5.8.10 Line Test ...................................................................................................232
5.8.10.1 Relay Test...........................................................................................232
5.8.10.2 Tonal send test ..................................................................................233
5.8.10.3 DTMF test ..........................................................................................234
5.9 T30 monitor print ...............................................................................................235
5.9.1 T30 monitor print procedure .......................................................................235
5.10 Printer maintenance ........................................................................................236
5.10.1 Personality.................................................................................................236
5.10.1.1 IBM 5577............................................................................................236
5.10.1.2 IBM PPR III XL...................................................................................236
5.10.1.3 EPSON FX.........................................................................................236
5.10.1.4 HP-GL/2.............................................................................................236
5.10.3.1 Operator panel...................................................................................237
5.10.2 Peak Power Control ..................................................................................237
5.10.3 Engine Diag Mode (Self-diagnostic) .........................................................237
5.10.3.2 Normal self-diagnostic mode (Level 1) ..............................................240
5.10.3.2.1 How to enter self-diagnostic mode (Level 1) ..................................240
5.10.3.2.2 How to exit self-diagnostic mode ....................................................240
5.10.3.3 Switch scan test ................................................................................241
5.10.3.4 Motor, clutch test ...............................................................................243
5.10.3.5 Test print ............................................................................................245
5.10.3.6 Color registration error correction test................................................249
5.10.3.7 Density error correction test ..............................................................250
5.10.3.8 Consumable item counter display .....................................................251
5.10.3.9 Printed sheets counter display...........................................................252
5.10.3.10 Factory/Shipping mode switching.....................................................252
5.10.3.11 Self-diagnostic function setting .......................................................253
5.10.3.12 LED head serial number display......................................................253
5.11 Initialization......................................................................................................254
5.11.1 Initialization by administrator ....................................................................254
5.11.1.1 Initialization operation by administrator .............................................254
5.11.1.2 Items that can be initialized by administrator.....................................256
5.11.2 Initialization by service engineer ...............................................................257
5.11.2.1 Initialization operation by service engineer .......................................257
5.11.2.2 Items that can be initialized by service engineer ...............................258
5.12 Special startup.................................................................................................260
5.12.1 Special startup operating procedure .........................................................260
5.12.2 Special startup...........................................................................................261
5.13 Maintenance utilities ........................................................................................262

43967002TH Rev.1 6 /
Oki Data CONFIDENTIAL CONTENTS
5.14 Setup after part replacement ..........................................................................264
5.14.1 Precautions when replacing the engine control PCB ...............................264
5.14.2 EEPROM setting after CU PCB is replaced..............................................265
5.14.3 Maintenance of scanner PCB by using the Maintenance Utilities.............266
5.14.4 List of data that are stored in the scanner side..........................................267
5.14.5 Precautions when writing scanner data using Maintenance Utilities.........267
5.14.6 Restrictions when using Maintenance Utilities .........................................267
5.15 Scanner registration adjustment method .......................................................268
5.15.1 Overview of the registration adjustment work ...........................................268
5.15.1.1 Operation method of the service function for registration adjustment 268
5.15.1.2 Adjustment item ................................................................................269
5.15.1.3 FBS scanning position adjustment (side registration) ......................269
5.15.1.4 FBS scanning position adjustment (top-end registration) .................270
5.15.1.5 ADF scanning position adjustment (side registration) .......................271
5.15.1.6 ADF scanning position adjustment (top-end registration) .................272
5.15.1.7 ADF scanning position adjustment (rear-end registration) ................273
6. Cleaning.................................................................................274
6.1 Cleaning.............................................................................................................275
6.2 How to clean the LED lens array........................................................................276
6.3 How to clean the pickup roller............................................................................278
6.4 How to clean inside of MFP...............................................................................279
6.5 How to clean paper path of RADF.....................................................................281
6.5.1 Clean the document transport roller and the document retainer roller.........281
6.6 How to clean under portion of RADF.................................................................283
6.7 How to clean document glass and glass surface...............................................284
7. Troubleshooting.....................................................................285
7.1 Precautions prior to repair..................................................................................286
7.2 Items to be checked prior to taking action on abnormal images........................286
7.3 Precautions when taking action on abnormal images........................................286
7.4 Preparations for troubleshooting........................................................................286
7.5 Troubleshooting method.....................................................................................287
7.5.1 LCD Message List.......................................................................................287
7.5.2 Troubleshooting ...........................................................................................316
7.5.2.(1) LCD display error...............................................................................317
7.5.2.(2) Abnormal operations of printer after the power is turned on .............318
7.5.2.(3) Paper feed jam (error 391: 1st tray) ..................................................327
7.5.2.(4) Feed jam (error code 380) ................................................................329
7.5.2.(5) Paper feed jam (error code 390: Multipurpose tray) .........................330
7.5.2.(6) Paper running jam (error code 381:...................................................332
7.5.2.(7) Paper running jam (error code 382)...................................................334
7.5.2.(8) Two-sided printing jam (error code: 370, 371, 372, 373, 383) ...........336
7.5.2.(9) Paper size error (error code 400) ......................................................338
7.5.2.(10) ID unit Up/Down error (Service call 140 to 143) ............................339
7.5.2.(11) Fuser unit error (error 170 to 177) .................................................340
7.5.2.(12) Motor fan error (error code 122, 127, 051) ....................................341
7.5.2.(13) Print speed is slow. (Performance is low.) .......................................341
7.5.2. (14) Option unit cannot be recognized...................................................342
7.5.2.(15) LED head cannot be recognized.
(error code 131, 132, 133, 134) ....................................................343
7.5.2.(16) Toner cartridge cannot be recognized.
(Error code 540, 541, 542, 543).........................................................343
7.5.2.(17) Fuse cut error (error codes 150 to 155) ..........................................345
7.5.2.(18) Dew condensation error (Error 123) ...............................................345
7.5.2.(19) Connection diagram.........................................................................346
7.5.3 Troubleshooting the abnormal images.........................................................347
7.5.3.(1) Color has faded-out and blurred entirely. (Refer to Figure 7-2 A)......348
7.5.3.(2) Stain on white print (Refer to Fig.7-2 B) ...........................................349
7.5.3.(3) All white page print (Refer to Fig.7-2 C)............................................350
7.5.3.(4) Vertical line is printed.........................................................................350
7.5.3.(5) Cyclic abnormal print (Refer to Fig.7-2 E).........................................351
7.5.3.(6) Color registration error is heavy ........................................................351
7.5.3.(7) All black page print ............................................................................352
7.5.4 Action after forced initialization of Flash .....................................................353
7.5.5 Network troubleshooting..............................................................................354
7.5.5.1 Connection error occurs with the Web browser ...................................354
7.5.5.2 Print operation is not possible..............................................................361
7.5.5.3 Cannot create Certificate.....................................................................362
7.5.5.4 Installation of Certificate is not possible...............................................362
7.5.5.5 Other questionnaires............................................................................365
7.5.5.6 Restrictions when using Internet Explore 7..........................................368
7.6 Fuse check.........................................................................................................369
7.7 Moving the MC860 and transportation method..................................................370
7.7.1 Moving the MC860 ......................................................................................370
7.7.2 Transporting the MC860 ..............................................................................372
8. Connection Diagrams............................................................377
8.1 Resistance value check .....................................................................................378
8.2 Parts location.....................................................................................................382
9. Appendix................................................................................392

Oki Data CONFIDENTIAL
1.
Configuration
1.1 System configuration .................................................................8
1.2 MFP configuration ....................................................................10
1.3 Options configuration................................................................16
1.4 Specifications ...........................................................................18
1.5 Interface specifications..............................................................28

43967002TH Rev.1 8 /
Oki Data CONFIDENTIAL 1. Configuration
1.1 System configuration
OPE-UNIT
SPEAKER
LCD
Module
PCB PANEL2
PCB PANEL
KEYs
KEYs
INVERTER
TP-Ctrl
FBS-UNIT
PCB MAIN
VOICE
IC
SF-ROM
2MB CPU
120MHz
RTC
SRAM
128KB
BATT.
F-ROM
8MB
ASIC SDRAM
8MB
SDRAM
32MB
USB
2.0
LVDS
ROM
4MB DRAM 384MB
CPU
400MHz
USB2.0
Host
CODEC
IC
NCU
PCB NCU PCB EXIT-LINE-DFX
PSTN
USB I/F
PCB _RADF-CODEC
PCB MZA
MODEM
IC CODEC IC
MF1
ASIC B5B
Power
LVDS I/F
WAKE-UP
PCI BUS
+5V +24V
PRINTER
Power
Unit Power
+5V
PCB TB2
LAN
IC
CIF2
(ASIC)
CC1
(ASIC)
CPU
500MHz NOR
FLASH NAND
FLASH
DRAM
256MB
DRAM
DIMM
256MB USB
Device
IEEE
1284
HDD
CU
FAN
PU I/F
+5V
+24V
PCB PVM
ARMORED
(ASIC)
Power
FAN 1 Power FAN 2
Duplex
Unit
PRINTER
ENGINE
UNIT
2nd Option Tray
3rd Option Tray
ASIC
ASIC
AFE
LVDS
CCD
PCB CCD
Motor
Driver
PCB INVERTER
INVERTER LAMP
PCB SCANNER
FBS
Motor
RADF-UNIT
PCB_RADF
Motor
Driver
Motor
Driver
Solenoid
Driver Solenoid
RADF
Motor
RADF
Motor
Scanner side
Printer side
MC860
Overall system configuration
of the MC860 is shown in
Figure 1-1.
Figure 1-1

43967002TH Rev.1 9 /
Oki Data CONFIDENTIAL 1. Configuration
20MHz
Centronics
EEP
ROM
CC1
ASIC
CIF2
ASIC
HDD
LAN USB
CUPCB
Flash
ROM
Option
RAM
CU
FAN CPU
Paper
feed
solenoid
Duplex
FAN Front
sensor
IN
sensor Cover
open
sensor
Rear
sensor Bottom sensor
2nd
P.E
sensor
2nd
IN
sensor
2nd
paper
size sw
Front sensor PCB
DUPLEXPCB 2ndTRAYPCB
IN1 IN2 WR
M
ID M HOP M
IDUP M
BELT
Feed
clutch
Paper
feed
transport
motor
Duplex
clutch
Separator
solenoid
Duplex
motor
Paper
size
SW
1st
P.E
sensor
Belt unit
Relay PCB
Fuserunit INLET
EXIT
sensor
Fuser
release
sensor
Fuse
entrance
sensor
Density
Color
registration
PCB,right
Color
registration
PCB,left
Beltunit,
fusecut
Fuser fuse cut,
UP& LOWupper center/
Upper side compensation/
Lower thermistor
LowvoltagePCB
FAN,heater control,others
Fuser entrance,release
5V,24V,0VL,0VP
AC-SW
M
HEAT
Fuser
section,
end
cooling
FAN
Shutter
solenoid
Low
voltage
FAN
ARMORED CPU
PUPCB
Fusecut
EXIT
Colorregistration,
density,
thermistor signals
FLASH
8Mbit
Environmentalhumidity,
high voltage I/F,
FAN control, cover open
EEPROM
HighvoltagePCB
PFIDPCB
K-ID Y-ID M-ID C-ID
Fuser
FAN Belt thermistor
ID UP/
DOWN
Cover
open
sensor
Environment
sensor
OperatorPanelPCB
Toner sensor PCB
K toner
sensor Y toner sensor Mtoner sensor Ctoner sensor ID fuse cut
KLED HEAD
HostUSB
PCB
YLED HEAD
MLEDHEAD
CLED HEAD LEISUS
commandI/F
DCONI/FLSYNC
Overall system configuration of the MC860 printer section is shown in Figure 1-2.
Figure 1-2

43967002TH Rev.1 10 /
Oki Data CONFIDENTIAL 1. Configuration
1.2 MFP configuration