Oki C5100 User manual

42049001TH Rev.1 1 / 148
C5300/C5100
Color LED Page Printer
MAINTENANCE MANUAL
ODA/OEL/INT
2003-3-28 Rev.1
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PREFACE
This manual describes the procedures of the maintenance of the C5300/C5100 printers.
Thedocumentisproducedformaintenancepersonneluse. Fordetailsontheproceduresforhandlingthe
C5300/C5100 of printers, see its user documentation.
Note! • The descriptions in this manual are subject to change without prior notice.
• Inpreparingthedocument,effortshavebeenmadetoensurethattheinformationinitisaccurate.
However, errors may be crept into the document. Oki Data assumes no responsibility for any
damage resulting from, or claimed to be the results of, those repairs, adjustments or modifica-
tions to the printers which are made by users using the manual.
• The parts used for the printers are sensitive and, if handled improperly, may be damaged. It is
strongly recommended that the products are maintained by maintenance men registered with
Oki Data.
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CONTENTS
1. SPECIFICATIONS ............................................................................................ 6
1.1 System Configuration....................................................................................................... 6
1.2 Printer Configuration ........................................................................................................8
1.3 Option Configuration ...................................................................................................... 10
1.4 Specifications................................................................................................................. 11
2. PARTS REPLACEMENT................................................................................ 13
2.1 Precautions in Replacing Parts...................................................................................... 13
2.2 Part Replacement Procedures....................................................................................... 15
2.2.1 Top Cover......................................................................................................... 15
2.2.2 Left Side Cover................................................................................................. 16
2.2.3 Right Side Cover .............................................................................................. 17
2.2.4 Face-Up Tray.................................................................................................... 18
2.2.5 Rear Cover ....................................................................................................... 19
2.2.6 LED Assy / LED Assy Springs.......................................................................... 20
2.2.7 Controller PWB................................................................................................. 21
2.2.8 Print Engine Controller PWB ............................................................................ 23
2.2.9 Top Cover Unit. ................................................................................................ 25
2.2.10 Controller Panel Assy ....................................................................................... 26
2.2.11 Board RSP / Environment Sensor / Top Cover Handle.................................... 27
2.2.12 Low Voltage Power Unit / FAN (ID) / FAN (PowL) / Hopping Motor /
Fuser Motor ...................................................................................................... 28
2.2.13 Board-PRD ....................................................................................................... 29
2.2.14 Guide - Eject Assy / Color Registration Assy / Board-RSM.............................. 30
2.2.15 FAN (Fuser) / Belt Motor / High Voltage Power Supply Board /
Cover Open Switch / Image Drum Up/Down Sensor........................................ 31
2.2.16 Multipurpose Tray (MPT) Assy ......................................................................... 32
2.2.17 Feeder Unit / Board-RSF / Multipurpose Tray (MPT) Hopping Roller /
Multipurpose Tray (MPT) Frame Separator / Cover-Front ............................... 33
2.2.18 Main Motors / Solenoid / Paper-End Sensor .................................................... 34
2.2.19 Feed Roller ....................................................................................................... 36
2.2.20 Shaft Eject Assy (FU) / Shaft Eject Assy (FD) / Eject Sensor .......................... 37
2.2.21 Fuser Unit ......................................................................................................... 38
2.2.22 Belt Unit ............................................................................................................ 39
3. ADJUSTMENTS .............................................................................................40
3.0 System Maintenance Menu ........................................................................................... 40
3.1 Maintenance Modes and Their Functions...................................................................... 41
3.1.1 Maintenance Menu........................................................................................... 41
3.1.2 Engine Maintenance Mode............................................................................... 42
3.1.2.1 Operator panel .................................................................................. 42
3.1.2.2 Normal self-diagnostic mode (level 1)............................................... 42
3.1.2.2.1 Entering self-diagnostic mode (level 1) ............................. 43
3.1.2.2.2 Exiting self-diagnostic mode ............................................. 43
3.1.2.3 Switch scan test ................................................................................ 43
3.1.2.4 Motor and clutch test......................................................................... 46
3.1.2.5 Test printing ...................................................................................... 48
3.1.2.6 Consumable counter display............................................................. 53
3.1.2.7 Consumable counter display - continuous ........................................ 53
3.1.2.8 Operator panel display ...................................................................... 54
3.1.3 Printing on Printer Equipped with Controller..................................................... 59
3.2 Adjustments after Parts Replacement ........................................................................... 60
3.2.1 Notes on Engine Controller Board Replacement ............................................. 60
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3.2.2 EEPROM Replacement after ARC Board / OWL Board Replacement ............ 61
3.2.3 Destination Setting (Check Method: Printing demo page)............................... 61
3.3 Print Density Adjustment................................................................................................ 62
3.4 Print Density Adjustment (Calibration Chip)................................................................... 63
4. REGULAR MAINTENANCE ........................................................................... 64
4.1 Parts Replaced Regularly .............................................................................................. 64
4.2 Cleaning......................................................................................................................... 64
4.3 Cleaning the LED Lens Array ........................................................................................ 64
4.4 Cleaning the Pick-up Roller ........................................................................................... 64
5. TROUBLESHOOTING PROCEDURES ......................................................... 65
5.1 Precautions before troubleshooting ............................................................................... 65
5.2 Precautions before handling an abnormal image .......................................................... 65
5.3 Precautions upon handling an abnormal image............................................................. 65
5.4 Preparing for Troubleshooting ....................................................................................... 66
5.5 Troubleshooting Procedure............................................................................................ 66
5.5.1 LCD message list ............................................................................................. 67
5.5.2 Preparing for troubleshooting ........................................................................... 72
5.5.3 Image Problem Troubleshooting ...................................................................... 83
5.6 Fuse Checking ............................................................................................................... 97
6. CONNECTION DIAGRAM.............................................................................. 98
6.1 Resistance Checks ........................................................................................................ 98
6.2 Program/Font ROM Layouts ........................................................................................ 102
7. PARTS LIST ................................................................................................. 108
APPENDIX A INTERFACE SPECIFICATIONS ................................................. 134
1. Parallel Interface Specifications (C5300)......................................................................... 134
1.1 Parallel Interface...................................................................................................... 134
1.2 Parallel Interface Connector and Cable................................................................... 134
1.3 Parallel Interface Level ............................................................................................ 134
1.4 Timing Charts .......................................................................................................... 135
1.5 Parallel I/F Signals................................................................................................... 136
2. Universal Serial Bus (USB) Interface Specifications ....................................................... 137
2.1 USB Interface .......................................................................................................... 137
2.2 USB Interface Connector and Cable ....................................................................... 137
2.3 USB Interface Signals ............................................................................................. 137
3 Network Interface Specifications ..................................................................................... 138
3.1 Network Interface..................................................................................................... 138
3.2 Network Interface Connector and Cable ................................................................. 138
3.3 Network Interface Signals........................................................................................ 138
APPENDIX B 2ND TRAY MAINTENANCE....................................................... 139
1. Parts Replacement .......................................................................................................... 139
1.1 PCB ......................................................................................................................... 139
1.2 Frame Assy- Hopping .............................................................................................. 140
2. PARTS LIST .................................................................................................................... 141
APPENDIX C DUPLEX UNIT MAINTENANCE................................................. 143
1. Parts Replacement .......................................................................................................... 143
1.1 Duplex Unit .............................................................................................................. 143
1.2 Upper Assy / Rear Assy .......................................................................................... 144
1.3 Duplex Transport Assy ............................................................................................ 145
2. PARTS LIST .................................................................................................................... 147
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K LED HEAD
Y LED HEAD
M LED HEAD
C LED HEAD
Environment
Sensor
Operator Panel
Board
Toner Sensor Board
High Voltage Board Low Voltage Board
MCON CPU
FAN
Paperfeed
Solenoid M KID
Front Sensor Board
Duplex Board 2nd Tray Board
IN1 IN2 WR
M
YID M MID M CID M HOP
1st
P.E
Belt Thermistor
Belt Unit
PU-Board
Driver Relay Board
Fuser Inlet
EXIT
Density
Color
Registration
M
BELT M HEAT
Belt Unit Fuse
Cut-Out/
Recognition
Fuser Fuse Cut-Out/
Recognition/
Thermistor
Fuse Cut-Out/
Recognition, Exit,
Motor Control
Color Registration,
Density, Thermistor
Signals
Environment Temperature
Humidity Signals
28MHz
FLASH
8M or
4Mbit
SRAM
256Kbit
High Voltage Interface,
Fan Control, Cover-Open Fan, Heater Control, etc 3.3V, 5V, 24V, 0VL, 0VP
EEPROM
K-ID Y-ID M-ID C-ID FAN AC-SW
FAN ID UP/
Down Cover- Open
K toner
sensor Y toner sensor M toner sensor C toner sensor Image drum fuse cut-out/recognition
DCON
33MHz
LEISUS Video
Interface
(data8bit ×4,
fsync ×4,
Isync, wclk)
LVDS
Driver
LAN, USB, Centro I/F HDD
CU Board
CU-FAN
CU Area
DCON I/F, LSYNC LEISUS
Command
Interface
1. SPECIFICATIONS 1.1 System Configuration C5300
Figure 1-1-1 shows the system configuration of C5300.
Figure 1-1-1
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C5100
Figure 1-1-2 shows the system configuration of C5100.
Figure 1-1-2
K LED HEAD
Y LED HEAD
M LED HEAD
C LED HEAD
Environment
Sensor
Operator Panel
Board
Toner Sensor Board
High Voltage Board Low Voltage Board
MCON CPU
FAN
Paperfeed
Solenoid M KID
Front Sensor Board
Duplex Board 2nd Tray Board
IN1 IN2 WR
M
YID M MID M CID M HOP
1st
P.E
Belt Thermistor
Belt Unit
PU-Board
Driver Relay Board
Fuser Inlet
EXIT
Density
Color
Registration
M
BELT M HEAT
Belt Unit Fuse
Cut-Out/
Recognition
Fuser Fuse Cut-Out/
Recognition/
Thermistor
Fuse Cut-Out/
Recognition, Exit,
Motor Control
Color Registration,
Density, Thermistor
Signals
Environment Temperature
Humidity Signals
28MHz
FLASH
8M or
4Mbit
SRAM
256Kbit
High Voltage Interface,
Fan Control, Cover-Open Fan, Heater Control, etc 3.3V, 5V, 24V, 0VL, 0VP
EEPROM
K-ID Y-ID M-ID C-ID FAN AC-SW
FAN ID UP/
Down Cover- Open
K toner
sensor Y toner sensor M toner sensor C toner sensor Image drum fuse cut-out/recognition
ASIC
(ARBOKS)
66MHz
LEISUS Video
Interface
(data8bit ×4,
fsync ×4,
Isync, wclk)
USB I/F LAN I/F
CU Board
CPU
CU Area
DCON I/F, LSYNC
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1.2 Printer Configuration
The inside of C5300 printers is composed of the following:
• Electrophotographic Processor
• Paper Paths
• Controller Block (CU and PU)
• Operator Panel
• Power Units (High Voltage Unit and Low Voltage Unit)
Figure 1-2-1 shows the configuration of each printer.
Figure 1-2-1
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The inside of C5100 printers is composed of the following:
• Electrophotographic Processor
• Paper Paths
• Controller Block (CU and PU)
• Operator Panel
• Power Units (High Voltage Unit and Low Voltage Unit)
Figure 1-2-2 shows the configuration of each printer.
Figure 1-2-2
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1.3 Option Configuration
The following options are available for C5300/C5100.
(1) 2nd Tray
(2) Duplex Unit
(3) Expansion Memory (ML5300) 64 MB
(4) Expansion Memory (ML5100) 64/256 MB
(5) Hard Disk (ML5300)
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1.4 Specifications
(1) External Dimensions
Height: 345 mm. Width: 422 mm. Length: 561 mm.
(2) Weight
Approx. 20 kg (except consumables)
(3) Paper
Type: Plain paper, Transparencies (Recommended: MLOHP01)
Size: Postal card, Legal 13" or 14", Executive, A4, A5, B5, A6 (A6 held in and fed from
only 1st tray and front feeder)
Weight: 1st tray 55 kg to 103 kg (64 to 120 g/m2)
Front feeder 55 kg to 172 kg (64 to 203 g/ m2)
(4) Print Speed
Color: 12 pages per minute (Transparencies: 6 pages per minute)
Monochrome: 20 pages per minute (Transparencies: 12 pages per minute)
Postal Cards, Labels, Thick Paper: 8 pages per minute
(5) Resolution
600 ×1200 dots per inch
(6) Power Input
100 VAC ±10%
(7) Power Consumption
Peak: 850W
Normal Operating: 400W (5% duty)
Idle: 80W
Power Save Mode: 18W or less
(8) Frequency
50Hz or 60Hz ±2 Hz
(9) Noise
Operating: 54 dB (Without duplex unit and 2nd tray)
Standby: 40 dB
Power Saving: Background noise
(10) Consumable Life
Toner Cartridges: 5,000 pages (images) (5% duty, Each of Y, M, C and K)
Image Drums: 22,000 pages (images) (5% duty, Continuous printing, Each of Y, M, C
and K)
(11) Parts Replaced Periodically
Fuser Unit: Every 45,000 pages (prints)
Belt Unit: Equivalent of 50,000 pages (images) (3 pages/job)
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(12) Temperature and Relative Humidity
Temperatures Temperature condition
Celsius
10 to 32
0 to 43
-10 to 43
-29 to 50
-29 to 50
Remarks
17 to 27 Celsius (Temperatures to assure full color
print quality)
Power off
With drum and toner
With drum and without toner
With drum and toner
Operating
Non-Operating
Storage (Max. One Year)
Delivery (Max. One Month)
Delivery (Max. One Month)
Relative
Humidity (%)
20 to 80
10 to 90
10 to 90
10 to 90
Max.Wet-Bulb
Temperature (Celsius)
25
26.8
35
40
Remarks
50 to 70% (for assurance of full color
print quality)
Power off
Operating
Non-Operating
Storage
Delivery
Humidities Humidity condition
(13) Printer Life
420,000 pages (on a A4-size basis) or five years
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Oki Data CONFIDENTIAL
(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 procedure.
(4) For maintenance, use designated tools.
(5) Followtheorderinstructedtodisassembletheprinter. Incorrectordermaydamagetheparts.
(6) Small parts such as screws and collars tend to get lost, so temporarily place and fix them in
their original positions.
(7) WhenhandlingICsandcircuitboardssuchasmicroprocessors,ROMsandRAMs,donotuse
gloves that likely to have static.
(8) Do not place the printed circuit boards directly on the printer or the floor.
2. PARTS REPLACEMENT
Thissectiondescribestheprocedureforreplacingtheparts,assembliesandunitsinthefield. 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 AC cable and the interface cable.
(a) To remove the AC cable, always use the following procedure.
i) Flip the power switch of the printer off (to “O”).
ii) Pull the AC inlet plug of the AC cable out of the AC receptable.
iii) Remove the AC cable and the interface cable from the printer.
(b) To connect the printer again, always use the following procedure.
i) Connect the AC cable and the interface cable to the printer.
ii) Insert the AC inlet plug into the AC receptacle.
iii) Flip the power switch of the printer on (to “I”).
Disconnect
Connect
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Oki Data CONFIDENTIAL
[Maintenance Tools]
Table 2-1 lists tools necessary to replace the printed circuit boards and the units.
Table 2-1 Maintenance Tools
No.
No. 1-100 Philips
screwdriver
Q' ty Place of use RemarksService Tools
1
2
3
4
5
6
8
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
1
1
1
1
1
1
1
2~2.5 mm screws
3~5 mm screws
Cleans LED head
9 1
7 1
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Oki Data CONFIDENTIAL
2.2 Part Replacement Procedures
This section describes the procedures for replacing the parts and assemblies shown in the
following disassembly chart:
2.2.1 Top Cover
(1) Open the top cover assy.
(2) Remove the eight screws 1to detach the cable cover 2and the top cover 3.
1
1
1
3
2
Figure 2-2-1 Top Cover
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Oki Data CONFIDENTIAL
3
1
2
4
2.2.2 Left Side Cover
(1) Open the top cover 1.
(2) Open the feeder unit 2.
(3) Remove the screw 3to detach the left side cover 4.
Figure 2-2-2 Left Side Cover
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Oki Data CONFIDENTIAL
2.2.3 Right Side Cover
(1) Open the top cover 1.
(2) Open the feeder unit 2.
(3) Loosen the screw 3to detach the right side cover 4.
Figure 2-2-3 Right Side Cover
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Oki Data CONFIDENTIAL
1
2.2.4 Face-Up Tray
(1) Open the face-up tray 1in the direction of the arrow, and disengage it at its two places to
detach it.
Figure 2-2-4 Face-Up Tray
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Oki Data CONFIDENTIAL
2
1
2.2.5 Rear Cover
(1) Remove the two screws 1to detach the rear cover 2.
Figure 2-2-5 Rear Cover
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Oki Data CONFIDENTIAL
1
2
Hook (each side)
3
2.2.6 LED Assy / LED Assy Springs
(1) Open the top cover 1.
(2) Removethecableconnectionof,anddisengagethetwohooksof,theLEDassy2todetach
the assy (the two springs 3become detached together with the LED Assy 2).
Figure 2-2-6 LED Assy / LED Assy Springs
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Oki Data CONFIDENTIAL
2.2.7 Controller PWB
C5300
(1) Remove the Print Engine Controller PWB (see section 2.2.8).
(3) Remove the screw 1and then the head cable 2.
(4) Remove the eight screws 3, then detach the controller PWB 4.
Figure 2-2-7-1 Controller PWB (C5300)
1
2
4
3
×8
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