OKI C911 / 931 / 941 Disassembly & Reassembly Procedures Distributed at the Oki Data C900 Series Service Classes Oki Data Training Department REV. 1.60 2000 Bishops Gate Blvd. Mt. Laurel, NJ 08054
Copyright 2014 by Oki Data Americas, Inc. All Rights Reserved. This document describes the disassembly of the Oki Data C900 series of printers. It is to be used during Oki Data Service Training. It is not designed to be a self-directed course, as Oki Data Trainers will provide additional information as required during the course. We are not responsible for typographical errors nor or we responsible for manufacturing changes that are considered part of a products life cycle. This document is being provided in conjunction with an Oki Data sponsored and instructor led course. Be aware that the machine you are working with may have already been disassembled, resulting in parts and / or screws being incorrectly replaced. You are responsible for your own personal safety as you work through this course. You are expected to know how to safely operate, disassemble, and repair machines of this type. Oki Data is providing disassembly, troubleshooting, repair and reassembly instructions specific to this series of printers. Oki Data assumes that each student has already demonstrated their knowledge of basic electronics, troubleshooting, disassembly and reassembly of this type of equipment. Important Safety Notes: This product generates potentially lethal voltages. While Oki Data has made every attempt to insure safe operation and voltage interruption by installing safety circuits, it is possible to by-pass these safety circuits. Oki Data will not be responsible for the safety of any attendee who knowingly by-passes any of these safety devices. The printer units are very heavy. The C911 printer weighs approximately 230 pounds. Safe lifting techniques are required and Oki Data assumes that the attendee is versed in established safe lifting techniques. These printers contain large amounts of metal that may have sharp edges or burrs on edges. Oki Data assumes no liability for carelessness that results in injuries to attendees. In short Be Aware Be Careful - Don t Fool Around! If you are unsure of something ask the Oki Data Trainer before continuing. Follow the disassembly instructions as they are written to insure your safety as well as your successful disassembly/reassembly of the printer(s) you ll be working with. II
1 All printer directions refer from front of printer IMPORTANT: Please keep all screws with the parts they came out of and during reassembly pay careful attention to installing the correct screw color and size. If you have leftover screws please return them to the instructors before the printers are re-packed. Front Left Side Rear Right Side 2 Lift the toner cartridge cover to view the installed toner cartridges. NOTE: The C911 / C931 each have 4 toner cartridges and drums while the C941 has 5 toner cartridges and drums. 1
3 Remove all toner cartridges by lifting the front edge and slowly pulling it out. You will see a blue handle on top of the toner of the toner cartridge when it is about half way out. Lift and support the toner cartridge by this handle. 4 Open the front door to reveal the installed drums. Remove the drums by lifting the front edge and pulling the drum out. As you slowly pull the drum out, grab the drum as shown to fully remove and support the drum as you remove it. CAUTION: Never grab the drum assembly around the bottom as your hands / fingers may touch the surface of the drum, leaving oil on the drum surface. NOTE: Never wipe the drum surface with anything! 2
5 Remove waste toner bottle by pulling the handle on the end of the waste toner bottle. As you remove the waster toner bottle, you will see a handle in the middle of the bottle. Grab and support the waste toner bottle by this handle to fully remove it from the printer. 6 Remove Belt Unit: On either side of the belt assembly are blue captive locks. Gently twist these 2 locks and lower the locking handles. Grasp the blue handle and move it to the right to unlock the transfer belt assembly 3
7 Grasp both transfer belt handles and gently pull the transfer belt assembly from the printer. About 2/3 of the way removed you will feel resistance just lift the belt assembly slightly to clear these safety stops. After removing the transfer belt assembly, push the blue handle to the left and close and re-lock the locking handles, Unlocked in Step 6. Failure to re-lock the 2 lock levers prior to closing the front drum door may break the lock levers or the front drum door! CAUTION: Do Not place the image belt in any position other than horizontal as you may create a toner spill if you do. Place the belt on a clean, smooth surface to protect the transfer belt from contamination. CAUTION: Do Not Touch the belt surface as you will leave fingerprints and this may cause printed image problems. 8 Steps 3 through 7 are required to clean and service the LED Print heads in the printer. Close the front drum door. 4
9 Remove the paper cassette by pulling the drawer straight out and lifting it slightly. 10 Remove toner cover door by removing the 4 black screws and gently lifting and pulling the door away from the printer. 11 Remove Operator Panel by removing the 2 black screws. 5
12 Gently lift the operator panel. Caution there are 2 wire harnesses attached to the rear of the operator panel. Reassembly Warning: It is very easy to unplug one of these connectors when reattaching the operator panel during reassembly. If the cable(s) are disconnected, symptoms may be no display and no initialization when powered up. 13 Unplug the 2 wire harnesses from the operator control panel board. 14 On the left side, remove the duplexer by lifting the handle and sliding it out. Caution: The duplexer on the C900 series is very short, so support it as you remove it. 6
15 Remove the 4 screws (2 on the outside / 2 on the inside) of the cover below the duplexer. 16 Remove the plastic cover. 17 Remove lower left cover which is held in by 2 screws and 4 tabs. NOTE: Metal plate which was removed in the previous step is still present in this picture. 18 Remove the low voltage power supply cover, which is secured by 3 screws and 4 tabs. Gently lift the corner over the main power switch. 7
19 On the rear cover, remove the HDD access cover w/1 captive screw. 20 Remove 7 sliver screws from the rear cover. There is also a tab on the left side of the printer, near the power switch, that you must depress to remove the cover. Release that tab and gently lift the cover over the lift handle extension on the side and slide off to remove. NOTE: Some units may have 1 additional screw in the middle of the back cover. 21 There are 2 tabs holding the offset cover in place, 1 in the rear of the printer and one at the front of the printer shown on next page. 8
Releasing the front offset cover tab. 22 Gently release these tabs and remove the offset cover. 23 Remove the stacker full lever which is clipped in. 9
24 Remove the photo interrupter sensor from the job offset assembly. It is clipped in with 3 tabs. 25 Unthread the photo interrupter sensor wiring harness and let hang over the rear of the printer. 26 Remove 3 screws securing the job offset into the printer. 1 short screw on the top frame and 2 longer screws into the base frame 1 in the rear and 1 in the front. (Front screw is shown on next page) 10
Front screw securing the job offset mechanism to the printer. 27 Gently lift and remove the job offset mechanism. 11
28 Remove 3 screws holding the top cover. 2 in the front 1 at right and one 1 left, facing down to the frame. 3 rd screw is at rear, facing down into the frame. 29 There are 4 tabs holding the top cover to the toner cartridge separators. Disengage the 4 tabs and lift the top cover off. 30 Open the paper jam door and remove it by gently spreading left side hinge pin and removing the door from the frame. 12
31 Open the eject assembly and pull the drawer out from the printer. 32 Lift the blue lock tab and remove the fuser by lifting it straight up. 33 Loosen the 9 screws on the rear shield plate, slide the shield to the left and slide the shield plate from the printer. 13
34 On the engine board (FIY2) locate the MPTIF connector (12 wire connector with purple cables) and gently unplug it. Unthread this cable / connector from the wire bundles and gently pull it towards the MPT assembly. 35 Remove the lift handle from the rear by removing 3 screws and unthreading the wire bundles from the handle assembly. 36 Remove 3 screws from the right side lower access cover. 37 Unclip the right side of the lower access cover by squeezing the clip. 14
38 From the paper tray opening, slip a small screw driver in to press and release the 2 tabs on the left side of the lower access cover. Remove the access cover. 39 Slide the paper guide towards the front of the printer to remove. 40 Open the front drum cover panel. 15
41 Open the multi-purpose paper tray (MPT) unit. 42 Locate the black plastic cover on the side frame. 16
43 Lift the tab on the black plastic cover (as shown in the last photo) and slide the plastic cover down and remove it. 44 Remove the 4 screws securing the multipurpose tray unit to the printer. Be Careful It may slip! 17
45 Ensure the 12 purple wire bundle and connector have plenty of slack in it and slowly pull the multi-purpose tray unit from the printer. NOTE: The following step is only necessary on the C911 / C931 46 Remove the fifth station guard by removing 1 black screw and unclip from the printer frame, left and top. NOTE: Production units may have this screw located in slightly different location. 18
47 Remove the black plastic wire guard on the left of the printer frame by removing 1 silver screw and lifting 1 tab on the bottom of the guard. CAUTION: The tab on the bottom of this guard can be easily broken. Gently lift the guard while you are removing it. 48 Disconnect 3 wire harnesses: (1) 9 pin red; (1) 6 pin red; and (1) purple along the printer frame. 19
CAUTION: Ensure the front drum door is supported! 49 Remove 3 screws from left and right side door frames. NOTE: There are white plastic clips (photo below, at left) on the left and right drum door hinges (arrow callouts). Do not remove them just ensure that these are in place during reassembly! 50 Gently unclip the left and right side door frames from the front door and remove the assembly. Be careful to also remove the 3 wire harnesses on the left side of the door. Gently close both the left and right side door frames. 20
51 On the right side, inside the MPT cavity, release 1 tab and slide the black plastic wiring protector to the printer s right. 52 Unplug the 13 pin purple wire connector from the registration sensor. NOTE: This is a plastic connector that is attached to the printer frame. Do Not Stress this connector when unplugging or plugging it in during reassembly! 53 Gently release the 3 tabs at the bottom of the black shield, and lift the shield outward from the bottom to release the 3 tabs at the top of the frame. Remove the black shield by sliding it down. 21
54 Remove the 3 black screws at the top of the metal guide, and the 4 silver screws as shown at right and remove the metal guide plate. 55 On the front of the printer, pull the right side door frame down. 56 Remove the black plastic cover on the paper guide frame by removing 2 black screws. Gently re-close the right side door frame 57 Remove 1 silver screw from the front and 2 silver screws from the rear of the registration plate. 22
58 Disengage the registration plate from the 2 locator pins on the front of the printer frame and 2 more on the rear of the printer frame and remove this assembly. 59 From the printer right side, remove the black plastic paper guide by removing 2 silver screws and pulling this guide out. 60 From the printer right side, unplug the 3 connectors from the frame as shown at right. 23
61 Unplug the 3 pin purple connector from the paper sensor 62 From the front of the printer, remove 1 silver screw from the front of the plate and 2 screws from the rear of the plate. 63 Make sure the eject assembly drawer is pulled out from the printer. Gently lift the registration roller / media thickness assembly, lifting at the rear first. CAUTION: This assembly contains an optical sensor / flag assembly which can be easily damaged. 24
64 Within the printer, remove 2 silver screws 1 at the front and one at the rear. 65 Gently lift the roller / synchro assembly. NOTE: After you lift the assembly you will see a 2 wire, white cable assembly in the middle of the assembly. Unplug this connector and gently remove the roller / synchro assembly. This is an optical sensor which can be damaged if mishandled. Do Not Forget to reconnect this when reassembling the unit! 66 Remove 4 silver screws from the side frame. 25
67 Remove 4 black screws under the hopping unit. 68 Unplug 7 wire (purple) connector from main board (TRAY SNS). Unplug 2 wire (red) connector from main board (HOP CL). Unplug 2 wire (red) connector from main board (REG ICL). Unplug 4 wire (red) connector from main board (HOP M). 69 Unthread these harnesses from the wire guide & frame. 70 Slide the hopping unit out as you guide the wire harness out. 71 On the back of the unit, remove 3 silver screws securing the metal sub-assembly shield. 26
72 Lift the shield over the 2 tabs at the top and remove the shield. 73 Unplug the toner supply motor connector on the sub-assembly board. NOTE: These cables are wrapped around the sub-assembly board. 74 On the front of the printer, locate the 1 st station toner block plastic piece to the left of the yellow station and unsnap to remove. Note: This only applies to the C911 / C931 models. 27
75 NOTE: The yellow station is the one nearest the paper exit. The yellow station has 7 screws 1 at the rear far left side, 1 at the front, 2 at the rear and 3 that secure the duct assembly to the toner cartridge guide assembly. There are also 2 clips to be released at the front of the guide assembly. NOTE: DO NOT SEPARATE THE DUCT ASSEMBLY FROM THE TONER CARTRIDGE GUIDE ASSEMBLY! 76 Starting at the left most station (yellow in this model) and gently lift the station out. CAUTION: There is a cable on the rear of each station. NOTE: Cartridge Guides are removed left to right (Spot Yellow Magenta Cyan Black). They Must Be Reinstalled Right to Left! Black (right most) Cyan Magenta Yellow Spot (left most). 28
77 Remove the remaining ducts (Magenta Cyan Black, in that order). NOTE: There are only 5 screws in each of the remaining ducts the left rear screw is not present on these ducts! 78 With the ducts removed, you will see the duct support tray. There are 5 screws that will be removed. NOTE: Screw in left front corner is also grounding for the Op Panel cables, as shown below. 79 This screw goes through the ground / locking collar for one of the Op Panel Cables. Do Not Forget to reattach this collar during reassembly. 80 There are 10 (C941 Only) or 8 duct support tray clips that are removed by sliding them out. The C911 and C931 clips are outlined in red while the C941 additional 2 clips are outlined in blue. 81 To remove the clips, slide them towards the front of the printer. NOTE: Do Not Lose these clips they secure the LED Mounting brackets and are critical! 29
82 In the left rear corner of the duct support tray there is a 2 wire connector. Gently pull the purple & white connector and set it aside. NOTE: A C941 has 3 connectors in this position that must be unplugged. 83 Grasp the duct support tray and gently lift it up. You will need to flex the black plastic cover on the right front edge of the frame to clear it. 84 Lift the duct support tray until the tabs at the rear of the duct support tray clear the printer frame. At this point the duct support tray can be removed. 85 The green highlighted area shows the LED Print Head cables and the bend they take to pass through the frame and into the PU / CU Board area. It also shows the cable supports as they run under the duct support tray and to the LED Print Head assemblies. NOTE: The LED Print Head Cable connectors are fragile. The following page shows how to successfully release the LED Print Head / PU / CU Board cable connectors. Be Very Careful when unplugging and plugging these cables into the connectors. Any contacts removed will create Fatal Errors and require replacement of the LED Print Head cable. 30
86 There are 8 ribbon cables to disconnect. NOTE: The LED Print Head cables have locking tabs that must be unlocked prior to unplugging / plugging in! See the photos and text below NOTE: The LED Print Head cable connectors look like this when the cables are removed. Cables are inserted with the locks in the unlocked position and then the tab is gently swung down to lock the cable in position. These tabs are easily dislodged so treat them gently! Unlocked Position Locked Position Unlocked Position Unlocked Position 31
CAUTION: The LED Print Head cables are easily damaged. Make sure you unlock the board / head connector tabs before you remove / reinstall the head cables. Damaged cables will cause errors on power up. As you can see, the cable at the right has 3 damaged connectors and the only solution is to replace the damaged cable. 87 There are 20 wire harness cables to disconnect. 88 Gently unplug all harnesses and cables from the main logic board. NOTE: Pay attention to how the wires are routed to and through the card cage for re-assembly procedures. 32
89 Remove 1 screw securing the USB port to the card cage / frame. 90 Remove 9 silver screws from the main logic board and gently remove the main logic board. 33
91 Gently disconnect the cable clips securing the cable harnesses to the card cage and carefully unthread the cable harnesses from the card cage. 92 Unplug the cables in the POW24 cable guide from board F1D. 93 Remove the 6 silver screws securing the card cage to the frame. 34
94 Gently unsnap the black cable guide from the top edge of the card. 95 Carefully remove the card cage and gently unthread all wire harnesses. 96 Remove the plastic insulator sheet by unsnapping the 3 plastic tabs at the bottom of the insulator sheet. 97 Remove 5 black screws and 1 silver screw holding the HVPS board to the frame. Gently unclip the 5 plastic tabs holding the HVPS board in place. 35
98 Unplug 2 Red wire cable connector form the board. Note there is still a ribbon cable attached to the board. Unplug this ribbon connector and remove the HVPS board from the printer. 99 On the front of the printer, gently pull the drum door frames into the open position. This will lift the motors to allow access to the screw securing them to the printer. NOTE: Each motor is held in place by 5 screws and has 2 wire harnesses attached except black, which only has one 10 pin wire harness connector. 100 On the left most motor (black) disconnect the 10 pin connector from the motor board. While supporting the drum motor, remove 5 screws that secure the motor to the frame. NOTE: DO NOT SPIN THE FLYWHEELS WHEN THE ASSEMBLY IS REMOVED FROM THE PRINTER! IT WILL CAUSE A DRUM LIFT FAILURE IN ANY OF THE COLOR MOTORS! 36
101 Reinstall the motor and screws, starting at the top and working your way down to the bottom screw. 102 On the left side of the printer, remove 1 silver screw from the black plastic securing the power switch to the frame. Remove the black plastic piece. 37
103 Gently release the power switch from the frame. 104 Remove the 8 silver screws & 6 black screws from the low voltage power supply. 105 As you pull the power supply out, you will see 3 wire harnesses connected. Unplug the harnesses and remove the low voltage power supply assembly. You Do Not need to remove the cables just reinstall the low voltage power supply. 106 Start Reassembly. FOLLOW THE DISASSEMBLY DIRECTIONS IN REVERSE TO REASSEMBLE THE PRINTER. NOTES for a Successful Reassembly: Ensure that you do not pinch / crimp wire harnesses as you reassemble the printer. Make sure that you are replacing the correct screws into the correct assemblies. Do Not Switch Black and Silver screws. TAKE YOUR TIME! If you are unsure - Ask Questions! 38