Oki C9800 Series, Service & Troubleshooting Manual

Page 1: ...turer assumes no responsibility for the results of errors beyond its control While all reasonable efforts have been made to make this document accurate and helpful as possible we make no warranty of a...

Page 2: ...tents Chapter 1 Printer Maintenance Procedures 1 1 Service Maintenance Procedures 1 2 Cleaning the Printer 1 3 Cleaning the Imaging Unit Contacts 1 4 Cleaning the LED Heads 1 5 Cleaning the Feed Rolle...

Page 3: ...just Shut Down Admin Setup Admin Setup Calibration Exit Calibration Auto Density Mode Auto BG Adjust Mode Adjust Density Adjust Registration Setup Calibration Calibrate Remove Calibration Print Statis...

Page 4: ...ity Troubleshooting Practices Light Prints in All Colors Light Print in Only One Color Blank Prints Mottled or Splotchy Prints Unexpected Colors Repeating Bands Lines Marks or Spots Random Bands Lines...

Page 5: ...Chapter 4 Troubleshooting Paper Jams 4 1 Open Cover Paper Jam Tray X Side Cover 4 2 Open Cover Paper Jam Side Cover 4 3 Open Cover Paper Jam Top Cover 4 4 Paper Jam Duplex Unit...

Page 6: ...r Fan Failure 121 Power Supply Fan Failure 127 Fuser 128 Fuser Belt 918 Duplex Fan Failure 181 919 Duplex Interface Failure 180 186 910 926 Tray 2 3 4 Com Errors 189 Inverter Unit Interface Failure 13...

Page 7: ...tion loaded Kodak Calibration Pack Clean dry lint free cloth Black light protective bag Perform these routine maintenance procedures during the course of servicing the printer Clean the feed rollers e...

Page 8: ...s 3 Turn off the printer 4 Clean all fans to remove excess dust 5 Ensure that all cover vents are clean and free of obstructions 6 Remove any debris or foreign objects from the Transfer Unit Fuser and...

Page 9: ...LED Head with a clean lint free cloth 1 5 Cleaning the Feed Rollers Clean the accumulated dust from the Feed Rollers Caution Use care not to scratch or otherwise abrade the roller surface while clean...

Page 10: ...Pages Print Pages Suspend Printing Resume Printing Print Secure Job Print Secure Job Menus Tray Configuration System Adjust Shut Down Admin Setup Admin Setup Calibration Exit Calibration Auto Density...

Page 11: ...ray Finisher Count Item Description Staple Displays total pages stapled Punch Displays total pages punched Finisher Displays total pages ejected into the finisher Supplies Life Item Description Drum C...

Page 12: ...er is 8 alphanumeric characters that can be assigned by a user Same as Asset Number of Menu Map CU Version Displays version no of CU Fiery Controller firmware Same as CU version of Menu Map PU Version...

Page 13: ...PostScript font list PCL Font List Prints PCL emulation font list Demo Page Prints a demo page E mail Log Prints e mail log Usage Report Prints a usage report must be activated from the Print Statist...

Page 14: ...fy a number of copies After specifying the number of copies press Enter to print all jobs with the specified number of copies Delete When you select Delete you are prompted to recheck by Yes No displa...

Page 15: ...e is 2 00 to 2 00 mm Vertically Default is 0 00mm Duplex X Adjust During the flip side printing of duplex printing adjusts the position of the whole printing image 0 25 mm at a time Range is 2 00 to 2...

Page 16: ...p Exits Setup Menu Server Setup See configuration sheet under Server Setup Network Setup See configuration sheet under Network Setup Parallel Setup See configuration sheet under Parallel Setup USB Set...

Page 17: ...tion Auto BG Adjust Mode Off 1 0 1 2 Adjustment of the Auto Background Adjust Density Item Description Adjust Density Yes No Select yes to execute density adjustment Adjust Registration Item Descripti...

Page 18: ...Screen Affects all Contin Yes No removes previous Calibration 12X6 Dot Screen Affects all Contin Yes No removes previous Calibration 12X6 Line Screen Affects all Contin Yes No removes previous Calibra...

Page 19: ...ation ID Check Pattern and Engine Status of the Function Menu If this item is disabled the Print Information ID Check Pattern and Engine Status of the Function Menu is never displayed The printer is r...

Page 20: ...n Arrow Scrolls down one menu item within a menu list Used to decrement data in tests requiring user input _____________________________________________________________________ Enter Enters the highli...

Page 21: ...onds FACEDOWN SOLENOID Face Down solenoid ON OFF for 10 seconds EXIT SOLENOID Exit solenoid ON OFF for 10 seconds MPT LIFT UP Runs the MPT tray lift up motor MPT MOTOR Runs the MPT tray paper feed mot...

Page 22: ...0 seconds INV SEPARATER Inverter Separator Clutch ON OFF for 10 seconds INV MOTOR B Runs the Inverter Motor B for 10 Seconds INV MOTOR A Runs the Inverter Motor A for 10 Seconds 2 5 Accessing the Swit...

Page 23: ...ull Sensor Face down H Full L Empty Stacker Full Sensor Face up H Full L Empty Job Offset Paper End Sensor H ON L OFF Job Offset Home Pos Sensor H ON L OFF REG L R_ DENS_WEIGHT Alignment Left Sensor A...

Page 24: ...Level H L 2nd Paper Size 4 Switch Port Level H L TRAY3 PE_PNE_CVO 3rd Paper End Sensor Port Level H L 3rd Paper Near End Port Level H L Cover Open 3rd Switch Port Level H L TRAY3 HOP_LIFT_FEED 3rd Ho...

Page 25: ...the home position Feed roller home position Sensor H Home position L Not in the home position Paddle home position PI2 H Home position L Not in the home position FIN S17_S18_ S19_S20 Staple fold moto...

Page 26: ...screen in order to execute the Adjust Density procedure 4 Next press the Down Arrow button down until Calibrate is highlighted and press the Enter button 5 In the Screen Setting window press the Down...

Page 27: ...tor on Laptop 1 2 or 2 0 High Power for the ES 1000 Step 1 Setting up the Service Laptop to communicate with the printer Set up the Service Laptop computer via the crossover cable to the printer Step...

Page 28: ...address and select Add If the device does not appear temporarily turn off all filtering Virus software on your laptop and try again The following screen will appear Select the watch icon and the Comm...

Page 29: ...Select the Administrator Key and select Log In You have now successfully logged in to Command Workstation C9800 9800A3 192 168 XX XX...

Page 30: ...Step 3 Setting up the ES 1000 Spectrophotometer...

Page 31: ...Once installation is complete re launch Command Workstation...

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Page 46: ...ine See the Repeating Defects chart When a single component of the Imaging Unit is causing a print quality defect replace the Imaging Unit When analyzing a print quality defect first determine if the...

Page 47: ...from the printer and to assist in troubleshooting The next section shows how to generate and analyze test prints 3 2 Generating and Analyzing Control Panel Test Prints Control panel test prints must...

Page 48: ...aper travel Uneven Density Voids Repeating Defects Mis registration Note Consult the Repeating Defect Spacing Chart below Repeating Defects Spacing Component Defect Spacing Replace Imaging Drum 94 mm...

Page 49: ...wering up the printer unit This may take up to 60 seconds The System Maintenance Menu will appear Down Arrow to Diagnostic Mode and press Enter Down arrow to Test Print and Select Enter Print Execute...

Page 50: ...To turn On Off the individual colors use the On Line key Once the desired color menu is set Select Enter Page down to Page Select Enter Select the number of prints desired Select Enter Page down to Ca...

Page 51: ...sing could indicate the incorrect paper weight has been selected Generating and Analyzing 25 Color Fill Test Pages The following print consists of 25 fill in CMYK Follow the service mode procedure abo...

Page 52: ...l colors thin white lines dark lines Color registration Comparing with the previous Demo page will ensure consistent output that will match the customer s expectations 1 3 2 4 1 Color Registration Hor...

Page 53: ...l Print the PS Test and Demo pages to see if it is an application problem Run the color calibration routine from Chapter 2 Note For troubleshooting purposes it is important to note the direction of pa...

Page 54: ...ing Steps Resolution 1 Verify all packaging material has been removed form the toner cartridges Yes Go to Step 2 No Remove packing material 2 Remove the Imaging Units and the Transfer Unit and check f...

Page 55: ...solated to one primary color Yes Go to Step 3 No Light Print in Only One Color 3 Remove the Toner Cartridge and check for toner starvation in the Imaging Unit Is there evidence of toner starvation Yes...

Page 56: ...ere application and printer settings 2 Remove the Toner Cartridge and check for toner starvation inside the Imaging Unit Is there evidence of toner starvation Yes Replace the Toner Cartridge No Go to...

Page 57: ...e loaded media Try different media to verify consistent reproducible problem Yes Go to Step 2 No Have the customer load approved media or correct the settings 2 Print the configuration page to verify...

Page 58: ...No Go to Step 6 4 Is there debris or contamination on the LED Head Yes Clean them with a dry lint free cloth No Go to Step 5 5 Swap the LED Head of the problem color with any other LED Head Print a So...

Page 59: ...to the Repeating Defects table Below to identify the problem component Areas of the Printer that Apply to Repeating Bands Lines Marks or Spots Imaging Unit Fuser Transfer Unit Note Consult the Repeati...

Page 60: ...can also be associated with Cold Offset which lifts toner off the page in certain areas Usually this will occur in high coverage areas where the fuser temperature is not high enough to fuse the toner...

Page 61: ...nter that Apply to Random Spots Imaging Unit Fuser Transfer Roller Troubleshooting Steps Resolution 1 Is there toner spilled inside the printer Yes Vacuum inside the printer and remove all visible ton...

Page 62: ...of toner across the surface of the drum Yes Replace the Imaging Unit No Go to Step 4 4 Verify the printer is operating within its environmental specifications Low humidity increases the degree of bac...

Page 63: ...from Print Quality Troubleshooting Practices Verify the correct media type is set at the Control Panel Print an internal test page to see if ghosting appears there as well Try printing with fresh med...

Page 64: ...Media Thickness Sensor Troubleshooting Steps Resolution 1 Remove the Fuser covers and inspect for debris between the rollers Is there dirt or debris wrapped around or on the Fuser rollers Yes Replace...

Page 65: ...Is the shutter functioning correctly Yes Go to Step 4 No Replace the solenoid and wiring harness 4 Inspect the Transfer Unit for tears or damage on the edges of the belt Is the belt damaged Yes Replac...

Page 66: ...the problem color with any other LED Head Print a Supplies page Has the problem moved with the LED Head Yes Replace the defective LED Head No Go to Step14 14 Replace the Registration Sensor Board Did...

Page 67: ...rify the printer is operating within its environmental specifications Yes Go to Step 3 No Advise customer on the specifications 3 Inspect the Transfer Unit Has the cleaning blade flipped or failing to...

Page 68: ...gainst the paper Yes Go to Step 3 No Adjust the guides 3 Verify the size of media reported by the printer is the actual size Yes Go to Step 7 No Go to Step 4 4 Test the Paper Size Switches Run the Ser...

Page 69: ...nit belt Troubleshooting Steps Resolution 1 Print the 100 Solid Fill Test print Is the problem with one primary color Yes Replace the defective Imaging Unit No Go to Step 2 2 Is the paper wrinkled dim...

Page 70: ...or debris in the printer s paper path Yes Clean or remove obstructions No Go to Step 3 3 Clean the LED Heads with at dry lint free cloth Did this fix the problem Yes Complete No Go to Step 4 4 Remove...

Page 71: ...rint the Color Test Pages Does the problem occur in one primary color Yes Replace the Imaging Unit of the defective color No Go to Step 2 2 Inspect the Transfer Unit Has the cleaning blade flipped or...

Page 72: ...om the printers Control Panel Did this fix the problem Yes Complete No Go to Step 2 2 Are there any obstructions dirt or debris in the printer s paper path Check for toner spills Yes Clean and remove...

Page 73: ...Chapter 4 Troubleshooting Paper Jams 4 1 Open Cover Paper Jam Tray X Side Cover 4 2 Open Cover Paper Jam Side Cover 4 3 Open Cover Paper Jam Top Cover 4 4 Paper Jam Duplex Unit...

Page 74: ...4 1 Open Cover Paper Jam Tray X Side Cover Squeeze the catch on tray X side cover 1 and open the cover Holding it by the tab 2 turn the paper guide outward 1 2...

Page 75: ...Return the paper guide back into position and close the cover Carefully remove the jammed paper 4 3...

Page 76: ...4 2 Open Cover Paper Jam Side Cover Pull the release lever 2 and open the side cover If the MP tray is open close it so that the side cover 1 is visible 2 1...

Page 77: ...Close the side cover Carefully remove the jammed paper 4 3...

Page 78: ...4 3 Open Cover Paper Jam Top Cover Squeeze the basket handle and raise the drum basket Squeeze the top cover handle 1 and open the top cover 1 2...

Page 79: ...in the fuser unit push the lock lever 3 in the direction shown to release it Carefully remove any paper on the belt Holding the fuser unit 4 by the handle lift it out of the printer and place it on a...

Page 80: ...Pull the jam release levers 5 and remove the paper Carefully replace the fuser unit into the printer and turn the lock lever in the direction shown to lock the fuser unit 7 6...

Page 81: ...Open the side cover paper exit 8 and remove the jammed paper If paper is jammed near the paper exit open the face up stacker 7 9 8...

Page 82: ...Close the side cover and then the face up stacker Return the drum basket 9 into position and check that it is locked 11 10...

Page 83: ...Close the top cover and ensure that it is latched 12...

Page 84: ...4 4 Paper Jam Duplex Unit Operate the duplex cover release lever 2 and open the duplex co e Carefully remove any jammed paper 1 2...

Page 85: ...Operate the levers 3 and pull out the duplex unit Holding the front top cover by the grip 4 push it gently inwards and raise it 4 3...

Page 86: ...In a similar manner check for and clear any jammed paper in the rear cover Remove any jammed paper 6 5...

Page 87: ...Raise the front cover of the duplex unit Replace the two top covers 8 7...

Page 88: ...Push the duplex unit back into position 9...

Page 89: ...MM Replace RAM DIMM Replace Fiery PCB must move EEPROM to new board 032 CU Slot 2 DIMM RAM Check Error Re mount RAM DIMM Replace RAM DIMM Replace CU PCB must move EEPROM to new board 036 Slot 1 RAM Sp...

Page 90: ...ntrol Board and Engine Board Replace CU PCB must replace EEPROM Replace PU PCB 073 to 075 Video Overrun Detected Check Connections Replace CU PCB must replace EEPROM 081 Parameter Match Check Error If...

Page 91: ...or See Fuser Fan Failure page 111 128 Engine Fan Motor Error 01 Fuser Fan 02 Power Fan 03 PU Motor Fan 04 Belt Fan 05 ID Fan 06 Top Cover Fan See Fan Failure page 106 131 to 134 LED Head Error 131 Y H...

Page 92: ...e Motor Driver Board Engine Control Board 189 Inverter Unit I F Error See Inverter Unit Interface Failure page 109 190 System Memory Overflow Replace CU PCB must replace EEPROM 200 to 202 PU Firmware...

Page 93: ...2 C 353 K See ID Unit Life Error page 132 354 Fuser Life Error See Fuser Life Error page 133 355 Belt Life Error See Belt Life Error page 134 360 Double Side Printer Unit Error See Unsupported Duplex...

Page 94: ...Tray5 Check Sensor Connections Replace Motor See Tray 1 2 3 4 Communication Errors page 108 917 Belt Slit Sensor Error Check Belt Unit is Turning Check Sensor Connections See Error in the Transfer Bel...

Page 95: ...nual 096 01 Paper Eject Motor Error Check All Connections Check Replace Motor Replace Finisher Control PCB 096 02 Tray Raise Lower Error Replace Shift Motor Finisher Controller as a set Check Clean Re...

Page 96: ...ce Error Check All Connections Check Replace Interface Cable Replace Finisher Control PCB Replace Engine PCB Self Diagnostic Error Codes Other Codes Code Cause Description Remedy 0101 to 0104 The data...

Page 97: ...power 3 Check the Fiery Control Board LED s for a fault indication 4 Systematically remove all printer options to isolate a possible problem component Printer Continually Displays Warming Up or Initia...

Page 98: ...g to the position of the tray s paper guides Upon installation of the tray the plate s position actuates the Paper Size Switch A Paper Size Mismatch error or Tray Missing error are sometimes the resul...

Page 99: ...wer 3 Test wall Voltage Parts of the Printer that Apply 1 Fuser 2 LVPS 3 Engine Control Board Troubleshooting Procedure Steps Action Taken Yes No 1 Replace the Fuser Does the error persist Go to Step...

Page 100: ...Board Troubleshooting Procedure Steps Action Taken Yes No 1 Test the Temp Humidity Sensor 1 Run the Scan Switch Test HUM_TEMP_OHP 2 Verify proper operation by blowing on the sensor Is the sensor opera...

Page 101: ...e procedure below Parts of the Printer that Apply 1 Imaging Unit Motors 2 Motor Driver Board Troubleshooting Procedure Steps Action Taken Yes No 1 Test the cooling fans for proper operation and adequa...

Page 102: ...w the procedure below Parts of the Printer that Apply 1 Engine Control Board EEPROM 2 Engine Control Board Troubleshooting Procedure Steps Action Taken Yes No 1 Cycle power to the printer Does the err...

Page 103: ...e Printer that Apply 1 LVPS Troubleshooting Procedure Steps Action Taken Yes No 1 Visually inspect the LVPS for damage or excessive dust Is the LVPS damaged or dirty Clean the LVPS if dirty If damaged...

Page 104: ...ken Yes No 1 Test the cooling fan for proper operation and adequate airflow Run the Motor Clutch Fan test Does the fan operate correctly Replace the Engine Control Board Go to Step 2 2 Check for 5 V t...

Page 105: ...n Run the Motor Clutch Test FAN POWER Does the Fan operate correctly Replace the Engine Control Board Go to Step 2 2 Check the LVPS Fan connection Is the fan securely connected Go to Step 3 Reconnect...

Page 106: ...of 30 minutes for cooling 4 Restart the printer 5 If the problem persists follow the procedure below 1 Fan Associated with the code 2 Engine Control Board Steps Action Taken Yes No 1 Test the cooling...

Page 107: ...e the Duplex Unit If the error persists go to Step 2 2 Check all pins on the DUPLEX Wiring Harness for continuity Disconnect the DUPLEX Harness Is the DUPLEX Harness conductive Replace the Motor Drive...

Page 108: ...below 1 High Capacity Feeder Control Board 2 Engine Control Board Steps Action Taken Yes No 1 Check the Hi Cap connector for damage Is the connector damaged Replace the connector Go to Step 2 2 Check...

Page 109: ...r Cord Is there any damage Replace any damaged parts Go to Step 2 2 Check the Inverter connection Is the Inverter interface cable securely connected at both ends Go to Step 3 Connect the Inverter to t...

Page 110: ...p 2 2 Ensure the LED Head harness is properly connected and not damaged Is the wiring harness defective Reconnect or replace the wiring harness Go to Step 3 3 Check harness continuity between the LED...

Page 111: ...ol Board Steps Action Taken Yes No 1 Test the cooling fan for proper operation and adequate airflow Run the Motor Clutch Fan test Does the fan operate correctly Replace the Engine Control Board Check...

Page 112: ...e procedure below 1 Fuser 2 Engine Control Board Steps Action Taken Yes No 1 Ensure the proper Fuser 110v vs 220v is installed in the printer Is the correct Fuser installed Replace the Engine Control...

Page 113: ...e Duplex Connector Is there any damage Replace any damaged parts Go to Step 2 2 Check that the Duplex Unit is correctly installed and fully seated Go to Step 3 Reseat the Duplex Unit 3 Check the Duple...

Page 114: ...1 Test the Fuser fuse Is the Fuse Cut Replace the Engine Control Board Go to Step 2 2 Replace the Fuser Cycle the power Does the error persist Go to Step 3 Complete 3 Check all pins of the harness bet...

Page 115: ...the Fuse cut Replace the Engine Control Board Go to Step 2 2 Check the connections between HVPS HVPS Cover and Transfer Unit Are the contacts clean and intact Install a new Transfer Unit and verify t...

Page 116: ...trol Board Steps Action Taken Yes No 1 Check the affected Imaging Drum Unit contacts for evidence of fault or damage Is there any damage debris or corrosion Replace the damaged parts Go to Step 2 2 Te...

Page 117: ...Board Steps Action Taken Yes No 1 Cycle power to the printer Does the error persist Go to Step 2 Complete 2 Reseat the Fiery Control Board to the Engine Board Does the error persist Replace the Engin...

Page 118: ...nterface Cable Power Cord Finisher connections Is there any damage Check the following for evidence of fault or damage Finisher Interface Cable Finisher connections Is there any damage Go to Step 2 2...

Page 119: ...wer Cord Inverter Power Supply Is there any damage Replace any damaged parts Go to Step 2 2 Check AC Power Is the AC voltage available at the outlet Go to Step 3 Advise customer 3 Check the Inverter c...

Page 120: ...n Is the Control Panel Harness connected to the Engine Control Board Go to Step 2 Connect the Control Panel harness 2 Check all pins on the Control Panel Harness for continuity Disconnect the harness...

Page 121: ...Interlock Switches for the test 2 Run the Motor Clutch test to test the Transfer Belt Motor Does the motor operate Replace the Transfer Unit If the error persists go to Step 3 Replace the motor If th...

Page 122: ...it Lift Up Down Mechanism Is there any damage Replace any damaged parts Go to Step 2 2 Test the Drum Phase Sensor Run the Scan Switch test for the indicated Imaging Unit Does the sensor function corre...

Page 123: ...go to Step 6 Check the Up Down Mechanism and associated gears See Drive Motors for a description of Up Down Mechanism operation 1 Access the Cyan Unit Motor 2 Rotate the Cyan Motor manually in both di...

Page 124: ...U Flash Memory 248 Inverter Flash Memory 1 Cycle the printer s power 2 If the problem persists follow the procedure below 1 Engine Control Board Steps Action Taken Yes No 1 Cycle power to the printer...

Page 125: ...ntrol Board Steps Action Taken Yes No 1 Check for evidence of fault or damage to the indicated unit Is there damage evident Replace any damaged parts Go to step 2 2 Go to Step 3 3 Replace the Engine C...

Page 126: ...t the affected Toner Motor 1 Remove the Toner Cartridge 2 Run the motor Clutch test to test the Toner Supply Motor test Does the motor rotate Go to Step 3 Replace the motor If the error persists repla...

Page 127: ...Test the Registration Motor Run the Motor Clutch test to test the motor Is the motor operating correctly Replace the MPT Assembly Replace the Registration Motor 3 Test the MPT Home Position Sensor Run...

Page 128: ...up any compacted toner Reinstall the cartridge Does the error persist Go to Step 3 Complete 3 Check the RFID Harness continuity 1 Remove the Top Cover 2 Disconnect the RFID cable from the RFID and on...

Page 129: ...Step 2 Replace the Engine Control Board 2 Test the Up Down Motor 1 Remove the Image Drum Units 2 Run the motor Clutch test to test the Up Down Motor Does the motor rotate Does the Up Down mechanism m...

Page 130: ...Go to Step 2 2 Test the Top Cover Interlock Switch Run the Scan Switch test to test the Switch Does the switch function correctly Replace the Engine Control Board Go to Step 3 3 Replace the Top Cover...

Page 131: ...age Fuser Fuser Connector Fuser Release Sensor Is there any damage Replace any damaged parts and then cycle printer power Replace the Fuser If the error persists Go to Step 2 2 Test the Fuser Release...

Page 132: ...sts follow the procedure below 1 C M Y K Imaging Unit 2 Engine Control Board Steps Action Taken Yes No 1 Generate a Configuration Page and check the indicated Drum Life counter under Supply Life Does...

Page 133: ...w 1 Fuser Unit 2 Engine Control Board Steps Action Taken Yes No 1 Generate a Configuration Page and check the indicated Fuser Life counter under Supply Life Does the counter indicate end of life Repla...

Page 134: ...1 Transfer Unit 2 Engine Control Board Steps Action Taken Yes No 1 Generate a Configuration Page and check the indicated Belt Life counter under Supply Life Does the counter indicate end of life Repla...

Page 135: ...Oki Toner Cartridge is installed Go to Step 3 Complete 3 Check all pins of the RFID Harness for continuity Remove the Top Cover Disconnect the RFID cable from the RFID reader board and the Engine Con...