OKI proColor™ A3/C9 Engine

Service Training & Disassembly Procedures

DISTRIBUTED AT THE PROCOLOR SERVICE TRAINING CLASSES

OKI DATA TRAINING DEPARTMENT REV. 3.21

2000 Bishops Gate Blvd.
Mt. Laurel, NJ 08054
Copyright 2013 by Oki Data Americas, Inc. All Rights Reserved.

This document describes the disassembly of the Oki Data A3/C9 series of printer
engines. 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 printer weighs approximately 190 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.

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Course Instructions:
1. The Oki Data A3/C9 printer engine weighs almost 200 pounds, so use
caution and common sense when lifting, moving, or placing it on a
surface.

2. Follow the procedures as they are written.

3. If you encounter any problems, notify the instructor.

4. NOTE: steel screws go into metal; Black screws go into plastic.

5. Use Electrostatic Discharge precautions when handling the electronics

portions of the printers.

6. Pay very close attention to the wiring harnesses and how they are routed.
This will save time when you reassemble your unit!

7. Pay particular attention to not pinching cable assemblies when

reassembling the unit.

8. Watch for sharp edges and burrs on the metal covers and support
brackets. This machine contains a lot of metal – Be careful!

9. Store the removed screws with the appropriate assembly they secure.

10. Notify the instructor if you have any left over parts/screws once you’ve
completed the re-assembly. This is IMPORTANT since these are training
machines and will be used for additional training classes.

11. We do not “booby trap” machines prior to disassembly or re-assembly.

We may introduce problems after your unit is reassembled and tested:
This is the best way to learn troubleshooting techniques.

12. Learn as much as you can - Enjoy the class – Ask questions

13. Remember; It Is Your Course! Ask questions of the instructors.

14. When completing the course critique, be honest; If you find a problem,
want to make a suggestion, utilize the comments section on the rear of the
critique form. We Do Pay Attention to These Comments! Remember:
Constructive Criticism is always welcome and it helps us to improve this
course.

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This Page Is Intentionally Blank

IV
A3/C9 Printer Engine Disassembly Procedures

All directions are referenced from the “Front / Operator Panel” of the machine

Install the consumables (First Time Use machines only)

Remove drum and toner assemblies from the black bags (if so equipped) and reinstall in
your printer.

1. Print the following pages:

1.1.1. “Configuration Pages”

1.1.2. “Demo Page 1”

2. Unplug the power cord from the wall

and from the printer.
2.1. Remove all consumables
from the printer.
2.1.1. Drum and toner
assemblies go back in the
black bags and fold the
tops of the bag to block
light leakage.
2.1.2. Remove the Transfer
Belt.
2.1.3. Remove the Fuser
assembly.
2.1.4. Remove Waste Toner
Box
2.2. Close the printer cover.

1
3. Remove the Paper
Cassette from the
printer.

4. Removing the Power

Supply Cover.
4.1. Remove 5
screws from
the Power
Supply Cover.

4.2. Remove the

Power Supply
Cover.

2
5. Removing the Right
Side Cover and the
Right Side Lower
Access Cover.

5.1. Remove 2
screws from
the Right Side
Cover and use
a flat blade
screwdriver to
release the
four tabs. Push
down (But
Don’t Pry!) on
the top taps
and up on the
bottom tabs.

5.2. Release the

latch.

5.3. Remove the

Right Side
Cover.

3
 5.4. Remove the
Right Side
Lower Access
Cover by
gently prying
the plastic pins
away from the
metal frame.

6. Removing the Rear

Right Side Cover.
6.1. Open the Top
Cover and
remove two
screws.

6.2. Remove the

Rear Right
Side Cover.

4
7. Remove the Duplexer
(if equipped) / Dummy
Duplex Cover from the
left side.
NOTE: This photo
shows a non-duplex
unit with the plastic
“dummy cover”

8. Removing the Left

Side Cover.
8.1. Remove the 4
screws and
release the
tabs by
pressing
down(But
Don’t Pry!)
with a flat
blade
screwdriver.

8.2. Remove the

Left Side
Cover.

5
9. Removing the Front
Cover Assy.

9.1. Lift the Op

Panel as far as
possible and
open the Front
Cover Assy.
Remove the 2
screws from
the support
straps.
NOTE: Be sure the
Waste Toner Box has
been removed.

9.2. Make sure the

cover is open
all the way –
remove it by
pushing to the
left on the
black hinges
and moving the
cover to the
right.

6
10. Removing the Right
Cover Guard
NOTE: Read the next 2
pages before starting this
step to familiarize yourself
with the procedure!
10.1. Remove 1
screw and use
a flat blade
screwdriver to
release the
tab.
10.2. Remove Right
Cover Guard.

7
10.3. Take note of
the wire routing
in the Right
Cover Guard
for the Waste
Toner Box
sensor and
unthread.

10.4. Remove the

Sensor board
and wiring
harness from
the right cover
card as an
assembly.

8
11. Removing the Left
Cover Guard
NOTE: Lift the Basket
Assy.
11.1. Remove 2
screws and
use a flat blade
screwdriver to
release the 3
latches.

11.2. Remove the

Left Cover
Guard.

9
12. Removing the Front
Cover Guard
12.1. Remove 3
screws and
remove the
Front Cover
Guard.

12.2. The Front

Cover Guard
has a very tight
fit even with
the screws
removed.
Gently work it
off.

10
13. Removing the
Operator Panel.
NOTE: Read the next 2
pages before starting this
step to familiarize yourself
with the procedure!

13.1. Remove 2
screws.

13.2. Remove the

Op Panel but
do not let it
drop as there
is ribbon cable
attached.

13.3. Release the 2

latches on the
underside of
the Op Panel.

11
13.4. Remove the
Op Panel
Cover.

13.5. Remove 1
screw

13.6. Gently unplug

the ribbon
cable.

12
14. Removing the Plate
Shield Assy. (Rear
Metal Cover)
14.1. Be sure the
Top Cover is
closed. Loosen
the 2 captured
thumb screws
on the side and
remove the 2
screws along
the top.

NOTE: Be careful when

handling any sheet metal
as there may be sharp
edges left over from the
manufacturing process.
14.2. Lifting up and
at the angle
shown, remove
the Plate
Shield Assy.

13
15. Removing the Engine
Board Fan and Air
Duct
15.1. Gently release
tab.

15.2. Remove the air

duct by pulling
it outward.

14
15.3. Unplug the fan
connector.

15.4. Release the

tabs that
secure the fan
to the Plate
Shield Box
Assy. (Card
Cage) and
remove the fan
by lifting up
and out.

15
NOTE: Oki Data manufactures and sells many different versions
of this A3/C9 Engine, employing different controller cards:
Some are EFI Fiery™ designed boards while others utilize
Oki Data designed controller boards. The controller
boards pictured in this document may be different from
the machine you are disassembling.

16. Removing the Controller

Board
16.1. Remove the single
screw from the I/O
panel.

16.2. Unplug the 2 power

connectors for the
fans.

16.3. Remove two

screws on the fan
bracket. Take note
that these screws
are longer than
rest.

16.4. Remove the

bracket and fans.

16
16.5. Remove two
screws from the
controller card as
shown.

16.6. Remove one screw

from the controller
bracket inside the
frame.

16.7. Remove one screw

on the outside of
the bracket.

17
 16.8. Slide the
Controller
Board slightly
to the right and
remove.

17. Removing the Engine

Board

18
 NOTE: Prior to
unplugging all of the
wiring connectors from the
engine controller board
make note of the wire
harness routing. Note
where the various cables/
harnesses enter the card
cage, etc.
It’s easier to note this
now, when the machine is
fresh, than to try and
figure it out when you’re
rushing to reassemble the
unit.
17.1. Unplug 17
connectors and
remove four
screws.

17.2. Push the Engine

Board slightly to
the left - pull the
bottom of the
board out then
remove entire
board.
NOTE: If replacing a
failed Engine Board, the
socketed EEPROM must
be retained and inserted
into the new Engine
Board.

18. Remove the Plate Shield

Box Assy. (Card Cage)
18.1. Remove 1 screw
to release the
Plate Clamp HCB
(LED Head Cable
clamp). Slide the
white plastic
bracket outward to
release it from the
Card Cage.

19
 18.2. Remove 11 screws
from the Card
Cage.

18.3. Remove Card

Cage.

NOTE: To help make the

reassembly process easier,
it is recommended that any
of the cables and
harnesses that enter the
Card Cage from the
bottom, be taped down in
their relative positions as
illustrated.

20
19. Removing the Eject-Assy.
(Exit Guide)
19.1. Release the five
tabs with a flat
blade screwdriver
– the two tabs on
the end of the
cover first – and
reach under the
area marked with
the Red arrow and
press to release
latches. Gently
pivot the cover up
to remove.
NOTE: Do Not Pull cover
outlined in the Yellow oval
area! Damage is sure to
occur if you do!

19.2. Unplug connector

at upper right of
the OR-S2R (exit
sensor board).

21
19.3. Remove Face-up
Output Stacker

19.4. Remove 1 screw

from the front of
the Exit Assembly.

19.5. Remove 1 screw

at the rear of the
Exit Assembly
(make sure you
remove the correct
screw – no way to
picture the correct
screw).

22
19.6. Release the tabs –
two inside the
printer cavity and
one outside.

19.7. Lift Exit Guide up

and out and gently
unthread the cable
bundle and
connector through
the side.

23
NOTE: On reassembly
insure that the paper exit
sensor on the bottom of the
exit guide is completely
snapped into its correct
position.

The correct threading for the

exit tray guide cable harness
is through the wire guide in
the rear of the printer cavity.

When reassembling also

ensure the cable threading
around the Exit Guide
Assembly gearing. It is very
easy to pinch wires or get
them too close to the gearing.

24
20. Removing the Belt Motor
at the front of the unit.
20.1. Remove 2 screws
and unplug
connector.

20.2. Remove the

Belt Motor

25
21. Removing the Sensor-
Registration Assy.
21.1. Remove the
Board-Regist-
Sensor(S2Z)
cover.

21.2. Unplug the yellow

wire harness
connector.
NOTE: The second
connector should stay
plugged in – it is removed just
for this picture.

26
 21.3. Remove eight
screws – seven
inside the printer
(arrows) and one
on the front
(circled).

NOTE: During reassembly,

don’t forget to reinstall the
screw through the front of the
chassis – it’s a step many
technicians forget!

21.4. A flat blade

screwdriver may
be required to pry
the side plate
away from the
frame at the front
of the printer.
Once done, lift the
Sensor-
Registration Assy.
up to remove and
while doing so,
unplug the two
connectors as
shown.

27
22. Removing the Duct Drive
Assy. Motor
22.1. Release the tab at
the rear and
remove the Middle
Cover.

22.2. Lift the connector

for the waste toner
motor to wiring
harness from
under the motor’s
printed wiring
board.
NOTE: Orange connectors
are soldered to the board and
are not removable. DO NOT
try to remove the orange
connector from the printed
wiring board.

28
22.3. Unplug the Waste
Toner Motor to
wiring harness
connector.

22.4. Remove the Waste

Toner Motor by
removing the two
screws (diagonally
mounted) and
lifting it out.

29
23. Removing the Multi-
Purpose Tray.
24. Gently pry out the top
center and pull up to
remove the Sensor Board
Cover.
NOTE: While gently prying,
lift up on the sides of the
cover to remove. This cover
is held in place by 2 plastic
tabs that attach to the frame –
outlined in the red boxes in
the photos.

30
24.1. Unplug the two
connectors that
come from the
Multi-Purpose Tray
and unthread them
from the guides.
24.2. Unplug the ribbon
cable to that
board.

24.3. Using the “Special

Oki Data Tool” (a
small piece of
transparent tape)
wrap the larger
white connector
parallel to the
purple & blue
cable bundle to
assist in the
removal of the MP
Tray. Leave a tab
of tape to assist
you in un-wrapping
this on the units
reassembly.

31
24.4. Open the Multi-
Purpose Tray
using the lever at
the front of the
unit. Remove one
screw from the
front stay.

24.5. Remove one

screw from the
rear stay. Take
note of the rear
stay as it will most
likely fall into the
machine.

24.6. Release the Multi-

Purpose Tray from
the hinges and
gently unthread
the two connectors
from step 22.2
through the
channel.

32
NOTE: During reassembly,
the plastic wire harness
protector must be carefully
and fully reinserted into the
channel. If it is not fully
reinserted it will become
damaged and the Multi-
Purpose (MP) Tray will not
close properly.
If this happens and the plastic
wire harness protector cannot
be repaired – the entire MP
Tray must be replaced.

33
25. Removing the
Registration Unit (Right
Paper Guide Assy)
NOTE: Be sure the Top
Cover is open and the basket
is up.

25.1. Remove four

screws. The screw
marked by the
arrow will also
remove the right
basket latch.

34
25.2. Remove the Multi-
Purpose Tray Lock
Plate Assy.

25.3. Remove two

screws from rear
of Registration
Unit.

25.4. Unthread the wires

at the front and
remove the
Registration Unit
being careful of the
spring loaded gear
at the front.

35
26. Removing the Paper Feed
Unit
26.1. Remove four
screws and
remove the Metal
Right Side Cover.

36
26.2. Remove nine
screws from the
right side and one
from the front.
Unplug 3
connectors from
the ORS2M (Motor
Driver Board).
Remove the Paper
Feed Unit.

37
27. Removing the High
Voltage Power Supply
(HVPS).
27.1. Remove two
screws and
release three tabs
along the back of
the HVPS cover.
Remove the HVPS
cover.
NOTE: When reinstalling the
HVPS cover insure that all 3
tabs are snapped under the
chassis plate. Failure to do
this may cause transfer
voltage problems resulting in
washed out images.

27.2. Remove two

screws and unplug
four connectors.
Gently slide the
HVPS toward the
rear of the unit
until it clears the
contacts and lift
the board out.

38
28. Removing the Low
Voltage Power Supply
(LVPS).
28.1. Release the power
switch linkage by
lifting up and
away.

28.2. Remove 14
screws.

28.3. Unplug four

connectors and
remove the LVPS.

39
29. Removing Motor-DC(ID)
(Drum Motors)

29.1. Remove two

screws and unplug
the connector from
the OR-S2M(Motor
Driver Board) and
not from the motor
assembly.
NOTE: Each of the four
motors is mounted with two
screws. Also, the Black ID
motor is mounted at a 90°
angle to the other three.
The 4 drum motors are
interchangeable.
When you reassemble the
printer make sure that you
hold the motor(s) securely
when you are installing the
holding screws. Also make
sure that the screws are
completely screwed down.

40
30. Removing OR-S2M(Motor
Driver Board)
30.1. Unplug remaining
connectors and
remove two
screws.

30.2. Remove Motor

Driver Board.

41
31. Removing Motor-
Pulse(Toner Shutter) aka
Toner Supply Motor.

31.1. Using a flat blade

screwdriver, push
up to release the
tab.
NOTE: Both the motors
and the mounting plates
are the same however
the motors are mounted
to the plates 180°
opposite of each other.
Be aware of this for
reassembly.

42
32. Removing the OR-SGG
(ID System SNS PWB)
aka Drum Contact and
Sensor Board Assy.
32.1. Remove four
screws, one each
from the Drum
Position Home
sensors. Use a flat
blade to release
the two Toner
Shutter Home
sensors and the
Drum Up/Down
Home sensor.

32.2. Use a flat blade

screwdriver to
release the tabs
securing the main
portion of the
Drum Contact and
Sensor Board
Assy. and unplug
one connector.
Remove the board
being careful of the
drum contact
springs as they
may fall out.
NOTE: There are 2
Grounding Springs (red
arrows, at right) that ground
the OR-SGG board to the
chassis ground. You Must
insure that both of these
springs are correctly installed
during the reassembly
process.

43
33. Removing the Fuser
Motor
33.1. Remove two
screws and
unthread wire
harness taking
note of the routing
for reassembly.
Remove the Fuser
Motor.

Congratulations! This concludes the disassembly of the bottom half

of the 9 Series A3/C9 Printer unit.

Prior to starting the next section (Top Cover Skin Removal) reassemble the
bottom half of the printer unit using this step-by-step disassembly manual in
reverse.

NOTE: Take your time and be very careful when reconnecting the wiring
harnesses to the (1) motor driver board, (2) the engine driver board and (3) when
reconnecting the 2 ribbon cables between the engine and motor controller
boards! A properly reassembled printer contains only one (1) empty red test
connector on the motor driver board! Take Your Time when rewiring and
reassembling this printer. HINT: If you’re unsure of something – ask one of the
instructors circling the room: it’s easier to ask for help than ask for a replacement
part.

Reassemble the Bottom Half

44
 Removing the Top Cover
1. Open the top
cover

2. Place media
(large sheet of
paper / plastic)
over top of the
consumables
cavity (to catch
any falling
screws).

NOTE: Fit the media

to go around the
hinge plates,
so the media
completely
covers the
cavity.

45
3. Remove the 9
black screws, as
shown.

4. Detach the small

cover (outlined in
red).

NOTE: Consumables
have been
removed for
image clarity.

5. Remove the
exposed black
screw.

46
6. Gently lift the top
cover skin off the
frame of the
printer’s top
cover.

7. Close the top

cover and gently
lower the metal
cover brace on
the printer’s left
side.

47
8. Mounted to the
top cover is a
small circuit
board; this is the
RFID board. The
4 leads coming
from this board
go to the
individual RFID
antennae,
mounted over the
toner cartridges.

NOTE: The ribbon

cable connector
mounted on the
circuit boards has
a locking collar
that must be
opened prior to
removing and
installing the
cable!

9. Reassemble the
Top Cover Skin
on the frame of
the printer’s Top
Cover
NOTE: Make sure
the Top Cover
Skin sits flush on
the frame before
you reinstall the 9
screws!

48