Oki OKIPAGE 4M, OKIPAGE 4W PLUS User Manual

OKIPAGE 4 /4

LED Page Printer

Maintenance Manual

OEL/INT

Approval

All specifications are subject to change without notice.

40245101TH

HP, LaserJet and PCL5e are trademarks of Hewlett-Packard Co.

PREFACE

This Maintenance Manual describes the field maintenance methods for LED Page Printers.

This manual is written for use by service persons. Please note that you should refer to the Printer Handbook for the handling and operating methods of the equipment.

			CONTENTS
1.	CONFIGURATION .....................................................................................			1 - 1
	1.1	System Configuration ........................................................................		1 - 1
	1.2.	Printer Configuration ..........................................................................		1 - 2
	1.3	Option	.................................................................................................	1 - 3
	1.4	Specification ......................................................................................		1 - 4
	1.5	Safety ...............................................................................Standards		1 - 6
		1.5.1 ....................................................................................	Certification Label	1	- 6
		1.5.2 .........................................................................................	Warning Label	1	- 6
2.	OPERATION ....................................................................DESCRIPTION			2 - 1
	2.1	Main Control ............................................................................Board		2 - 4
	2.2	Power .............................................................................Supply Unit		2 - 5
	2.3	High-Voltage ....................................................Power Supply Board		2 - 5
	2.4	Electro ........................................................-Photographic Processor		2 - 7
	2.5	Electro ...........................................................-Photographic Process		2 - 11
		2.5.1 ..................................................	Explanation of Each Process Operation	2	- 13
	2.6	Paper .........................................................................Jam Detection		2 - 19
	2.7	Toner ..........................................................................Low Detection		2 - 21
	2.8	Cover .......................................................................................Open		2 - 22
3.	PARTS REPLACEMENT ...........................................................................			3 - 1
	3.1	Precautions ...................................................for Parts Replacement		3 - 1
	3.2	Parts Layout.......................................................................................		3 - 3
	3.3	Replacing .................................................................................Parts		3 - 6
		3.3.1 ...........................................................................................	Hopper Plate	3	- 6
		3.3.2 ....................................................................	LED Head and Head Spring	3	- 7
		3.3.3 .........................................................................................	Transfer Roller	3	- 8
		3.3.4 ...................................................................................	Upper Cover Assy	3	- 9
		3.3.5 ..........................................................	High - Voltage Power Supply Board	3	- 10
		3.3.6 ......................................................	Top Cover Assy and Flat Cable Assy	3	- 11
		3.3.7 ...........................................................................................	Paper Holder	3	- 12
		3.3.8 .....................................................................	Side Plate M and Idle Gear	3	- 13
		3.3.9 ................................................................................................	Heat Assy	3	- 14
		3.3.10 .....................................................	Drive Shaft E (Eject) and Eject Roller	3	- 17
		3.3.11 .........................................................	Pressure Roller B (Back Up Roller)	3	- 18
		3.3.12 ......................................................................................	Separator Guide	3	- 19
		3.3.13 ..................................................................................	Pulse Motor (Main)	3	- 21
		3.3.14 .................................................................................	Hopping Shaft Assy	3	- 22
		3.3.15 ............................................................................................	Resist Roller	3	- 23
		3.3.16 .................	Paper Sensor E, Paper Sensor Exit and Toner Sensor Assy	3	- 24
		3.3.17 ...............................................................................................	Base Plate	3	- 25

4. ADJUSTMENT ...........................................................................................			4 - 1
4.1	Adjustment Types and Functions ......................................................		4 - 1
	4.1.1	Printer Driver ...........................................................................................	4 - 1
	4.1.2	Engine Maintenance Utility ......................................................................	4 - 3
4.2	Adjustment When Replacing a Part ...................................................		4 - 3
	4.2.1	Setting LED Head Drive Time .................................................................	4 - 3
	4.2.2	Setting the LED Head Dot Count ............................................................	4 - 4
	4.2.3	Uploading and Downloading EEPROM Data ..........................................	4 - 5

5. PERIODICAL MAINTENANCE .................................................................		5 - 1
5.1	Periodical Replacement Parts ...........................................................	5 - 1
5.2	Cleaning.............................................................................................	5 - 1
	5.2.1 Cleaning of LED Lens Array ....................................................................	5 - 1

6. TROUBLESHOOTING PROCEDURES ....................................................			6 - 1
6.1	Troubleshooting Tips .........................................................................		6 - 1
6.2	Check Points Before Correcting Image Problems .............................		6 - 1
6.3	Notes When Correcting Image Problems ..........................................		6 - 1
6.4	Preparation Before Troubleshooting ..................................................		6 - 1
6.5	Troubleshooting .................................................................................		6 - 2
	6.5.1	Status Monitor Message List ...................................................................	6	- 2
	6.5.2	Status Message Troubleshooting ............................................................	6	- 6
	6.5.3	Image Troubleshooting ............................................................................	6	- 13

7.	WIRING DIAGRAM ...................................................................................				7 - 1
	7.1	Interconnect Signal Diagram .............................................................			7 - 1
	7.2	PCB Layout ........................................................................................			7 - 3
		7.2.1 Main Control Board (HBMC-2 PCB)(OKIPAGE 4w plus) ........................			7 - 3
		7.2.2 Main Control Board (HBMC-3 PCB)(OKIPAGE 4m) ...............................			7 - 4
		7.2.3 High-Voltage Power Sapply Board ..........................................................			7 - 5
8.	PARTS LIST			..............................................................................................	8 - 1
APPENDIX			A	LOCAL PRINTING ...............................................................	A - 1
APPENDIX			B	PARALLEL INTERFACE .....................................................	B - 1
APPENDIX			C	MACINTOSH INTERFACE ...................................................	C - 1
APPENDIX			D	MAINTENANCE UTILITY .....................................................	D - 1

1. CONFIGURATION

1.CONFIGURATION

1.1System Configuration

The OKIPAGE 4w Plus/4m consists of a control block, a power supply unit, and an engine block. (See Figure 1-1.)

ENGINE UNIT

Paper Feed Mechanism

Hopper

Plate

Electro-photographic

Processor

High-Voltage Power

Supply Board

Main Control Board

Power Supply Unit

*2MB Memory

Expansion Board

*: Option (OKIPAGE 4m Only)

Figure 1-1

1 - 1

1.2Printer Configuration

The printer unit consists of the following five hardware components:

•Electro-Photographic Processor

•Paper Feeder

•Main Control Board

•High-Voltage Power Supply Board

•Power Supply Unit

Figure 1-2 is the configuration of the printer unit.

Upper Cover Assy

EP Unit

Top Cover Assy

Heat Assy

Power Supply Unit

Main Control Board

High-Voltage Power

Supply Board

1 - 2

1.3Option

(1)2MB HBRB-PCB Option Memory Board(Only OKIpage 4m)

1 - 3

1.4Specification

(1)	Type	Desktop
(2)	Outside dimensions	Height 5.9”	(150 mm)
	(excludes protruding	Width 12.2”	(310 mm)
	portion)	Depth 7.5”	(191 mm)
(3)	Weight	3.8 kg
(4)	Development method	Dry non-magnetic development system
	Exposure method	LED stationary head
(5)	Paper used	<Type>

•Standard paper

–Xerox 4200 (20 lbs)

•Application paper (manual face-up feed)

–Label

–Envelope

–OHP paper (Transparency)

<Size>

		14" (355.6 mm) (Max.) x 8.5" (215.9 mm)
		<Thickness>
		– Automatic feed:	16 to 28 lbs (60 to 90 g/m2)
		– Manual feed:	Label, Envelope, OHP paper (trans-
			parency)
(6)	Printing speed	First print:	23 seconds (A4) (after warm-up)
		Continuous print:	4 sheets/minute (A4)
		Warm-up time:	40 seconds (120 VAC for ODA, 230
			VAC for OEL/INT) (at room tempera-
			ture 77 ˚F (25 ˚C))
(7)	Paper feeding method	Automatic paper feed or manual paper feed
(8)	Paper delivery method	Face down
(9)	Resolution	300 dpi x 300 dpi, 600 dpi x 600 dpi (quasi)
(10) Power input		230 VAC +15%, -14% (for OEL/INT)
		120 VAC +6%, -15% (for ODA)
(11) Power consumption		Peak:	450W
		Typical operation:	100W
		Idle:	30W
		Power save mode:	5W

1 - 4

(12) Temperature and humidity

	Temperature	Humidity
During operation	10 to 32 ˚C	20 to 80% RH (relative humidity)
In storage	–10 to +43 ˚C	10 to 90% RH (relative humidity)
		No condensation is permissible.

Caution: Temperature and humidity in storage are measured with the OKIPAGE 4w plus/4m being packed; they are valid for one year.

(13) Noise	During operation:	48 dB (A) or less
	Standby:	38 dB (A) or less
(14) Consumables	Toner cartridge kit	1,000 (5% duty)
	Image drum cartridge	10,000 (at continuouts printing)

1 - 5

1.5Safety Standards

1.5.1Certification Label

The safety certification label is affixed to the following location of the OKIPAGE 4w:

OKI-INT

4w Plus

1.5.2Warning Label

Warning labels are affixed to the locations that may cause bodily injury.

During maintenance, do work with enough care while following instructions on these warning labels.

For OEL

For OEL, OKI-INT

For Korea

For China, TAIWAN

1 - 6

2.OPERATION DESCRIPTION

2.OPERATION DESCRIPTION

The OKIPAGE 4w Plus/4m consists of a main control board, a high-voltage power supply board, a power supply unit, and an electro-photographic processor. The OKIPAGE 4w Plus/4m receives print data from a higher-level interface and sequentially stores it in memory. The OKIPAGE 4w Plus/4m decodes and edits the received data while storing print data from the interface in memory. It sequentially transfers the edited data to the LED head for each dot line. The electrophotographic processor then prints the data on sheets of paper.

The display of the higher-level host is used for device operation and status display.

Figure 2-1 is the block diagram of the OKIPAGE 4w Plus/4m.

2 - 1

2 - 2

10 MHz

A8 ~ A15

	MSM65917
EEPROM	(nX-8 core)	AD0 ~ AD7

Parallel

I/F

LED head

Main motor

Electromagnetic

clutch

Sensors

A0 ~ A10

TEMP TR-VSEN TR-ISEN

	5V	Reset
		circuit
		Driver
		5V

EPROM

(52 KByte)

A0 ~ A7

Address

latch

OE CS

D0 ~ D3

D-RAM

(512 KB: For INT)

(128 KB: For OEL)

High-voltage power I/F

OVL

LED

HEAT ON

<Main Control Board>

D0 ~ D7	Parallel
	I/F

LED head

Main motor

Electromagnetic

clutch

LED

Sensors

CN

Parallel

I/F

LS07

		LED head
	Driver	M	Main motor
	Driver	Electromagnetic
		clutch
LED	Manual feed sensor
	Paper sensor
	Outlet sensor
	Toner sensor
	Cover open switch

	TEMP		Thermistor
	High-voltage	High voltage
	power I/F
		power	EP cartridge
	TR-VSEN
		supply
	TR-ISEN
		<High-voltage Power Supply Board>

HEAT ON

Driver

+24 V

+5 V 0VL 0VP

	AC output ON/OFF	Heater
		(Halogen lamp)
	Switching	AC
	power supply	(120 V/230 V)

<Power Supply Unit>

Figure 2-1 Block Diagram (OKIPAGE 4w Plus)

		10 MHz
		EEPROM
		Parallel
		I/F
	Mac I/F
		IC Driver
		LED head
		Main motor
	Electromagnetic
		clutch
	3 - 2	Sensors
		TEMP
		TR-VSEN
		TR-ISEN
	5V	Reset
		circuit
		5V
		OVL

							CN
	A8 ~ A15			D0 ~ D7	Parallel
				EPROM	I/F		Parallel
				(52 KByte)
MSM65917							I/F
(nX-8 core)						LS07
	AD0 ~ AD7			A0 ~ A7
		Address
		latch		OE
				CS
					LED head			LED head
					Main motor		Driver	M	Main motor
				(Option RAM-PCB)	Electromagnetic		Driver	Electromagnetic
					clutch			clutch
		D0 ~ D3
					LED	LED	Manual feed sensor
							Paper sensor
					Sensors		Outlet sensor
	A0 ~ A10			D-RAM			Toner sensor
		D-RAM
							Cover open switch
				(2 MByte)
		(512 KByte)
				option
					TEMP				Thermistor
					High-voltage	High voltage
					power I/F
							power		EP cartridge
					TR-VSEN
							supply
					TR-ISEN
	Driver		High-voltage power I/F			<High-voltage Power Supply Board>
		LED		HEAT ON	Driver	AC output ON/OFF			Heater
									(Halogen lamp)
		HEAT ON
					+24 V
							Switching
					+5 V				AC
		<Main Control Board>			0VL	power supply			(120 V/230 V)
					0VP

<Power Supply Unit>

Figure 2-1 Block Diagram (OKIPAGE 4m)

2.1Main Control Board

The main control board consists of a one-chip CPU, a program ROM, a DRAM, an EEPROM, a host interface circuit, and a mechanism driving circuit. The mechanism driving circuit consists of a LED head, a main motor, and an electromagnetic clutch.

(1)One-chip CPU

The one-chip CPU is a custom CPU (8-bit internal bus, 8-bit external bus, 10-MHz clock) incorporating mask ROM and CPU peripheral devices. This CPU has the functions listed in the table below.

	Built-in Device	Function
	DRAM controller	Controls DRAM.
	DMA controller	Transfers image data from Parallel I/F to DRAM, from DRAM to a video output port and
		between CPU and DRAM.
	Parallel interface controller	Controls the parallel interface.
	Video output port	Controls LED head.
	LED STB output port
	Timer	Generates various control timings for monitoring paper feeding and a paper size.
	I/O port	Inputs and outputs the sensor signals and motor signals, etc.
		Also performs I/O for EEPROM.
	A/D converter	Inputs the feedback signals from a high-voltage generation circuit and thermistor signal.

(2)Program ROM

Program ROM contains a program for the equipment. EPROM is used as program ROM. When mask ROM in the one-chip CPU explained in (1) above is valid, the EPROM is not mounted. (For details on short wiring setting, see Section 7.2.)

(3)DRAM

DRAM is used as resident memory.

(4)EEPROM

EEPROM holds the following data:

•Menu data

•Counter value

•Adjustment value

(5)Parallel interface

The parallel interface receives parallel data from the host; it conforms to the IEEE1284 specification.

(6)Macintosh interface <only OKIPAGE 4m>

Mcintosh interfacce receives serial data from the host ; it conforms to the IEEE1284.

2 - 4

2.2Power Supply Unit

The power supply unit supplies +5 V and +24 V to the main control board according to 230 VAC /120 VAC.

Output voltage	Application
+5 V	Used to generate a logic circuit and a high voltage.
+24 V	Used to drive the motor and electromagnetic clutch.

The power supply unit also contains a heater drive circuit.

2.3High-Voltage Power Supply Board

(1)High-Voltage power supply circuit

The high-voltage power supply circuit generates the following voltages required for the electro-photographic processor from +5 V according to the control sequence from the main control board. When the cover is open, +5 V supply is automatically interrupted to stop highvoltage output.

Output		Voltage	Application
CH	–1.35 KV		Voltage to be applied to a charge roller.
DB	–300 V/+300 V		Voltage to be applied to a developing roller.
SB	–450 V/ 0 V		Voltage to be applied to a sponge roller.
CB	+400	V	Voltage to be applied to a cleaning roller.
TR	+500	V ~ +3.5 KV/–750 V	Voltage to be applied to a transfer roller.

Caution: The TR voltage varies with medium and transfer roller impedance.

2 - 5

(2)Sensors

The high-voltage power supply board consists of the high-voltage power supply circuit that supplies power to the electro-photographic processor system and the photosensor that detects a paper feeding system and toners.

Figure 2-2 shows the sensor layout drawing.

Exit roller

Paper feeding direction

Outlet sensor

Heat roller

Transfer roller

Feed roller

Paper sensor

	Toner	Hopping
	sensor
		roller
	assy
		Manual feed sensor

Figure 2-2

Sensor	Function	Sensing State
Manual feed	Monitors whether paper was inserted into the manual feed sensor	ON: Paper exists.
sensor	section.	OFF: No paper exists.
Paper sensor	Detects the leading part of the paper.	ON: Paper exists.
	Monitors paper feeding.	OFF: No paper exists.
Outlet sensor	Monitors paper feeding and the paper size according to the paper	ON: Paper exists.
	sensor arrival and passing time.	OFF: No paper exists.
Toner sensor	Detects the low toner status.	ON (long): Toner low
		OFF (short): Toner High

2 - 6

2.4Electro-Photographic Processor

The electro-photographic processor prints out the image data to be sent from the main control board on sheets of paper. Figure 2-3 shows the layout drawing of the electro-photographic processor.

(1)Image drum unit

The image drum unit makes a toner adhere to the formed electrostatic latent image with static electricity. This electrostatic latent image is formed by the lights irradiated from LED heads.

(2)Electromagnetic clutch

The electromagnetic clutch controls the rotation of the hopping roller according to signals from the control block.

2 - 7

Charge roller (ø 9.000)

6.77

LED head

Drum roller (ø 16.000)

17.23

Developing roller (ø 14.000)

23.18

12.72

8 - 2

Paper sensor

Feed roller

10

Manual

printing

OFF

Manual feed sensor

10

ON OFF

Tray printing

Exit roller

Heat roller (ø 19.910)

Cleaning roller

Outlet sensor

(ø 9.000)

6.85

10 OFF

26.50

ON

20.32

64.60

Single tray

	Transfer roller
32.00	(ø 15.000)

Hopping roller

Figure 2-3 Layout Drawing of Electro-Photographic Processor

(3)Pulse motor (Main)

This pulse motor of 48 steps/rotation is two-phase excited by the signal from the main control board; it performs feeding control by switching normal rotation to reverse rotation or vice versa and turning on/off the electromagnetic clutch. The relationship between the main motor, electromagnetic clutch, resist gear, drum gear, hopping roller is shown in the table below and on the subsequent pages.

Main Motor	Electromagnetic Clutch		Hopping Roller	Regist Gear	Drum Gear	Operation
Normal rotation	OFF		Non-rotation	Non-rotation	Rotation	Warm-up
Reverse rotation	ON		Rotation	Rotation	Rotation	Hopping
	OFF		Non-rotation	Rotation	Rotation	Prinitng

(4)LED head

The shift and latch registers receive image data from the main control board for each dot line. 2,560 or 2,496 LEDs are driven to radiate the image drum.

(5)Heat Assy

The heat Assy consists of a heater, a heat roller, a thermistor, and a thermostat.

The power supply unit supplies AC voltage to the heater according to the HEATON signal from the main control board to heat the heat roller. The main control board monitors the heat roller temperature via the thermistor and keeps the temperature constant by turning on/off the heater AC voltage supply.

If the heat roller temperature rises abnormally, the thermostat of the heater voltage supply circuit functions to forcibly suspend the AC voltage supply.

2 - 9

10 - 2

2Roller to be driven by reverse rotation of pulse motor (Main)

1Motor to be driven by normal rotation of pulse motor (main)

	Developing roller	Drum roller
		CH roller

Cleaning roller

Exit roller

Heat roller

Feed roller

Manual printing

Manual	Paper sensor	Outlet
feed		sensor
sensor
		Transfer roller

Hopping roller

TRAY printing

Roller control by pulse motor (main)

1 Normal rotation of pulse motor (main): Drum roller, transfer roller, cleaning roller, CH roller, developing roller, heat roller, exit roller rotation

2 Reverse rotation of pulse motor (main): Drum roller, transfer roller, cleaning roller, CH roller, developing roller, heat roller, exit roller, feed roller, hopping roller rotation

Hopping operation from the tray, however, is performed when the electromagnetic clutch is turned on.

Figure 2-4 Schematic Drawing of OKIPAGE4w Plus/4m Paper Feeding

2.5Electro-Photographic Process

(1)Electro-photographic process

The electro-photographic process is outlined below.

1 Charging

The surface of the OPC drum is charged negatively and uniformly by applying the DC voltage to the CH roller.

2Exposure

Light emitted from the LED head irradiates the negatively charged surface of the OPC drum. The surface potential of the irradiated surface attenuates to form the electrostatic latent image corresponding to the image signal.

3Development and residual toner recovery

The negatively charged toner is brought into contact with the OPC drum, adhering to the electrostatic latent image on the OPC drum by static electricity. This adhesion causes the electrostatic latent image to change to a visible image.

At the same time, the residual toner on the OPC drum is attracted to the developing rollerby static electricity.

4Transfer

When paper is placed over the image drum surface, the positive charge which is opposite in polarity to that of the toner, is applied to the reverse side by the transfer roller. The toner is attracted by the positive charge and is transferred onto the paper. This results in the transfer of the toner image formed on the image drum onto the paper.

5Cleaning

The cleaning roller temporarily attracts the residual toner on the transferred OPC drum with static electricity, then returns the toner to the OPC drum.

6Fusing

The transferred unfused toner image is fused to a sheet of paper by applying heat and pressure to the image.

Figure 2-5 is a flow for the electro-photographic process.

2 - 11

12 - 2

Power supply

Paper delivery Charge

roller

Power supply

	Paper eject	Paper feeding	Cleaning
	roller
			roller
	Outlet sensor
		Fusing

Heat roller

Back-up

roller

Paper ejection	Fusing	Cleaning

Control signal

LED head

	Exposure
Charging			Power
			supply
Cleaning		Development	Developing
			roller
	Transfer			Paper
				supply
		Paper sensor
Power	Transfer roller		Feed roller	Hopping
supply				roller

Toner cartridge

Paper holder

Manual feed section

Manual feed sensor

Transfer

Development

Paper feed

Paper hopping

:OPC drum rotation direction

:Paper feeding path

Figure 2-5 Flow for Electro-Photographic Process

2.5.1Explanation of Each Process Operation

(1)Hopping

As shown in the figure below, the clutch for hopping is turned on/off according to current ON/ OFF to a coil.

When the clutch is OFF

	Spring for resetting
Hopping gear	Clutch plate

Coil

Magnetic substance plate

Pin

Hopping shaft

Hopping roller

Engagement section

When the clutch is ON

Hopping gear

Clutch plate

When the clutch is on, the hopping gear engages with the clutch plate to rotate the hopping roller.

When the clutch is off, the hopping gear is separated from the clutch plate by the spring for resetting, disabling the rotation of the hopping roller.

2 - 13

(2) Printing and warm-up

At warm-up

Triple gear

Transfer gear

Resist gear

Idle gear

Planetary gear

a"

a'

a

Hopping gear

Gear A

Pulse motor (main)

Rotate the pulse motor (main) in the a direction. The planetary gear rotates in the a’ direction, dislocating its position in the a” direction. This causes the planetary gear to be separated from gear A. The hopping gear will not rotate. The triple gear and transfer gear rotate via the idle gear to drive the EP unit.

At printing	Triple gear
	Transfer gear
	Resist gear

Idle gear

Planetary gear

b"

b'

b

Hopping gear

Gear A

Pulse motor (main)

The paper is further advanced in synchronization to the print data.

2 - 14

(3)Charging

Charging is performed by applying DC voltage to the charge roller that is in contact with the surface of the OPC drum.

Highvoltage

power Charge roller supply

OPC drum

(4)Exposure

Light emitted from the LED head irradiates the negatively charged surface of the OPC drum. The surface potential of the irradiated surface attenuates to form the electrostatic latent image corresponding to the image signal.

LED head

LED head Charge roller

Highvoltage power

supply

OPC drum

OPC drum

Paper

2 - 15

(5)Development

The electrostatic latent image on the surface of the OPC drum is changed to a visible toner image by applying a toner to it. Development is performed in the contact part between the OPC drum and developing roller.

1 The sponge roller negatively charges a toner and applies it to the developing roller.

Developing blade

Charge roller

Sponge roller

Developing roller

OPC drum

2 The toner applied to the developing roller is thin-coated by the developing blade.

3A toner adheres to the exposure part of the OPC drum in the contact part between the OPC drum and developing roller. This causes the electrostatic latent image to be changed to a visible image.

2 - 16

(6)Transfer

The transfer roller is composed of conductive sponge material. This roller is set so that the surface of the OPC drum and sheets of paper will adhere closely.

A sheet of paper is placed on the surface of the OPC drum and the positive charge opposite to the negative charge of a toner is applied from the reverse side by the transfer roller.

When a high negative voltage is applied from the power supply to the transfer roller, the positive charge induced on the surface of the transfer roller moves to the paper side at the contact part between the transfer roller and the sheet of paper. The positive charge on the lower side of the sheet of paper then causes the negatively charged toner adhering to the surface of the OPC drum to move to the upper side of the sheet. This enables transfer to the sheet of paper.

OPC drum

Paper

Transfer roller	High-voltage
	power supply

2 - 17