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OKIPAGE 4w Plus
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OKI OKIPAGE 4w Plus, OKIPAGE 4m Service manual

OKIPAGE
4 /4
LED Page Printer
Maintenance Manual
OEL/INT
Approval
All specifications are subject to change without notice.
40245101TH
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

1.1 System 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
Power Supply Unit
Main Control Board
*2MB Memory
Expansion Board
*: Option (OKIPAGE 4m Only)
Figure 1-1
1 - 1

1.2 Printer 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
Power Supply Unit
High-Voltage Power
Supply Board
Heat Assy
Main Control Board
1 - 2

1.3 Option

(1) 2MB HBRB-PCB Option Memory Board(Only OKIpage 4m)
1 - 3

1.4 Specification

(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
Humidity During operation In storage
Caution:
Temperature and humidity in storage are measured with the OKIPAGE 4w plus/4m being packed; they are valid for one year.
Temperature 10 to 32 ˚C –10 to +43 ˚C
20 to 80% RH (relative humidity) 10 to 90% RH (relative humidity)
No condensation is permissible.
(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

1.5 Safety Standards

1.5.1 Certification Label The safety certification label is affixed to the following location of the OKIPAGE 4w:
OKI-INT 4w Plus
1.5.2 Warning 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
1 - 6
For OEL, OKI-INT
For China, TAIWANFor Korea

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
EEPROM
Parallel
I/F
LED head
Main motor
Electromagnetic
clutch
Sensors
TEMP
TR-VSEN
TR-ISEN
Reset
circuit
10 MHz
MSM65917
(nX-8 core)
Address
latch
EPROM
(52 KByte)
OE
CS
A8 ~ A15
AD0 ~ AD7 A0 ~ A7
D0 ~ D3
A0 ~ A10
D0 ~ D7
D-RAM
(512 KB: For INT)
(128 KB: For OEL)
Driver High-voltage power I/F
LED
HEAT ON
5V
5V
OVL
CN
Parallel
I/F
Parallel
I/F
LED head
Main motor
Electromagnetic
clutch
LS07
Driver
Main motor
Electromagnetic
clutch
LED head
Driver
Driver
AC output ON/OFF
Switching
power supply
<Power Supply Unit>
<Main Control Board>
<High-voltage Power Supply Board>
LED
Thermistor
EP cartridge
Heater
(Halogen lamp)
AC
(120 V/230 V)
Manual feed sensor
Paper sensor
Outlet sensor
Toner sensor
Cover open switch
LED
Sensors
TEMP
High-voltage
power I/F
TR-VSEN
TR-ISEN
HEAT ON
+24 V
+5 V
0VL
0VP
M
High voltage
power
supply
Figure 2-1 Block Diagram (OKIPAGE 4w Plus)
2 - 2
EEPROM
Parallel
I/F
LED head
Main motor
Electromagnetic
clutch
Sensors
TEMP
TR-VSEN
TR-ISEN
Reset
circuit
10 MHz
MSM65917
(nX-8 core)
Address
latch
EPROM
(52 KByte)
OE
CS
A8 ~ A15
AD0 ~ AD7 A0 ~ A7
D0 ~ D3
A0 ~ A10
D0 ~ D7
D-RAM
(512 KByte)
D-RAM
(2 MByte)
Driver High-voltage power I/F
LED
HEAT ON
5V
5V
OVL
CN
Parallel
I/F
Parallel
I/F
LED head
Main motor
Electromagnetic
clutch
LS07
Driver
Main motor
Electromagnetic
clutch
LED head
Driver
Driver
AC output ON/OFF
Switching
power supply
<Power Supply Unit>
<Main Control Board>
<High-voltage Power Supply Board>
LED
Thermistor
EP cartridge
Heater
(Halogen lamp)
AC
(120 V/230 V)
Manual feed sensor
Paper sensor
Outlet sensor
Toner sensor
Cover open switch
LED
Sensors
TEMP
High-voltage
power I/F
TR-VSEN
TR-ISEN
HEAT ON
+24 V
+5 V
0VL
0VP
M
High voltage
power
supply
option
Driver IC
Mac I/F
(Option RAM-PCB)
Figure 2-1 Block Diagram (OKIPAGE 4m)
2 - 3

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

2.2 Power 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
+24 V
Used to generate a logic circuit and a high voltage. Used to drive the motor and electromagnetic clutch.
The power supply unit also contains a heater drive circuit.

2.3 High-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 high-
voltage output.
Output Application
CH
–1.35 KV
DB
–300 V/+300 V
SB
–450 V/ 0 V
CB
+400 V
TR
+500 V ~ +3.5 KV/–750 V
Voltage
Voltage to be applied to a charge roller. Voltage to be applied to a developing roller. Voltage to be applied to a sponge roller. Voltage to be applied to a cleaning roller. 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
Outlet sensor
Heat roller
Transfer roller
Paper sensor
Toner sensor assy
Manual feed sensor
Paper feeding direction
Feed roller
Hopping
roller
Figure 2-2
Sensor Function Sensing State
Manual feed sensor
Paper sensor
Outlet sensor
Toner sensor
Monitors whether paper was inserted into the manual feed sensor section.
Detects the leading part of the paper. Monitors paper feeding.
Monitors paper feeding and the paper size according to the paper sensor arrival and passing time.
Detects the low toner status.
ON: Paper exists. OFF: No paper exists.
ON: Paper exists. OFF: No paper exists.
ON: Paper exists. OFF: No paper exists.
ON (long): Toner low OFF (short): Toner High
2 - 6

2.4 Electro-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
Exit roller
Heat roller
(ø 19.910)
6.85
10
OFF
ON
26.50
Outlet sensor
Cleaning roller
(ø 9.000)
Charge roller
(ø 9.000)
6.77
LED head
Drum roller
(ø 16.000)
Developing roller
(ø 14.000)
17.23
12.72
23.18
20.32
64.60
Single tray
Transfer roller
(ø 15.000)
Hopping roller
OFF
32.00
10
Tray printing
10
ON
OFF
Manual feed sensor
Manual
printing
Feed roller
Paper sensor
2 - 8
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
Normal rotation
Reverse rotation
OFF
ON
OFF
Hopping Roller
Non-rotation
Rotation
Non-rotation
Regist Gear Drum Gear Operation
Non-rotation
Rotation Rotation
Rotation Rotation Rotation
Warm-up
Hopping
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
Exit roller
Heat roller
Transfer roller
Cleaning roller
CH roller
Drum roller
Developing roller
Outlet
sensor
Paper sensor
Hopping roller
TRAY printing
Feed roller
Manual
feed
sensor
Manual printing
2
Roller to be driven by reverse
rotation of pulse motor (Main)
1
Motor to be driven by normal
rotation of pulse motor (main)
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 - 10

2.5 Electro-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.
2 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.
3 Development 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.
4 Transfer
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.
5 Cleaning
The cleaning roller temporarily attracts the residual toner on the transferred OPC drum with static electricity, then returns the toner to the OPC drum.
6 Fusing
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
Paper
holder
section
Manual feed
Control signal
LED head
Power
supply
Exposure
Toner
cartridge
roller
Developing
Paper
supply
Transfer
Manual feed
roller
Hopping
Feed roller
Paper sensor
Transfer roller
sensor
: OPC drum rotation direction
: Paper feeding path
Power
supply
roller
Charge
Paper delivery
Charging
Power
supply
Cleaning Development
roller
Cleaning
Paper feeding
Outlet sensor
roller
Paper eject
Fusing
Power
supply
roller
Back-up
Heat roller
Figure 2-5 Flow for Electro-Photographic Process
Paper ejection Fusing Cleaning Transfer Development Paper feed Paper hopping
2 - 12
2.5.1 Explanation 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
Coil
Hopping gear
Spring for resetting
Clutch plate
Magnetic substance plate
Pin
Hopping roller
When the clutch is ON
Hopping shaft
Hopping gear
Engagement section
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
Pulse motor (main)
Hopping gear
a"
a'
Gear A
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
Transfer gear
Resist gear
Hopping gear
Triple gear
b"
b'
Gear A
The paper is further advanced in synchronization to the print data.
Idle gear
Planetary gear
b
Pulse motor (main)
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.
High-
voltage
power
supply
OPC drum
Charge roller
(4) Exposure
High-
voltage
power supply
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
Charge roller
OPC drum
LED head
2 - 15
Paper
OPC drum
(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. 3 A 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
Transfer roller
Paper
High-voltage
power supply
2 - 17
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