Okidata OKIJET 2500 Service Manual

Front Cover

Page: 1

Service Manual - OKIJET 2500

Chapter 0 Introduction

OKIJET 2500 Service Manual

P/ N 59228801

Adobe Acrobat printable reference copy

of the OKIDATA Service Training Manual.

03/20/98

Note: This Adobe Acrobat version of the Okidata Service Training Manual was built with

the pictures rendered at 300 dpi, which is ideal for printing, but does not display well

on most displays.

Table of Contents Page

Service Manual - OKIJET 2500

0 Introduction

Front Cover 1 Disclaimer/Copyright 2 About This Manual 3 Organization 4

....Section 1 - SERVICE CALL PROCEDURES 5

....Section 2 - REPAIR ANALYSIS PROCEDURES (RAPs) 6

....Section 3 - IMAGE QUALITY REPAIR ANALYSIS

PROCEDURES (RAPs)

....Section 4 - REPAIR / ADJUSTMENT PROCEDURES 8

....Section 5 - PARTS LIST 9

....Section 6 - GENERAL PROCEDURES 10

....Section 7 - WIRING DATA 11

How To Use This Manual 12 Reference Symbology 13 Special Symbols 14 Signal Nomenclature 15 DC Voltage Levels 16 Switches and Relay Contacts 17 Back Cover 18

1 Service Call Procedures

Introduction 19

....Printer Maintenance 20

....Initial Actions 21

....System Checkout / Final Action 22

2 Repair Analysis Procedures (RAPs)

Error LED On RAP 23 Power LED Blinking RAP 24 Low Ink LED(s) On RAP 25 Error LED Flashing RAP 26

1.1 Power on RAP 27

2.1 Selection/Indication RAP 28

6.1 Carriage TAP 29

6.2 Encoder RAP 30

8.1 Paper Feed RAP 31

9.1 Blank Print RAP 32

3 Image Quality RAPs

IQ 1 Image Defect Entry RAP 33 IQ 1 Image Defect Entry RAP Table 34

4 Repair / Adjustment Procedures

REP 1.0 Printhead 35 REP 1.1 Paper Tray Assembly 36

Table of Contents Page

REP 1.2 Cartridge Cover 37 REP 1.3 Top Cover 38 REP 1.4 Exit Guide 39 REP 1.5 Paper Feed / Carriage Assy. 40 REP 1.6 Power Supply 41 REP 1.7 Main Control Board 42 REP 1.8 Waste Ink Pad 43 REP 1.9 Pump 44 REP 1.10 Maintenance Station 45 REP 1.11 Encoder 46 REP 1.12 Control Panel Assembly 47 REP 1.13 Paper Path Sensor (SW 1) 48 REP 1.14 Back Pad 49 REP 1.15 Printhead Ribbon Cable 50 REP 1.16 Ink Level Sensor 51 ADJ 2.0 Printhead Alignment 52

5 Parts List

PL 1.1 Printer Components 53 PL 2.1 Paper Feed / Carriage Assembly Components (Part 1 of3)54

PL 2.1 Paper Feed / Carriage Assembly Components (Part 2 of3)55 PL 2.1 Paper Feed / Carriage Assembly Components (Part 3 of3)56 Part Number Index 57

6 General Procedures

Diagnostics 58

....GP 1 Printhead Test 59

....GP 2 Printing with DOS 60

Product Specifications 61

....Physical Characteristics 62

....Electrical Requirements 63

....Printer Capabilities 64

....Supplemental Items 65

Printer Overview and Technical Overview Introduction 66

....Printer Overview 67

........Printer Specifications 68

........Features and Operation 69

........Safety Notes 70

........Printer Installation 71

....Printer Operation 72

........Loading the paper 73

........Test print mode 74

........Connecting the printer to a computer 75

Table of Contents Page

........Control panel 76

........Printing 77

....Printer Maintenance 78

........Cleaning 79

........Replacing the Printhead 80

........Troubleshooting 81

........Removal / Replacement of the printer components 82

Technical Overview 83

....Power and Control 84

........Standby power 85

........Run control functions 86

........Main Control Board 87

........Control Panel Assembly 88

........Bi-Directional Cable 89

....Printing and Priming 90

........Printing 91

........Print control 92

........Cleaning and Priming 93

....Ink Level Sensing 94

........Ink Cartridge Present 95

........Low Ink Detection 96

........Out of Ink Detection 97

....Carriage Drive 98

........Carriage drive 99

........Carriage movement at power on 100

....Encoder 101

........Status code 102

....Paper Supply / Paper Feed 103

........Paper supply 104

........Paper feed 105

........Load and eject mechanism 106

....Sensors and status indicators 107

........Sensors 108

........Status indicators 109

7 Wiring Data

Plug / Jack Location Index 110 Plug / Jack Location Drawings 111

....Figure 7-1. Main Control Board and Power Supply 112

....Figure 7-2. Carriage Assembly (Bottom View) 113

....Figure 7-3. Carriage 114

....Figure 7-4. Front View 115

Block Schematic Diagrams (BSDs) 116

....Chain 1 AC/DC Power Generation 117

....Chain 2 Selection and Indication 118

Table of Contents Page

....Chain 3 Machine Run Control 119

....Chain 8 Paper Feed 120

....Chain 9 Print Control 121

Front Cover

Page: 1

Service Manual - OKIJET 2500

Chapter 0 Introduction

OKIJET 2500 Service Manual

P/ N 59228801

Adobe Acrobat printable reference copy

of the OKIDATA Service Training Manual.

03/20/98

Note: This Adobe Acrobat version of the Okidata Service Training Manual was built with

the pictures rendered at 300 dpi, which is ideal for printing, but does not display well

on most displays.

Service Manual - OKIJET 2500

Chapter 0 Introduction

Disclaimer/Copyright

Disclaimer

This document may not be reproduced without the written permission of Okidata Training and Publications. Every effort has been made to ensure the accuracy of the information contained in this training course. Okidata is not responsible for errors beyond its control.

Edited by:

Okidata Training and Publications

Prepared by:

Multinational Customer and Service Education Xerox Corporation, Rochester, New York 14644

Page: 2

Please address any comments on this publication to: Okidata's web site at: Telephone 609- 235- 2600 Facsimile 609- 222- 5320 Okilink Technical Training

OKIDATA is a registered trademark of Oki Electric Industry Company, Ltd.; marques deposee de Oki Electric Industry Company, Ltd.; marca registrada, Oki Electric Industry Company, Ltd.

XEROX is a trademark of Xerox Corporation

Notice

All service documentation is supplied for informational purposes only. Okidata service documentation is intended for use by certified, product trained service personnel only. Okidata does not warrant or represent that such documentation is complete, nor does Okidata represent or warrant that it will notify or provide to such customer any future changes to this documentation. Customer performed service of equipment, or modules, components or parts of such equipment may affect the warranty offered by Okidata with respect to such equipment. You should consult the applicable warranty for its terms regarding customer or third party provided service. If the customer services such equipment, modules, components or parts thereof, the customer releases Okidata from any and all liability for the customer actions, and the customer agrees to indemnify, defend and hold Okidata harmless from any third party claims which arise directly or indirectly from such service.

www.okidata.com

Page: 3

Service Manual - OKIJET 2500

Chapter 0 Introduction

About This Manual

This manual contains Repair Analysis Procedures, Repair Procedures, Adjustment Procedures, Parts List, Diagnostic Procedures, and Wiring Data information that will enable a Service Representative to repair the Printer.

Page: 4

Service Manual - OKIJET 2500

Chapter 0 Introduction

Organization

This manual is divided into seven sections. The title and description of each section are listed below.

Page: 5

Service Manual - OKIJET 2500

Chapter 0 Introduction

Section 1 - SERVICE CALL PROCEDURES

This section contains the following:

Initial Actions / System Checks



System Checkout



Final Action



Initial Actions / System Checks

This diagram identifies how to collect the data necessary to decide how to proceed with the service call. It classifies the problem and refers you to the appropriate Repair Analysis Procedure.

System Checkout

The System Checkout procedure is used to verify that the printer is operating properly after a repair has been made.

Final Action

The Final Action procedure identifies the steps that must be performed before finishing the repair.

Page: 6

Service Manual - OKIJET 2500

Chapter 0 Introduction

Section 2 - REPAIR ANALYSIS PROCEDURES (RAPs)

This section contains the Repair Analysis Procedures (RAPs) necessary to repair faults. When using a RAP, always exit the procedure when the fault is fixed. Do not perform the remaining steps.

Page: 7

Service Manual - OKIJET 2500

Chapter 0 Introduction

Section 3 - IMAGE QUALITY REPAIR ANALYSIS PROCEDURES (RAPs)

This section contains the Repair Analysis Procedures (RAPs) necessary to repair print quality faults. The first RAP, IQ 1 Image Defect Entry RAP, is used to classify a print quality problem and will reference the RAP to be used to repair the problem. When using a RAP, exit the procedure when the fault is fixed. Do not perform the remaining steps.

Page: 8

Service Manual - OKIJET 2500

Chapter 0 Introduction

Section 4 - REPAIR / ADJUSTMENT PROCEDURES

This section contains the repair and adjustment procedures for the printer.

Page: 9

Service Manual - OKIJET 2500

Chapter 0 Introduction

Section 5 - PARTS LIST

This section contains the detailed Parts List for the printer.

Page: 10

Service Manual - OKIJET 2500

Chapter 0 Introduction

Section 6 - GENERAL PROCEDURES

This section contains Diagnostic Procedures and Product Specifications for the Printer. An Overview and Technical Overview section are also included.

Page: 11

Service Manual - OKIJET 2500

Chapter 0 Introduction

Section 7 - WIRING DATA

This section contains Plug/ Jack Location Drawings and Block Schematic Diagrams (BSDs).

Page: 12

Service Manual - OKIJET 2500

Chapter 0 Introduction

How To Use This Manual

The Service Call Procedures will direct you to the proper section of the Service Manual. You should begin the service call with the Initial Actions / System Checks Procedure. From there, you will

be referenced to either Section 2, Status Indicator RAPs or Section 3, Image Quality RAPs. If you are sent to Section 3, you will perform the IQ 1 Image Defect Entry RAP to classify the print quality

problem. You will then be directed to the proper RAP to begin your troubleshooting. From these RAPs you may be referenced to other sections of the manual to make checks, adjustments or to replace parts.

When you have made a repair, return to the System Checkout / Final Action to complete the call.

Page: 13

Service Manual - OKIJET 2500

Chapter 0 Introduction

Reference Symbology

Notes, adjustments, and parts lists support the checklists and the RAP information. The symbols that refer to this supportive data are shown below.

Note

This symbol is used to refer to notes found on the same page.

Adjustments

ADJ 4.1 This symbol refers to an adjustment procedure located in Section 4 of this Service Manual. The number adjacent to the symbol indicates the number that is assigned to that adjustment.

Parts List

PL 10.6

Refers to the parts list located in Section 5 of this Service Manual. The number after the PL designation indicates the number that is assigned to that part.

Page: 14

Service Manual - OKIJET 2500

Chapter 0 Introduction

Special Symbols

Descriptions of all commonly used graphic symbols are included in order to aid in troubleshooting when using the RAPs.

Interrupt Horizontal Signal

This indicates the continuation of a signal line which is interrupted in a horizontal direction.

Standby Power Input

This indicates the continuation of a standby power line which is interrupted in the vertical direction.

Left to Right Flow

This indicates the direction of signal flow.

Feedback

This indicates a feedback signal.

Flag

This is used to identify an area of a Circuit Diagram that you should check.

Ground

This indicates a machine ground.

LED / Phototransistor Sensor

This type of sensor is used in the paper path. It uses reflected light to switch the sensor off and on.

Without Tag Change

This signal indicates that the area the triangle points to has not been modified by the tag number in the circle.

This symbol indicates that the entire page has not been modified by the tag number in the circle.

With Tag Change

This symbol indicates that the area the triangle points to has been modified by the tag number in the circle.

This symbol indicates that the entire page has been modified by the tag number in the circle.

WARNING

A warning is used to alert the personnel to an operating or maintenance procedure, practice, or condition that, if not strictly observed, could result in injury or loss of life.

CAUTION

A caution is used to alert the personnel to an operating or maintenance procedure, practice or condition that, if not strictly observed, could result in damage to, or destruction of, equipment.

Page: 15

Service Manual - OKIJET 2500

Chapter 0 Introduction

Signal Nomenclature

The signal is named to imply the condition of the machine when the signal is available. For example:

Logic state when the signal is available in its named state. In this case, the signal is LOW when a document jam is sensed.

Page: 16

Service Manual - OKIJET 2500

Chapter 0 Introduction

DC Voltage Levels

DC voltages should be measured between the test point and machine GND, unless instructed otherwise. The table below shows the values of the voltages.

Nominal Voltage

+5 VDC H +42 VDC H

Logic State Actual Voltage Ranges

+4.8 to +5.2 VDC

L L

0.0 to +1.0 VDC +39.0 to +44.0 VDC

0.0 to +3.0 VDC

Page: 17

Service Manual - OKIJET 2500

Chapter 0 Introduction

Switches and Relay Contacts

Safety interlock switch that is open.

Safety interlock switch that is closed.

Switch or relay contacts with momentary contacts shown normally open.

Switch or relay contacts with momentary contacts shown normally closed.

Back Cover

OKI

OKIJET 2500 Service Manual

P/ N 59228801

Printed in the U. S. A.

Page: 18

Service Manual - OKIJET 2500

Chapter 0 Introduction

Page: 19

Service Manual - OKIJET 2500

Chapter 1 Service Call Procedures

Introduction

Use the Service Call Procedures as a maintenance guide when performing any service on the printer.

Printer Maintenance - This section contains a list of the printer subsystem components to be cleaned



and /or lubricated and the cleaning and lubricating materials to be used, when that subsystem is accessed during a repair.

Initial Actions / System Checks - This diagram identifies and classifies the printer problem and refers



you to the appropriate RAP in order to repair the problem. When the problem has been repaired, perform the System Checkout / Final Action.

System Checkout / Final Action - This procedure should be completed at the end of every repair call



to ensure that the printer is operating properly.

Service Manual - OKIJET 2500

Chapter 1 Service Call Procedures

Printer Maintenance

Introduction

When the printer is being serviced, the following maintenance procedure should be performed.

Procedure

Clean the following parts every time the printer is serviced:

Page: 20

Description

Cover Clean using a Lint Free Tissue and water. Paper Feed Roller Clean using a Lint Free Tissue and water. Paper Feed Pinch rollers and Paper Feed Guide Clean using a Lint Free Tissue and water. Maintenance Station Clean using a Lint Free Tissue and water.

Procedure

Service Manual - OKIJET 2500

Chapter 1 Service Call Procedures

Initial Actions

1. QUESTION THE OPERATOR.

2. VERIFY, CLASSIFY AND REPAIR THE PROBLEM.

Page: 21

Service Manual - OKIJET 2500

Chapter 1 Service Call Procedures

System Checkout / Final Action

Reset the Ink Level Sensing count to zero. Perform the following:

Install a Color Printhead with empty ink cartridges.



Run a Test Print.



Remove the Printhead and install a Color Printhead with full ink cartridges.



Run a Test Print.



The NVM counts are now set to zero.



Print a file.

The Printer prints the selected file. YN

Refer to Initial Action / System Checks to begin your repair.

Evaluate the print.

Is the image quality acceptable? YN

Go to the image quality RAP identified by the IQ 1 Image Defect Entry RAP (Section 3).

Page: 22

Print and check the "Printing Alignment Test pattern".

The alignment is good. YN

Go to the Printhead Alignment Procedure (Section Four).

Clean exterior of machine. Use a lint free tissue and water. Provide a sample of the Test Print.

Service Manual - OKIJET 2500

Chapter 2 Repair Analysis Procedures (RAPs)

Error LED On RAP

Initial Action:

Ensure a color printhead is installed.

Remove the power cord from the printer for 10 seconds, then reinstall it. Press the Power switch.

The Error LED is on steady. YN

The Error LED is flashing. YN

Press and hold the

The Error LED is steady.

The Error LED is flashing.

Resume/FF

button for 2 seconds to print the demo print.

Page: 23

Check the interface cable and connectors for an open wire or bad connection. If OK, replace the Main Control Board.

Go to Error LED Flashing RAP.

Remove the power cord from the printer for 10 seconds, then reinstall it. Press and hold the Power switch for about 2 seconds.

The carriage was noisy. YN

The printhead stopped at each ink cartridge during the power-on cycle. YN

Go to 6.2 Encoder RAP.

ABCD

Go to 8.1 Paper Feed RAP.

Go to 6.1 Carriage RAP.

Go to Error LED Flashing RAP.

One or more low ink LED(s) are blinking. YN

Go to 6.1 Carriage RAP.

Go to Low Ink LED(s) on RAP.

Page: 24

Service Manual - OKIJET 2500

Chapter 2 Repair Analysis Procedures (RAPs)

Power LED Blinking RAP

Remove the power cord from the printer for 10 seconds, the reinstall it.

The Power LED blinks. YN

Printer is OK.

Go to 2.1 Selection/Indication RAP.

+ 130 hidden pages

Okidata OKIJET 2500 Service Manual

Specifications and Main Features

Frequently Asked Questions

User Manual