Okidata Okipage 4w Service Manual

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Service Guide OKIPAGE4w

Chapter 0 General Manual Information

OKIDATA OKIPAGE4w

LED Page Printer

Service Manual

Adobe Acrobat printable reference

copy of the OKIDATA Service Training Manual.

09/17/97

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 view on most displays well.

Okidata is a registered trademark, and OkiPage is a trademark of Oki Electric Industry Co., Ltd. HP, LaserJet and PCL5e are trademarks of Hewlett-Packard Co. Adobe and Acrobat are trademarks of Adobe Systems Incorporated.

Table of Contents Page

Service Guide OKIPAGE4w

0 General Manual Information

Front Cover 1 Preface 2

1 Configuration

CONFIGURATION 3 Printer Configuration 4 Specification 5 Safety Standards - Certification Label 6

....Warning Label 7

2 Operation Description

OPERATION DESCRIPTION 8 Main Control Board 9 Power Supply Unit 10 High-Voltage Power Supply Board 11 Electro-Photographic Processor 12 Electro-Photographic Process 13

....Explanation of Each Operation - Hopping 14

....Printing and warm-up 15

....Charging 16

....Exposure 17

....Development 18

....Transfer 19

....Fusing 20

....Cleaning 21

Paper Jam Detection 22 Toner Low Detection 23 Cover Open 24

3 Parts Replacement

Parts Replacement 25 Precautions for Parts Replacement 26 Parts Layout 27

....Base Frame Unit 28

....Base Plate Unit 29

Replacing Parts 30

....Extend Plate 31

....LED Head and Head Spring 32

....Transfer Roller 33

....Upper Cover Assy 34

....High-Voltage Power Supply Board 35

....Top Cover Assy and Flat Cable Assy 36

....Paper Holder 37

....Side Plate M and Idle Gear 38

....Registration Roller 39

....Eject Roller Shaft and Eject Roller 40

....Fuser Assy 41

....Pressure Roller B (Back Up Roller) 42

....Separator Guide 43

....Pulse Motor (Main) 44

....Hopping Shaft Assy 45

Table of Contents Page

....Paper Sensor E, Paper Sensor Exit and Toner Sensor Assy 46

....Base Plate 47

4 Adjustment

Adjustment 48

....Adjustment Types and Functions 49

....Adjustment When Replacing a Part 50

5 Periodical Maintenance

Periodical Maintenance - Periodical Replacement Parts 51 Cleaning 52

6 Troubleshooting Procedures

Troubleshooting Procedures - Troubleshooting Tips 53 Check Points Before Correcting Image Problems 54 Notes When Correcting Image Problems 55 Preparation Before Troubleshooting 56 Troubleshooting 57

....Status Monitor Message List 58

....Status Message Troubleshooting 59

........The OKIPAGE 4w malfunctions after the power supply has

been turned on.

........[JAM error] - Paper input jam 61

........[JAM error] - Paper feed jam 62

........Paper exit jam 63

........Paper size error 64

........Fuser assy error 65

....Image Troubleshooting 66

........An image is light or blurred entirely. 67

........Dark background density 68

........Paper is blank. 69

........Vertical black band/stripe 70

........Cyclic defect 71

........Print voids. 72

........Poor fusing 73

........Vertical white band/stripe 74

........Figure 6-4 75

........Figure 6-5 76

7 Wiring Diagram

Wiring Diagram - Interconnect Signal Diagram 77 PCB Layout 78

8 Parts List

Cover Assy Upper 79 Base Frame Unit 80 Base Plate Unit 81

A Local Printing

Local Printing 82

B Parallel Interface

Parallel Interface - (1) Connector 83 Cable 84 Parallel I/F signals 85 Signal level 86 Interface circuit 87

Table of Contents Page

Timing charts 88

C Maintenance Utility

Maintenance Utility - Outline Of Maintenance Utility 89 ROLE OF MAINTENANCE UTILITY 90 OUTLINE OF MAINTENANCE UTILITY FUNCTIONS 91 DETAIL OF EACH FUNCTION - Engine Menu Setting 92

....Engine Counter 93

....Exit 94

....Printer Status 95

....Test Print 96

....Option 97

....About 98

....Reload 99

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Service Guide OKIPAGE4w

Chapter 0 General Manual Information

PREFACE

This Service Manual describes the maintenance procedures for OKIPAGE 4w LED Page Printers. This manual is written for use by service personnel. Refer to the customer documentation for handling and operating procedures.

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Service Guide OKIPAGE4w

Chapter 1 Configuration

1. CONFIGURATION

1.1 System Configuration The OKIPAGE 4w consists of a control block, a power supply unit, and an engine block. (See Figure 1-1.)

Figure 1-1

Service Guide OKIPAGE4w

Chapter 1 Configuration

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.

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Figure 1-2

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(2) Outside dimensions Height 5.9" (150 mm) (excludes protruding Width 12.2" (310 mm) portion) Depth 7.5" (191 mm)

Service Guide OKIPAGE4w

Chapter 1 Configuration

Specification

(1) Type Desktop

(3) Weight 1.71 lb (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/m 2 ) – Manual feed: Label, Envelope, OHP paper (transparency)

(6) Printing speed First print: 25 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 temperature 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 (12) Temperature and humidity

Caution: Temperature and humidity in storage are measured with the OKIPAGE 4w 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 continuous printing)

Service Guide OKIPAGE4w

Chapter 1 Configuration

Safety Standards

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

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Service Guide OKIPAGE4w

Chapter 1 Configuration

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.

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Service Guide OKIPAGE4w

Chapter 2 Operation Description

OPERATION DESCRIPTION

The OKIPAGE 4w consists of a main control board, a high-voltage power supply board, a power supply unit, and an electro-photographic processor. The OKIPAGE 4w receives print data from a higher-level interface and sequentially stores it in memory. The OKIPAGE 4w 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 electro-photographic 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.

Figure 2-1 Block Diagram

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Service Guide OKIPAGE4w

Chapter 2 Operation Description

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 an 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.

(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.

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Service Guide OKIPAGE4w

Chapter 2 Operation Description

Power Supply Unit

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

The power supply unit also contains a heater drive circuit.

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Service Guide OKIPAGE4w

Chapter 2 Operation Description

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.

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

Figure 2-2

Sensor Function Sensing State

Manual feed sensor

Paper sensor Detects the leading edge of the paper.

Outlet sensor Monitors paper feeding and the paper size

Monitors whether paper was inserted into the manual feed sensor section.

Monitors paper feeding.

according to the paper sensor arrival and

ON: Paper exists. OFF: No paper exists.

passing time.

Toner sensor Detects the low toner status. ON (long): Toner low

OFF (short): Toner high

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Service Guide OKIPAGE4w

Chapter 2 Operation Description

Electro-Photographic Processor

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

(1) Image drum unit The image drum unit makes toner adhere to the electrostatic latent image with static electricity. This electrostatic latent image is formed by light from the LED heads.

(2) Electromagnetic clutch The electromagnetic clutch controls the rotation of the hopping roller according to signals from the control board.

(3) Pulse motor (Main) This pulse motor of 48 steps/rotation is two-phase controlled by the signal from the main control board; it controls feeding by changing rotation direction and turning on/off the electromagnetic clutch. The relationship between the main motor, electromagnetic clutch, regist gear, drum gear, and hopping roller is shown in the table below and on the subsequent pages.

Main Motor Electromag-

netic Clutch

Hopping Roller

Regist Gear Drum Gear Operation

Normal

OFF Non-rotation Non-rotation Rotation Warm-up

rotation Reverse

ON Rotation Rotation Rotation Hopping

rotation Reverse

OFF Non-rotation Rotation Rotation Printing

rotation

(4) LED head The shift and latch registers receive image data from the main control board for each dot line. They control the 2,560 or 2,496 LEDs, which illuminate the image drum.

(5) Fuser Assy The fuser Assy consists of a heater, a heat roller, a thermistor, and a thermostat. The power supply unit applies AC voltage to the heater according to the HEATON signal from the main control board; this heats 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 voltage.

If the heat roller temperature rises abnormally, the thermostat in the heater voltage supply circuit cuts off the AC voltage supply.

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Service Guide OKIPAGE4w

Chapter 2 Operation Description

Electro-Photographic Process

(1) Electro-photographic process The electro-photographic process is outlined below. 1 Charging

The surface of the image drum is given a uniform negative charge by applying DC voltage to the CH roller.

2 Exposure Light emitted from the LED head illuminates the negatively charged surface of the image drum. The surface potential of the lighted 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 image drum, adhering to the electrostatic latent image on the image 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 image drum is attracted to the developing rollerby static electricity.

4 Transfer When paper is placed over the image drum surface, the transfer roller applies a positive charge--which is opposite in polarity to that of the toner--to the reverse side. The toner is attracted by the positive charge and transfers the toner image from the image drum onto the paper.

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

6 Fusing The transferred toner image is fused to the paper by applying heat and pressure . Figure 2-5 is a flow diagram of the electro-photographic process.

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Service Guide OKIPAGE4w

Chapter 2 Operation Description

Explanation of Each Operation

(1) Hopping As shown in the figure below, the clutch for hopping is turned on/off according to whether current to the coil is on or off.

When the clutch is OFF

When the clutch is ON

When the clutch is on, the hopping gear engages with the clutch plate to turn the hopping roller. When the clutch is off, the hopping gear is separated from the clutch plate by the spring for resetting, so that the hopping roller does not turn.

Printing and warm-up

At warm-up

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Service Guide OKIPAGE4w

Chapter 2 Operation Description

Rotate the pulse motor (main) in direction a. The planetary gear rotates in direction a', dislocating its position in direction a''. 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 image drum unit. At printing

The paper advances further in synchronization with the print data.

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Service Guide OKIPAGE4w

Chapter 2 Operation Description

Charging

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

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Service Guide OKIPAGE4w

Chapter 2 Operation Description

Exposure

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

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Service Guide OKIPAGE4w

Chapter 2 Operation Description

Development

Toner is attracted to the electrostatic latent image on the image drum surface, converting it into a visible toner image. Developing occurs through contact between the image drum and the developing roller.

1 As the toner supply roller rotates while rubbing on the developing roller, a friction charge is generated between the developing roller and the toner, attracting the toner to the developing roller. (The developing roller surface has a positive charge, while the toner has a negative charge.)

2 The toner attracted to the developing roller is scraped off by the developing blade, forming a thin coat of toner on the developing roller surface.

3 Toner is attracted to the exposed (low-potential) portion of the image drum at the point of contact between the image drum and the developing roller, making the electrostatic latent image visible.

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Service Guide OKIPAGE4w

Chapter 2 Operation Description

Transfer

The transfer roller is composed of conductive sponge material. It is designed to bring the image drum and the paper into close contact.

A sheet of paper is placed over the image drum surface, and a positive charge, opposite to that of the toner, is applied to the paper from the reverse side.

High voltage from the power supply creates a positive charge on the surface of the transfer roller, which, in turn transfers the charge to the paper as it contacts the transfer roller. The image drum surface attracts the negatively charged toner, and the toner transfers to the paper as a result of the positive charge on the reverse side of the paper.

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Okidata Okipage 4w Service Manual

Specifications and Main Features

Frequently Asked Questions

User Manual