Okidata OL810e Service Manual
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Service Guide OL810e
Chapter 0 About This Manual
OL810e
LED Page Printer
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.
Copyright 1997, Okidata, Division of OKI America, Inc. All rights reserved. See the OKIDATA Business
Partner Exchange (BPX) for any updates to this material. (http://bpx.okidata.com)
Table of Contents Page
Service Guide OL810e
0 About This Manual
Front Cover 1
Manual Copyright 2
1 Configuration
1.1 System Configuration 3
1.2 Printer Configuration 4
1.3 Options available for use with OL810e 5
1.4 Specification 6
1.5 Safety Standards - Certification & Warning Labels 7
....1.5.3 Warning/Caution Marking 8
2 Operation Description
Operation Description 9
2.1 Main Control Board 10
2.2 Power Supply/Sensor Board 11
2.3 Electrophotographic Process 12
....2.3.2 Electrophotographic Process 13
....2.3.3 Process Operation Descriptions 14
....2.3.4 Revision of LED Head Illumination 15
2.4 Paper Jam Detection 16
2.5 Cover Open 17
2.6 Toner Low Detection 18
3 Parts Replacement
Parts Replacement 19
3.1 Precautions for Parts Replacement 20
3.2 Parts Layout 21
3.3 How to Change Parts 22
....3.3.1 Upper Cover Assy 23
....3.3.2 IC Card Cover 24
....3.3.3 LED Head 25
....3.3.4 Operator Panel Assy 26
....3.3.5 Pulse Motor (Main/Drum) 27
....3.3.6 Pulse Motor (Registration) 28
....3.3.7 Face Up Stacker Assy 29
....3.3.8 Lower Base Unit 30
....3.3.9 Eject Roller Assy 31
....3.3.10 Motor Assy 32
....3.3.11 Hopping Roller Shaft Assy 33
....3.3.12 Stacker Cover Assy 34
....3.3.13 Registration Roller 35
....3.3.14 Transfer Roller 36
....3.3.15 Fusing Unit 37
....3.3.16 Back-up Roller 38
Table of Contents Page
....3.3.17 Sensor Plate (Inlet) 39
....3.3.18 Sensor Plate (Outlet) 40
....3.3.19 Manual Feed Guide Assy 41
....3.3.20 Sensor Plate (Paper Supply) 42
....3.3.21 TQCB-PCB 43
....3.3.22 Transformer 44
....3.3.23 Power Supply/Sensor Board and Contact Assy 45
....3.3.24 Cassette Guide L Assy 46
....3.3.25 Cassette Guide R Assy 47
4 Adjustments
Adjustment 48
....4.1.1 User Maintenance Mode 49
....4.1.2 System Maintenance Mode 50
....4.1.3 Engine Maintenance Mode 51
....4.1.4 EEPROM initialization 52
4.2 Adjustment When Replacing a Part 53
....4.2.1 Setting of LED Head Drive Time 54
5 Periodical Maintenance
5.1 Periodical Replacement Parts 55
5.2 Cleaning 56
....5.2.1 Cleaning of LED Lens Array 57
........Cleaning Page Function 58
5.3.1 Lubrication 59
6 Troubleshooting
6. Troubleshooting Procedures 60
6.1 Troubleshooting Tips 61
6.2 Points to Check before Correcting Image Problems 62
6.3 Tips for Correcting Image Problems 63
6.4 Preparation for Troubleshooting 64
6.5 Troubleshooting Flow 65
....6.5.1 LCD status message/problem list 66
....6.5.2 LCD message troubleshooting 67
........1 Printer doesn't work normally after the power is turned
on.
........2 - 1 Paper input jam 69
........2 - 2 Paper feed jam 70
........2 - 3 Paper exit jam 71
........3 Paper size error 72
........4 Fusing unit error (ERROR 71) (ERROR 72) (ERROR
73)
........5 Synchronous serial I/O error (ERROR 74) or I/F timeout
between printer and optional tray (ERROR 81)
........6 Fan error (ERROR 70) 75
....6.5.3 Image troubleshooting 76
68
73
74
Table of Contents Page
........1 Images are light or blurred entirely. 77
........2 Dark background density 78
........3 Blank paper is output. 79
........4 Black vertical belts or stripes 80
........5 Cyclical defect 81
........6 Prints voids 82
........7 Poor fusing (images are blurred or peels off when the
printed characters and images on the paper are touched by
hand)
........8 White vertical belts or streaks 84
7 Wiring Diagrams
7.1 Interconnect Signal Diagram 85
7.2 PCB Layout and Connector Signal List 86
....FAN Pin Assignment (To fan motor) 87
....DM Pin Assignment (To main/drum motor) 88
....RM Pin Assignment (To registration motor) 89
....HEAD1 Pin Assignment (To LED head) 90
....HEAD2 Pin Assignment (To LED head) 91
....PANEL Pin Assignment (To operator panel) 92
....2ND TRAY Pin Assignment (To option feeder I/F) 93
....Power Pin Assignment 94
....CENT Pin Assignment 95
....SERIAL Pin Assignment (To RS232C) 96
....CARD Pin Assigment 97
....OPTION Pin Assignment 98
....7.3 Resistance Check 99
7.4 Short Plug Setting 100
8 Parts List
Lower Base Unit 101
............Part #25 Face down Stacker Assy : Jim
Homeuser/Okidata; 10/14/96
Upper cover unit 103
Base Unit 2 104
A RS-232 Interface
Rs-232C Serial Interface 105
....Interface Parameter Setting 106
B Centronics Parallel Interface
Centronics Parallel Interface 107
....Interface Parameter Setting 108
C Loop Test (RS-232C Interface)
Loop Test (Rs-232C Interface) 109
D Diagnostic Tests
1. Maintenance Modes 110
....1.1 User Maintenance Mode 111
83
102
Table of Contents Page
....1.2 System Maintenance Mode 112
....1.3 Engine Maintenance Mode 113
....1.4 User Factory Set Operation 114
E Option: Multi-Purpose Feeder
Multi-Purpose Feeder Paper Specifications 115
....External View and Component Names 116
....Mechanism Description 117
....Parts Layout 118
....Parts Replacement Methods 119
........3.3.1 Link 120
........3.3.2 Separator 121
........3.3.3 OLEV-11-PCB 122
........3.3.4 Pulse Motor 123
........3.3.5 Planet Gear 124
........3.3.6 Roller-A and B 125
....Troubleshooting Problems with the Multi-Purpose Feeder 126
....Multi-Purpose Feeder Connection Diagram 127
....Multi-Purpose Feeder Parts List 128
F Option: Second Paper Mech.
Second Paper Mech. Paper Specifications 129
....External View and Component Names 130
....Mechanism Description 131
Parts Replacement 132
....Parts Layout 133
....Parts Replacement Methods 134
........3.3.1 Pulse Motor (Hopping) 135
........3.3.2 TQSB-PCB 136
........3.3.3 Hopping Roller Assy and One-way Clutch Gear 137
Troubleshooting the 2nd Paper Tray Mech. 138
Second Paper Mech. Connection Diagram 139
....Second Paper Mech. PCB Layout TQSB-PCB 140
Second Paper Mech. Parts List 141
Page: 2
Service Guide OL810e
Chapter 0 About This Manual
OKIDATA is a registered trademark of Oki America, Inc.
OKIDATA est une marque déposée de Oki America, Inc.
Copyright 1997, Okidata, Division of OKI America, Inc. All rights reserved. See the OKIDATA Business
Partner Exchange (BPX) for any updates to this material. (http://bpx.okidata.com)
Service Guide OL810e
Chapter 1 Configuration
1.1 System Configuration
OL810e consists of control and engine blocks in the standard configuration, as shown in Figure 1-1.
In addition, the options marked with asterisk (*) are available.
Figure 1-1
Page: 3
Note:
Power Envelope Feeder is compatible with OL400e series printers.
Copyright 1997, Okidata, Division of OKI America, Inc. All rights reserved. See the OKIDATA Business
Partner Exchange (BPX) for any updates to this material. (http://bpx.okidata.com)
Service Guide OL810e
Chapter 1 Configuration
1.2 Printer Configuration
The printer unit consists of the following hardware components:
- Electrophotographic Processor
- Paper Feeder
- Controller
- Operator Panel
- Power Supply Unit
The printer unit configuration is shown in Figure 1-2.
Page: 4
Copyright 1997, Okidata, Division of OKI America, Inc. All rights reserved. See the OKIDATA Business
Partner Exchange (BPX) for any updates to this material. (http://bpx.okidata.com)
Service Guide OL810e
Chapter 1 Configuration
1.3 Optional Configuration
The options shown below are available for use with OL810e. These are available separately from
the printer unit.
(1) Memory Expansion Board (1MB to 32MB)
Page: 5
(2) SIMM Memory SIMM memory is available with memory of 1MB (min.) to 16MB (max.). The
access time of SIMM memories are 60ns, 70ns, 80ns, and 100ns.
(3) IC Card
(4) Universal Paper Cassette
(5) High Capacity Second Paper Feeder
(6) Power Envelope Feeder
Copyright 1997, Okidata, Division of OKI America, Inc. All rights reserved. See the OKIDATA Business
Partner Exchange (BPX) for any updates to this material. (http://bpx.okidata.com)
Page: 6
Service Guide OL810e
Chapter 1 Configuration
1.4 Specification
(1) Type Desktop
(2) External dimensions Height 7.9 (200 mm) (excludes protruding Width 12.8 (370 mm) portion) Depth
14.6 (370 mm)
(3) Weight 10 kg
(4) Developing method Dry electrophotography Exposing 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>
- Standard sizes Letter Legal Executive CON-10 Monarch DL C5 COM-9 Envelope A4 A5 B5
(JIS) A6
- Applicable sizes Width: 3.87 to 8.5 (116 to 216 mm) Length: 5.83 to 14 (148 to 355.6 mm)
<Thickness> Automatic feed: 16 to 36 lbs (60 to 135 g/m 2 ) Manual feed: Label, OHP paper
(transparency) Envelope
(6) Printing speed First print: 25 sec. Continuous print: 8 sheets/min. for letter size paper Warm-up time:
60 sec. [at room temperature 77°F (25°C) and rated voltage (120 VAC)]
(7) Paper feeding method Automatic feed or manual feed
(8) Paper delivery method Face down/face up
(9) Resolution 600 x 600 dots/inch
(10) Power input 120 VAC + 5.5%, -15% 230 VAC + 6%, -14% 230 VAC + 10%, -10%
(11) Power consumption Peak: Approx. 600W Typical operation: Approx. 130W Idle: Approx. 41W
Power save mode: Approx. 13W
(12) Temperature and humidity During operation: 50 to 90°F (10 to 32°C) In storage: -14 to 112°F (-20 to
50°C)
(13) Noise During operation: 48 dB (A) or less Standby: 36 dB (A) or less Quiet mode: 32 dB (A) or less
(14) Consumables Toner cartridge kit 2,000 (5% duty) Image drum cartridge 20,000 (at continuous
printing) 15,000 (3 page/job) 10,000 (1 page/job)
Copyright 1997, Okidata, Division of OKI America, Inc. All rights reserved. See the OKIDATA Business
Partner Exchange (BPX) for any updates to this material. (http://bpx.okidata.com)
Service Guide OL810e
Chapter 1 Configuration
1.5 Safety Standards
1.5.1 Certification Label
The safety certification and serial number labels are affixed to the printer in the positions
described below.
Page: 7
1.5.2 Warning Label
The warning labels are affixed to the sections which may cause bodily injury.
Follow the instructions on warning labels during maintenance.
Copyright 1997, Okidata, Division of OKI America, Inc. All rights reserved. See the OKIDATA Business
Partner Exchange (BPX) for any updates to this material. (http://bpx.okidata.com)
Service Guide OL810e
Chapter 1 Configuration
1.5.3 Warning/Caution Marking
The following warning and caution markings are made on the power supply/sensor board.
Page: 8
ENGLISH Heatsink and transformer core present risk of electric shock. Test before touching.
FRENCH Le dissipateur thermique et le noyau du transformateur présentent des risques de choc
électrique. Testez avant de manipuler.
SPANISH Las disipadores de color el núcel del transformador pueden producir un choque
eléctrico. Compruebe antes de tocar. PORTUGUESE O dissipador de calor e o núcleo do
fransiormador apresentam risco de choque elétrico. Teste antes de focar.
ENGLISH Circuits maybe live after fuses open.
FRENCH Il se peut que les circuits soient sous tension une fois que les fusibles ont éfé rerirés.
SPANISH Las circuitos pueden estar activos una vez que se hayan abierio los fusibles.
PORTUGUESE Os circuitos podem estar energizados após os fusiveis se queimarem.*
Copyright 1997, Okidata, Division of OKI America, Inc. All rights reserved. See the OKIDATA Business
Partner Exchange (BPX) for any updates to this material. (http://bpx.okidata.com)
Service Guide OL810e
Chapter 2 Operation Description
2. OPERATION DESCRIPTION
OL810e consists of a main control board, a power supply/sensor board, an operator panel, an
electrophotographic process mechanism, and revision for illumination of LED head.
The main control board receives data via the host I/F, it then decodes, edits and stores the data in
memory. After completing the editing of a single page of data, it references the font memory and
generates bit image data, which is transferred to the LED head in one dot line units.
Through the electrophotographic process mechanism, the data is printed on the paper.
The operator panel is used for operations and status display.
OL810e block diagram is shown in Figure 2-1.
Page: 9
Copyright 1997, Okidata, Division of OKI America, Inc. All rights reserved. See the OKIDATA Business
Partner Exchange (BPX) for any updates to this material. (http://bpx.okidata.com)
Page: 10
Service Guide OL810e
Chapter 2 Operation Description
2.1 Main Control Board
The main control board consists of a single chip CPU, a program ROM, a font ROM, four DRAMs, an
EEPROM, a host interface circuit, and a mechanism driving circuit.
(1) Single chip CPU
The single chip CPU is a custom CPU (32-bit internal bus, 32-bit external bus, 25.54-MHz clock, with input
frequency from a 12.27-MHz clock) which incorporates the RISC CPU and its peripheral devices, and has
the following functions:
Built-in device
Chip select controller Control of ROM, DRAM and I/O device Bus controller
DRAM controller
DMA controller Transfer of image data from DRAM to video output port
Parallel interface controller Control of Centronics parallel interface
Serial interface controller Control of RS-232C serial interface
Video output port Control of LED head
LED STB output port
Timer Generation of various control timing
Serial I/O port Control of operator panel, EEPROM, and options
I/O port Input and output of sensor and motor signals
(2) Program and Font ROMs
The Program and Font ROMs store the equipment program and various types of fonts. EPROM or Mask
ROM is used as Program and Font ROMs. The mounting locations of these Program and Font ROMs vary
depending on the type of the ROMs (for the mounting location see Section 7.4).
Function
Monitoring of paper running and paper size
(3) DRAM
The DRAM is a 2MB resident memory which is used as a buffer, that stores edited data, image data, DLL
data and macro data.
(4) EEPROM
1,024-bit Electrically Erasable PROM (EEPROM), is loaded with the following kinds of data:
- Menu data
- Various counter data (page counter, drum counter)
- Adjusting parameters (LED head drive time, print start position, paper feed length)
(5) Parallel Interface
Parallel data is received from a host system via parallel interface which conforms to the Centronics
specification.
(6) RS232C Serial Interface
Serial data is sent to and received from a host system via serial interface which conforms to EIA RS232C.
Following items are selectable:
Flow control: DTR HI/DTR LO/XONXOFF/RBSTXON
Baud rate: 300/600/1200/2400/4800/9600/19200
Data bits: 7 BITS/8 BITS
Parity: NONE/EVEN/0DD
Minimum busy: 200 mSEC/1 SEC
Copyright 1997, Okidata, Division of OKI America, Inc. All rights reserved. See the OKIDATA Business
Partner Exchange (BPX) for any updates to this material. (http://bpx.okidata.com)
Page: 11
Service Guide OL810e
Chapter 2 Operation Description
2.2 Power Supply/Sensor Boar
The power supply/sensor board consists of an AC filter circuit, a low voltage power supply circuit, a high
voltage power supply circuit, heater drive circuit, and photosensors.
(1) Low Voltage Power Supply Circuit
This circuit generates the following voltages.
Output voltage Use
+5 V Logic circuit supply voltage
+30 V Motor and fan drive voltage and source voltage for high-voltage supply
+8 V RS-232C line voltage
+8 V RS-232C line voltage and PS board supply voltage
+3.3V LED head supply voltage
(2) High Voltage Power Supply Circuit
This circuit generates the following voltages required for electrophotographic process from +5 V,
according to the control sequence from the main control board. When cover open state is detected, +5 V
supply is interrupted automatically to stop the supply of all high-voltage outputs.
Output
CH -1.35 KV Voltage applied to charging roller
DB -300 V/+300 V Voltage applied to developing roller
SB -450 V/ 0 V Voltage applied to toner supply roller
TR +500 V to +4 KV/-750 V Voltage applied to transfer roller Variable
CB +400 V Voltage applied to clearing roller
(3) Photosensor
The photosensor mounted on this power supply/sensor board monitors the status of paper being fed
through the printer during printing.
Voltage Use Remarks
The sensor layout diagram is shown in Figure 2-2.
Function Sensing state
Inlet sensor 1 Detects the leading part of
the paper and gives the
monitor timing for switching
from hopping operation to
feeding operation. Monitors
paper feeding situation and
paper size based on the
paper arrival time and
running time.
Intel sensor 2 Detects the paper width. ON: A4 or larger OFF:
Paper sensor Detects the leading portion of
the paper. Monitors the paper
feeding situation.
Outlet sensor Monitors the paper feeding
and size according to the
time of arrival to and leaving
past the sensor.
Paper end sensor Detects the end of the paper. ON: Paper exists. OFF: No
Toner low sensor Detects the lack of toner
Sensor
ON: Paper exists. OFF: No
paper exists.
Smaller than A4
ON: Paper exists. OFF: No
paper exists.
ON: Paper exists. OFF: No
paper exists.
paper exists.
- - - - -
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Partner Exchange (BPX) for any updates to this material. (http://bpx.okidata.com)
Page: 12
Service Guide OL810e
Chapter 2 Operation Description
2.3 Electrophotographic Process
2.3.1 Electrophotographic Process Mechanism
This mechanism actuates the printing of image data supplied by the main control board on the paper by
electrophotographic process.
The layout of the electrophotographic process mechanism is shown in Figure 2-3.
(1) Image Drum Unit
The image drum unit consists of a sensitive drum, a charger, and a developer. The unit forms a toner
image on the sensitive drum, using a electrostatic latent image formed by the LED head.
(2) Registration Motor
The registration motor is a pulse motor of 48 steps/rotation with two-phase excitement by the signal from
the main control board. It drives the hopping and registration rollers via two one-way clutches according to
the direction of rotation.
(3) Main (Drum) Motor
The main or drum motor is a pulse motor of 48 steps/rotation with two-phase excitement by the signal
from the main control board and is the main motor of this mechanism.
(4) LED Head
Image data for each dot line from the main control board is received by the shift register and latch register.
The 4992 LED's are driven to radiate the image data on the image drum.
(5) Fuser
The fuser consists of a heater, a heat roller, a thermistor and a thermostat.
The AC voltage from the power supply/sensor board is applied to the heater controlled by the HEATON
signal from the main control board. This AC voltage heats the heater. The main control board monitors the
heat roller temperature via the thermistor, and regulates the heater roller to keep it at a designated
temperature in the menu, depending on the thickness of the paper (tray 1&2: light=165°C, medium
light=170°C, medium=175°C, medium heavy and heavy=195°C; manual feeding and power envelope
feeder: light=175°C, medium light=180°C, medium=185°C, medium heavy=190°C, heavy=195°C) by
connecting or disconnecting the AC voltage supply to the heater.
When an abnormal rise of the heater roller temperature takes place, the thermostat of the heater voltage
supply circuit becomes active and forcibly cuts the AC voltage supply.
The temperature setting of the fuser can be changed through operator panel setting.
Copyright 1997, Okidata, Division of OKI America, Inc. All rights reserved. See the OKIDATA Business
Partner Exchange (BPX) for any updates to this material. (http://bpx.okidata.com)
Page: 13
Service Guide OL810e
Chapter 2 Operation Description
2.3.2 Electrophotographic Process
The electrophotographic processing is outlined below. The electrophotographic printing process is shown
in Figure 2-4.
1 Charging
The surface of the image drum is charged uniformly with a negative charge by applying the negative
voltage to the charge roller.
2 Exposure
Light emitted from the LED head irradiates the negatively charged surface of the image drum. The surface
potential of the irradiated portion of the image drum surface becomes lower, forming the electrostatic
latent image associated with the print image.
3 Developing and toner recovery
When the negatively charged toner is brought into contact with the image drum, it is attracted to the
electrostatic latent image by static electricity, making the image visible.
At the same time, the residual toner on the image drum is attracted to the developing roller by 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 of the paper 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 Temporary cleaning
Residual toner which remains on the image drum without being transferred is evened out by the cleaning
roller and is temporarily attracted to the cleaning roller by static electricity.
6 Fusing
The toner image transferred onto the paper is fused to the paper by heat and pressure.
An electrophotographic process timing chart is shown in Figure 2-5.
Copyright 1997, Okidata, Division of OKI America, Inc. All rights reserved. See the OKIDATA Business
Partner Exchange (BPX) for any updates to this material. (http://bpx.okidata.com)
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