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Okidata Color 8(n) Service Manual


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                                                          Service Guide - OKICOLOR8                       Page: 1
                                                                 Chapter 0 Introduction


Front Cover




                    Service Guide
                                  OKICOLOR 8 & OKICOLOR 8n
                                    Digital LED Page Printers


                                    Adobe Acrobat printable reference copy
                                   of the OKIDATA Service Training Manual.
                                                  12/20/99




              Note: This Adobe Acrobat version of the Okidata Service Training Manual was built with the pictures
                     rendered at 72 dpi, which is ideal for screen viewing. For future updates to this manual, and
                     more on-line information visit our Business Partner Exchange (BPX) at
                     http://bpx.okidata.com.
                      Copyright 1999, Okidata, Division of OKI America, Inc. All rights reserved.
      Table of Contents                                               Page

Service Guide - OKICOLOR8
   0 Introduction
       ....Preface                                                     2
   1 Specifications
       1.1 Basic System Configuration                                  3
       1.2 Printer Specifications                                      4
       1.3 Option Specifications                                       5
       1.4 Basic Specifications                                        6
   2 Operation
       2. Operation                                                    7
       2.1 Main Control Board (PCE PCB)                                8
       2.2 Engine Control Board (PX4 PCB)                              9
       2.3 Power/Board                                                 10
       2.4 Mechanical Processes                                        11
       ....2.4.1 Electrophotographic processing mechanism              12
       ....2.4.2 Paper running process                                 13
       2.5 Sensors                                                     14
       ....2.5.1 Paper Related Sensors                                 15
       ....2.5.2 Other sensors                                         16
       2.6 Correction of Color Deviation                               17
       2.7 Transfer Control according to Environmental Changes         18
       2.8 Form Jam Detection                                          19
       2.9 Cover Opening                                               20
       2.10 Toner Lower Detection                                      21
       2.11 Page Size Detection                                        22
       2.12 Power-on Processing                                        23
   3 Disassembly
       3.0 Parts Replacement                                           24
       3.1 Precautions for Parts Replacement                           25
       3.2 Parts Layout                                                26
       3.3 How to Change Parts                                         27
       ....3.3.1 Cover Assy Rear                                       28
       ....3.3.2 Motor-Fan (80-25)                                     29
       ....3.3.3 Paper Eject Assy                                      30
       ....3.3.4 Cover Assy Stacker, Guide Eject FD Assy               31
       ....3.3.5 Upper Frame Assy                                      32
       ....3.3.6 Plate Support Assemblies                              33
       ....3.3.7 Limiter 2way (L), (R) / Plate Guide (L), (R)          34
       ....3.3.8 Cover                                                 35
       ....3.3.9 PCE PCB Assy                                          36
       ....3.3.10 Motor Fan (CU)                                       37
       ....3.3.11 PXF PCB / PX4 PCB                                    38
       ....3.3.12 Gear Heat Assy                                       39
       ....3.3.13 Main Motor (A), (B) Assy                             40
       ....3.3.14 Gear One-way (Z30)                                   41
       ....3.3.15 Motor Assy Belt                                      42
       ....3.3.16 Power Supply Unit, Holder Inlet, Sheet Insulation    43
       ....3.3.17 Sensor Assy Box Toner                                44
       ....3.3.18 Square-shaped Connector                              45
       ....3.3.19 Motor - Pulse (ID)                                   46
       ....3.3.20 One-way Gears                                        47
   Table of Contents                                                 Page
    ....3.3.21 Feeder Unit Front                                      48
    ....3.3.22 Manual Feed Hopper Assy                                49
    ....3.3.23 Guide Paper Input Assy                                 50
    ....3.3.24 Two Lever Input Sensors, Lever 2nd Feed Sensor         51
    ....3.3.25 Roller Registration, Roller Assy Hopping               52
    ....3.3.26 Hopping Roller Assy                                    53
    ....3.3.27 PXU PCB/PXM PCB, Lever Resist Sensor                   54
    ....3.3.28 Paper End Lever                                        55
    ....3.3.29 PCO PCB (Operator Panel)                               56
    ....3.3.30 Holder Gear Toner Assy                                 57
    ....3.3.31 Plate Latch Lever (FD), Spring Latch Lever (FD)        58
    ....3.3.32 Transfer Belt                                          59
    ....3.3.33 High Voltage Power Supply Unit, Bracket HV (BT)        60
    Assy
    ....3.3.34 Eraser Bracket Assy, Eraser Bracket (KCM) Assy         61
    ....3.3.35 Shaft Link                                             62
    ....3.3.36 Contact Bracket (BL-R) Assy, Contact Bracket (CL-R)    63
    Assy
    ....3.3.37 Contact (BL-L) Assy, Contact (CL-L) Assy               64
    ....3.3.38 Contact SB Assy                                        65
    ....3.3.39 PXC PCB                                                66
    ....3.3.40 Heat Unit Assy (Fuser unit and oil roller)             67
    ....3.3.41 Oil Roller Kit                                         68
    ....3.3.42 Lever Lock Heat (L)/(R), Guide Side Heat, Spring       69
    Lock
    ....3.3.43 PXL PCB                                                70
    ....3.3.44 Heat Unit Guide Assy                                   71
    ....3.3.45 Holder LED Assy, LED Head                              72
4 Adjustments
    4. Adjustments                                                    73
    4.1 Maintenance Modes and Their Functions                         74
    ....4.1.1 User maintenance mode                                   75
    ....4.1.2 System maintenance mode                                 76
    ....4.1.3 Engine maintenance mode                                 77
    4.2 Adjustments after Parts Replacement                           78
    ....4.2.1 Confirm the LED head driving time                       79
    ....4.2.2 Color Registration Using the Operator Panel (Color      80
    deviation correction)
5 Maintenance
    Periodic Maintenance                                              81
    ....5.1 Periodically Replaced Parts                               82
    ....5.2 Cleaning                                                  83
    ....5.3 Cleaning the LED Lens Array                               84
    ....5.4 Cleaning the Pickup Roller                                84
6 Troubleshooting Procedures
    6.0 Troubleshooting Procedures                                    85
    ....6.1 Troubleshooting Tips                                      86
    ....6.2 Points to Check before Correcting Image Problems          87
    ....6.3 Tips for Correcting Image Problems                        87
    ....6.4 Preparation for Troubleshooting                           88
    ....6.5 Troubleshooting Flow                                      89
    Table of Contents                                                        Page
     ........6.5.1 LCD status message/trouble list                            90
     ........6.5.2 LCD message troubleshooting                                91
     ............(1) The printer does not work normally after turned on.      91
     ............(2) JAM ERROR                                                91
     ............(3) Paper Size Error                                         91
     ............(4) Image Drum Unit (IDU) Up/Down Error                      91
     ............(5) Fusing Unit Error                                        91
     ............(6) Fan Motor Error                                          91
     ............(7) Cannot Receive Data from Parallel Interface              91
     ........6.5.3 Image Troubleshooting                                      92
     ............(1) Light or blurred images on the whole printout area       92
     ............(2) Dark background                                          92
     ............Printout colors different from original colors
     ............(3) Blank paper                                              93
     ............(4) Vertical black (black stripe or lines in the vertical    94
     direction)
     ............(5) Vertical white (White stripe or lines in the vertical    95
     direction)
     ............(6) Poor fusing (Images are blurred or peeled off when       96
     touched)
     ............(7) Evenly spaced, repeating marks (Cyclical printout        97
     defects)
     ............(8) Missing characters or colors                             98
     ............(9) Poor synthesization Color                                99
     ............(10) Printout colors diferent from original colors           99
7 Wiring Diagram
     7.1 Resistance Check                                                    100
     7.2 Program/Font ROM Location                                           101
8 Illustrated Parts List
     Figure 8-1: Covers (Top & Sides)                                        102
     Figure 8-2: Printer Unit                                                102
     Figure 8-3: Main Chassis Unit (1)                                       102
     Figure 8-4: Main Chassis Unit (2)                                       102
     Figure 8-5: Main Chassis Motor/PCB                                      102
     Figure 8-6: Frame Upper Assy                                            102
     Figure 8-7: Guide Cassette (R) Assy                                     102
     Figure 8-8: Main Motor (A) Assy                                         102
     Figure 8-9: Main Motor (B) Assy                                         102
A Centronics Parallel Interface
     Centronics Parallel Interface                                           102
                                                             Service Guide - OKICOLOR8                      Page: 1
                                                                    Chapter 0 Introduction


Preface
This manual provides procedures and techniques for the troubleshooting, maintenance, and repair of OKICOLOR8.

This manual is written for maintenance personnel, but it should always be accompanied with the OKICOLOR8 User's
Manual for procedures for handling and operating OKICOLOR8. For repairing each component of OKICOLOR8, see
the Troubleshooting Manual.

[Notices]
The contents of this manual are subject to change without prior notice. Although reasonable efforts have been taken
in the preparation of this manual to assure its accuracy, this manual may still contain some errors and omissions.
OKI will not be liable for any damage caused or alleged to be caused, by the customer or any other person using this
maintenance manual to repair, modify, or alter OKICOLOR8 in any manner.

[Warning]
Many parts of OKICOLOR8 are very sensitive and can be easily damaged by improper servicing. We strongly
suggest that OKICOLOR8 be serviced by OKI's authorized technical service engineers.
                         Copyright 1999, Okidata, Division of OKI America, Inc. All rights reserved.
                                                        Service Guide - OKICOLOR8                     Page: 2
                                                             Chapter 1 Specifications


1.1 Basic System Configuration
This diagram shows the basic system configuration of OKICOLOR 8 is illustrated in Figure 1.1 below.




                                                    Figure 1.1




< same diagram -- different view >
Copyright 1999, Okidata, Division of OKI America, Inc. All rights reserved.
                                                                 Service Guide - OKICOLOR8                 Page: 3
                                                                       Chapter 1 Specifications


1.2 Printer Specifications
This printer unit is composed of the following hardware.

l   Electro-photographic processor
l   Paper feeder
l   Controller (CU part / PU Part)
l   Operator panel
l   Power board (High voltage part / PU part)


This diagrams shows the printer unit configuration.




                                                            Figure 1.2

                             Copyright 1999, Okidata, Division of OKI America, Inc. All rights reserved.
                                                                Service Guide - OKICOLOR8                 Page: 4
                                                                      Chapter 1 Specifications


1.3 Option Specifications
The OKICOLOR8 options are listed below.

(1) Second Paper Feeder




(2) RAM SIMM module (72 pin SIMM, 4MB/8MB/16MB/32MB)

l   Make sure to use a set of 2 of the same volume size modules.




                            Copyright 1999, Okidata, Division of OKI America, Inc. All rights reserved.
                                                             Service Guide - OKICOLOR8                        Page: 5
                                                                Chapter 1 Specifications


1.4 Basic Specifications

(1)    Dimensions            Width: 18.8" Length: 24.5" Height: 15.6"
(2)    Weight                Approx. 106 lbs. without box
(3)    Form
                       Type: Ordinary paper (Hammermill xx lb.) and Transparency (Only 3M CG3710)
                             Recommended paper (for color printing)
                             Color laser paper (20 lb to 24 lbs.)
                             Note: the printout color tones are dependent upon the whiteness of the print paper.
                      Sizes: Letter, Legal (13" or 14"), Executive, A4, A5, B5, and B6 (1st tray and front feeder)
                     Reams: 1st tray - 20 lbs. to 28 lbs.
                             2nd tray - 20 lbs. to 28 lbs.
                             Front feeder - 20 lbs. to 53 lbs. (110 lbs. index)
(4)    Printing speed:       8 pages per minute (5 pages per minute: Card Stock, Labels & OHP / 34 lbs. ~ 44
                             lbs.)
(5)    Resolution            600 dots per inch x 600 dots per inch
(6)    Input voltage         120VAC +5.5%, -15%
                             230VAC +10%
(7)    Power consumption Peak: Typical operation
                             Idle: Power save mode
(8)    Frequency             50Hz or 60Hz +2%, -2%
(9)    Noises                Operating: 54 decibels (without 2nd tray), 55 decibels (with 2nd tray)
                             Standby: 45 decibels
                             Power-saving: 43 decibels
(10)   Expendables and       Toner Cartridge: Approx. 3000 pages (5% density) (each of C, M, Y, and K)
       service life          Image Drum: Up to 13,000 pages (5% density, continuous) (each of C, M, Y and K)
                             Waste Toner Box: Up to 25,000 sheets (under typical printout conditions: Single
                             images of 5% density, equivalent to printout using 14 toner cartridges)
                             Oil Roller Unit: Up to 10,000 sheets (Life defined in the number of actual printed
                             paper sheets)
                             Note: Y=Yellow, M=Magenta, C=Cyan, K=Black
(11)   Periodically          Fuser Heat Unit Assy: 60,000 pages
       replaced parts        Transfer Belt Cassette Assy: 50,000 pages

(12) Temperatures and relative humidities

Temperature

                                              Temperature conditions
                            Fahrenheit           Celsius         Remarks
Operating                      60.8 to 89.6         16 to 32     17 Celsius to 27 Celsius (for assurance of
                                                                 full-color printout quality)
Non-operating                  50 to 109.4           10 to 43    Power off
Storage (1 year max.)          -33 to 109.4         -.6 to 43    with drum and toner
Delivery (1 month max.)         -20 to 122          -29 to 50    without drum and toner and Belt Cassette Assy
Delivery (1 month max.)         -20 to 122          -29 to 50    with drum and toner

Humidity

                                                Humidity condition
                            Fahrenheit           Celsius         Remarks
Operating                        20 to 80              25        50% to 70% (for assurance of full-color printout
                                                                 quality)
Non-operating                    10 to 90             26.8       Power off
Storage                          10 to 90              35
Delivery                         10 to 90              40
(13) Printer life - 300,000 (A4) pages or 5 years

                          Copyright 1999, Okidata, Division of OKI America, Inc. All rights reserved.
                                                         Service Guide - OKICOLOR8                          Page: 6
                                                                 Chapter 2 Operation


2. Operation
OKICOLOR8 is a tandem color electrophotographic page printer, using 4992 Pixel-LED technologies, OPC, dry
single-component non-magnetic developing, roller transfer, heat-compression fixing (fusing). The printing method
used is a Black Writing method which applies light beams to printout areas.

Here is the Functional Block Diagram of OKICOLOR8.




                                                    Figure 2.1

< same diagram - side view >
Copyright 1999, Okidata, Division of OKI America, Inc. All rights reserved.
                                                        Service Guide - OKICOLOR8                          Page: 7
                                                               Chapter 2 Operation


2.1 Main Control Board (PCE PCB)

The control board consists of a CPU block, a memory control LSI block, an interface control LSI block, a DRAM
block, an EEPROM block, a mask ROM block, and an interface block.

Here is the Functional Block Diagram of the main control board (PCE PCB).
Functional Block Diagram of Main Control Board

(1)     CPU
        The CPU is a 64-bit RISC architecture processor (provided by NEC). It inputs a frequency of 50
        MHz and runs at 200 MHz. It transfers data to a from memory at 50 MHz.
(2)     Mask ROM
        The mask ROM block consists of four 16 Mbit (1M x 16 bits) chips and its total size is 8M bytes.
        The chips are mounted on the PCE-PCB by means of IC sockets and store programs and
        character fonts.
(3)     DRAM
        The DRAM block consists of eight 16 Mbit (1M x 16bits) chips and its total size is 16M bytes. The
        chips are mounted on the PCE-PCB and can be expanded up to 144M bytes by adding the 32M
        byte SIMMs to the SIMM slots on the PCE-PCB.
(4)     EEPROM
        The EEPROM block consists of 16K-bit chips mounted on a board by means of IC sockets and
        stores the following:
          l Menu data
          l Counter values
          l Adjustment values
(5)     Flash ROM
        The Flash ROM block consists of four 4M bit (256K x 16bits) chips and its total size is 2M bytes.
        The chips are mounted on the PCE-PCB and are used for storing fonts, macro and demo pages.
(6)     Memory control LSI
        This block mainly consists of memory control, CPU control, compression and decompression, and
        video interface functions.
(7)     Interface control LSI
        This block mainly consists of PU interface control, operator panel interface control, EEPROM
        control, parallel interface control, and HSP control functions.
(8)   Host interface
      The printer has the following interfaces to the host.

        l   Centronics bi-directional parallel interface
        l   Network interface (Option)

      The single effective interface or the automatic interface select mode can be selected using the
      menu. If the busy state of the printer continues for a long time period, the buffer near-full control
      releases the busy status at constant intervals even if the host side is busy so as not to cause
      interface time-out at the host side.

      (a) Centronics bi-directional parallel interface

      This is an interface confirming to IEEE-1284 and provides either unidirectional ad bi-directional
      communications according to each of the following communication modes.

        l   Compatibility mode - Unidirectional communications from the host to the printer.
        l   Nibble mode - This mode transfers 4-bit wide data from the printer to the host. In this mode,
            each bit of 1-byte data transmits in the form of two nibbles using ERROR, BUSY, FAULT,
            and SELECT signal leads. This mode can provide bi-directional operation in combination
            with the compatibility mode.
        l   ECP mode - This mode provides the asynchronous bi-directional interface and transmits and
            receives 1-byte data using eight data signal leads under semi-duplex control by the host.

      When the power is turned on, the compatibility mode is automatically selected. The change to
      another mode form the compatibility mode is made through negotiation. (When the BI-DIRECTION
      is set to ENABLE in the menu, this change can be performed.) (For the electrical/physical
      characteristics of this interface, see APPENDIX B).

      (b) Network interface (Option)

      Network interface card uses the power line only.




(9)   This printer has the 2nd Cache unit which type is Write Through Cache and size is 512 KByte.
      There are any difference between the instruction and data. All of the CPU read/write access are
      cached to same 2nd cache memory.
(10)   RAM module

        l   Pin layout




        l   Basic specification

                     Type:
                     Access time:               72 pins SIMM (32 bits buss width)
                     Capacity:                  60ns, 70ns, 80ns
                     Parity:                    4, 8, 16, or 32
                                                None

                         Copyright 1999, Okidata, Division of OKI America, Inc. All rights reserved.
                                                      Service Guide - OKICOLOR8                     Page: 8
                                                             Chapter 2 Operation


2.2 Engine Control Board (PX4 PCB)
ANALOG INPUT

(Heater temperatures and environmental humidity and temperature)




Engine Control Board Block Diagram

The engine control block (PU) is controlled by the engine control board (PX4 PCB) which consists of a CPU
(MSM65524), general purpose LSI chips, EPROM, EEPROM, pulse motor drivers, and video memory. Refer to the
Engine Control Board Block Diagram above.
(1)   CPU
      This is an 8-bit CPU (OKI MSM65524) containing the AD converter and controls the whole system.
(2)   General-purpose LSI
      This LSI (MB87D113PFV) is provided in the printer engine control block and has controller-engine
      video interface, LED interface, motor control, sensor input, video memory control, main scanning color
      correction, skew correction, high-voltage power control, and OST-EX2 functions.
(3)   EPROM
      This EPROM (275C512-150) has a storage capacity of 512K bits and stores programs for the PU
      block.
(4)   EEPROM
      This EEPROM (NM93C66N-NW) has a storage capacity of 4K bits. It is mounted on the board by
      means of IC socket and stores adjustment values.
(5)   Pulse motor drivers
      These drivers (MTD2005F) drive eight pulse motors for moving up and down the image drum (EP) and
      transferring medium.
(6)   Video memory
      This SRAM received print data through video interface and stores it.

                         Copyright 1999, Okidata, Division of OKI America, Inc. All rights reserved.
                                                              Service Guide - OKICOLOR8                           Page: 9
                                                                       Chapter 2 Operation


2.3 Power/Board
The power board consists of an AC filter circuit, a low voltage power supply circuit, a high voltage power supply
circuit, and heater drive circuit, and photo sensors.

(1) Low voltage power supply circuit.

This circuit generates the following voltages.

      Output voltage                                                  Use
         +3.3 V           CU Unit CPU, LED HEAD
          +5 V            Logic circuit supply voltage
         +32 V            Motor and fan drive voltage and source voltage for high-voltage supply, discharge
                          lamp
          +12 V           HSP, OP Amp, high voltage power supply
          -12 V           HSP

(2) High voltage power supply circuit

This circuit generates the following voltages necessary for electro-photographic processing from +32 V in
accordance with the control sequence from the control board. When cover open state is detected, +32 V supply is
automatically interrupted to stop the supply of all high-voltage outputs.

Y M C K = Yellow, Magenta, Cyan, Black

      Output                         Voltage                                       Use                  Remarks
CH                -1.35 KV 



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