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Okidata Jet 2500 Service Manual


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                                                                                                    Page: 1
                                               Service Manual - OKIJET 2500
                                                          Chapter 0 Introduction




Front Cover




                                         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.


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 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        7
       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 of    54
   3)
   PL 2.1 Paper Feed / Carriage Assembly Components (Part 2 of    55
   3)
   PL 2.1 Paper Feed / Carriage Assembly Components (Part 3 of    56
   3)
   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
                                                                                                    Page: 1
                                               Service Manual - OKIJET 2500
                                                          Chapter 0 Introduction




Front Cover




                                         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.


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: 2
                                                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.

Copyright 1998 by Okidata
All rights reserved.

Edited by:
Okidata Training and Publications

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

Please address any comments on this publication to: Okidata's web site at: www.okidata.com

Telephone 609- 235- 2600

Facsimile 609- 222- 5320

Okilink Technical Training

Copyright Listing

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.


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: 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.



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: 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.


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: 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.


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 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.


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: 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.


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: 8
                                               Service Manual - OKIJET 2500
                                                          Chapter 0 Introduction




Section 4 - REPAIR / ADJUSTMENT PROCEDURES

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


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: 9
                                                  Service Manual - OKIJET 2500
                                                             Chapter 0 Introduction




Section 5 - PARTS LIST

This section contains the detailed Parts List for the printer.


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 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.


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 Manual - OKIJET 2500
                                                        Chapter 0 Introduction




Section 7 - WIRING DATA

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


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: 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.


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 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.




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: 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.




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: 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.


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: 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       Logic State       Actual Voltage Ranges
+5 VDC                H                 +4.8 to +5.2 VDC
                      L                 0.0 to +1.0 VDC
+42 VDC               H                 +39.0 to +44.0 VDC
                      L                 0.0 to +3.0 VDC



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: 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.



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: 18
                                              Service Manual - OKIJET 2500
                                                        Chapter 0 Introduction




Back Cover




OKI
OKIJET 2500 Service Manual

P/ N 59228801

Printed in the U. S. A.


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: 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.


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: 20
                                                 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:


Description                                           Procedure
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.



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: 21
                                              Service Manual - OKIJET 2500
                                                  Chapter 1 Service Call Procedures




Initial Actions

1. QUESTION THE OPERATOR.

2. VERIFY, CLASSIFY AND REPAIR THE PROBLEM.




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: 22
                                                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.
Y N
     Refer to Initial Action / System Checks to begin your repair.

Evaluate the print.
Is the image quality acceptable?
Y N
     Go to the image quality RAP identified by the IQ 1 Image Defect Entry RAP (Section 3).

Print and check the "Printing Alignment Test pattern".
The alignment is good.
Y N 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.




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: 23
                                               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.
Y      N
       The Error LED is flashing.
       Y     N
             Press and hold the Resume/FF button for 2 seconds to print the demo print.

        The Error LED is steady.
              Y     N
                    The Error LED is flashing.

                       Y      N
                              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.
               Y      N
                      The printhead stopped at each ink cartridge during the power-on cycle.
                      Y     N
                            Go to 6.2 Encoder RAP.

A       B      C       D

                      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.
Y      N
       Go to 6.1 Carriage RAP.
Go to Low Ink LED(s) on RAP.



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: 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.
Y     N
      Printer is OK.

Go to 2.1 Selection/Indication RAP.



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: 25
                                                   Service Manual - OKIJET 2500
                                                 Chapter 2 Repair Analysis Procedures (RAPs)




Low Ink LED(s) On RAP

Initial Action:

Ensure all the ink cartridges are full and properly seated.

Go to Flags 1 and 2. Check the wires and connections for an open circuit. The wires are good.

Y    N
     Repair the wires or connections if possible.
     Replace the main control board.
     If the problem still exists, replace the Printer.

Replace the Ink Level Sensor (PL 2.1) located in Chapter 5.
Replace the main control board.
If the problem still exists, replace the printer.




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: 26
                                                   Service Manual - OKIJET 2500
                                                 Chapter 2 Repair Analysis Procedures (RAPs)




Error LED Flashing RAP

Note: This procedure will work only when the Error LED is flashing.

Note: In the following procedure, the Error LED and Power LED will be used to display an 8 bit binary
error code. The LEDs will flash in 1/2 second intervals. The code will be displayed 4 bits at a time. The
LED code is as follows (See Figure 1):

1 = Both Error and Power LEDs lit

0 = Error LED only is lit

1. Press and release the Resume/ FF button, while observing the Error and Power LEDs.
2. 4 bits will be flashed in 1/ 2 second intervals followed by a pause, then 4 more bits in 1/ 2 second
   intervals. After the cycle, the Error LED will continue to flash.
3. Determine the code and go to the Error Code Chart (Table 1) for the corrective action.
4. Repeat step 1 as many times as necessary to determine the code.




Error Code                  Error Description               Corrective Action
1000 1000                   ROM error                       Replace the Main Control Board
1000 1100                   RAM error                       Replace the Main Control Board
1100 1000                   EPROM error                     Replace the Main Control Board
1110 1000                   CPU error                       Replace the Main Control Board
1100 1111                   Carriage home position error    Go to 6.1 Carriage RAP



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: 27
                                               Service Manual - OKIJET 2500
                                             Chapter 2 Repair Analysis Procedures (RAPs)




1.1 Power on RAP

Refer to Figure 1. There is +42 VDC measured on the Main Control Board.



Y     N
      Disconnect the power cord.
      Check fuse F1 on the Power
      Supply.
      F1 is blown.
      Y        N
               Go to Flag 1 (Figure 2) and check the wires for an open circuit. If good, replace the Power
               Supply. If problem still exists, replace the Main Control Board.
      Replace the blown fuse.
      If the problem is not corrected, replace the Power Supply (PL 1.1).

Refer to Figure 1. There is +5 VDC measured on the Main Control Board.
Y     N
      Go to Flag 2 and check for a short to ground. If OK, replace the Power Supply. If problem still
      exists, replace Main Control Board.

Replace the Main Control Board before replacing the Control Panel Assembly.
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: 28
                                              Service Manual - OKIJET 2500
                                            Chapter 2 Repair Analysis Procedures (RAPs)




2.1 Selection/Indication RAP


Load paper.
Disconnect and then reconnect the power cord while observing the LEDs.

All LEDs light momentarily when the power cord is reconnected.
Y     N
      One or more LEDs light.
      Y      N
              Go to 1.1 Power on RAP.

       Go to Flag 1 and Flag 2 and check for an open wire. If OK, replace the Control Panel
       Assembly.


All LEDs go out in approximately 10 seconds.
Y     N
      If the Power LED remains on (flashing), go to Flag 3 and check for an open wire. If OK,
      replace the Control Panel Assembly.

Press and hold the Power button for approximately 2 seconds to turn on the printer.

Press and hold the Resume/FF button for 2 seconds.

Paper feeds.
Y     N
      Go to Flag 5 and check for an open wire.
      If good, go to 8.1 Paper Feed RAP.


A


A
Press the Cartridge Change button.
The carriage moves to the center position.
Y      N
       Go to Flag 4 and check for an open wire.
       If OK, replace the Control Panel Assembly.

For printer set up problems when printing from a DOS application, consult GP 2 Printing with
DOS Procedure in Section 6.

Examples of printer set up problems.
Just a few lines of data are printed and then the paper continues to line feed without printing.




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                                                                                                Page: 29
                                              Service Manual - OKIJET 2500
                                            Chapter 2 Repair Analysis Procedures (RAPs)




6.1 Carriage TAP


Disconnect and then reconnect the power cord.
Press and hold the Power switch.
The carriage moves.
Y      N
          Go to Flag 1 and check the ribbon cable for being open or damaged.
          Go to Flag 2 and check for an open circuit. If the wire is good, replace the Main
            Control Board.
          Check / replace the ribbon carriage cable.
          Check the teeth on the belt.
          Check the teeth on the carriage motor.
          Check for 42 volts.
          If 42 volts aren't being supplied by the power supply, replace the power supply.
          Check / replace the carriage motor.

Perform the following:
          Check that the Printhead ribbon cable going to CN4 on the Main Control Board is
            connected properly.
          Go to Flag 2 and Flag 3 and check for an open circuit.
          If the wires are good, replace the Printhead Ribbon Cable (PL 2.1---see Chapter 5).
          If the problem continues replace the Main Control Board (PL 1.1).
                   Check / replace the ribbon carriage cable.
                   Check the teeth on the belt.
                   Check the teeth on the carriage motor.
                   Check for 42 volts.
                   If 42 volts aren't being supplied by the power supply, replace the power
                      supply.
                   Check / replace the carriage motor.


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                                                                                              Page: 30
                                                 Service Manual - OKIJET 2500
                                            Chapter 2 Repair Analysis Procedures (RAPs)




6.2 Encoder RAP


   Go to Flag 1 and check the ribbon
   Go to Flag 4 and check for an open circuit.
   Replace the Encoder.
   Go to 6.1 Carriage RAP.




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                                                                                                 Page: 31
                                               Service Manual - OKIJET 2500
                                             Chapter 2 Repair Analysis Procedures (RAPs)




8.1 Paper Feed RAP


Clear any paper in the printer.
Disconnect and then reconnect the power cord.
Press and hold the Power switch for about 2 seconds.
Press and hold the Resume/FF button for 2 seconds to print the demo print.
The paper feeds or partially feeds.
Y         N
             Check that the Paper Tray is installed correctly (REP 1.1)
             Go to Flag 1 and check the cam sensor circuit for an open.
             If OK, go to Flag 3 and check for an open circuit. If paper feed motor circuit is
               defective, replace the paper feed motor.
             If the wires are good, replace the Main Control Board.

     Go to Flag 2 and check the paper feed switch circuit for an open.
     If OK, go to Flag 3 and check for an open circuit.
     Replace the Back pad.
     If the problem still exists, replace the Main Control Board.
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                                                                                                       Page: 32
                                                  Service Manual - OKIJET 2500
                                                Chapter 2 Repair Analysis Procedures (RAPs)




9.1 Blank Print RAP

Initial Action:

Ensure that the Printhead latch is positioned towards the rear.

Unlatch the Printhead, reset the Printhead and latch it back into position. If problem still exists:

    Replace the Printhead.
    Go to Flag 1 and check the ribbon cable for being damaged.
    Check the terminals of J11 on the Carriage Assembly and J12 on the Ink Cartridge for being
    contaminated or damaged. Clean or repair as necessary.
    If the problem still exists, replace the Printhead Ribbon Cable (PL 2.1--see Chatper 5).




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                                                                                                       Page: 33
                                                    Service Manual - OKIJET 2500
                                                            Chapter 3 Image Quality RAPs




IQ 1 Image Defect Entry RAP

1. Print the Test Print:

a. Load paper into the Paper Tray.

b. Press and hold the Power on / Reset button for approximately 2 seconds and then release, to switch
the Printer power off.

c. While pressing and holding the Resume/ FF button press and release the Power on / Reset button.
The printer prints the test print shown in Figure 1. When the test print is complete, the printer initializes
and returns to the Ready status.

d. If the test print fails to print, repeat steps a through c.

2. Refer to the DEFECT Column in Table 1 that best describes the image quality problem.

3. If the problem is with external input only, replace the Main Control Board.




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                                                                                                   Page: 34
                                              Service Manual - OKIJET 2500
                                                     Chapter 3 Image Quality RAPs




IQ 1 Image Defect Entry RAP Table


         DEFECT                    CAUSE                                  SOLUTION
Blank print                   Printhead                 1. Remove and reinstall the Printhead.
                                                        2. Press the Cartridge Change / Clean
                                                             button for 2 seconds to clean and restore
                                                             the Printhead. Repeat if necessary.
                                                      If the problem still exists go to the 9.1 Blank
                                                      Print RAP.
White horizontal lines and    The Printhead           Perform the following:
Streaks                         nozzles may be          1. Press the Cartridge Change / Clean
                                blocked.                     button for 2 seconds to clean and restore
                                                             the Printhead.
                                                        2. Make another Test Print. If the print still
                                                             has lines and streaks repeat the above
                                                             process up to 5 times.
                                                        3. If the problem still exists, replace the
                                                             Printhead.
Print is faint or missing     A non                   Replace the paper.
                                recommended
                                paper is being used
                                or the paper is
                                damp.
                                Defective Cartridge. Perform the following:
                                The ink supply may 1. Press and hold the Cartridge Change /
                                be nearly empty.            Clean button for 2 seconds to clean and
                                The Printhead               restore the Printhead.
                                nozzles may be         2. Run a Test Print. If the print is still faint,
                                blocked.                    repeat the process up to 2 more times.
                                                       3. If the problem is still not corrected
                                                            replace the Printhead.
Blurry or jagged vertical       Printhead            Perform ADJ 2.0 Printhead Alignment
lines                           Alignment            Procedure
                                                     If the problem still exists switch the printer to
                                                     the High Quality print mode (in the printer
                                                     driver).
                                Paper                Turn the paper over to print on the opposite
                                                     side.
Print image is clipped or       Print off edge of    Ensure that the Print Driver setup has the
off edge of media               media.               correct selection of media size and type.
                                Document margins Adjust margins in the application as necessary.
                                may exceed printer
                                margins.
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                                                                                                   Page: 35
                                                 Service Manual - OKIJET 2500
                                                 Chapter 4 Repair / Adjustment Procedures




REP 1.0 Printhead

Parts List on PL 2. 2

Removal

1. Open the Cartridge Cover (PL 1.1).

2. Center the carriage using either of the following procedures:

    Press the Cartridge Change / Clean button.

WARNING: Switch off the power. Disconnect the power cord from the wall outlet.

    Grasp and manually move the belt (PL 2.1) in order to center the Printhead (Figure 1).

CAUTION: Store the Printhead in the Storage Box. Leaving the Printhead removed for long periods of
time will cause the ink nozzles to dry out. Image quality defects or a blank page could result. If necessary,
prime the printhead after reinstallation. (See below to Refer to the Replacement / Priming section of this
procedure.)

3. Move the Printhead lock lever toward the front of the printer.

4. Lift and remove the Printhead. Store it in the Storage Box.

Replacement / Priming

1. Install the Printhead onto the Printhead vertical guide.

2. Move the Printhead lock lever toward the rear of the printer.

3. Close the Cartridge Cover.

4. Press the Resume / FF button to prime the Printhead.

NOTE: The optional high capacity printhead is shown. Refer to the User's Documentation for illustrations
of the standard printhead.
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Partner Exchange (BPX) for any updates to this material. (http://bpx.okidata.com)
                                                                                                  Page: 36
                                                Service Manual - OKIJET 2500
                                                Chapter 4 Repair / Adjustment Procedures




REP 1.1 Paper Tray Assembly

Parts List on PL 1. 1

Removal

1. Remove the Output Tray (PL 1.1).

2. Press the two handles toward the rear of the printer to release the latches (Figure 1).

3. Pivot the Paper Tray Assembly toward the back of the printer to disengage the three tabs at the bottom
of the Paper Tray Assembly from the tabs on the Paper Feed / Carriage Assembly.

4. Lift the Paper Tray Assembly from the printer.




Replacement

1. Retract the moveable face of the Paper Tray Assembly by pressing it toward the back of the Paper Tray
Assembly.

2. Insert the Paper Tray Assembly into the printer (with bottom of tray touching the bottom of the tray
opening on the printer) ensuring the moveable face is behind the white cam (near the bottom, on the left).
See Figure 2.

3. Engage the three tabs at the bottom of the Paper Tray Assembly with the tabs on the Paper Feed /
Carriage Assembly.

4. Rotate the Paper Tray Assembly toward the front of the printer.

5. Engage the two latches by gently pulling the handles downward and toward the front of the printer until
the latches snap into position.
6. Reinstall the Output Tray.




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                                                                                                     Page: 37
                                                 Service Manual - OKIJET 2500
                                                 Chapter 4 Repair / Adjustment Procedures




REP 1.2 Cartridge Cover

Parts List on PL 1. 1

Removal

1. Open the Cartridge Cover (PL 1.1).

2. Utilizing a screwdriver or similar tool, slightly separate the Cartridge Cover and Top Cover at either pivot
to release the Cartridge Cover pivot from the Top Cover (Figure 1).

3. Lift the Cartridge Cover from the printer.

Replacement

1. Insert either Cartridge Cover pivot into the corresponding Top Cover pivot hole.

2. Utilizing a screwdriver or similar tool, slightly separate the Cartridge Cover and Top Cover at the
opposite pivot.

3. Position the Cartridge Cover pivot to engage with the pivot hole of the Top Cover.

4. Close the Cartridge Cover.




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Partner Exchange (BPX) for any updates to this material. (http://bpx.okidata.com)
                                                                                                      Page: 38
                                                  Service Manual - OKIJET 2500
                                                  Chapter 4 Repair / Adjustment Procedures




REP 1.3 Top Cover

Parts List on PL 1. 1

Removal

CAUTION: Store the Printhead in the Storage Box. Leaving the cartridge removed for long periods of time
will cause the ink nozzles to dry out. Image quality defects or a blank page could result. If necessary,
prime the printhead after
reinstallation. (REP 1.0)

1. Remove the Printhead (REP 1.0). Store the Printhead in the Storage Box.

WARNING: Switch off the power. Disconnect the power cord from the wall outlet.

2. Remove the Output Tray (PL 1.1).

3. Remove the Paper Tray Assembly (REP 1.1).

4. Remove the Cartridge Cover (REP 1.2).

5. Lay the printer on it's back; release the three front latch tabs (Figure 1).

CAUTION: While removing the Top Cover from the printer, take care not to damage the ribbon cable that
is connected to the Control Panel Assembly, which is located inside the Top Cover.

NOTE: The rear of the Top Cover has three locator tabs and two latch tabs.

6. Return the printer to its normal operating position. Lift and hold the front of the cover slightly while
releasing the two rear latch tabs. Then lift the rear of the cover and pivot towards the FRONT of the printer
to remove.

Replacement

1. Ensure the ribbon cable is properly routed and not twisted during Top Cover installation.

2. If previously disconnected, reconnect ribbon cable to the Control Panel Assembly.

3. Position the Top Cover on the printer. Align and latch the rear latches; then the front latches.

4. Reinstall the following:

a. Cartridge Cover (REP 1.2)

b. Paper Tray Assembly (REP 1.1)
c. Output Tray (PL 1.1)

d. Printhead (REP 1.0)




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Partner Exchange (BPX) for any updates to this material. (http://bpx.okidata.com)
                                                                                                    Page: 39
                                                 Service Manual - OKIJET 2500
                                                 Chapter 4 Repair / Adjustment Procedures




REP 1.4 Exit Guide

Parts List on PL 2. 2

Removal

CAUTION: Store the Printhead in the Storage Box. Leaving the Printhead removed for long periods of
time will cause the ink nozzles to dry out. Image quality defects or a blank page could result. If necessary,
prime the printhead after reinstallation. (REP 1.0)

1. Remove the Printhead (REP 1.0). Store the Printhead in the Storage Box.

WARNING: Switch off the power. Disconnect the power cord from the wall outlet.

2. Remove the Output Tray (PL 1.1).

3. Remove the Cartridge Cover (REP 1.2).

4. Position both thumbs at the lower, front corners of the Exit Guide (Figure 1). Apply modest pressure
simultaneously toward the rear and up to unlatch the Exit Guide.

5. Rotate the guide approximately 90



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