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OKIDATA OL1200ex Service Manual

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Chapter 1
%1. Configuration
1. CONFIGURATION
1.1 System Configuration
OL1200 consists of control and engine blocks as the standard configuration (See Figure 1-1.) In addition,
the following options are also available.

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Summary of Contents for OKIDATA OL1200ex

  • Page 1 Chapter 1 %1. Configuration 1. CONFIGURATION 1.1 System Configuration OL1200 consists of control and engine blocks as the standard configuration (See Figure 1-1.) In addition, the following options are also available.

  • Page 2: Printer Configuration

    %1.2 Printer Configuration 1.2 Printer Configuration The printer unit consists of the following hardware components: • Electro-photographic processor • Paper feeder • Controller • Operator panel • Power/sensor board Figure 1-2 shows the printer unit configuration.

  • Page 3: Optional Configuration

    %1.3 Optional Configuration 1.3 Optional Configuration The options below are available for use with OL1200. They are sold separately from the printer unit. (1) Power Envelope Feeder (2) High Capacity Second Paper Feeder (3) Font Card (4) RAM module • 8MB RAM module •...
  • Page 4 %1.4 Specification 1.4 Specification (1) Type Desk top (2) External dimensions Height 10.6 (270 mm) (excludes protruding Width 14.4 (366 mm) Portion) Depth 16.9 (430 mm) (3) Weight 15.2 kg (33.5 lbs) (4) Development method Dry electrophotography Exposure method LED stationary head (5) Paper used <Type>...

  • Page 5: Safety Standards

    %1.5 Safety Standards 1.5 Safety Standards 1.5.1 Certification label The safety certification label is affixed to the printer in the position below.

  • Page 6: Warning Label

    %1.5.2 Warning Label 1.5.2 Warning label The warning label is affixed to the portion which may cause an injury to human body. Follow the instructions on warning labels during maintenance.
  • Page 7 Chapter 2 %2. Operation Description 2. OPERATION DESCRIPTION OL1200 consists of a control board, a power supply/sensor board, a driver board, an operator panel and an electro-photographic process mechanism. The control board receives data through a host I/F, decodes and edits the data, and stores the edited data in a memory.
  • Page 9 %2.1 Main Control Board (Aolm-Pcb) 2.1 Main Control Board (AOLM-PCB) The control board consists of a one chip CPU, LSIs, a program/font ROM, a DRAM, an EEPROM, a host interface circuit, and a mechanism driving circuit. (1) One-chip CPU The one-chip CPU is a custom CPU (32-bit internal bus, 32-bit external bus, 33-MHz clock) that incorporates a RISC CPU and its peripheral devices, and has the following functions: Built-in device Function...
  • Page 10 Page buffer Adds print information to the Expandable analyzed receive data and stores the resulted data. DLL/macro buffer Stores soft fonts and macro data. Expandable Font cache buffer Stores bit map fonts generated by Enable Expandable the font rasterizer based on scalable font information (4) EEPROM The EEPROM has a 4-kbit capacity and stores the following data.
  • Page 11 • Pin layout • Basic specificaton - Type: 72 pins SIIM (32 bits buss width) - Access time: 60ns, 70ns, 80ns, 100ns - Capacity: 1, 2, 4, 8, or 16MB (16 MB RAM will not be sold by Okidata) - Parity: None...
  • Page 12 %2.2 Power/Sensor Board 2.2 Power/Sensor Board The power/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 +5 V Logic circuit supply voltage +30 V...
  • Page 13 Sensor Function Sensing state Inlet sensor 1 Detects the leading part of the ON: Paper exists. paper and gives the OFF: No paper exists. supervision timing for switching from hopping operation to feeding opera-tion. Supervises the paper running state and the paper size accord-ing to the paper reach time and running time.
  • Page 14 %2.3 Relay/Driver Board (Aolc Board) 2.3 Relay/Driver Board (AOLC board) This board relays signals between the Control board and the Power/Sensor board and includes the registration motor and drum motor driver IC.
  • Page 15 %2.4 Electro-Photographic Process 2.4 Electro-photographic Process 2.4.1 Electro-photographic process mechanism This mechanism prints image data from the control board on the paper by electro-photographic process. The Figure 2-4 shows the layout of the electro-photographic process mechanism. (1) Image drum unit The image drum unit consists of a sensitive drum, a charger, and a developer.
  • Page 17 %2.4.2 Electro-Photographic Process 2.4.2 Electro-photographic process The electro-photographic processing is outlined below. Figure 2-5 shows the electro-photo-graphic printing process. 1 Charging The surface of the image drum is uniformly charged with negative charges by applying a negative voltage to the charge roller. 2 Exposure Light emitted from the LED head irradiates the negatively charged surface of the image drum.

  • Page 19: Process Operation Descriptions

    %2.4.3 Process Operation Descriptions 2.4.3 Process operation descriptions (1) Hopping Hopping from the first tray and the front feeder are effected by a single hopping motor in the mechanism shown below. Turning the Hopping motor in the a direction drives the hopping roller of the first tray. Turning the Hopping motor in the b direction drives the Hopping roller of the front feeder.
  • Page 20 (b) Hopping (front feeder) 1 Rotating the pulse motor in the direction b (Counter Clock-wise direction) drives the hopping roller of the front feeder to advance the paper until the inlet sensor turns on. At the same time, the one-way clutch gear A also rotates. However, the hopping roller of the 1st tray will not rotate due to the one-way bearing.
  • Page 21 2 After turning on the inlet sensor, the paper advances further by a predetermined length until it hits the registration roller. (The skew of the paper can thus be corrected.)
  • Page 22 %(2) Feeding (2) Feeding After the end of hopping, the pulse motor drives the registration roller. The registration roller advances the paper until it comes out of the registration roller. When leading edge of the paper causes the paper sensor to turn on, the printing is started synchronously.
  • Page 23 %(3) Charging (3) Charging Charging is effected by applying a DC minus voltage to the charge roller that is in contact with the image drum surface.
  • Page 24 %(4) Exposure (4) Exposure Light emitted from the LED head irradiates the image drum surface with negative charges. The surface potential of the irradiated part of the image drum drops, thereby forming an electrostatic latent image associated with the image signal.
  • Page 25 %(5) Developing (5) Developing Toner is attracted to the electrostatic latent image on the image drum surface to convert it into a visible toner image. Developing takes place at the contact between the image drum and the developing roller. 1 As the toner supply roller rotates while rubbing on the developing roller, a friction charge is generated between the developing roller and the toner, allowing the toner to be attracted to the developing roller.
  • Page 26 %(6) Transfer (6) Transfer The transfer roller is composed of conductive sponge material and is designed to make the image drum surface and the paper closely into contact. Paper is placed over the image drum surface, and a positive charge, opposite in polarity to the toner, is applied to the paper from its reverse side.
  • Page 27 %(7) Fusing (7) Fusing After the end of the transfer, the unfused toner image is fused on the paper under heat and pressure as it passes between the heater roller and the back-up roller. The heater roller with a Teflon coating incorporates a 400W heater (Halogen lamp), which heats the heat roller. A thermistor which is in contact with the heater roller regulates the heater roller at a predetermined temperature (about 185 ~ 188°C).
  • Page 28 %(8) Cleaning (8) Cleaning After the end of the transfer, residual toner on the image drum is attracted to the cleaning roller temporarily by static electricity to clean the image drum surface.
  • Page 29 %(9) Cleaning Of Rollers (9) Cleaning of rollers The charge roller, transfer roller and cleaning roller are cleaned in the following cases: • In warming up at power-on time • In warming up after the cover is opened and closed •...

  • Page 30: Paper Jam Detection

    %2.5 Paper Jam Detection 2.5 Paper Jam Detection The paper jam detection function supervises the paper state at power-on time and during printing. In the event that a jam occurs, this function interrupts the printing process. If any of the following errors is presented, recovery printing will be performed by removing the jammed paper ( by opening the upper cover, removing the jammed paper and closing the upper cover).

  • Page 31: Cover Open

    %2.6 Cover Open 2.6 Cover Open When the stacker cover is opened, the cover open microswitch on the power/sensor board is turned off to cut the supply of +30V to the high voltage power supply circuit. As a result, all high-voltage outputs are interrupted.

  • Page 32: Toner Low Detection

    %2.7 Toner Low Detection 2.7 Toner Low Detection • Composition The device consists of the stirring gear which rotates at a constant rate, the stirring bar and the magnet on the stirring bar. The stirring bar rotates through the link on the protrusion in the stirring gear.
  • Page 33 TONER FULL state TONER LOW state • When the toner low state is detected 2 times consecutively, Toner Low is established. • When the toner full state is detected 2 times consecutively, Toner Low is cancelled. • When there is no change with the toner sensor for 2 cycles (5.8 sec. x 2) or more, then the Toner Sensor Alarm is activated.
  • Page 34 %2.8 Stacker-Full Detection 2.8 Stacker-full Detection The sensor lever at the paper outlet to the stacker detects a stacker-full state (about 250 sheets) and stops printing of the ensuing pages.

  • Page 35: Page Size Detection

    %2.9 Page Size Detection 2.9 Page Size Detection The four tab pieces are driven according to the setting position of the paper guide through the cam interlocked with the paper guide of the paper cassette. When the paper cassette is inserted into the printer, the state of the tab pieces is detected by the microswitch to recognize the paper size.
  • Page 36 Chapter 3 3. Parts Replacement 3. PARTS REPLACEMENT The section explains the procedures for replacement of parts, assemplies, and units in the field. Only the removal procedures are explained here. Reverse the procedure for the installation.

  • Page 37: Precautions For Parts Replacement

    %3.1 Precautions For Parts Replacement 3.1 Precautions for Parts Replacement Always practice good Anti-Static procedures when handling equipment. (1) Before starting parts replacement, remove the AC cable and interface cable. (a) Remove the AC cable in the following procedure: i) Turn off ("o") the power switch of the printer ii) Disconnect the AC inlet plug of the AC cable from the AC receptacle.

  • Page 38: Service Tools

    %[Service Tools] [Service Tools] Table 3-1 shows the tools required for field replacement of printed circuit boards and units. Table 3-1 Service Tools...
  • Page 39 3.2 Parts Layout 1- 4 3.2 Parts Layout 1 - 4...
  • Page 40 %Parts Layout 2 - 4 Parts Layout 2 - 4...
  • Page 41 %Parts Layout 3 - 4 Parts Layout 3 - 4...
  • Page 42 %Parts Layout 4 - 4 Parts Layout 4 - 4...
  • Page 43 %3.3 How To Change Parts 3.3 How to Change Parts This section explains how to change parts and assemblies appearing in the disassembly diagram below.
  • Page 44 %3.3.1 Rear Cover, Side Cover (L) Assy, Face-Up Stacker Assy, And I/F Cover Assy. 3.3.1 Rear cover, side cover (L) Assy, face-up stacker Assy, and I/F cover Assy. (1) Turn the AC power switch off. Unplug the AC power cord from the outlet. (2) Remove the interface cable 1.
  • Page 45 %3.3.2 Contact Assy 3.3.2 Contact Assy (1) Turn the AC power switch off. Unplug the AC power cord from the outlet. (2) Remove the side cover (L) Assy (see 3.3.1 (1) to (4)). (3) Remove two screws 1. Remove the contact plate (cover) 2 and the contact Assy 3. Pull bottom of Assy 3 out first, then the top of Assy.
  • Page 46 %3.3.3 Dc Fan Motor 3.3.3 DC fan motor (1) Turn the AC power switch off. Unplug the AC power cord from the outlet. (2) Remove the side cover (L) Assy (see 3.3.1 (1) to (4)). (3) Unplug the connector of the DC fan motor 1 and remove the DC fan motor 1.
  • Page 47 %3.3.4 Manual Feed Hopper Assy 3.3.4 Manual feed hopper Assy (1) Turn the AC power switch off. Unplug the AC power cord from the outlet. (2) Open manual feed hopper Assy 1. Disengage the lower portion of this Assy. (3) Hold manual feed hopper Assy 1 vertically and remove the left and right levers 2 with a downward motion.
  • Page 48 %3.3.5 Side Cover (R) (Operator Panel Assy) 3.3.5 Side cover (R) (operator panel Assy) (1) Turn the AC power switch off. Unplug the AC power cord from the outlet. (2) Remove interface cable 1. (3) Open stacker cover 2. Remove two screws 3. Remove I/F cover Assy 4. (4) Remove two screws 5 and flexible cable 6 (use care to not damage flexible cable).
  • Page 49 %3.3.6 Earth Plate Bk (R) (Aolm-Pcb, Ic Cover) 3.3.6 Earth plate BK (R) (AOLM-PCB, IC cover) (1) Turn the AC power switch off. Unplug the AC power cord from the outlet. (2) Remove side cover (R) (see 3.3.5). (3) Remove five screws 1 and eight connectors 2. Remove AOLM-PCB 3. (4) Remove two screws 4 Remove IC card cover 5.

  • Page 50: Remove The Side Plate (R) (See 3.3.6 (1)

    %3.3.7 Stacker Cover Assy, Damper Arm, And Washer 3.3.7 Stacker cover Assy, damper arm, and washer (1) Turn the AC power switch off. Unplug the AC power cord from the outlet. (2) Remove the rear cover (see 3.3.1). (3) Remove the side cover (R) (see 3.3.5). (4) Remove the side plate (R) (see 3.3.6 (1) to (5)).
  • Page 51 %3.3.8 Damper 3.3.8 Damper (1) Turn the AC power switch off. Unplug the AC power cord from the outlet. (2) Remove the damper arm (see 3.3.7). (3) Remove two screws 1 and then remove two dampers 2.

  • Page 52: Stacker Full Sensor Assy

    %3.3.9 Stacker Full Sensor Assy 3.3.9 Stacker full sensor Assy (1) Turn the AC power switch off. Unplug the AC power cord from the outlet. (2) Remove the stacker cover Assy (see 3.3.7). (3) Remove four screws 1. Remove stacker mount 2 by releasing the tabs at position 2A (4) Remove stacker full sensor Assy 3 by spreading the plastic tabs on each side of sensor Assy 3 and lifting switch from cover.
  • Page 53 %3.3.10 Cable Cover (Cable Guides A And B) 3.3.10 Cable cover (cable guides A and B) (1) Turn the AC power switch off. Unplug the AC power cord from the outlet. (2) Remove the stacker cover Assy (see 3.3.7). (3) Remove two screws 1 release tabs at position 1A . Remove cable cover 2, cable guide A 3.

  • Page 54: Eject Roller Assy

    %3.3.11 Eject Roller Assy 3.3.11 Eject roller Assy (1) Turn the AC power switch off. Unplug the AC power cord from the outlet. (2) Remove the rear cover (se 3.3.1). (3) Remove the side cover (R) (see 3.3.5). (4) Remove the side plate (R) (see 3.3.6 (1) to (5)). (5) Remove the stacker cover Assy (see 3.3.7).

  • Page 55: Remove Paper Supply Guide

    %3.3.12 Paper Supply Guide D 3.3.12 Paper supply guide D (1) Turn the AC power switch off. Unplug the AC power cord from the outlet. (2) Remove the side cover (R) (see 3.3.5). (3) Remove four screws 1. Lift up and remove front feeder roller Assy 2. (4) Lift up and remove paper supply guide D 3.
  • Page 56 %3.3.13 Separator F 3.3.13 Separator F (1) Turn the AC power switch off. Unplug the AC power cord from the outlet. (2) Remove the manual feed hopper Assy (see 3.3.4). (3) Remove the side cover (R) (see 3.3.5). (4) Remove the front feeder Assy (see 3.3.12 steps (1) to (3)). Make a diagram of wire locations and routing.

  • Page 58: Remove The Manual Feed Hopper Assy (See 3

    %3.3.14 Front Feeder Roller Assy 3.3.14 Front feeder roller Assy (1) Turn the AC power supply switch off. Unplug the AC power cord from the outlet. (2) Remove the manual feed hopper Assy (see 3.3.4). (3) Remove the side cover (R) (see 3.3.5). (4) Remove the front feeder roller Assy (see 3.3.12 (1) to (3).

  • Page 59: Remove The Side Cover (R) (See 3

    %3.3.15 Hopping Motor 3.3.15 Hopping motor (1) Turn the AC power switch off. Unplug the AC power cable from the outlet. (2) Remove the manual feed hopper Assy (see 3.3.4). (3) Remove the side cover (R) (see 3.3.5). (4) Remove the front feeder Assy (see 3.3.12.(1) to (3)). (5) Remove the inner cover and square-shaped connector (see 3.3.13.(5) and (6)).

  • Page 60: Front Feeder Paper End Sensor

    %3.3.16 Front Feeder Paper End Sensor 3.3.16 Front feeder paper end sensor (1) Turn the AC power switch off. Unplug the AC power cord from the outlet. (2) Remove the manual feed hopper Assy (see 3.3.4). (3) Remove the side cover (R) (see 3.3.5). (4) Remove the front feeder roller Assy (see 3.3.12.

  • Page 61: Remove The Stacker Cover Assy (See 3

    %3.3.17 Main Chassis Unit 3.3.17 Main chassis unit (1) Turn the AC power switch off. Unplug the AC power cord from the outlet. (2) Remove the rear cover (see 3.3.1). (3) Remove the contact Assy (see 3.3.2). (4) Remove the side cover (R) (see 3.3.5). (5) Remove the side plate (R) (see 3.3.6 (1) to (5)).

  • Page 63: Remove The Front Feeder Roller Assy (See 3.3.12. (1)

    %3.3.18 Registration Roller 3.3.18 Registration roller (1) Turn the AC power switch off. Unplug the AC power cord from the outlet. (2) Remove the front feeder roller Assy (see 3.3.12. (1) to (3)). (3) Remove four screws 1. Lift and remove the registration roller Assy 2, left side first then right side.

  • Page 64: Drum Motor

    %3.3.19 Drum Motor 3.3.19 Drum motor (1) Turn the AC power switch off. Unplug the AC power cord from the outlet. (2) Remove the main chassis unit (see 3.3.17). (3) Remove the registration roller Assy (see 3.3.18 (1) to (3)). (4) Remove fuser Assy.

  • Page 65: Idle Gear

    %3.3.20 Idle Gear 3.3.20 Idle gear (1) Turn the AC power switch off. Unplug the AC power cord from the outlet. (2) Remove the main chassis unit (see 3.3.17). (3) Remove the motor Assy (see 3.3.19 (1) to (8)). (4) Remove three screws 1 and then remove motor bracket B (2). (5) Remove idler gear E (3), idle gear D (4), idle gear B (5), idle gear C (6), idle gear A (7), and two resist idle gears 8.

  • Page 66: Fusing Assy

    %3.3.21 Fusing Assy 3.3.21 Fusing Assy (1) Turn the AC power switch off. Unplug the AC power cord from the outlet. (2) Remove the side cover (L) Assy (see 3.3.1 (1) to (3)). (3) Unplug connector 1. (4) Remove four screws 2 and then remove fusing Assy 3.

  • Page 67: Fuser Pressure Roller

    %3.3.22 Fuser Pressure Roller 3.3.22 Fuser pressure roller (1) Turn the AC power switch off. Unplug the AC power cord from the outlet. (2) Remove the main chassis unit (see 3.3.17). (3) Remove the fusing Assy (see 3.3.21). (4) Remove the fuser pressure roller release lever (see 3.3.19 (5)). (5) Remove two screws 2 and release three locks on the fusing guide.

  • Page 68: Ep Lock Shaft

    %3.3.23 Ep Lock Shaft 3.3.23 EP lock shaft (1) Turn the AC power switch off. Unplug the AC power cord from the outlet. (2) Remove the main chassis unit (see 3.3.17). (3) Remove screw 1. Turn EP lock level (L) Assy 2 in the direction of arrow A . (4) Remove spring 3.

  • Page 69: Hopping Roller Assy

    %3.3.24 Hopping roller Assy 3.3.24 Hopping roller Assy (1) Turn the AC power switch off. Unplug the AC power cord from the outlet. (2) Remove the main chassis unit (see 3.3.17). (3) Release the latch. Remove hopping roller gear 1 and bearing P 2. Then, remove idle gear HF 3. (4) Remove the left side of hopping roller shaft 4 from the groove.

  • Page 70: Outlet Sensor Lever

    %3.3.25 Outlet sensor lever 3.3.25 Outlet sensor lever (1) Turn the AC power switch off. Unplug the AC power cord from the outlet. (2) Remove the main chassis unit (see 3.3.17). (3) Press the clamp part of outlet sensor lever 1. Remove the outlet sensor lever 1 by pushing it upward from the lower side.

  • Page 71: Toner Sensor Lever

    %3.3.26 Toner sensor lever 3.3.26 Toner sensor lever (1) Turn the AC power switch off. Unplug the AC power cord from the outlet. (2) Remove the main chassis unit (see 3.3.17). (3) Squeeze the clamp part of toner sensor lever 1 and remove the toner sensor lever 1 by pushing it upward from the lower side.

  • Page 72: Paper Sensor Lever

    %3.2.27 Paper sensor lever 3.2.27 Paper sensor lever (1) Turn the AC power switch off. Unplug the AC power cord from the outlet. (2) Remove the main chassis unit (see 3.3.17). (3) Squeeze the clamp part of the paper sensor lever 1. Remove the paper sensor lever 1 by pushing it upward from the lower side.

  • Page 73: Inlet Sensor Lever

    %3.3.28 Inlet sensor lever 3.3.28 Inlet sensor lever (1) Turn the AC power switch off. Unplug the AC power cord from the outlet. (2) Remove the main chassis unit (see 3.3.17). (3) Squeeze the clamp part of two inlet sensor levers 1. Remove the inlet sensor levers 1 by pushing them downward.
  • Page 74 %3.3.29 Insulator 3.3.29 Insulator (1) Turn the AC power switch off. Unplug the AC power cord from the outlet. (2) Remove the main chassis unit (see 3.3.17). (3) Remove two screws 1 and then remove inlet holder 2. At this time, remove inlet 3 from inlet holder 2.

  • Page 75: Paper End Lever

    %3.3.30 Paper end lever 3.3.30 Paper end lever (1) Turn the AC power switch off. Unplug the AC power cord from the outlet. (2) Remove the main chassis unit (see 3.3.17). (3) Release the lock and remove paper end lever 1.
  • Page 76 %3.3.31 Guide rail (L) Assy 3.3.31 Guide rail (L) Assy (1) Turn the AC power switch off. Unplug the AC power cord from the outlet. (2) Remove the main chassis unit (see 3.3.17). (3) Remove the insulator (see 3.3.29). (4) Remove screw 1 and then remove base plate 2. (5) Remove two screws 3 and then remove guide rail (L) Assy 4.
  • Page 78 %3.3.32 Guide rail (R) Assy 3.3.32 Guide rail (R) Assy (1) Turn the AC power switch off. Unplug the AC power cord from the outlet. (2) Remove the main chassis unit (see 3.3.17). (3) Remove the insulator (see 3.3.29). (4) Remove screw 1 and then remove base plate 2. (5) Remove two screws 3 and then remove guide rail (R) Assy 4.

  • Page 80: Remove Interface Cable

    %3.3.33 IC card cover 3.3.33 IC card cover (1) Turn the AC power switch off. Unplug the AC power cord from the outlet. (2) Remove interface cable 1. (3) Open stacker cover 2. Remove two screws 3 and then remove IC card cover 4.

  • Page 81: Led Head

    %3.3.34 LED head 3.3.34 LED head (1) Turn the AC power switch off. Unplug the AC power cord from the outlet. (2) Open stacker cover 1. (3) Remove PC connectors 2 and two LED cables 3 from LED head 4. (4) Push the hook on the left side of stacker cover 1 in the direction of arrow and remove LED head 4.

  • Page 82: Separator Assy

    %3.3.35 Separator Assy 3.3.35 Separator Assy (1) Turn the AC power switch off. Unplug the AC power cord from the outlet. (2) Pull out the paper cassette Assy 1 from the printer. (3) Release two locks and remove separator Assy 2. (At this time, leaf spring 3 and coil spring 4 are also removed.

  • Page 83: Transfer Roller

    %3.3.36 Transfer roller 3.3.36 Transfer roller (1) Turn the AC power switch off. Unplug the AC power cord from the outlet. (2) Open stacker cover 1. (3) Lift the left side of the gear TR 2 and release the lock. Remove gear TR 2 and transfer roller 3. (At this time, two bearings (TR) 4 and two transfer roller springs 5 are also removed.) (4) Remove diselectrification bar 6 and diselectrification film 7 from the chassis unit.
  • Page 84 Chapter 4 4. Adjustment 4. ADJUSTMENT This chapter explains the adjustment necessary when replacing a part. Adjustment is made by changing a parameter value set in EEPROM on the controller PCB. A parameter is set with the use of the keys on the operator panel. This printer has three kinds of maintenance mode. You will utilize one of the maintenance modes when replacing key parts.

  • Page 85: Maintenance Modes And Functions

    %4.1 Maintenance Modes And Functions 4.1 Maintenance Modes And Functions • User maintenance mode To enter the user maintenance mode, turn on the POWER switch while pressing the MENU key. Function There are six functions as follows. • Menu reset •...

  • Page 86: User Maintenance Mode

    %4.1.1 User maintenance mode 4.1.1 User maintenance mode • To enter the user maintenance mode, turn the power supply ON while pressing the Menu key. • This mode uses the menu for function selection. • The user maintenance mode provides the following functions: (1) Menu reset •...
  • Page 87 %User maintenance mode menu system User maintenance mode menu system...

  • Page 88: System Maintenance Mode

    %4.1.2 System maintenance mode 4.1.2 System maintenance mode • The system maintenance mode is set when the power is turned ON while pressing the Recover key. • This mode adopts the menu for function selection. • The system maintenance mode is provided with the following functions: (1) Page count display •...
  • Page 90 %System maintenance mode menu system System maintenance mode menu system...

  • Page 91: Engine Maintenance Mode

    %4.1.3 Engine maintenance mode 4.1.3 Engine maintenance mode • The engine maintenance mode is activated when the power is turned ON while pressing to the Form Feed key and Enter key. • This mode adopts the menu for function selection. •...
  • Page 92 Note: Do not change the default value of (2), (5) ~ (9) they are the parameters for adjusting in the factory.
  • Page 93 %Engine maintenance mode menu system Engine maintenance mode menu system...

  • Page 95: Eeprom Initialization

    %4.1.4 EEPROM initialization 4.1.4 EEPROM initialization The corresponding area of the EEPROM is initialized for each event as shown Table 4-1.

  • Page 96: Adjustment When Replacing A Part

    %*4.2 Adjustment When Replacing A Part 4.2 Adjustment When Replacing A Part Adjustment necessary when replacing one of the followimg parts. Part Replaced Adjustment LED Head Set the LED head drive time. (Refer to Chapter 4.2.1) Image Drum Cartridge Reset the image drum counter. (Refer to User's manual) Fuser Unit Reset the fuser counter.

  • Page 97: Setting Of Led Head Drive Time

    %4.2.1 Setting of LED head drive time 4.2.1 Setting of LED head drive time Note: When the luminous intensity marking of the replaced LED head (new part) is same as that of the used LED head (old part), do not set the LED head drive time. •...
  • Page 98 0.97 ~ 1.03 1.04 ~ 1.10 1.11 ~ 1.18 1.19 ~ 1.26 1.27 ~ 1.35 b. Setting Example: Setting method the parameter to 14 (in case of privous parameter is 17).

  • Page 99: Resetting The Fuser Counter

    %4.2.2 Resetting the fuser counter 4.2.2 Resetting the fuser counter (1) The fuser counter can be reset in the engine maintenance mode. (2) Resetting method...

  • Page 100: Destination Setting

    %4.2.3 Destination setting 4.2.3 Destination setting The desired destination can be set by turning the power on while depressing two keys corresponding to the destination according to the following table. Destination Keys to be depressed MENU, > MENU, < Non-Europe 1 MENU, PAPER SIZE (Australia, etc.) Non-Europe 2...
  • Page 101 Chapter 5 %5.1 Periodic Parts Replacement 5.1 Periodic Parts Replacement The parts are to be replaced periodically as specified below: Part name Condition for Cleaning Remarks replacement • Toner cartridge 5,000 • LED head. Consumables • Image drum 30,000 • LED head. Consumables cartridge...
  • Page 102 %5.2 Cleaning 5.2 Cleaning Remove any toner and dust. Clean inside and around the printer with a piece of cloth when necessary. Use the handy cleaner (VACCUM) for cleaning the printers interior. Note: Do not touch image drum, LED lens array, and LED head connector block. Do not use any solvents.

  • Page 103: Cleaning Of Led Lens Array

    %5.2.1 Cleaning of LED Lens Array 5.2.1 Cleaning of LED Lens Array Clean the LED lens array or replace the toner cartridge when white lines or stripes (void, light printing) are generated vertically down the page, as shown below. Note: The LED lens array must be cleaned with an LED head cleaner. LED Lens cleaner pads are included with replacement toner cartridges.

  • Page 104: Cleaning Page Function

    %5.2.2 Cleaning Page Function 5.2.2 Cleaning Page Function There is a Charge Roller cleaning function within this printer, which can be executed by the user. (1) While the printer is in off-line mode press both the left arrow and right arrow keys on the printer operator panel for at least 2 seconds.
  • Page 105 %5.3 Lubrication - General Information 5.3 Lubrication 5.3.1 General Information Lubrication should be performed once a year or as needed. Use Lithium Grease. When applying the grease, do not over-lubricate. Do NOT allow lubrication to contact the surface of any rollers or paper guides. Lubricate the items listed in the table below.
  • Page 106 Chapter 6 %6.1 Troubleshooting Tips 6.1 Troubleshooting Tips (1) Check the basic check points covered in the users manual. (2) Gather as much information on the problem from the customer as possible. (3) Perform inspections in conditions close to those in which the problem had occurred.

  • Page 107: Points To Check Before Correcting Image Problems

    %6.2 Points to Check before Correcting Image Problems 6.2 Points to Check before Correcting Image Problems (1) Is the printer being run in proper ambient conditions? (2) Have the supplies (toner) and the routine replacement part (image drum cartridge) been replaced properly? (3) Is the paper normal? See paper specifications section.

  • Page 108: Tips For Correcting Image Problems

    %6.3 Tips for Correcting Image Problems 6.3 Tips for Correcting Image Problems (1) Do not touch, or bring foreign matter into contact with the surface of the image drum. (2) Do not expose the image drum to direct sunlight. (3) Keep hands off the fuser unit as it is heated during operation. (4) Do not expose the image drum to light for longer than 5 minutes at room temperature.

  • Page 109: Preparation For Troubleshooting

    %6.4 Preparation for Troubleshooting 6.4 Preparation for Troubleshooting (1) Operator panel display The failure status of this printer is displayed on the liquid crystal display (LCD) in the operator panel. Take proper corrective action as directed by messages that are displayed on the LCD.
  • Page 110 %6.5 Troubleshooting Flow 6.5 Troubleshooting Flow If troubles should develop in this printer, troubleshoot in the following procedure flow:...
  • Page 111 %6.5.1 LCD status message/trouble list 6.5.1 LCD status message/trouble list Table 6-1 lists the status and troubles that may be indicated by messages on the LCD.
  • Page 112 %LCD Status Messages: (1-4) General LCD Status Messages: (1-4) General Category LCD Status Message Trouble or Status Remedy Daily status The printer is in the on-line mode. Normal operation xxx: Emulation in use (HP4, PS, HxD, AUT) tttttt: Tray being selected (TRAY 1, TRAY 2, FRONT, MANUAL, ENVLOP) mmmmmmmmm: Paper size in the tray being...
  • Page 113 Daily status A fault occurred in the toner sensor. Check the Normal operation can be continued. operation of the toner sensor lever. Replace the Power-Sensor board (hereinafter simply called the Power board) Replace the Control board Note: When replacing the Control board, install the EEPROM...
  • Page 114 Daily status The fuser is running down. Replace Normal operation can be continued. the fuse unit. Note: After replacing the fuser unit reset the fuser counter. (Refer to chapter 4.2.2.) Daily status When the number of copies being printed is two Normal operation or more, the number of copies being printed is displayed.
  • Page 115 %LCD Status Messages: (2-4) General %LCD Status Messages: (2-4) General Category LCD Status Message Trouble of Status Remedy Paper Loading of paper indicated by the • Load the requested paper in request first line message is requested. the tray. Tray paper The tray has run out of paper.
  • Page 116 Paper size Paper of improper size was fed • Check the paper in the tray error from the tray. or check to see if more than tttttt: MANUAL, TRAY 1, TRAY one sheet of copy were fed 2 or ENVLOP simultaneously.
  • Page 117 Optional A checksum error occurred when a • Remove the card. card card was inserted. • Replace the card. error If a card other than the cards for OL series is inserted, no error is displayed to ignore the inserted card.
  • Page 118 %LCD Status Messages: (3-5) Error Controller nn %LCD Status Messages:3-5 A fault occurred in the printer. Turn the power off, then on to release the error display. If the error display cannot be released by this procedure, call a service person.
  • Page 119 I/F timeout occurred between the printer main See chapter 6.5.2. unit and the operator panel. I/F timeout occurred between the printer main See chapter 6.5.2. unit and the optional tray (2nd tray, envelope feeder, etc.) A watchdog timer timeout occurred. Turn the power off, then on.
  • Page 121 %LCD Status Messages: (4-4) Error Controller On= xxxxx %LCD Status Messages: (4-4) Proccesor errors Remedy Exception Error code Address Error Exception See Below (Lead instruction, instruction fetch) Address Error Exception (Store instruction) See Below Bus Error Exception (Instruction Fetch) See Below Bus Error Exception See Below (Load instruction, store instruction)

  • Page 122: Table Of Contents

    %6.5.2 LCD message troubleshooting 6.5.2 LCD message troubleshooting If problems are not correctable from the LCD message trouble list, follow the troubleshooting flowcharts given here to deal with them. Trouble Flowchart number The printer does not work normally after being turned Jam alarm Paper input jam (1st Tray) Paper input jam (Front...

  • Page 123: The Printer Does Not Work Normally After Being Turned On

    %1. The printer does not work normally after being turned on. The printer does not work normally after being turned on. message shown in the LCD display (for less than 1 second)? Is the AC cable connected properly? Connect the cable properly. Is the message (16 columns display only on the top row ) shown in the LCD display?
  • Page 124 Is the operator panel connected to the Control board properly? Connect the operator panel properly. Is the connecting cord defective? Replace the connecting cord. Replace the operator panel assembly. Is the printer recovered? Replace the Control board. YES END. message shown in the LCD display? Replace the Control board.
  • Page 125 Fig. 6-2 Measurement by a Multimeter Fig. 6-3 Connector and Pin Location...

  • Page 126: Paper Input Jam (1St Tray)

    %2-1 Paper input jam (1st tray) [JAM error] Paper input jam (1st tray) Does a jam error occur when the power is turned on? Is the paper at the inlet sensor lever? Remove the paper. Does the inlet sensor lever operate smoothly? Replace the inlet sensor lever Clean the inlet sensor on the Power/sensor board or replace the Power/sensor board.

  • Page 127: Paper Input Jam

    %2-2 Paper input jam (front feeder) Paper input jam (front feeder) Does jam error occur when the power is turned on? Is the paper at the inlet sensor lever? Remove the paper. No Does the inlet sensor lever operate smoothly? Replace the inlet sensor lever.

  • Page 128: Paper Feed Jam

    %2-3 Paper feed jam Paper feed jam Does a paper feed jam occur when the power is turned on? Is the paper on the paper sensor lever? Remove the paper. Does the paper sensor lever operate smoothly? Replace the paper sensor lever. Clean the paper sensor.
  • Page 129 From on the preceding page . From on the preceding page . Is the image drum set properly? Set the image drum properly. In case of paper feed from the front feeder, check the hopping roller of the front feeder assembly. In case of paper feed from the tray, check the hopping roller assembly and the tray.
  • Page 130 From on the preceding flow . Is the transfer roller rotating smoothly? Is there any defective gear of the transfer roller? Replace the defective gear. Replace the transfer roller. Is the fuser unit installed properly? Install the fuser unit properly. Is the image drum cartridge set properly? Set the image drum cartridge properly.

  • Page 131: Paper Exit Jam

    %2-4 Paper exit jam Paper exit jam Does a paper exit jam error occur when the power is turned on? YES Is the paper on the outlet sensor lever? Remove the paper Does the outlet sensor lever operate smoothly? Replace the outlet sensor lever. Clean the outlet sensor on the Power/sensor board.

  • Page 132: Paper Size Error

    %3 Paper size error Paper size error Is paper of the specified size used? Use paper of the specified size. Do the inlet sensor lever and paper width sensor lever operate smoothly? Replace the inlet sensor lever or paper width sensor lever. Is the printer recovered? Clean the inlet sensor or paper width sensor on the Power/sensor board.
  • Page 133 %4 Fuser unit error (ERROR 71), (ERROR 72), (ERROR 73) Fuser unit error (ERROR 71), (ERROR 72), (ERROR 73) Turn the power OFF/ON. Does a fuser unit error occur immediately? Is the thermistor open or shorted? Measure the resistance between thermistor contacts. (About 220 kW at room temperature, 25°C) (See chapter 7.3 for the measuring points.) Replace the fuser unit.
  • Page 134 Is the heater or thermistor open? Measure the resistance between the heater contacts (normal resistance: 220 kW (25°C) between pins 1 and 2, 2.3 W (120 V) and 8.5 W (240 V) between pins 3 and 4) (See chapter 7.3.) Replace the fuser unit.
  • Page 135 %5 Synchronous serial I/O error (ERROR 74) or I/F time-out between printer and optinal tray (ERROR 81) Synchronous serial I/O error (ERROR 74) or I/F time-out between printer and optinal tray (ERROR 81) Is an optional tray (2nd tray or envelope feeder) used? Is the connection between the Control board and the optional tray connected properly.

  • Page 136: I/F Time-Out (No Response)

    %6. I/F time-out occurs between the printer and the operator panel (ERROR 80) . 6. I/F time-out occurs between the printer and the operator panel (ERROR 80) . Is the connecting cord of the operator panel connected to the PANEL connector of the Control board properly? (See chapter 7.1.) Connect the connecting cord of the operating panel to the PANEL connector of the...
  • Page 137 %7. Communications with the host cannot be performed via the parallel 7. Communications with the host cannot be performed via the parallel interface. Is the parallel interface or auto interface selected in menu level 1? Select the parallel interface or auto interface in menu level 1. Is the host set to the bidirectional communication? Set the parallel I/F to the bidirectional communication enable state (DISABLE Æ...
  • Page 138 %8. Data from the host not received via the serial interface. 8. Data from the host not received via the serial interface. Is message displayed? Select the auto interface or RC232C for the host interface in menu level 1. Do the following items selected for RS232C SERIAL in menu level 2 coincide with those selected at the host side? FLOW CONTROL PARITY...

  • Page 140: Data Cannot Be Received Through The Oki Hsp Interface

    %9. Data cannot be received through the OKI HSP interface 9. Data cannot be received through the OKI HSP interface Is the interface board (option) connected to the OKI HSP interface connector on the Control board properly? Connect the interface board (option) to the OKI HSP interface connector properly. Is there any broken or bent pin in the interface board (option)? Ask the user to replace the interface board (option).

  • Page 141: Image Troubleshooting

    %6.5.3 Image troubleshooting 6.5.3 Image troubleshooting Procedures for troubleshooting if abnormal images have been printed out are explained below. Figure 6-3 below shows typical abnormal images. Trouble Flowchart number Images are light or blurred as a whole (Figure 6-4, Dark background density (Figure 6-4, ) Blank paper is output (Figure 6-4, ) Black stripes in the vertical direction (Figure 6-4, Cyclical defect (Figure 6-4, )

  • Page 142: Images Are Light Or Blurred As A Whole

    %1. Images are light or blurred a whole. 1. Image are light or blurred a whole. Is toner low? (Is the TONER LOW message displayed?) Supply toner. Is paper of the specified grade used? Use paper of the specified grade. Is the lens surface of the LED head dirty? Clean the lens.

  • Page 143: Dark Background Density (Figure 6-4, )

    %2. Dark background density Dark background density Has the image drum been exposed to external light? Mount the image drum in the printer and wait for about 30 minutes. Is the heat roller of the fusing unit dirty? Clean the heat roller. Is the contact of the cleaning roller of the image drum cartridge contacted with e contact assembly properly? (See Figure 6-5 C .) Adjust the contact of the cleaning roller to contact the contact assembly properly.
  • Page 144 Replace the control board or Power/Sensor board.

  • Page 145: Black Belts Or Stripes In The Vertical Direction

    %4. Black belts or stripes in the vertical direction 4. Black belts or stripes in the vertical direction Replace the image drum cartridge. Has the trouble been removed? Note: After replacing the image drum cartridge, set the printer in the user maintenance mode by turning the power on while pressing the MENU key, and reset the drum counter, (Refer to User's Manual.) Replace the LED head.

  • Page 146: Cyclic Error

    %5. Cyclic error 5. Cyclic error Frequency Remedy Image drum 3.71 (94.2 mm) Replace or clean the image drum cartridge. Developing roller 2.50 (63.5 mm) Replace the image drum cartridge. Toner supply roller 2.13 (54.0 mm) Replace the image drum cartridge. Charging roller 1.73 (43.9 mm) Replace the image drum cartridge.

  • Page 147: Print Voids

    %6. Print voids 6. Print voids Is the contact plate of the transfer roller contacted with the power/sensor board properly? (See Figure 6-5.) Adjust the contact plate contact to contact the power/sensor board properly and the shaft of the transfer roller. Replace the transfer roller.

  • Page 148: Poor Fusing

    %7. Poor fusing 7. Poor fusing Is paper of the specified grade used? Use paper of the specified grade. Is the spring of the back-up roller normal? Replace the spring. Is the contact of the fusing unit assy contacted with the contact assy properly? (See Figure 6-5 G.) Adjust the contact of the fusing unit assy to contact the contact assembly properly.

  • Page 149: White Belts Or Streaks In The Vertical Direction

    %8. White belts or streaks in the vertical direction White belts or streaks in the vertical direction Are the LED lens dirty? Clean the LED lens. Is the contact plate of the transfer roller contacted with the power/sensor board properly? (See Figure 6-6.) Make the contact plate contact with the power/sensor board properly.
  • Page 152 Chapter 7 %7. Wiring Diagram 7. WIRING DIAGRAM 7.1 Interconnect Signal Diagram...
  • Page 153 %7.2 PCB Layout 7.2 PCB Layout (1) Control board (AOLM)
  • Page 155 %7.3 Resistance Check 7.3 Resistance Check...

  • Page 156: Short Plug Setting

    %7.4 Short Plug Setting 7.4 Short Plug Setting (1) Control board (AOLM) Short plug Plug setting Description Factory setting +5 V is supplied to pin 18 of Centronics parallel I/F connector. +5 V is not supplied to pin 18 of Centronics parallel I/F connector.
  • Page 157 Chapter 8 8. Parts List 8. PARTS LIST Figure 8-1 Printer Unit 1000 Name/Rating OKI-J Part Remarks...
  • Page 158 Side cover (L) 3PP4128-111 53073501 Assy Side cover (R) 1PP4128-106 53073601 IC cover 2PP4128-111 53073701 I/F cover assy 2PA4128-106 53073801 Rear cover 1PP4128-106 53073901 Operator panel 2YX4128-107 50108101 assy (ODA) Flexible cable 238A1071P00 56627901 (OP panel) Face-up stacker 2PA4128-107 50108201 assy Manual feed...
  • Page 159 AOLM-PCB 4YA4046-163 55077311 4G11...

  • Page 160: Main Chassis Unit

    Main Chassis Unit Main Chassis Unit Name / Rating Parts No. Q'ty 1000 Remarks Main chassis assy 2PP4076-5751G1 1 50107901 Spring [EP lock 4LB-192600-6 50928306 lever (L) assy] Stacker cover 4PB4083-6197P1 51229401 damper Idle gear (exit) 4PP4043-4532P1 51234301 Hopping roller assy 4PA4076-5755G1 1 without shaft 50407901...
  • Page 161 Idle gear C 4PP4076-5063P1 51233901 Idle gear D 4PP4076-5064P1 51234001 Idle gear E 4PP4076-5065P1 51234101 Registration idle 4PP4076-5068P1 51234201 gear Main motor 4PB4076-5075P2 56511801 Registration motor 4PB4076-5076P1 50408001 EP lock lever 4PP4076-5044P1 50807301 EP lock spring 4PP4076-5045P1 50928401 Pressure release 3PP4076-5046P1 50807401 lever...
  • Page 162 Fusing guide 2PP4076-5021P1 51016001 Idle gear (HF) 4PP4043-4535P1 50234601 Fusing assy 1YX4076-5100G1 1 50219901 120Volt Fusing assy 1YX4076-5100G2 1 50219902 230Volt Exit roller assy Exit roller assy 50408401 4PP4076-5191G1 1 53073101 Stacker cover assy 2YX4128-1080G1 1 53073201 Washer 4PP4076-5009P1 50516701 Fuser pressure 3PP4076-5347P1 50808101...
  • Page 163 Front Feeder Unit Front Feeder Unit Name / Rating Parts No. Q'ty 1000 Remarks Paper supply guide 3PP4076-5348G1 1 51016101 A (Affix) Paper supply guide 1PP4076-5303P1 51016201...
  • Page 164 Paper supply guide 1PP4076-5304P1 51016301 FF roller assy 4PA4076-5757G1 1 50408501 FF plate (Affix) 4PP4076-5310G1 1 51016601 FF cam 4PP4076-5313P1 51235601 Front feeder gear 4PB4076-5314P1 51234701 4YB4076-5316P1 50408901 Separator assy 4PP4076-5317G1 1 53346301 Idle gear Idle gear 51234801 Hopping motor 4PB4076-5330P1 56511701 Connector cord...
  • Page 165 Base Unit Base Unit Name / Rating Parts No. Q'ty 1000 Remarks Guide rail (L) Assy 2PP4076-5753G1 1 51016701 Pull block 4PP4122-1217P1 51500301 Link support 4PP4076-5358P1 50516801 Cassette lock 4PP4076-5417P1 50927302 spring Cassette stopper 4PP4076-5359P1 50607201...
  • Page 166 Pressure coil spring 4PP4043-4526P1 50928801 Guide rail (R) assy 2PP4076-5754G1 1 51016801 AOLS-PCB 4YA4046-1621G1 55077101 Square shaped Square shaped 56730640 connector connector (fixed side) (fixed side) Detector spring 4PP4076-5360P1 50928901 Insulator 3PB4076-5144P1 51711001 Paper end lever 4PP4076-5154P1 50808201 Power/sensor-PCB 4YB4049-1764P2 56413702 (120V) Power/sensor-PCB...
  • Page 167 Appendix A Rs-232 Serial Interface Appendix A RS-232C SERIAL INTERFACE 1) Connector • Printer side : 25-pin receptacle (Female) Type DB-25S or equivalent • Cable side : 25-pin plug (Male) Type DB-25P or equivalent Note: Plug shall be able to be fixed with a lock screw. 2) Cable •...
  • Page 168 4) Signal level • MARK polarity : -3V to -15V (LOGIC = 1) • SPACE polarity: +3V to +15V (LOGIC = 0) 5) Specifications Item Description Mode Start-stop synchronous system Line speed 300, 600,1200, 2400, 4800, 9600, 19200 (bps) Data bit length 8 bits, 7 bits Parity Odd, even, none (space, mark, and ignore not...
  • Page 169 Appendix B %Centronics Parallel Interface Appendix B CENTRONICS PARALLEL INTERFACE 1) Connector • Printer side : 36-pin receptacle (Female) Type 57-40360-12-D56 (made by Daiichi Denshi) or equivalent • Cable side : 36-pin plug (Male) Type 57-30360 (made by Daiichi Denshi) or equivalent Plug-552274-1 (AMP), 552073-1 (AMP) or equivalent 2) Cable •...
  • Page 170 4) Signal level • LOW : 0 V to +0.8 V • HIGH : +2.4 V to +5.0 V 5) Specifications Item Description Mode Compatibility mode, Nibble mode, ECP mode Data bit length 8 bits: Compatibility mode, 4 bits: Nibble mode, 9 bits: ECP mode Input prime Valid/Invalid Receive buffer 8K, 20K, 50K, 100K, 1M Bytes...
  • Page 171 Appendix A 2.1 General Mechanism General Mechanism The sheet (or envelope) at the very bottom of the stack is fed into the printer, one at a time, when the Power Envelope Feeder receives the signal from the printer. (1) The hopping motor rotates in the direction of arrow D. The planet gear F moves in the direction of arrow G, and drives rollers A and B.
  • Page 172 Appendix C %High Capacity Second Paper Feeder 1.1 Functions The printer is mounted on top of this High Capacity Second Paper Feeder, and it supplies paper automatically through the operation of hopping motor, which is driven by signals sent from the printer. The main functions are the followings: •...
  • Page 173 %1.2 External View and Component Names 1.2 External View and Component Names...

  • Page 174: Mechanism Description

    %2. Mechanism Description 2. MECHANISM DESCRIPTION 2.1 General Mechanicsm The sheet at the very top of the stack in the paper cassette is fed into the printer, one at a time, when the High Capacity Second Paper Feeder receives the signal from the printer. (1) First, the hopping motor rotates in the direction of arrow A.
  • Page 175 %2.2 Hopper Mechanism 2.2 Hopper Mechanism The hopper automatically feeds the printer with the paper being set, single sheet at a time. When the paper is loaded in the paper cassette, it is then transported by the hopping motor, carrying forward only a single sheet caught by the brake shoe at a time.
  • Page 176 %3. Parts Replacement 3. PARTS REPLACEMENT This section covers the procedures for the disassembly, reassembly and installations in the field. This section describes the disassembly procedures. For reassembly procedures, reverse the dis-assembly instructions. 3.1 Precautions Concerning Parts Replacement (1) Parts replacements must be carried out, by first turning the printer power switch off O and removing the High Capacity Second Paper Feeder from the printer.
  • Page 177 %3.2 Parts Layout 3.2 Parts Layout This section describes the layout of the main components.
  • Page 178 %3.3 Parts Replacement Methods 3.3 Parts Replacement Methods This section describes the parts replacement methods for the components listed in the disassembly order diagram below.

  • Page 179: Idle Rollers

    %3.3.1 Idle rollers 3.3.1 Idle rollers (1) Remove two screws 1 and remove the front panel assy 2. (2) Remove two idle rollers 3.
  • Page 180 %3.3.2 AOLT-PCB 3.3.2 AOLT-PCB (1) Remove the screw 1 and remove the PCB cover 2. (2) Remove three connectors 3 and two screws 4, then remove the AOLT-PCB 5.
  • Page 181 %3.3.3 Hopping motor 3.3.3 Hopping motor (1) Remove the front panel assy (see 3.3.1 step1). (2) Remove the PCB cover (see 3.2.2 step1). (3) Remove two connectors 1 and two screws 2, then remove the hopping motor assy 3. The three gears 4, the connecting lever 5, as well as the wave washer 6 all come off at the same time, so be careful not to lose them.
  • Page 182 %3.3.4 Feed roller 3.3.4 Feed roller (1) Remove the front panel assy (see 3.3.1 step1). (2) Remove the AOLT-PCB (see 3.3.2). (3) Remove the hopping motor assy (see 3.3.3). (4) Remove the latch on the feed roller gear 1 and remove the feed roller gear 1. (5) Remove the latch on the feed roller bearing 2 and remove the feed roller bearing 2.
  • Page 183 %3.3.5 Hopping roller rubber 3.3.5 Hopping roller rubber (1) Remove the feed roller (see 3.3.4). (2) Remove the latch on the hopping roller gear 1 and remove the hopping roller gear 1. The bearing F 2 comes off at the same time, so be careful not to lose it. (3) Remove the latch on bearing L 3 and remove the bearing L 3.
  • Page 184 %3.3.6 Side frame (L) assy 3.3.6 Side frame (L) assy (1) Remove the hopping roller (see 3.3.5). (2) Remove three screws 1 and remove the upper plate 2. (3) Remove two screws 3 and remove the side frame (L) assy 4. (4) Remove the cassette lock spring 5, link 6, pull block 7 (note the directions of the hooks of the cassette lock spring 5).
  • Page 185 %3.3.7 Side frame (R) assy 3.3.7 Side frame (R) assy (1) Remove the hopping roller (see 3.3.5). (2) Remove three screws 1 and remove the upper plate 2. (3) Remove two screws 3 and remove the side frame (R) assy 4. (4) Remove the cassette lock spring 5, link 6, pull block 7 and earth plate 8 (note the directions of the hooks of the cassette lock spring 5).
  • Page 186 %4. Troubleshooting 4. TROUBLESHOOTING 4.1 Precautions Prior to the Troubleshooting (1) Use the basic trouble-shooting steps provided in the Operator Guide. (2) Obtain detailed information concerning the problem from the user. (3) Try to recreate the conditions similar to that in which the problem occurred. 4.2 Preparations for the Troubleshooting (1) Display on the Operator panel The status of the problem is displayed on the LCD (Liquid Crystal Display) on the Operator panel.
  • Page 187 %4.3 Troubleshooting Method Troubleshooting Method When a problem occurs, go through the troubleshooting according to the following procedure.

  • Page 188: Lcd Status Message List

    %4.3.1 LCD Status Message List 4.3.1 LCD Status Message List The listing of the statuses and problems displayed in the form of messages on the LCD is provided in Table 4-1. Classification LCD Status Message Description Recovery method Jam error Notifies of occurrence Check the paper in the of jam while the paper...
  • Page 189 %4.3.2 Troubleshooting Flow 4.3.2 Troubleshooting Flow ( JAM error ) Paper Input Jam Does paper jam at the inlet when the power is turned on? Is the paper located above the sensor plate (Inlet)? Remove the paper. Is the sensor plate (Inlet) operating normally? Replace the sensor plate (Inlet).
  • Page 190 %5. Connection Diagram CONNECTION DIAGRAM Interconnection Diagram...
  • Page 191 %5.2 PCB Layout PCB Layout AOLT-PCB...
  • Page 192 %6. Parts List PARTS LIST Table 6-1 High Capacity Second Paper Feeder Description Part No. Q•ty Remarks AOLD-PCB 4YA4046-1646G11 Feed roller 3PB4076-5707P1 56408701 Hopping motor 4PB4076-5718P1 56511901 Hopping gear 4PB4043-4486P1 51235001 Hopping roller assy 4PA4076-5755G1 50407901 Feed roller gear 4PB4043-4488P1 Feed roller bearing 4PP4043-4489P1 Feed idle gear...
  • Page 193 AOLT-PCB 4YA4046-1645G11 55077511 Connector cord 4YS4011-4448P3 56730803 Square-shaped connector 220A1866P0141 56730641 Earth plate 4PP4076-5717P1 53346701 Bush 4PP4076-3949P1 51607301 Shaft earth plate 4PP4076-5719P1 53346801 Paper cassette assy 1PA4076-5430G1 50108001 Separator frame assy 3PP4083-5663G1 53345601...
  • Page 194 %1.1 Functions Functions This Power Envelope Feeder is installed on the front section of the printer, and it supplies paper automatically through the operation of hopping motor, which is driven by signals sent from the printer. The main functions are the followings: Paper that can be used:...
  • Page 195 %1.2 External View and Component Names External View and Component Names...
  • Page 196 Appendix D %2. General Mechanism General Mechanism The sheet (or envelope) at the very bottom of the stack is fed into the printer, one at a time, when the Power Envelope Feeder receives the signal from the printer. (1) The hopping motor rotates in the direction of arrow D. The planet gear F moves in the direction of arrow G, and drives rollers A and B.
  • Page 197 %2.2 Hopper Mechanism Hopper Mechanism The hopper automatically feeds the printer with the paper being set, single sheet at a time.
  • Page 198 %3. Parts Replacement PARTS REPLACEMENT This section covers the procedures for the disassembly, reassembly and installation in the field. This section describes the disassembly procedures. For reassembly procedures, reverse the disassembly steps. Precautions Concerning Parts Replacement (1) Parts replacements must be carried out, by first turning the printer power switch off O and removing the Power Envelope Feeder from the printer.

  • Page 199: Parts Layout

    %3.2 Parts Layout Parts Layout This section describes the layout of the main components.
  • Page 200 %3.3 Parts Replacement Methods Parts Replacement Methods This section describes the parts replacement methods for the components listed in the disassembly order diagram below. Power Envelope Feeder Separator (3.3.1) AOLE-PCB (3.3.2) Square-shaped connector (3.3.3) Hopping motor (3.3.4) Planet gear (3.3.5) Roller B (3.3.6) Roller A (3.3.7) Mini pitch belt &...

  • Page 201: Separator (3.3.1)

    %3.3.1 Separator 3.3.1 Separator (1) Turn the printer power off and remove the Power Envelope Feeder. (2) Disengage the link and hopper cover. (3) Remove two screws 1, disengage two locks of the upper cover 2 using a flat-head screwdriver, and remove the upper cover 2. (4) Remove two pan-head screws 3 and remove the cover frame 4.

  • Page 202: Aole-Pcb (3.3.2)

    %3.3.2 AOLE-PCB 3.3.2 AOLE-PCB (1) Remove the upper cover (see 3.1.1 (1) to (3)). (2) Remove two screws 1 and remove the AOLE-PCB 2. (3) Remove the connector 3. (4) Remove the connector 4. Caution: Be careful to set the sensor plate properly when pounting th AOLE-PCB...

  • Page 203: Square-Shaped Connector (3.3.3)

    %3.3.3 Square-shaped connector 3.3.3 Square-shaped connector (1) Remove the upper cover and remove the cover frame 5 (see 3.3.1 (1) to (4)). (2) Remove the AOLE-PCB (see 3.3.2). (3) Remove the screw 1 and remove the square-shaped connector 2. (4) Remove the nylon cord 3 from the square-shaped connector 2. [Confirmation after assembly] 1.

  • Page 204: Hopping Motor (3.3.4)

    %3.3.4 Hopping Motor 3.3.4 Hopping Motor (1) Remove the upper cover (see 3.3.1 (1) to (3)). (2) Remove the AOLE-PCB. (see 3.3.2) (3) Remove two screws 1, then remove the hopping motor 2.

  • Page 205: Planet Gear (3.3.5)

    %3.3.5 Planet gear 3.3.5 Planet gear (1) Remove the upper cover (see 3.3.1 (1) to (3)). (2) Remove the AOLE-PCB (see 3.3.2). (3) Remove two screws 1, then remove the motor bracket assy 2 and the planet gear 3.

  • Page 206: Roller B (3.3.6)

    %3.3.6 Roller B 3.3.6 Roller B (1) Remove the upper cover (see 3.3.1 (1) to (3)). (2) Disengage the plate and frame (on both sides). (3) Remove the separator assy (see 3.3.1 (4) to (5)). (4) Remove the AOLE-PCB (see 3.3.2). (5) Remove the motor bracket assy (see 3.3.5).

  • Page 207: Roller A (3.3.7)

    %3.3.7 Roller A 3.3.7 Roller A (1) Remove the motor bracket assy (see 3.3.5). (2) Remove two gears 1 and then another gear 2. (3) Disengage the plate 3 and the frame 4. (4) Remove four screws 5 and remove the frame 4 (see 3.3.6). (5) Move the belt to the right and remove it from the one-way pulley 6.

  • Page 208: Mini Pitch Belt & Feed Roller (3.3.8)

    %3.3.8 Mini pitch belt & Feed roller 3.3.8 Mini pitch belt & Feed roller (1) Remove the roller A (see 3.3.7). (2) Remove the bearing 1 and remove the feed roller assy 2. (3) Remove two bearings 3 and remove the plate 4. (4) Remove the mini pitch belt 5 and the feed roller 6.

  • Page 209: Troubleshooting

    %4. Troubleshooting TROUBLESHOOTING Precautions Prior to the Troubleshooting (1) Go through the basic checking items provided in the Operator Guide. (2) Obtain detailed information concerning the problem from the user. (3) Go through the checking in the conditions similar to that in which the problem occurred. Preparations for the Troubleshooting (1) Display on the operator panel The status of the problem is displayed on the LCD (Liquid Crystal Display) on the operator...
  • Page 210 Paper size error Notifies of incorrect Check the paper in size paper feeding the Power Envelope from the Power Feeder. Envelope Feeder. Also check to see if there was a feeding of multiple sheets. Carry out the recovery printing by opening the cover, removing paper and closing the cover, and...
  • Page 211 %4.3.2 Troubleshooting Flow 4.3.2 Troubleshooting Flow ( JAM error ) Paper Input Jam Does paper jam at the inlet when the power is turned on? Is the paper located above the sensor plate (Inlet)? Remove the paper. Is the sensor plate (Inlet) operating normally? Replace the sensor plate (Inlet).
  • Page 213 %5. Connection Diagram CONNECTION DIAGRAM Interconnection Diagram AOLE PCB...
  • Page 214 %5.2 PCB Layout PCB Layout AOLE-PCB...
  • Page 215 6. Parts List 6. PARTS LIST #### Table 6-1 Power Envelope Feeder Description Part No. Remarks Separator 4PP4083-5544G1 53344201 Roller-A 3PB4083-5514P1 53343801 Planet gear 4PP4083-5520P1 51229601 Hopping motor 4PB4083-6075P1 56510701 Roller-C 3PB4083-5524P1 53343901 One-way pulley 4PB4043-4614P1 51235701 Mini pitch belt 4LP-1313-338 51304901 Roller-B...

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