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Service Guide - OKICOLOR8 Page: 1
Chapter 0 Introduction
Front Cover
Service Guide
OKICOLOR 8 & OKICOLOR 8n
Digital LED Page Printers
Adobe Acrobat printable reference copy
of the OKIDATA Service Training Manual.
12/20/99
Note: This Adobe Acrobat version of the Okidata Service Training Manual was built with the pictures
rendered at 72 dpi, which is ideal for screen viewing. For future updates to this manual, and
more on-line information visit our Business Partner Exchange (BPX) at
http://bpx.okidata.com.
Copyright 1999, Okidata, Division of OKI America, Inc. All rights reserved.
Table of Contents Page
Service Guide - OKICOLOR8
0 Introduction
....Preface 2
1 Specifications
1.1 Basic System Configuration 3
1.2 Printer Specifications 4
1.3 Option Specifications 5
1.4 Basic Specifications 6
2 Operation
2. Operation 7
2.1 Main Control Board (PCE PCB) 8
2.2 Engine Control Board (PX4 PCB) 9
2.3 Power/Board 10
2.4 Mechanical Processes 11
....2.4.1 Electrophotographic processing mechanism 12
....2.4.2 Paper running process 13
2.5 Sensors 14
....2.5.1 Paper Related Sensors 15
....2.5.2 Other sensors 16
2.6 Correction of Color Deviation 17
2.7 Transfer Control according to Environmental Changes 18
2.8 Form Jam Detection 19
2.9 Cover Opening 20
2.10 Toner Lower Detection 21
2.11 Page Size Detection 22
2.12 Power-on Processing 23
3 Disassembly
3.0 Parts Replacement 24
3.1 Precautions for Parts Replacement 25
3.2 Parts Layout 26
3.3 How to Change Parts 27
....3.3.1 Cover Assy Rear 28
....3.3.2 Motor-Fan (80-25) 29
....3.3.3 Paper Eject Assy 30
....3.3.4 Cover Assy Stacker, Guide Eject FD Assy 31
....3.3.5 Upper Frame Assy 32
....3.3.6 Plate Support Assemblies 33
....3.3.7 Limiter 2way (L), (R) / Plate Guide (L), (R) 34
....3.3.8 Cover 35
....3.3.9 PCE PCB Assy 36
....3.3.10 Motor Fan (CU) 37
....3.3.11 PXF PCB / PX4 PCB 38
....3.3.12 Gear Heat Assy 39
....3.3.13 Main Motor (A), (B) Assy 40
....3.3.14 Gear One-way (Z30) 41
....3.3.15 Motor Assy Belt 42
....3.3.16 Power Supply Unit, Holder Inlet, Sheet Insulation 43
....3.3.17 Sensor Assy Box Toner 44
....3.3.18 Square-shaped Connector 45
....3.3.19 Motor - Pulse (ID) 46
....3.3.20 One-way Gears 47
Table of Contents Page
....3.3.21 Feeder Unit Front 48
....3.3.22 Manual Feed Hopper Assy 49
....3.3.23 Guide Paper Input Assy 50
....3.3.24 Two Lever Input Sensors, Lever 2nd Feed Sensor 51
....3.3.25 Roller Registration, Roller Assy Hopping 52
....3.3.26 Hopping Roller Assy 53
....3.3.27 PXU PCB/PXM PCB, Lever Resist Sensor 54
....3.3.28 Paper End Lever 55
....3.3.29 PCO PCB (Operator Panel) 56
....3.3.30 Holder Gear Toner Assy 57
....3.3.31 Plate Latch Lever (FD), Spring Latch Lever (FD) 58
....3.3.32 Transfer Belt 59
....3.3.33 High Voltage Power Supply Unit, Bracket HV (BT) 60
Assy
....3.3.34 Eraser Bracket Assy, Eraser Bracket (KCM) Assy 61
....3.3.35 Shaft Link 62
....3.3.36 Contact Bracket (BL-R) Assy, Contact Bracket (CL-R) 63
Assy
....3.3.37 Contact (BL-L) Assy, Contact (CL-L) Assy 64
....3.3.38 Contact SB Assy 65
....3.3.39 PXC PCB 66
....3.3.40 Heat Unit Assy (Fuser unit and oil roller) 67
....3.3.41 Oil Roller Kit 68
....3.3.42 Lever Lock Heat (L)/(R), Guide Side Heat, Spring 69
Lock
....3.3.43 PXL PCB 70
....3.3.44 Heat Unit Guide Assy 71
....3.3.45 Holder LED Assy, LED Head 72
4 Adjustments
4. Adjustments 73
4.1 Maintenance Modes and Their Functions 74
....4.1.1 User maintenance mode 75
....4.1.2 System maintenance mode 76
....4.1.3 Engine maintenance mode 77
4.2 Adjustments after Parts Replacement 78
....4.2.1 Confirm the LED head driving time 79
....4.2.2 Color Registration Using the Operator Panel (Color 80
deviation correction)
5 Maintenance
Periodic Maintenance 81
....5.1 Periodically Replaced Parts 82
....5.2 Cleaning 83
....5.3 Cleaning the LED Lens Array 84
....5.4 Cleaning the Pickup Roller 84
6 Troubleshooting Procedures
6.0 Troubleshooting Procedures 85
....6.1 Troubleshooting Tips 86
....6.2 Points to Check before Correcting Image Problems 87
....6.3 Tips for Correcting Image Problems 87
....6.4 Preparation for Troubleshooting 88
....6.5 Troubleshooting Flow 89
Table of Contents Page
........6.5.1 LCD status message/trouble list 90
........6.5.2 LCD message troubleshooting 91
............(1) The printer does not work normally after turned on. 91
............(2) JAM ERROR 91
............(3) Paper Size Error 91
............(4) Image Drum Unit (IDU) Up/Down Error 91
............(5) Fusing Unit Error 91
............(6) Fan Motor Error 91
............(7) Cannot Receive Data from Parallel Interface 91
........6.5.3 Image Troubleshooting 92
............(1) Light or blurred images on the whole printout area 92
............(2) Dark background 92
............Printout colors different from original colors
............(3) Blank paper 93
............(4) Vertical black (black stripe or lines in the vertical 94
direction)
............(5) Vertical white (White stripe or lines in the vertical 95
direction)
............(6) Poor fusing (Images are blurred or peeled off when 96
touched)
............(7) Evenly spaced, repeating marks (Cyclical printout 97
defects)
............(8) Missing characters or colors 98
............(9) Poor synthesization Color 99
............(10) Printout colors diferent from original colors 99
7 Wiring Diagram
7.1 Resistance Check 100
7.2 Program/Font ROM Location 101
8 Illustrated Parts List
Figure 8-1: Covers (Top & Sides) 102
Figure 8-2: Printer Unit 102
Figure 8-3: Main Chassis Unit (1) 102
Figure 8-4: Main Chassis Unit (2) 102
Figure 8-5: Main Chassis Motor/PCB 102
Figure 8-6: Frame Upper Assy 102
Figure 8-7: Guide Cassette (R) Assy 102
Figure 8-8: Main Motor (A) Assy 102
Figure 8-9: Main Motor (B) Assy 102
A Centronics Parallel Interface
Centronics Parallel Interface 102
Service Guide - OKICOLOR8 Page: 1
Chapter 0 Introduction
Preface
This manual provides procedures and techniques for the troubleshooting, maintenance, and repair of OKICOLOR8.
This manual is written for maintenance personnel, but it should always be accompanied with the OKICOLOR8 User's
Manual for procedures for handling and operating OKICOLOR8. For repairing each component of OKICOLOR8, see
the Troubleshooting Manual.
[Notices]
The contents of this manual are subject to change without prior notice. Although reasonable efforts have been taken
in the preparation of this manual to assure its accuracy, this manual may still contain some errors and omissions.
OKI will not be liable for any damage caused or alleged to be caused, by the customer or any other person using this
maintenance manual to repair, modify, or alter OKICOLOR8 in any manner.
[Warning]
Many parts of OKICOLOR8 are very sensitive and can be easily damaged by improper servicing. We strongly
suggest that OKICOLOR8 be serviced by OKI's authorized technical service engineers.
Copyright 1999, Okidata, Division of OKI America, Inc. All rights reserved.
Service Guide - OKICOLOR8 Page: 2
Chapter 1 Specifications
1.1 Basic System Configuration
This diagram shows the basic system configuration of OKICOLOR 8 is illustrated in Figure 1.1 below.
Figure 1.1
< same diagram -- different view >
Copyright 1999, Okidata, Division of OKI America, Inc. All rights reserved.
Service Guide - OKICOLOR8 Page: 3
Chapter 1 Specifications
1.2 Printer Specifications
This printer unit is composed of the following hardware.
l Electro-photographic processor
l Paper feeder
l Controller (CU part / PU Part)
l Operator panel
l Power board (High voltage part / PU part)
This diagrams shows the printer unit configuration.
Figure 1.2
Copyright 1999, Okidata, Division of OKI America, Inc. All rights reserved.
Service Guide - OKICOLOR8 Page: 4
Chapter 1 Specifications
1.3 Option Specifications
The OKICOLOR8 options are listed below.
(1) Second Paper Feeder
(2) RAM SIMM module (72 pin SIMM, 4MB/8MB/16MB/32MB)
l Make sure to use a set of 2 of the same volume size modules.
Copyright 1999, Okidata, Division of OKI America, Inc. All rights reserved.
Service Guide - OKICOLOR8 Page: 5
Chapter 1 Specifications
1.4 Basic Specifications
(1) Dimensions Width: 18.8" Length: 24.5" Height: 15.6"
(2) Weight Approx. 106 lbs. without box
(3) Form
Type: Ordinary paper (Hammermill xx lb.) and Transparency (Only 3M CG3710)
Recommended paper (for color printing)
Color laser paper (20 lb to 24 lbs.)
Note: the printout color tones are dependent upon the whiteness of the print paper.
Sizes: Letter, Legal (13" or 14"), Executive, A4, A5, B5, and B6 (1st tray and front feeder)
Reams: 1st tray - 20 lbs. to 28 lbs.
2nd tray - 20 lbs. to 28 lbs.
Front feeder - 20 lbs. to 53 lbs. (110 lbs. index)
(4) Printing speed: 8 pages per minute (5 pages per minute: Card Stock, Labels & OHP / 34 lbs. ~ 44
lbs.)
(5) Resolution 600 dots per inch x 600 dots per inch
(6) Input voltage 120VAC +5.5%, -15%
230VAC +10%
(7) Power consumption Peak: Typical operation
Idle: Power save mode
(8) Frequency 50Hz or 60Hz +2%, -2%
(9) Noises Operating: 54 decibels (without 2nd tray), 55 decibels (with 2nd tray)
Standby: 45 decibels
Power-saving: 43 decibels
(10) Expendables and Toner Cartridge: Approx. 3000 pages (5% density) (each of C, M, Y, and K)
service life Image Drum: Up to 13,000 pages (5% density, continuous) (each of C, M, Y and K)
Waste Toner Box: Up to 25,000 sheets (under typical printout conditions: Single
images of 5% density, equivalent to printout using 14 toner cartridges)
Oil Roller Unit: Up to 10,000 sheets (Life defined in the number of actual printed
paper sheets)
Note: Y=Yellow, M=Magenta, C=Cyan, K=Black
(11) Periodically Fuser Heat Unit Assy: 60,000 pages
replaced parts Transfer Belt Cassette Assy: 50,000 pages
(12) Temperatures and relative humidities
Temperature
Temperature conditions
Fahrenheit Celsius Remarks
Operating 60.8 to 89.6 16 to 32 17 Celsius to 27 Celsius (for assurance of
full-color printout quality)
Non-operating 50 to 109.4 10 to 43 Power off
Storage (1 year max.) -33 to 109.4 -.6 to 43 with drum and toner
Delivery (1 month max.) -20 to 122 -29 to 50 without drum and toner and Belt Cassette Assy
Delivery (1 month max.) -20 to 122 -29 to 50 with drum and toner
Humidity
Humidity condition
Fahrenheit Celsius Remarks
Operating 20 to 80 25 50% to 70% (for assurance of full-color printout
quality)
Non-operating 10 to 90 26.8 Power off
Storage 10 to 90 35
Delivery 10 to 90 40
(13) Printer life - 300,000 (A4) pages or 5 years
Copyright 1999, Okidata, Division of OKI America, Inc. All rights reserved.
Service Guide - OKICOLOR8 Page: 6
Chapter 2 Operation
2. Operation
OKICOLOR8 is a tandem color electrophotographic page printer, using 4992 Pixel-LED technologies, OPC, dry
single-component non-magnetic developing, roller transfer, heat-compression fixing (fusing). The printing method
used is a Black Writing method which applies light beams to printout areas.
Here is the Functional Block Diagram of OKICOLOR8.
Figure 2.1
< same diagram - side view >
Copyright 1999, Okidata, Division of OKI America, Inc. All rights reserved.
Service Guide - OKICOLOR8 Page: 7
Chapter 2 Operation
2.1 Main Control Board (PCE PCB)
The control board consists of a CPU block, a memory control LSI block, an interface control LSI block, a DRAM
block, an EEPROM block, a mask ROM block, and an interface block.
Here is the Functional Block Diagram of the main control board (PCE PCB).
Functional Block Diagram of Main Control Board
(1) CPU
The CPU is a 64-bit RISC architecture processor (provided by NEC). It inputs a frequency of 50
MHz and runs at 200 MHz. It transfers data to a from memory at 50 MHz.
(2) Mask ROM
The mask ROM block consists of four 16 Mbit (1M x 16 bits) chips and its total size is 8M bytes.
The chips are mounted on the PCE-PCB by means of IC sockets and store programs and
character fonts.
(3) DRAM
The DRAM block consists of eight 16 Mbit (1M x 16bits) chips and its total size is 16M bytes. The
chips are mounted on the PCE-PCB and can be expanded up to 144M bytes by adding the 32M
byte SIMMs to the SIMM slots on the PCE-PCB.
(4) EEPROM
The EEPROM block consists of 16K-bit chips mounted on a board by means of IC sockets and
stores the following:
l Menu data
l Counter values
l Adjustment values
(5) Flash ROM
The Flash ROM block consists of four 4M bit (256K x 16bits) chips and its total size is 2M bytes.
The chips are mounted on the PCE-PCB and are used for storing fonts, macro and demo pages.
(6) Memory control LSI
This block mainly consists of memory control, CPU control, compression and decompression, and
video interface functions.
(7) Interface control LSI
This block mainly consists of PU interface control, operator panel interface control, EEPROM
control, parallel interface control, and HSP control functions.
(8) Host interface
The printer has the following interfaces to the host.
l Centronics bi-directional parallel interface
l Network interface (Option)
The single effective interface or the automatic interface select mode can be selected using the
menu. If the busy state of the printer continues for a long time period, the buffer near-full control
releases the busy status at constant intervals even if the host side is busy so as not to cause
interface time-out at the host side.
(a) Centronics bi-directional parallel interface
This is an interface confirming to IEEE-1284 and provides either unidirectional ad bi-directional
communications according to each of the following communication modes.
l Compatibility mode - Unidirectional communications from the host to the printer.
l Nibble mode - This mode transfers 4-bit wide data from the printer to the host. In this mode,
each bit of 1-byte data transmits in the form of two nibbles using ERROR, BUSY, FAULT,
and SELECT signal leads. This mode can provide bi-directional operation in combination
with the compatibility mode.
l ECP mode - This mode provides the asynchronous bi-directional interface and transmits and
receives 1-byte data using eight data signal leads under semi-duplex control by the host.
When the power is turned on, the compatibility mode is automatically selected. The change to
another mode form the compatibility mode is made through negotiation. (When the BI-DIRECTION
is set to ENABLE in the menu, this change can be performed.) (For the electrical/physical
characteristics of this interface, see APPENDIX B).
(b) Network interface (Option)
Network interface card uses the power line only.
(9) This printer has the 2nd Cache unit which type is Write Through Cache and size is 512 KByte.
There are any difference between the instruction and data. All of the CPU read/write access are
cached to same 2nd cache memory.
(10) RAM module
l Pin layout
l Basic specification
Type:
Access time: 72 pins SIMM (32 bits buss width)
Capacity: 60ns, 70ns, 80ns
Parity: 4, 8, 16, or 32
None
Copyright 1999, Okidata, Division of OKI America, Inc. All rights reserved.
Service Guide - OKICOLOR8 Page: 8
Chapter 2 Operation
2.2 Engine Control Board (PX4 PCB)
ANALOG INPUT
(Heater temperatures and environmental humidity and temperature)
Engine Control Board Block Diagram
The engine control block (PU) is controlled by the engine control board (PX4 PCB) which consists of a CPU
(MSM65524), general purpose LSI chips, EPROM, EEPROM, pulse motor drivers, and video memory. Refer to the
Engine Control Board Block Diagram above.
(1) CPU
This is an 8-bit CPU (OKI MSM65524) containing the AD converter and controls the whole system.
(2) General-purpose LSI
This LSI (MB87D113PFV) is provided in the printer engine control block and has controller-engine
video interface, LED interface, motor control, sensor input, video memory control, main scanning color
correction, skew correction, high-voltage power control, and OST-EX2 functions.
(3) EPROM
This EPROM (275C512-150) has a storage capacity of 512K bits and stores programs for the PU
block.
(4) EEPROM
This EEPROM (NM93C66N-NW) has a storage capacity of 4K bits. It is mounted on the board by
means of IC socket and stores adjustment values.
(5) Pulse motor drivers
These drivers (MTD2005F) drive eight pulse motors for moving up and down the image drum (EP) and
transferring medium.
(6) Video memory
This SRAM received print data through video interface and stores it.
Copyright 1999, Okidata, Division of OKI America, Inc. All rights reserved.
Service Guide - OKICOLOR8 Page: 9
Chapter 2 Operation
2.3 Power/Board
The power board consists of an AC filter circuit, a low voltage power supply circuit, a high voltage power supply
circuit, and heater drive circuit, and photo sensors.
(1) Low voltage power supply circuit.
This circuit generates the following voltages.
Output voltage Use
+3.3 V CU Unit CPU, LED HEAD
+5 V Logic circuit supply voltage
+32 V Motor and fan drive voltage and source voltage for high-voltage supply, discharge
lamp
+12 V HSP, OP Amp, high voltage power supply
-12 V HSP
(2) High voltage power supply circuit
This circuit generates the following voltages necessary for electro-photographic processing from +32 V in
accordance with the control sequence from the control board. When cover open state is detected, +32 V supply is
automatically interrupted to stop the supply of all high-voltage outputs.
Y M C K = Yellow, Magenta, Cyan, Black
Output Voltage Use Remarks
CH -1.35 KV