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1. displayed when switching between software modes Postscript and Emulation 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 opx okidata com Page 44 OKIDATA Chapter A Retrence Charla A 1 OVERVIEW A 1 01 General Information This section describes the characteristics of the printed circuit boards used in the printer The following areas are covered Firmware Fuses Jumpers Switches Sensors Test Points Where an item is not applicable the word NONE will be listed 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 opx okidata com Page 45 OKIDATA Chapter A Retrence Charla A 2 CHARTS Index to Charts Description Acronym Section Main Control Board without ROM RPSS A 2 01 Program ROM Board RPSR A 2 02 RAM Board REXM A 2 03 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 opx okidata com Page 46 Service Guide OL840 OKIDATA a ee Charts A 2 01 Main Control Board RPSS Firmware NONE Fuses NONE Jumpers T1 5vdc at Pin 18 of Centronics Parallel Interface 1 2 5vdc not present 2 3 5vdc present T2 5vdc at Pin 18 of2. The 1 Kbit Electrically Erasable PROM EEPROM is loaded with the data listed below Total number of sheets printed after installation Modified page count Total number of sheets printed with the current drum Total number of sheets printed with the current fuser Setting of time required from the completion of printing to Quiet Mode Feed time needed to feed the paper to a printable position Vertical Registration Top margin LED head drive time Notes The EEPROM preserves the data while the supply voltage is off The counters stored in the EEPROM can be accessed by using SW1 on the Engine Board to place the printer in the Maintenance MODE See Section 3 The count of the total number of sheets printed after installation cannot be reset The count of the total number of sheets printed with the drum currently in use should be taken as a rough measure of the useful life of the drum It is reset to zero when the drum is replaced by holding down the RESET button and applying power to 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 opx okidata com Page 21 Service Guide OL840 OKIDATA Chapter 2 Principles of Operation 2 3 03 Power Supply Unit The power supply unit generates the following voltages from the AC input voltage High Voltage Drive The high voltage circuit provides the charg
3. Thank You for purchasing this Factory Service Manual on EBAY from PCTECHI NFO Click Here for more Factory Service Manuals for other Computer and Printer Copier Manufacturers from PCTECHI NFO Page 1 OKIDATA Chapter 0 About The Manuel OKIDATA Service Manual OL840 LED Page Printer Adobe Acrobat printable reference copy of the OKIDATA Service Training Manual 09 17 97 Note This Adobe Acrobat version of the Okidata Service Training Manual was built with the pictures rendered at 300 dpi which is ideal for printing but does not view on most displays well Copyright 1997 Okidata Division of OKI America Inc All rights reserved See the OKIDATA Business Partner Exchange BPX for any updates to this material http opx okidata com Table of Contents Page Service Guide OL840 0 About This Manual Front Cover Copyright Manual Revision 1 Product Specifications 1 1 Overview 4 1 2 Product Specifications 5 1 3 Paper Specifications 6 7 8 9 oO N 1 4 Physical Specifications 1 5 Power Requirements 1 6 Environmental Conditions 1 7 Agency Approvals 10 2 Principles of Operation 2 1 Overview 11 2 2 Printer Overview 12 2 2 02 Main Control Unit 13 2 2 03 Main Controller Board RPSS 14 2 2 04 Program ROM Board RPSR 15 2 2 05 Connection Board LNKZ 16 2 2 06 Expansion RAM Board REXM 17 2 2 07 Font Card 18 2 3 Printer Control Unit 19 2 3 02 Engine Driv
4. Copyright 1997 Okidata Division of OKI America Inc All rights reserved See the OKIDATA Business Partner Exchange BPX for any updates to this material http opx okidata com Page 16 Service Guide OL840 OKIDATA Chapter 2 Principles of Operation 2 2 05 Connection Board LNKZ The LNKZ connection board contains a buffer used to connect the optional font cards to the Main Controller Board 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 opx okidata com Page 17 w Service Guide OL840 OKIDATA Chapter 2 Principles of Operation 2 2 06 Expansion RAM Board REXM Sixteen 1 Mbit 1bit x 1Mbit dynamic RAM total 2M bytes are mounted to the Expansion RAM Board The RAM capacity is detected during the power on sequence The RAM capacity is printed during MENU PRINT in the Emulation Mode or START PAGE in Postscript mode 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 opx okidata com Page 18 w Service Guide OL840 OKIDATA Chapter 2 Principles of Operation 2 2 07 Font Card Up to two font cards for additional fonts can be installed If the printer is in the off line state the READY lamp is off the cards can be inserted and removed without removing power When the font card is
5. Face down face up 1 2 07 Print Resolution 300 x 300 dots inch 1 2 01 Print Specifications Development method Dry electrophotography Exposure method Stationary LED head 1 2 02 Print Speed First print 28 seconds maximum letter size Continuous print 8 sheets minute letter size Warm up time 40 seconds maximum at room temperature 770F 250C and rated voltage 120 VAC Postscript Initialization time 120 seconds maximum with 4 MB memory installed and Do Start Page deselected 1 2 03 Symbol Sets HP Emulation Thirty nine symbol sets are available through the OL840 1 2 04 Available Fonts Postscript 35 Adobe Fonts HP Emulation 36 resident fonts HP A B C F L Y S1 and S2 Cartridge Fonts Diablo 630 Emulation 18 resident fonts 1 2 05 Paper Feed Method Automatic feed Manual Feed 1 2 06 Paper Delivery Method Face down face up 1 2 07 Print Resolution 300 x 300 dots inch 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 opx okidata com OKID AT A Service Guide OL840 Chapier 1 Product Specifications 1 3 PAPER SPECIFICATIONS 1 3 01 Paper Types Letter Size 8 5 x 11 Feed Automatic or Manual Weight Minimum 16 Ibs Maximum 24 Ibs Recommended 20 Ibs Legal Size 8 5 x 14 Feed Automatic with optional paper tray or Manual Weight Minimum 16 Ibs Maximum 24 Ibs Recommended 2
6. Operation 2 2 02 Main Control Unit The control unit controls reception of the data from the host through the interface processes command analysis bit image development and raster buffer read It also controls signal flow with the Engine Driver Board and the Operator Panel Reception Control The control unit has three interface ports centronics parallel RS 232C serial and Appletalk RS 422 serial ports Through the MENU one of the I F ports can be selected at a time The other ports output BUSY in emulation mode but not in PostScript mode The Appletalk port is the default port Command Analysis Processing The OL840 has PostScript and the following emulation modes which are selected through the printer MENU LaserJet Series Il Hewlett Packard Diablo 630 Xerox In the Postscript mode each typeface style is stored as a series of outlines one for each character comprised of lines and Bezier curves The shape of each character in a typeface style is actually determined by a mathematical formula When the document is to be printed the host sends information to the printer in the form of the Postscript page description language The printer then reads the file it receives sizes and orients each character outline as required and prints the page In the HP and Diablo modes the OL840 prints fonts as bit mapped outlines The outline of each character is determined by placing dots in a grid A complete set of these grids one fo
7. Product Specifications 1 5 POWER REQUIREMENTS 1 5 01 Input Power 120 VAC 5 5 15 220 240 VAC 10 1 5 02 Power Consumption Approximately 800 W maximum during operation 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 opx okidata com Page 9 Service Guide OL840 OKIDATA Chapier 1 Product Specifications 1 6 ENVIRONMENTAL CONDITIONS 1 6 01 Ambient Temperature and Relative Humidity Operation 50 to 89 F 10 to 32 C 20 to 80 Relative Humidity Storage 14 to 122 F 10 to 50 C 1 6 02 Printer Noise Level During operation 50 dB maximum At standby 43 dB maximum 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 opx okidata com Page 10 w Service Guide OL840 OKIDATA Chapter 1 Product Specifications 1 7 AGENCY APPROVALS FCC Class B UL 478 Ver 5 CSA 22 2 220 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 opx okidata com Page 11 Service Guide OL840 OKIDATA Chapter 2 Principles of Operation 2 1 OVERVIEW 2 1 01 Outline of Printer Operation The primary control boards of the printer are the Engine Driver Board LLAB 2 and th
8. inserted and removed in the on line state the READY lamp is on the message CARD REMOVED ONLINE will be displayed on the Operation Panel 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 opx okidata com Page 19 Service Guide OL840 OKIDATA Chapter 2 Principles of Operation 2 3 PRINTER CONTROL UNIT 2 3 01 General Information The principal hardware components of the printer control unit are listed below Engine Board Power Supply Unit Fuser Unit Main Motor LED Head Sensors and Switches Resist Motor Fan Operation Panel Second Paper Tray Mechanism option 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 opx okidata com Page 20 ae Service Guide OL840 OKIDATA Chapter 2 Principles of Operation 2 3 02 Engine Driver Board LLAB 2 The Engine Driver Board contains an 80051 Microprocessor 8 bit an EPROM which stores the Engine Control Program and an EEPROM The Engine Driver Board turns the LED Array diodes ON to place an electrostatic image on the photosensitive drum The Engine Driver Board also controls the paper feed paper transport and electrophotographic processing actions so that the electrostatic image can be printed by fusing toner on the paper
9. 0 OKIDATA Chapter 3 Maintenance amp Disassembly 3 2 01 Main Controller Board RPSS Power OFF the printer Remove the AC connector Remove the interface cable Pull the rear panel 1 backward and remove Loosen the four screws 2 on the inner panel 3 Open the lock clips 4 and pull the main controller board 5 out Remove the inner panel NOOR OND Note The screws 2 are captive they cannot be completely removed The Program ROM Board is not shown in this drawing 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 opx okidata com Page 36 w Service Guide OL840 OKIDATA Chapter 3 Maintenance amp Disassembly 3 2 02 Program ROM Board RPSR 1 Remove the main controller board RPSS See 3 2 01 2 Using a needle nose pliers detach the nylon latches 1 3 Lift the program ROM board 2 from the main controller board being careful not to lose the circuit board retainer clip 3 w 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 opx okidata com Page 37 w Service Guide OL840 OKIDATA Chapter 3 Maintenance amp Disassembly 3 2 03 Optional Expansion RAM Board REXM 1 Remove the main controller board RPSS See 3 2 01 2 P
10. 0 Ibs Executive Size 7 25 x 10 5 Feed Automatic with optional paper tray or Manual Weight Minimum 16 Ibs Maximum 24 Ibs Recommended 20 Ibs A4 Size 8 27 x 11 69 Feed Automatic with optional paper tray or Manual Weight Minimum 16 Ibs Maximum 24 Ibs Recommended 20 Ibs Envelopes Size Minimum 3 5 x 7 5 Maximum 7 2 x 10 1 Feed Automatic with optional paper tray or Manual Weight Minimum 16 Ibs Maximum 24 Ibs Recommended 20 Ibs Labels Manual feed Face up delivery only Use labels designed specifically for laser printers Transparencies Manual feed Face up delivery only Must be able to withstand the heat of the fusing process CAUTION Page 6 Envelopes labels and transparencies should only be fed from the top paper tray Copyright 1997 Okidata Division of OKI America Inc All rights reserved See tne OKIDATA Business Partner Exchange BPX for any updates to this material http opx okidata com Page 7 Service Guide OL840 OKIDATA Chapier 1 Product Specifications 1 4 PHYSICAL SPECIFICATIONS 1 4 01 Outside Dimensions Width 17 72 Height 9 49 Length 17 72 1 4 02 Printer Weight 37 Ibs 1 4 03 LED Array Number of LED Elements 2560 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 opx okidata com Page 8 Service Guide OL840 OKIDATA Chapter 1
11. 5051601 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 opx okidata com OKIDATA Service Guide OL840 Chapter B Illustrated Parts Listing Interchangeable Parts OL800 OL820 and OL840 Parts which are interchangeable between the OL800 OL820 and OL840 Description Okidata Part Number Assembly Exit Roller 50066501 Assembly Face Up Stacker 50066601 Cover Upper Program Cartridge 50070201 Cover Lower Program Cartridge 50070301 Assembly Resist Roller 50079101 Assembly Back Up Roller 50079201 Assembly Transfer Charger 50081601 Roller Hopping Assembly 50081701 Panel Operation Assembly 50213502 Unit Lower 50213602 Cover Upper Assembly 50213902 Panel Inner 50214402 Unit Paper Delivery 50214502 Spring Bias LED Head 50914101 Spring Clamp LED 50914301 16 Spring Fusing Unit 50914601 Page 50 17 Spring Backup Roller 50914801 18 Cassette 50917001 19 Separator 50917101 20 Spring Image Drum Tray 50917205 21 Gear Idle A 51218401 22 Idle B 51218501 23 Idle Base 51218601 24 Speed Reduction 51218701 25 Lower 53059401 26 53059501 27 53059601 28 53059701 29 53059801 30 Post 53329501 31 Separator 53500501 32 Fuser Pad 53500901 33 Contact Ground 53505201 34 Foot Rubber 53505301 35 Cable 53505430 3
12. 6 Cable 53505431 37 Panel Inner 53534201 38 PCB LLAB 2 Engine Controller w o ROM 55044402 39 LLCC Engine Connection 55044601 40 Fusing 120V 55044901 41 55046001 42 55046201 43 55046301 44 55046401 45 PCB LLBB High Voltage 55047301 46 Microswitch Assembly Cover Open 55050701 47 Filter Ozone 55503501 48 Unit LED Head 55619501 49 IC EEPROM LLAB 84 55921901 50 Power Supply 120V 56407702 51 Motor Pulse Resist 56507401 52 Motor Pulse Main 56507701 53 Assembly DC Fan 56508501 54 Cord AC 56609701 55 Connector AKJ 40A 56725201 56 Unit Upper 240V 50213702 57 Roller Hopping 2nd Tray 53534301 58 Unit Fusing 240V 55044902 59 PCB LLFC 2nd Tray 55051401 60 Power Supply 240V 56408102 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 opx okidata com
13. OKI America Inc All rights reserved See the OKIDATA Business Partner Exchange BPX for any updates to this material http opx okidata com Page 26 Service Guide OL840 OKIDATA Chapter 2 Principles of Operation 2 3 08 DC Fan The fan is controlled by the FAN ON P signal from the LSI MSM73H019 In order for the printer to operate the signal FAN SENSE N must be active Note The fuser and the fan are not enabled when the cover is open If the fan fails to run the fuser will turn off and FAN ALARM is set Printing is disabled In accordance with the TIME TO QUIET setting of the level 2 Menu the Fuser will maintain the proper fusing temperature for 1 or 8 minutes after the last page has been printed If printing is not requested within the selected time frame the fuser will turn OFF and the fan speed will be reduced 50 Selecting DISABLE allows the FUSER to maintain the proper fusing temperature continuously 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 opx okidata com Page 27 Service Guide OL840 OKIDATA Chapter 2 Principles of Operation 2 3 09 Operation Panel The following components make up the operation panel 4 bit MPU LC6543C LCD control driver MSM6222B or HD44780 LCD display 16 characters per line Operation panel sheet LEDs for online mode indication Operati
14. PX for any updates to this material http bpx okidata com Page 48 OKIDATA Chapter A Retrence Charla A 2 03 RAM Board REXM Option Firmware NONE Fuses NONE Jumpers NONE Sensors NONE Switches NONE Testpoints NONE cs 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 opx okidata com Page 49 Service Guide OL840 OKIDATA Chapter B Illustrated Parts Listing B 1 COMPATIBILITY CHARTS Parts which are unique to the OL800 and OL820 Item Description Okidata Part Number 61 PCB CTLZ Main Controller 55046101 62 PCB PRGZ w o ROM 55046501 Parts which are unique to the OL820 Item Description Okidata Part Number 63 PCB OkiXpress 21025001 Scalable Font Card w ROM Options which are interchangeable between the OL800 and OL820 Item Description Okidata Part Number 64 PUB MEMZ 55046601 65 PCB CMIZ 55050001 Multi port 66 PCB RMIZ 55050101 Multi port Parts Unique to the OL840 67 PCB RPSS Main Controller 55051001 Board 68 EEPROM For use on Engine 55921901 Control Board 69 PCB RPSR PROM Board w o 55051101 ROM Options Unique to the OL840 Item Description Okidata Part Number 70 PCB REXM 2MB RAM Option 5
15. RS232 C Serial Interface 1 2 5vdc not present 2 3 5vdc present Sensors NONE Switches NONE Test Points NONE 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 47 OKIDATA Chapter A Retrence Charla A 2 02 Program ROM Board RPSR Firmware O1A 4M bit Masked Bit mapped Fonts O1B 4M bit Masked Bit mapped Fonts 02A through 09A 8 PROMS Postscript Interpreter 02B 03B Program for Emulation Mode Fuses NONE Jumpers NONE Sensors NONE Switches NONE Test Points NONE Notes When using XON XOFF Protocol the OL840 will lockup when receiving serial data after the buffer fills and it attempts to send the first DC3 In order to correct this problem on field units FCO 7761 should be installed The emulation PROMS 02B 03B on the program ROM board RPSR are replaced with Rev 1 41 Field Units Covered by the FCO Serial Numbers 010A0015157 and below 120 volt Serial Numbers 010A0000144 and below 220 volt Kit Part Number 58221301 Order this kit through Okidata Logistics Deore eeeeeseen Co etueereueees osB Desproonsns0en n un_ nn n O78 IPPC PPP Pee n n o u 068 058 Copyright 1997 Okidata Division of OKI America Inc All rights reserved See the OKIDATA Business Partner Exchange B
16. SCC and one gate array The CPU is a MC68000 with a clock frequency of 12 5MHz Sixteen 1Mbit 1 bit x 1Mbit dynamic RAM chips are mounted as resident RAM total 2Mbytes The VIA Versatile Interface Adapter ICO6G 65NC22 controls the Operation Panel interface Printer Unit interface read write operations of FIFO IC14G and the EEPROM ICO5H X24C16 The FIFO First in First out Buffer connects the CPU to the video interface The FIFO has a capacity of over 2 lines 2 rasters The data written to the FIFO by the CPU is sequentially read according to the VIDEO I F synchronous signal The Serial Communications Controller SCC controls the RS 232C interface RS 422 interface and the AppleTalk interface The RS 422 and AppleTalk interfaces use the same connector and are usable only in the PostScript mode 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 opx okidata com Page 15 Service Guide OL840 OKIDATA Chapter 2 Principles of Operation 2 2 04 Program ROM Board RPSR The Program ROM RPSR Board is connected to the Main Controller Board The RPSR board consists of Ten 1 Mbit EPROM chips eight are for PostScript two are for Emulation Mode Two 4 Mbit MASK ROM chips which store the bit map fonts used in HP Laserjet and Diablo emulations Three TTL IC chips which function as an address decoder
17. and dry electrophotography as its exposure and development methods In addition to supporting Adobe Postscript 35 Fonts the OL840 provides two additional emulations The HP Laserjet Series Il emulation has 36 resident fonts The Diablo 630 emulation has 18 resident fonts Two optional font cards can be installed with the Diablo and HP emulations Six cards are available at this time The OL840 also accepts HP compatible downloadable fonts A 2MB page memory is standard on the OL840 this can be expanded to 4MB with an optional RAM printed circuit board A Centronics parallel interface an RS 232C serial interface and an AppleTalk interface are standard Two consumables are used in the printer The toner cartridge kit contains a toner cartridge a fuser cleaner pad and an LED lens cleaner The other consumable the image drum cartridge kit includes an image drum cartridge and an ozone filter Toner and drum life depend on printer use Based on a 5 print density and 10 pages per job a toner cartridge should last approximately 2 500 pages a drum should last approximately 15 000 pages A 200 sheet letter size paper tray is included with the printer and a second tray can be added providing an additional 200 pages Legal Envelope Executive and A4 paper trays are also available Paper feeding can be done automatically or manually Pages can be printed face down or face up A rear exit path is provided for items such as card stock envelopes
18. beyond its control 1994 by Okidata All rights reserved First Edition March 1992 Second Edition May 1994 Written and produced by the Okidata Technical Training Group Please address any comments on this publication to Technical Training Group Okidata 532 Fellowship Road Mount Laurel NJ 08054 3499 Fax Number 609 235 2600 ext 7034 Okilink Login Name Technical Training OKIDATA is a registered trademark of Oki Electric Industry Company Ltd Marque deposee de Oki Electric Industry Company Ltd Marca Registrada Oki Electric Industry Company Ltd BAR CODES PLUS MICRO DOCS and OKIPRO 65 are trademarks of OKIDATA Division of OKI America Inc Adobe Adobe Illustrator and PostScript are registered trademarks of Adobe Systems Incorporated Apple AppleTalk LaserWriter LaserWriter Il LocalTalk and Macintosh are registered trademarks of Apple Computer Incorporated Bitstream is a registered trademark and Dutch Fontware and Swiss are trademarks of Bitstream Inc Fontware is licensed to Bitstream Inc in West Germany France and the United Kingdom by Electronic Printing Systems Ltd Diablo 630 is a registered trademark of Xerox Corporation Helvetica Optima Palatino Present and Times are registered trademarks of Linotype AG and or its subsidiaries Hewlett Packard HP LaserJet and LaserJet Series Il are registered trademarks of Hewlett Packard Company IBM PC PC DOS and Proprinter XL are reg
19. ding by the resist motor a FEED JAM ERROR will be displayed on the Operation Panel 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 opx okidata com Page 30 Service Guide OL840 OKIDATA Chapter 3 Maintenance amp Disassembly 3 1 MAINTENANCE 3 1 01 General Information This section lists the parts replacement adjustment cleaning and lubrication procedures Disassembly should not be performed unless absolutely necessary NEVER perform disassembly on a malfunctioning unit Follow the procedures listed in Adjustments and Service Settings Adjustments may be required when either consumables Cleaning procedures must be performed correctly if high print quality is to be achieved 3 1 02 Maintenance Tools The following tools are required to service the unit 2 Phillips Screwdriver with magnetic tip Straight slot Screwdriver Needle Nose Pliers 4 Inch Digital Multimeter Shop Vacuum with filter for toner Cloth soft and lint free All purpose Cleaner Grease Dow Corning BR2 or equivalent 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 opx okidata com Page 31 Service Guide OL840 OKIDATA Chapter 3 Maintenance amp Disassembly 3 1 02 Maintenance Tools The f
20. e Main Controller Board RPSS The Engine Driver Board controls the printer mechanism and drives the LED head The Main Controller Board receives data from the host device analyzes commands and processes the data for printing To help you understand the structure of the printer system refer to the Printer Block Diagram The RPSS PCB is connected to the host system through a Centronics parallel interface RS 232C interface or an AppleTalk interface Interface selection is accomplished through menu settings Once an interface is selected the remaining interface connectors output BUSY Emulation Mode only The Main Controller Board receives print data and command strings from the host system and generates bit image data When one page of print data is ready the Main Controller Board turns on the PRINT N signal which is one of the video interface signals Upon receipt of the PRINT N signal the Engine Driver Board turns ON the main motor resist motor and fuser in preparation for printing The Engine Driver Board then sends the FSYNC N and LSYNC N signals to the Main Controller Board Once the Main Controller Board receives the FSYNC N and LSYNC N signals the WDATA N signal image data signal is sent to the Engine Driver Board in synchronization with the WCLK N signal The Engine Driver Board turns ON the appropriate LEDs in conformance with the WDATA N signal In addition to the above the Engine Driver Board controls the paper feed paper transpo
21. e voltage about 6 Kvdc transfer voltage about 5 Kvdc grid voltage about 600vdc and developer bias voltages about 550vdc and 400vdc Of these voltages the charge voltage and the transfer voltage are generated by a high voltage power supply The grid connects to ground via a varistor on the medium voltage generation circuit This keeps the grid at about 680vdc during charging Low Voltage Circuit This circuitry produces the voltages listed below 5 vdc Printer Logic 12 vdc Interface Signal Levels 38 vdc Resist Main Motor Drive Fan Drive Note 5 vdc and 38 vdc are also supplied to the LLFC on the 2nd Paper Tray Mechanism 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 opx okidata com Page 22 Service Guide OL840 OKIDATA Chapter 2 Principles of Operation 2 3 04 Fuser Unit The Fuser Unit is controlled by a thermistor a comparator an LSI and the CPU to keep the heat roller surface temperature within a predetermined range about 150 degrees Celsius A thermal fuse within the Fuser Unit prevents abnormal temperature rises in case the thermistor fails Note The CPU checks for an open circuit in the thermistor at power on setting a fuser alarm if this error is detected The CPU also sets a fuser alarm if the proper temperature is not attained within a specified period of time a
22. er Board LLAB 2 20 2 3 03 Power Supply Unit 21 2 9 04 Fuser Unit 22 2 3 05 Main Motor Drum Motor 23 2 3 06 LED Array 24 2 3 07 Resist Motor 25 2 3 08 DC Fan 26 2 3 09 Operation Panel 27 2 3 10 Second Paper Tray Mechanism Option 28 2 9 11 Sensor Functions 29 3 Maintenance amp Disassembly 3 1 Maintenance 30 3 1 02 Maintenance Tools 31 3 1 03 Maintenance Precautions 32 3 2 Disassembly Assembly Procedures 33 sequence of Procedures 34 3 2 01 Main Controller Board RPSS 35 3 2 02 Program ROM Board RPSR 36 3 2 03 Optional Expansion RAM Board REXM 37 3 3 Adjustments And Service Checks 38 Table of Contents Page 3 4 Cleaning 39 3 5 Lubrication 40 3 6 Consumables 41 4 Failure amp Repair Analysis 4 1 OL840 Troubleshooting 42 4 1 02 LCD Display Messages PostScript Mode 43 A Reference Charts A 1 Overview 44 A 2 Charts 45 A 2 01 Main Control Board RPSS 46 A 2 02 Program ROM Board RPSR 47 A 2 03 RAM Board REXM Option 48 B Illustrated Parts Listing 01800 01820 01840 Parts Compatibility List 49 Interchangeable Parts OL800 OL820 and OL840 50 Page 2 OKIDATA Chapter 0 About The Manuel This document may not be reproduced without written permission of the Okidata Technical Training Group Every effort has been made to ensure the accuracy of the information contained in this training course Okidata is not responsible for errors
23. fter power on Upon detecting a fuser alarm the CPU will halt after printing the current page 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 opx okidata com Page 23 Service Guide OL840 OKIDATA Chapter 2 Principles of Operation 2 3 05 Main Motor Drum Motor The Main Motor is controlled by the motor control LSI IC5 M54646 The motor used is a four phase motor driven by the DM PHL 1 2 3 and 4 signals generated by the LSI 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 opx okidata com Page 24 Service Guide OL840 OKIDATA Chapter 2 Principles of Operation 2 3 06 LED Array Data for the 2 560 LEDs in the LED Array is placed in the shift register by the HD CLK signal The data is loaded in the latch circuit by the HD LD signal 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 opx okidata com Page 25 Service Guide OL840 OKIDATA Chapter 2 Principles of Operation 2 3 07 Resist Motor The Resist Motor is driven clockwise for hopping then counterclockwise for Paper Feeding by the motor drive IC LB1731 Copyright 1997 Okidata Division of
24. gnal is received from the Engine Driver Board Once LSYNC is received reading starts Then in response to WCLK parallel to serial conversion and data transfer takes place The amount of data that is read from the FIFO is sensed by the 64NC22VIA counter The CPU writes another line of data to the FIFO immediately after a line of data is read from the FIFO Engine I F Processing The engine I F is divided into the engine control interface and the command interface The engine control interface signal is allocated to a signal line through bits of the register TTL The CPU can obtain the engine status by sensing each bit or run the engine by manipulating each bit The command I F is a bidirectional serial signal The register TTL is used for serial parallel or parallel serial conversion Operation Panel Control The operation panel I F is a bidirectional serial Interface Each signal line is allocated to the 65NC22VIA port The CPU then sends the shift clock and executes serial or serial parallel conversion 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 opx okidata com Page 14 Service Guide OL840 OKIDATA Chapter 2 Principles of Operation 2 2 03 Main Controller Board RPSS The Main Controller Board RPSS can be accessed from the rear of the printer The RPSS board consists of the CPU RAM VIA FIFO
25. iples of Operation 2 3 11 Sensor Functions The following alarms are detected by sensors and switches During Power ON The inlet and outlet sensors are checked for their on and off states at power on time Inlet sensor on Inlet jam error paper supply jam Outlet sensor on Outlet jam error paper eject jam The thermistor sensor detects if the fuser temperature reaches the desired temperature within the specified time If the desired temperature is not reached the fuser is turned OFF The fan sensor circuitry checks for the rotation of the fan If fan motion is not detected the fuser is turned OFF and power is removed from the fan When a paper cassette with no paper loaded has been detected the Paper End Sensor sends the PAPER END signal to the Control Unit When the power supply is turned ON the number of printed pages of the fusing unit and drum cartridge is checked If the Fuser or Drum life has been exceeded this information is transmitted to the Control Unit During Hopping Whenever the inlet sensor fails to detect paper within a predetermined time after a feed command has been issued to the paper supply system the failure is counted The hopping operation is then attempted up to three times If the hopping operation still fails an INLET JAM ERROR is displayed on the Operation Panel During Feeding If the leading part of the paper does not reach the outlet sensor within a predetermined time after the start of fee
26. istered trademarks of International Business Machines Corporation 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 opx okidata com Page 3 OKIDATA Chapter 0 About The Manuel Note The OL800 820 Service Training course is part of the OL Series Training Course and can not be purchased separately 1994 by Okidata All rights reserved First Edition March 1992 Second Edition May 1994 Written and produced by the Okidata Technical Training Group THE OL400 800 820 830 840 VIDEO TRAINING KIT covers the following products o OL400 o OL800 o OL820 o OL830 o OL840 The following items are included in the kit o OL400 Service Handbook OL800 820 Service Handbook OL830 Service Handbook OL840 Service Handbook Service Training Video OL400 800 820 User s Documentation OL830 User s Documentation OL840 User s Documentation ooo 0000 Price 95 00 124 00 Canadian P N 58226902 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 opx okidata com Page 4 Service Guide OL840 OKIDATA Chapter 1 Product Specifications 1 1 OVERVIEW 1 1 01 General Information The OL840 is an 8 page per minute page printer with true Adobe Postscript capability The OL840 uses a stationary LED head
27. labels or overhead transparencies An OL800 may be upgraded to an OL840 by removing the Program Cartridge and replacing the Main Controller Board with the Postscript Controller Board The OL840 Printer is amember of the family of OL Series Printers which presently includes the OL400 OL800 OL820 and OL830 Okidata s own proprietary engine assures built in quality and reliability 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 opx okidata com Page 5 Service Guide OL840 OKIDATA Chapter 1 Product Specifications 1 2 PRODUCT SPECIFICATIONS 1 2 01 Print Specifications Development method Dry electrophotography Exposure method Stationary LED head 1 2 02 Print Speed First print 28 seconds maximum letter size Continuous print 8 sheets minute letter size Warm up time 40 seconds maximum at room temperature 770F 250C and rated voltage 120 VAC Postscript Initialization time 120 seconds maximum with 4 MB memory installed and Do Start Page deselected 1 2 03 Symbol Sets HP Emulation Thirty nine symbol sets are available through the OL840 1 2 04 Available Fonts Postscript 35 Adobe Fonts HP Emulation 36 resident fonts HP A B C F L Y S1 and S2 Cartridge Fonts Diablo 630 Emulation 18 resident fonts 1 2 05 Paper Feed Method Automatic feed Manual Feed 1 2 06 Paper Delivery Method
28. nter when a new drum cartridge is installed 1 Power OFF the unit 2 Press and hold RESET while powering ON the unit 3 The drum counter will reset Clear the fuser counter when a new fusing unit is installed Refer to Section 3 3 Adjustments in this Service Handbook 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 opx okidata com Page 33 Service Guide OL840 OKIDATA Chapter 3 Maintenance amp Disassembly 3 2 DISASSEMBLY ASSEMBLY PROCEDURES General Information This section contains the printer disassembly procedures Only the removal procedures are explained Reverse the procedure for the installation This Service Handbook lists the disassembly procedures for major components of the unit Okidata does NOT recommend disassembling a unit which is operating normally If you decide to perform disassembly during this training Okidata recommends that you perform only the disassembly procedures for RSPL items All other procedures are provided to assist you in identifying parts It is not likely that you will perform these procedures while servicing the product Read all notes cautions and warnings They contain important information regarding assembly disassembly Copyright 1997 Okidata Division of OKI America Inc All rights reserved See the OKIDATA Business Partner Exchange BPX for any updates t
29. o this material http opx okidata com Page 34 Service Guide OL840 OKIDATA Chapter 3 Maintenance amp Disassembly Sequence of Procedures Note The disassembly procedures for the OL840 are identical to the OL800 820 All hardware assemblies except the Main Controller Board Program ROM Board and Memory Expansion Board are identical The OL840 does NOT use a Program Cartridge The only procedures listed in this manual are for the OL840 Main Controller Board Program ROM Board and Memory Expansion Board Refer to the OL800 820 Service Handbook for the remaining procedures 4A The printer will be disassembled in the order listed below 1 Upper Cover 2 Engine Unit 3 LED Head 4 Transfer Charger Assembly 5 Paper Supply Unit 6 Resist Motor 7 Tray Detection Circuit Board LLCC 8 Resist Roller Assembly 9 Engine Controller Circuit Board LLAB 2 10 Main Motor Assembly 11 Idle Gears A and B and Reduction Gear 12 DC Fan Assembly 13 Power Supply Unit 14 Upper Unit 15 Fusing Unit 16 Backup Roller 17 Idle Gear C 18 Main Controller Board RPSS 19 Program ROM Board RPSR 20 Connection PCB LLIC 21 Connection Board LNKZ 22 Font Card Motherboard CMBZ 23 Optional RAM PCB REXM 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 opx okidata com Page 35 w Service Guide OL84
30. ollowing tools are required to service the unit 2 Phillips Screwdriver with magnetic tip Straight slot Screwdriver Needle Nose Pliers 4 Inch Digital Multimeter Shop Vacuum with filter for toner Cloth soft and lint free All purpose Cleaner Grease Dow Corning BR2 or equivalent 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 opx okidata com Page 32 n 0 Service Guide OL840 OKIDATA Chapier 3 Maintenance amp Disassembly 3 1 03 Maintenance Precautions Do NOT disassemble the unit if it is operating normally Before starting disassembly and assembly always power OFF the unit and detach the power cord Detach the interface cable if installed Do not remove parts unnecessarily Try to keep disassembly to a minimum Use the recommended maintenance tools When disassembling follow the listed sequence Failure to follow the correct sequence may result in damaged parts Screws collars and other small parts are easily lost Temporarily attach these parts to their original positions When handling circuit boards use extreme care Integrated circuits microprocessors ROM and RAM can be destroyed by static electricity Do not place printed circuit boards directly on conductive surfaces Follow the recommended procedures when replacing assemblies and units Clear the drum cou
31. on Buttons The Operation Panel is connected to the Main Controller Board via the Engine Connection Board the Engine Driver Board and the Program Cartridge Connection Board The Operation Panel is controlled by the Main Controller Board The LCD control driver MSM622B or HD44780 converts 4 bit character codes received from the MPU into 8 bit character codes and retrieves the character pattern data font from the internal character generator for display on the LCD Operation Panel Interface The operation panel is controlled by the operation panel interface located on the Main Controller Board Control is via the Engine Driver Board 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 opx okidata com Page 28 Service Guide OL840 OKIDATA Chapter 2 Principles of Operation 2 3 10 Second Paper Tray Mechanism Option The Second Paper Tray Mechanism is controlled by the Second Tray Driver Board LLFC This board is attached to the left side of the second paper tray mechanism The resist motor and paper tray detection sensors for the second paper tray are mounted on this board 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 opx okidata com Page 29 Service Guide OL840 OKIDATA Chapter 2 Princ
32. p opx okidata com Page 40 Service Guide OL840 OKIDATA Chapter 3 Maintenance amp Disassembly 3 5 LUBRICATION 3 5 01 General Information Refer to Section 3 5 of the OL830 Service Handbook for information on lubricating the printer lt 3 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 opx okidata com Page 41 Service Guide OL840 OKIDATA Chapter 3 Maintenance amp Disassembly 3 6 CONSUMABLES The OL840 uses the same consumables as the OL800 and OL820 3 6 01 Image Drum Counter Reset When the image drum cartridge is replaced the image drum counter must be reset 1 Press and hold RECOVER RESET while powering on the printer 2 This resets the counter 3 6 02 Ozone Filter The ozone filter is replaced when the image drum cartridge is replaced 1 Power off the printer 2 Place a screwdriver in the slot under the lower portion of the fan cover and lift the screwdriver slightly to remove the fan cover 3 Replace the filter 4 Replace the cover 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 opx okidata com Page 42 Service Guide OL840 OKIDATA Chapter 4 Failure amp Repair Analysis 4 1 OL840 TROUBLESHOOTING 4 1 01 General Information Section Four of
33. r each character in the font is stored in ROM Since no special calculations are used in the HP mode each typeface style weight orientation and size is stored separately Down Line Loaded DLL fonts and macro registration are stored in the DLL and macro areas of memory RAM Emulation and Postscript interpretation is performed under program control by the CPU Font Processing In the emulation mode the bit image in the font ROM is loaded by the CPU into the raster buffer RAM The raster buffer has a band buffer structure new data is written to the raster buffer once the buffer has been read and becomes empty In Postscript mode the outline data stored in the programmed ROM is loaded into the RAM area called the font cache the required font pattern is then transferred to the raster buffer The buffer has a full page buffer structure One page of data is written at a time After a page is written another raster buffer read operation starts Raster Buffer Read Operation The bit image written to the raster buffer by the CPU is converted to serial dot data to be read in response to the VIDEO SYNCH signal The first in first out FIFO buffer is between the raster buffer and the serial dot data of the video interface WDATA The CPU can transfer data from the raster buffer to the FIFO automatically when the CPU reads the OR ING memory area of the raster buffer The CPU reads a line of data from the raster buffer before the LSYNC si
34. receives data but does not process any data ON LINE PS The printer is processing the Normal Indication PROCESSING received data ON LINE PS Waiting for receive data Normal Indication WAITING ON LINE PS The printer is printing received data Normal Indication PRINTING ON LINE PS The ON LINE key is pressed during Recovers automatically PRINTER BUSY processing waiting or printing Otherwise press the RECOVER key to return to IDLE ON LINE PS FLUSHING JOB DOING START PAGE After PRINTER BUSY appeared the RECOVER key was pressed and all data in the receive buffer was invalidated The start page setting was ON when the power was turned on Printing starts from the start page in about one minute Normal Indication Normal Indication ON LINE PS CHANGE DRUM ON LINE PS FUSER LIFE The drum is aging End of thermal fuser life Replace the drum Change the software to the emulation mode hold down the recover key and turn on the power Check that DRUM CTR RESET appears on the LCD Replace the thermal fuser and reset the fuser counter ON LINE PS TONER LOW The printer is low on toner Replace the toner cartridge WARMING UP The printer is warming up Normal Indication ERROR CARD There is an error in the data on the Try reinstalling the Font font card checksum error Card Replace the Font Card INITIALIZING Firmware is initializing Normal Indication Will be
35. rt and xerographic processing actions necessary for printing The Operation Panel is connected to the Main Controller Board via the LLCC PCB the Engine Driver Board and the LNKZ PCB The Operation Panel is controlled by the Main Controller Board The optional Second Paper Tray LLFC POB is controlled by the Engine Driver Board The Main Controller Board contains 2 MByte of dynamic RAM The Expansion Memory Board REXM provides an additional 2 Mbyte of dynamic RAM Two font cards slots are available Each font card contains ROM which provides additional fonts The two connectors for the font cards are provided on the CMBZ PCB The font card data is sent to the Main Controller Board through the LNKZ PCB 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 opx okidata com Page 12 Service Guide OL840 OKIDATA Chapter 2 Principles of Operation 2 2 PRINTER OVERVIEW 2 2 01 General Information This section describes the operation of the OL840 Printer in the following order Main Control Function Printer Control Function Mechanical Operation Sensors and Switches 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 opx okidata com Page 13 Service Guide OL840 OKIDATA Chapter 2 Principles of
36. the OL800 820 Service Handbook should be used to troubleshoot the OL840 Listed below are the differences between troubleshooting the OL800 820 printers and the OL840 printers When told to replace the CTLZ Board replace the RPSS Board Both boards are Main Controller Boards When told to replace the Program Cartridge replace the Program ROM Board There is no Program Cartridge in the OL840 The printers firmware is located on the Program ROM Board This board is attached to the Main Controller Board When told to replace the Memory Expansion Chip Set replace the Memory Expansion Board REXM When the Engine Control Board LLAB 2 is replaced remember that the OL840 EEPROM is NOT identical to the OL800 820 EEPROM 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 opx okidata com OKIDATA Page 43 Service Guide OL840 Chapter 4 Failure amp Repair Analysis 4 1 02 LCD Display Messages PostScript Mode The following messages may be displayed when the printer is in the PostScript mode Refer to Section Four of the OL800 820 Service Handbook for LCD Messages displayed in the Emulation Mode 4 LCD MESSAGE DEFINITION CORRECTIVE ACTION ON LINE PS IDLE The printer is in the online mode Normal Indication OFF LINE PS The printer is in the off line mode Normal Indication The printer
37. ull up and remove the optional Expansion RAM PCB 1 from the connectors MEM 2 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 opx okidata com Page 38 w Service Guide OL840 OKIDATA Chapter 3 Maintenance amp Disassembly 3 3 ADJUSTMENTS AND SERVICE CHECKS 3 3 01 General Information The first four adjustments Actual Page Count Modified Page Count Vertical Print Start Position and LED Head Drive Time are performed by changing addresses on the EEPROM located on the Engine Controller Printer circuit board Please refer to Section Three of the OL800 820 Service Handbook for these procedures zu 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 opx okidata com Page 39 w Service Guide OL840 OKIDATA Chapter 3 Maintenance amp Disassembly 3 4 CLEANING 3 4 01 General Information Remove any dropped toner and dust Clean inside and around the printer with a vacuum cleaner equipped with a toner filter when necessary Refer to Section 3 4 of the OL800 820 Service Handbook for information on cleaning the printer D Copyright 1997 Okidata Division of OKI America Inc All rights reserved See the OKIDATA Business Partner Exchange BPX for any updates to this material htt
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