OKIJET 2500 InkJet Printer
Contents
1. chain 3 Machine Run Control 119 Chain 8 Paper Feed 120 chain 9 Print Control 121 Page 1 OKIDATA a iia Front Cover OKIDATA Service Guide OKIJET 2500 Service Manual P N 59228801 Adobe Acrobat printable reference copy of the OKIDATA Service Training Manual 03 20 98 Note This Adobe Acrobat version of the Okidata Service Training Manual was built with the pictures rendered at 300 dpi which is ideal for printing but does not display well on most displays Copyright 1997 Okidata Division of OKI America Inc All rights reserved See the OKIDATA Business Partner Exchange BPX for any updates to this material http bpx okidata com Page 2 OKIDATA ee Disclaimer Copyright Disclaimer This document may not be reproduced without the written permission of Okidata Training and Publications Every effort has been made to ensure the accuracy of the information contained in this training course Okidata is not responsible for errors beyond its control Copyright 1998 by Okidata All rights reserved Edited by Okidata Training and Publications Prepared by Multinational Customer and Service Education Xerox Corporation Rochester New York 14644 Please address any comments on this publication to Okidata s web site at www okidata com Telephone 609 235 2600 Facsimile 609 222 5320 Okilink Technical Training Copyright Listing OKIDATA is a registered trademark of Oki Electric Indu2. 17 YING r VIG zi i F LI Ae Sa cry Wh AT GAR 5 OT RAC Th POL LAG amp OTH 5 OA oo WKEH THE CARA GE E Wr HE THE VOUT AGE 18 APARATET 2 VO 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 R Service Manual OKIJET 2500 OKIDATA Chapter 2 Repair Analysis Procedures RAPs 8 1 Paper Feed RAP Clear any paper in the printer Disconnect and then reconnect the power cord Press and hold the Power switch for about 2 seconds Press and hold the Resume FF button for 2 seconds to print the demo print The paper feeds or partially feeds Y N e Check that the Paper Tray is installed correctly REP 1 1 e Go to Flag 1 and check the cam sensor circuit for an open e f OK go to Flag 3 and check for an open circuit If paper feed motor circuit is defective replace the paper feed motor e ifthe wires are good replace the Main Control Board Go to Flag 2 and check the paper feed switch circuit for an open If OK go to Flag 3 and check for an open circuit Replace the Back pad If the problem still exists replace the Main Control Board 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
3. Y N e Goto Flag 1 and check the ribbon cable for being open or damaged Go to Flag 2 and check for an open circuit If the wire is good replace the Main Control Board Perform the following Check replace the ribbon carriage cable Check the teeth on the belt Check the teeth on the carriage motor Check for 42 volts If 42 volts aren t being supplied by the power supply replace the power supply Check replace the carriage motor e Check that the Printhead ribbon cable going to CN4 on the Main Control Board is connected properly e Goto Flag 2 and Flag 3 and check for an open circuit e Ifthe wires are good replace the Printhead Ribbon Cable PL 2 1 see Chapter 5 e lf the problem continues replace the Main Control Board PL 1 1 Check replace the ribbon carriage cable Check the teeth on the belt Check the teeth on the carriage motor Check for 42 volts If 42 volts aren t being supplied by the power supply replace the power supply Check replace the carriage motor 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 30 DATA Service Manual OKIJET 2500 OKI l Chapter 2 Repair Analysis Procedures RAPs 6 2 Encoder RAP Go to Flag 1 and check the ribbon Go to Flag 4 and check for an open circuit Replace the Encoder Go to 6 1 Carriage RAP
4. WARNING Switch off the Power Disconnect the power cord at the wall outlet 2 Remove the Output Tray PL 1 1 3 Remove the Paper Tray Assembly REP 1 1 4 Remove the Cartridge Cover REP 1 2 5 Remove the Top Cover REP 1 3 6 Remove the Paper Feed Carriage Assembly REP 1 5 7 Disconnect Power Supply power cord connector CN1 from the Power Supply Figure 1 8 Remove the four mounting screws 9 Slide the Power Supply toward the right side of the printer to disengage Power Supply connector CN2 from the Main Control Board connector CN1 lift the Power Supply from the printer Replacement 1 Position the Power Supply into the printer base 2 Slide the Power Supply toward the left side of the printer to engage Power Supply connector CN2 with the Main Control Board Figure 1 3 Install the four mounting screws 4 Reconnect the Power Supply power cord connector CN1 5 Replace the following a Paper Feed Carriage Assembly REP 1 5 b Top Cover REP 1 3 c Cartridge Cover REP 1 2 d Paper Tray Assembly REP 1 1 e Output Tray PL 1 1 f Printhead REP 1 0 ecraws 4 Figure 1 CHOOT 61 A LAT 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 DATA Service Manual OKIJET 2500 OKI in la Chapter 4 Repair Adjustment Procedures REP 1 7 Main Co
5. Go to Flag 5 and check for an open wire If good go to 8 1 Paper Feed RAP A Press the Cartridge Change button The carriage moves to the center position Y N Go to Flag 4 and check for an open wire If OK replace the Control Panel Assembly For printer set up problems when printing from a DOS application consult GP 2 Printing with DOS Procedure in Section 6 Examples of printer set up problems Just a few lines of data are printed and then the paper continues to line feed without printing Contre Panel Assembly 1 1 Brewer On yD ol ZHI 8 YDG Al on fara ff amoiiomom AH CH LUDI jbh eT Vis i f GAY AES UWE FF ACTUATED iL 15W05 tot POWER RESET ACTUATED iLi 50 lt B FJ toe CARTRIDGE CHANGE CLEAN ACTUATED F a h u ee L l toy BLACE IMK LED oy o DH Y DYAH Hia LED Hj e BLAS ENMT 4 KWK LED Hi i GAT YELLA IWK LED IH 8085 l i i ze a Tare 5 VD be T 0 es ew 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 aire AW A Service Manual OKIJET 2500 OKIDATA Chapter 2 Repair Analysis Procedures RAPs 6 1 Carriage TAP Disconnect and then reconnect the power cord Press and hold the Power switch The carriage moves
6. Paper Feed Carriage Assembly REP 1 5 Top Cover REP 1 3 Cartridge Cover REP 1 2 Paper Tray Assembly REP 1 1 f Output Tray PL 1 1 g Printhead REP 1 0 Removal CAUTION Store the Printhead in the Storage Box Leaving the Printhead removed for long periods of time will cause the ink nozzles to dry out Image quality defects or a blank page could result If necessary prime the printhead after reinstallation REP 1 0 1 Remove the Printhead REP 1 0 Store the Printhead in the Storage Box WARNING Switch off the power Disconnect the power cord at the wall outlet 2 Remove the following a Output Tray PL 1 1 b Paper Tray Assembly REP 1 1 c Cartridge Cover REP 1 2 d Top Cover REP 1 3 e Paper Feed Carriage Assembly REP 1 5 3 Remove Waste Ink Pad retainer by releasing the four locking tabs with screwdriver or other similar tool Figure 1 Replacement 1 Ensure flange on one end of the pad retainer is toward the right side of the printer 2 Snap the retainer into position 3 Replace the following a Paper Feed Carriage Assembly REP 1 5 b Top Cover REP 1 3 c Cartridge Cover REP 1 2 d Paper Tray Assembly REP 1 1 e Output Tray PL 1 1 f Printhead REP 1 0 Waste Ink Pad retainer 000781 4 LAT Figure 1 Copyright 1997 Okidata Division of OKI America Inc All rights reserved See the OKIDATA Business Partner Exchange BPX for
7. 5 VDC measured on the Main Control Board Y N Go to Flag 2 and check for a short to ground If OK replace the Power Supply If problem still exists replace Main Control Board Replace the Main Control Board before replacing the Control Panel Assembly Figure 1 Voltage Measurements i H Escodar Aenembls i ml dJi Csr Fone Assama lt _ lt _ 77 i A SHO PROT PE Ald FIBBOK CAJN os WOH 175 WAG H PLo4 piii VAC EHZ oe Figure 2 Power distribution 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 D AT A Service Manual OKIJET 2500 OKI in ta Chapter 2 Repair Analysis Procedures RAPs 2 1 Selection Indication RAP Load paper Disconnect and then reconnect the power cord while observing the LEDs All LEDs light momentarily when the power cord is reconnected Y N One or more LEDs light Y N Go to 1 1 Power on RAP Go to Flag 1 and Flag 2 and check for an open wire If OK replace the Control Panel Assembly All LEDs go out in approximately 10 seconds Y N If the Power LED remains on flashing go to Flag 3 and check for an open wire If OK replace the Control Panel Assembly Press and hold the Power button for approximately 2 seconds to turn on the printer Press and hold the Resume FF button for 2 seconds Paper feeds Y N
8. Image quality defects or a blank page could result If necessary prime the printhead after reinstallation REP 1 0 1 Remove the Printhead REP 1 0 Store the Printhead in the Storage Box WARNING Switch off the power Disconnect the power cord from the wall outlet 2 Remove the Output Tray PL 1 1 3 Remove the Cartridge Cover REP 1 2 4 Position both thumbs at the lower front corners of the Exit Guide Figure 1 Apply modest pressure simultaneously toward the rear and up to unlatch the Exit Guide 5 Rotate the guide approximately 90 up and toward the rear of the printer 6 Lift the Exit Guide from the printer Replacement 1 Hold the Exit Guide so the star wheels 10 are facing the front of the printer 2 Lower the Exit Guide into the printer to engage the pivots with the slots in the Paper Feed Carriage Assembly 3 Rotate the Exit Guide completely toward the front of the printer 4 Position both thumbs at the lower front corners of the Exit Guide Figure 1 Apply moderate pressure simultaneously toward the rear and down to latch the Exit Guide 5 Reinstall the Cartridge Cover REP 1 2 6 Reinstall the Output Tray PL 1 1 7 Reinstall the Printhead REP 1 0 e141 ALA 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 40 DATA Service Manual OKIJET 2
9. PL 1 1 e Reinstall the Printhead REP 1 0 xe I A mounting ribbon cable screws 33 connector Figure 1 DEN 12714 LAT 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 48 DATA Service Manual OKIJET 2500 OKI in ta Chapter 4 Repair Adjustment Procedures REP 1 13 Paper Path Sensor SW 1 Parts List on PL 2 1 Removal CAUTION Store the Printhead in the Storage Box Leaving the Printhead removed for long periods of time will cause the ink nozzles to dry out Image quality problems or a blank print could result If necessary prime the printhead after reinstallation REP 1 0 1 Remove the Printhead REP 1 0 Store the Printhead in the Storage Box WARNING Switch off the power Disconnect the power cord at the wall outlet 2 Remove the following a Output Tray PL 1 1 b Paper Tray Assembly REP 1 1 c Cartridge Cover REP 1 2 d Top Cover REP 1 3 e Exit Guide REP 1 4 f Paper Feed Carriage Assembly REP 1 5 3 Position the Paper Feed Carriage Assembly as shown in Figure 1 4 Disconnect J3 from the Relay Board See Figure 1 5 Remove mounting screw 6 Remove Paper Path Sensor Replacement 1 Position the Paper Path Sensor SW 1 in the Paper Feed Carriage Assembly Reinstall the mounting screw 2 Connect J3 to the Relay BOARD
10. any updates to this material http opx okidata com Page 44 DATA Service Manual OKIJET 2500 OKI in la Chapter 4 Repair Adjustment Procedures REP 1 9 Pump Parts List on PL 2 1 Removal CAUTION Store the Printhead in the Storage Box Leaving the Printhead removed for long periods of time will cause the ink nozzles to dry out Image quality defects or a blank page could result If necessary prime the printhead after reinstallation REP 1 0 1 Remove the Printhead REP 1 0 Store the Printhead in the Storage Box WARNING Switch off the power Disconnect the power cord at the wall outlet 2 Remove the following a Output Tray PL 1 1 b Paper Tray Assembly REP 1 1 c Cartridge Cover REP 1 2 d Top Cover REP 1 3 e Paper Feed Carriage Assembly REP 1 5 3 Remove the Pump from the Paper Feed Carriage Assembly a Note routing of inlet tube disconnect tube at connector beneath Maintenance Station Figure 1 b Note routing of outlet tube remove cable tie slide tube through frame c Remove two Pump mounting screws Figure 2 d Slide pump from motor shaft Replacement 1 Install the pump onto the motor shaft 2 Reinstall the two mounting screws CAUTION Ensure the pump tubing is not kinked or otherwise restricted during reinstallation 3 Route inlet tube as shown in Figure 1 reconnect clamp into position 4 Route outlet tube as shown in Figure 1 install two cable ties on tube at eit
11. fee ae Printer Installation 71 Printer Operation 72 seen Loading the paper 73 MENER Test print mode 74 aera Connecting the printer to a computer 75 Table of Contents Page ee Control panel 76 eee Printing ae Printer Maintenance 78 EET Cleaning 79 EER Replacing the Printhead 80 er Troubleshooting 81 eto Removal Replacement of the printer components 82 Technical Overview 83 Power and Control 84 eer Standby power 85 Run control functions 86 seen Main Control Board 87 Scie Control Panel Assembly 88 eee Bi Directional Cable 89 Printing and Priming 90 cease Printing 91 ene Print control 92 ae Cleaning and Priming 93 Ink Level Sensing 94 eee Ink Cartridge Present 95 susie Low Ink Detection 96 eee Out of Ink Detection 97 Carriage Drive 98 eae Carriage drive 99 ee Carriage movement at power on 100 Encoder 101 ieee Status code 102 Paper Supply Paper Feed 103 oe Paper supply 104 ee Paper feed 105 odie Load and eject mechanism 106 9ensors and status indicators 107 ee sensors 108 seers Status indicators 109 7 Wiring Data Plug Jack Location Index 110 Plug Jack Location Drawings 111 Figure 7 1 Main Control Board and Power Supply 112 Figure 7 2 Carriage Assembly Bottom View 113 Figure 7 3 Carriage 114 Figure 7 4 Front View 115 Block Schematic Diagrams BSDs 116 Chain 1 AC DC Power Generation 117 Chain 2 Selection and Indication 118 Table of Contents Page
12. mera Section 5 PARTS LIST This section contains the detailed Parts List for the printer Copyright 1997 Okidata Division of OKI America Inc All rights reserved See the OKIDATA Business Partner Exchange BPX for any updates to this material http opx okidata com Page 10 OKIDATA NEN eo bataan Section 6 GENERAL PROCEDURES This section contains Diagnostic Procedures and Product Specifications for the Printer An Overview and Technical Overview section are also included Copyright 1997 Okidata Division of OKI America Inc All rights reserved See the OKIDATA Business Partner Exchange BPX for any updates to this material http bpx okidata com Page 11 s gt ae Service Manual OKIJET 2500 OKIDATA Chapter 0 Introduction Section 7 WIRING DATA This section contains Plug Jack Location Drawings and Block Schematic Diagrams BSDs Copyright 1997 Okidata Division of OKI America Inc All rights reserved See the OKIDATA Business Partner Exchange BPX for any updates to this material http opx okidata com Page 12 OKIDATA a How To Use This Manual The Service Call Procedures will direct you to the proper section of the Service Manual You should begin the service call with the Initial Actions System Checks Procedure From there you will be referenced to either Section 2 Status Indicator RAPs or Section 3 Image Quality RAPs If you are sent to Section 3 you will perf
13. time The LED code is as follows See Figure 1 1 Both Error and Power LEDs lit 0 Error LED only is lit 1 Press and release the Resume FF button while observing the Error and Power LEDs 2 4 bits will be flashed in 1 2 second intervals followed by a pause then 4 more bits in 1 2 second intervals After the cycle the Error LED will continue to flash 3 Determine the code and go to the Error Code Chart Table 1 for the corrective action 4 Repeat step 1 as many times as necessary to determine the code Power LED Error LED Hesume FF button vite PPR Figure 1 LED Code 1110 1000 Replace the Main Control Board 1100 1111 Carriage home position error Go to 6 1 Carriage RAP Copyright 1997 Okidata Division of OKI America Inc All rights reserved See the OKIDATA Business Partner Exchange BPX for any updates to this material http opx okidata com Page 27 DATA Service Manual OKIJET 2500 OKI rer Chapter 2 Repair Analysis Procedures RAPs 1 1 Power on RAP Refer to Figure 1 There is 42 VDC measured on the Main Control Board Y N Disconnect the power cord Check fuse F1 on the Power Supply F1 is blown Y N Go to Flag 1 Figure 2 and check the wires for an open circuit If good replace the Power Supply If problem still exists replace the Main Control Board Replace the blown fuse If the problem is not corrected replace the Power Supply PL 1 1 Refer to Figure 1 There is
14. 26 1 1 Power on RAP 2 2 1 Selection Indication RAP 28 6 1 Carriage TAP 29 6 2 Encoder RAP 30 8 1 Paper Feed RAP 31 9 1 Blank Print RAP 32 3 Image Quality RAPs IQ 1 Image Defect Entry RAP 33 IQ 1 Image Defect Entry RAP Table 34 4 Repair Adjustment Procedures REP 1 0 Printhead 35 REP 1 1 Paper Tray Assembly 36 Table of Contents Page REP 1 2 Cartridge Cover 37 REP 1 3 Top Cover 38 REP 1 4 Exit Guide 39 REP 1 5 Paper Feed Carriage Assy 40 REP 1 6 Power Supply 41 REP 1 7 Main Control Board 42 REP 1 8 Waste Ink Pad 43 REP 1 9 Pump 44 REP 1 10 Maintenance Station 45 REP 1 11 Encoder 46 REP 1 12 Control Panel Assembly 47 REP 1 13 Paper Path Sensor SW 1 48 REP 1 14 Back Pad 49 REP 1 15 Printhead Ribbon Cable 50 REP 1 16 Ink Level Sensor 51 ADJ 2 0 Printhead Alignment 52 5 Parts List PL 1 1 Printer Components 53 PL 2 1 Paper Feed Carriage Assembly Components Part 1 of 54 3 PL 2 1 Paper Feed Carriage Assembly Components Part 2 of 55 3 PL 2 1 Paper Feed Carriage Assembly Components Part3 of 56 3 Part Number Index 57 6 General Procedures Diagnostics 58 GP 1 Printhead Test 59 GP 2 Printing with DOS 60 Product Specifications 61 Physical Characteristics 62 Electrical Requirements 63 Printer Capabilities 64 upplemental Items 65 Printer Overview and Technical Overview Introduction 66 Printer Overview 67 ee Printer Specifications 68 en Features and Operation 69 ee Safety Notes 70
15. 3 Reinstall the following a Paper Feed Carriage Assembly REP 1 5 b Exit Guide REP 1 4 c Top Cover REP 1 3 d Cartridge Cover REP 1 2 e Paper Tray Assembly REP 1 1 f Output Tray PL 1 1 g Printhead REP 1 0 maunting Screw Figure 1 O401131A LAT 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 DATA Service Manual OKIJET 2500 OKI in ta Chapter 4 Repair Adjustment Procedures REP 1 14 Back Pad Parts List on PL 2 1 Removal CAUTION Leaving the Printhead removed for long periods of time will cause the ink nozzles to dry out Image quality problems or a blank print could result If necessary prime the printhead after reinstallation REP 1 0 1 Remove the Printhead REP 1 0 Store the Printhead in the Storage Box WARNING Switch off the power Disconnect the power cord at the wall outlet 2 Remove the following a Output Tray PL 1 1 b Paper Tray Assembly REP 1 1 c Cartridge Cover REP 1 2 d Top Cover REP 1 3 e Exit Guide REP 1 4 f Paper Feed Carriage Assembly REP 1 5 3 Position the Paper Feed Carriage Assembly as shown in Figure 1 4 Remove the Back Pad mounting screw Figure 1 5 Remove the retainer bracket and spring 6 Remove the Back Pad Replacement 1 Position the Back Pad in the Paper Feed Carri
16. 500 OKI in ta Chapter 4 Repair Adjustment Procedures REP 1 5 Paper Feed Carriage Assy Parts List on PL 2 1 Removal CAUTION Store the Printhead in the Storage Box Leaving the Printhead removed for long periods of time will cause the ink nozzles to dry out Image quality defects or a blank page could result If necessary prime the printhead after reinstallation REP 1 0 1 Remove the Printhead REP 1 0 Store the Printhead in the Storage Box WARNING Switch off the power Disconnect the power cord at the wall outlet 2 Remove the Output Tray PL 1 1 3 Remove the Paper Tray Assembly REP 1 1 4 Remove the Cartridge Cover REP 1 2 5 Remove the Top Cover REP 1 3 6 Loosen screw disconnect ground wire from ground plate near front left corner of Paper Feed Carriage Assembly Figure 1 O4001 S1A LAT Figure 1 Left side 7 Disconnect ground wire from grounding plate at right side of printer Figure 2 ground wire Figure 2 Right side ibara AT 8 Remove the screws 2 from the two front corners of the Paper Feed Carriage Assembly Figure 3 Cel 5 LaAT Figure 3 9 Lift the front of the assembly slightly then slide the assembly toward the front of the printer until it contacts the front wall of the base 10 Lift the front of the assembly to access the Main Control Board ribbon cable connectors CN3 amp CN4 disconnect from the Main Control Board Figure 4 CN3 amp C
17. A Service Manual OKIJET 2500 OKI ers Chapter 4 Repair Adjustment Procedures REP 1 12 Control Panel Assembly Parts List on PL 1 1 Removal CAUTION Store the Printhead in the Storage Box Leaving the Printhead removed for long periods of time will cause the ink nozzles to dry out Image quality problems or a blank page could result If necessary prime the printhead after reinstallation REP 1 0 1 Remove the Printhead REP 1 0 Store the Printhead in the Storage Box WARNING Switch off the power Disconnect the power cord at the wall outlet 2 Remove the following a Output Tray PL 1 1 b Paper Tray Assembly REP 1 1 c Cartridge Cover REP 1 2 d Top Cover REP 1 3 3 Position the Top Cover on its top NOTE There is non captured hardware under the Control Panel Assembly DO NOT reposition the Top Cover with the control panel assembly board removed 4 Remove the mounting screws 3 from the Control Panel Assembly remove the board Figure 1 5 Disconnect the ribbon cable from the board Replacement 1 Connect the ribbon cable to the Control Panel Assembly 2 Ensure the buttons and lenses are properly positioned in the Top Cover Carefully install the board into the Top Cover Secure with the three mounting screws 3 Reinstall the following a Reinstall the Top Cover REP 1 3 b Reinstall the Cartridge Cover REP 1 2 c Reinstall the Paper Tray Assembly REP 1 1 d Reinstall the Output Tray
18. LT 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 46 DATA Service Manual OKIJET 2500 OKI in la Chapter 4 Repair Adjustment Procedures REP 1 11 Encoder Parts List on PL 2 1 Removal CAUTION Store the Printhead in the Storage Box Leaving the Printhead removed for long periods of time will cause the ink nozzles to dry out Image quality problems or a blank page could result If necessary prime the printhead after reinstallation REP 1 0 1 Remove the Printhead REP 1 0 Store the Printhead in the Storage Box WARNING Switch off the power Disconnect the power cord at the wall outlet 2 Remove the following a Paper Output shelf PL 1 1 b Paper Tray Assembly REP 1 1 c Cartridge Cover REP 1 2 d Top Cover REP 1 3 e Paper Feed Carriage Assembly REP 1 5 f Maintenance Station REP 1 10 3 Remove the belt PL 2 1 from the carriage motor pulley right end 4 Remove the belt from the Encoder pulley left end CAUTION A ribbon cable is attached to the bottom of the carriage assembly Do not damage it while removing the carriage assembly 5 Rotate the carriage shaft cams so that their flats are aligned with the sides of the slot on each side frame Figure 1 Side frame Cam CHT 11 14 LAT Figure 1 NOTE Expect moderate to heavy resista
19. N4 MOO 1S14 LAT Figure 4 11 Remove the assembly from the base Replacement 1 Lift the front of the assembly to access the Main Control Board ribbon cable connectors CN3 amp CN4 reconnect to the Main Control Board Figure 4 see above 2 Allow the Paper Feed Carriage Assembly to rest on the printer base Slide the assembly rearward to engage the rear mounts Sansor 4011 i2A LAT 3 Reinstall the two front screws 4 Reconnect the ground wire to the ground plate on the right side of the printer 5 Reconnect the ground wire to the ground plate on the left front corner of the printer tighten screw 6 Reinstall the following a Top Cover REP 1 3 b Cartridge Cover REP 1 2 c Paper Tray Assembly REP 1 1 d Output Tray PL 1 1 e Printhead REP 1 0 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 41 DATA Service Manual OKIJET 2500 OKI in le Chapter 4 Repair Adjustment Procedures REP 1 6 Power Supply Parts List on PL 1 1 Removal CAUTION Store the Printhead in the Storage Box Leaving the Printhead removed for long periods of time will cause the ink to dry out Image quality defects a blank page could result If necessary prime the printhead after reinstallation REP 1 0 1 Remove the Printhead REP 1 0 Store the Printhead in the Storage Box
20. Page 1 OKIDATA a iia Front Cover OKIDATA Service Guide OKIJET 2500 Service Manual P N 59228801 Adobe Acrobat printable reference copy of the OKIDATA Service Training Manual 03 20 98 Note This Adobe Acrobat version of the Okidata Service Training Manual was built with the pictures rendered at 300 dpi which is ideal for printing but does not display well on most displays Copyright 1997 Okidata Division of OKI America Inc All rights reserved See the OKIDATA Business Partner Exchange BPX for any updates to this material http bpx okidata com Table of Contents Page Service Manual OKIJET 2500 0 Introduction Front Cover 1 Disclaimer Copyright 2 About This Manual 3 Organization 4 oection 1 SERVICE CALL PROCEDURES 5 oection 2 REPAIR ANALYSIS PROCEDURES RAPs 6 oection 3 IMAGE QUALITY REPAIR ANALYSIS 7 PROCEDURES RAPs oection 4 REPAIR ADJUSTMENT PROCEDURES 8 oection 5 PARTS LIST 9 Section 6 GENERAL PROCEDURES 10 9ection 7 WIRING DATA 11 How To Use This Manual 12 Reference Symbology 13 Special Symbols 14 Signal Nomenclature 15 DC Voltage Levels 16 Switches and Relay Contacts 17 Back Cover 18 1 Service Call Procedures Introduction 19 Printer Maintenance 20 Initial Actions 21 oystem Checkout Final Action 22 2 Repair Analysis Procedures RAPs Error LED On RAP 23 Power LED Blinking RAP 24 Low Ink LED s On RAP 25 Error LED Flashing RAP
21. Refer to the DEFECT Column in Table 1 that best describes the image quality problem 3 If the problem is with external input only replace the Main Control Board ELELEE kj d i m By i Fae rik a il Bh J S r 1 i Sy ne art sa ling ab GEE A P Sa B EL R dP aaa EREN fanaa SCCM CWE PPM ol Se th LS TP Figure 1 Test Print Copyright 1997 Okidata Division of OKI America Inc All rights reserved See the OKIDATA Business Partner Exchange BPX for any updates to this material http opx okidata com Page 34 FA Service Manual OKIJET 2500 OKIDATA Chapter 3 Image Quality RAPs IQ 1 Image Defect Entry RAP Table DEFECT CAUSE SOLUTION Blank print e Printhead 1 Remove and reinstall the Printhead 2 Press the Cartridge Change Clean button for 2 seconds to clean and restore the Printhead Repeat if necessary lf the problem still exists go to the 9 1 Blank Print RAP White horizontal lines and The Printhead Perform the following Streaks nozzles may be 1 Press the Cartridge Change Clean blocked button for 2 seconds to clean and restore the Printhead Make another Test Print If the print still has lines and streaks repeat the above process up to 5 times If the problem still exists replace the Printhead Print is faint or missing A non Replace the paper recommended paper is being used or the paper is damp Defective Cartridge Perform the following The
22. age Assembly 2 Reinstall the spring then the mounting bracket 3 Reinstall the mounting screw 4 Reinstall the following a Paper Feed Carriage Assembly REP 1 5 b Exit Guide REP 1 4 c Top Cover REP 1 3 d Cartridge Cover REP 1 2 e Paper Tray Assembly REP 1 1 f Output Tray PL 1 1 g Printhead REP 1 0 retainer bracket Back Pad Mounting screw 107 17414 LAT Figure 1 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 50 DATA Service Manual OKIJET 2500 OKI in la Chapter 4 Repair Adjustment Procedures REP 1 15 Printhead Ribbon Cable Parts List on PL 2 1 Removal CAUTION Store the Printhead in the Storage Box Leaving the Printhead removed for long periods of time will cause the ink nozzles to dry out Image quality problems or a blank page could result If necessary prime the printhead after reinstallation REP 1 0 1 Remove the Printhead REP 1 0 Store the Printhead in the Storage Box WARNING Switch off the power Disconnect the power cord at the wall outlet 2 Remove the following a Output Tray PL 1 1 b Paper Tray Assembly REP 1 1 c Cartridge Cover REP 1 2 d Top Cover REP 1 3 e Paper Feed Carriage Assembly REP 1 5 3 Remove the belt PL 2 1 from the carriage motor pulley right end 4 Remove the bel
23. arts List Diagnostic Procedures and Wiring Data information that will enable a Service Representative to repair the Printer Copyright 1997 Okidata Division of OKI America Inc All rights reserved See the OKIDATA Business Partner Exchange BPX for any updates to this material http bpx okidata com Page 4 OKIDATA sean mera Organization This manual is divided into seven sections The title and description of each section are listed below Copyright 1997 Okidata Division of OKI America Inc All rights reserved See the OKIDATA Business Partner Exchange BPX for any updates to this material http opx okidata com Page 5 OKIDATA a ia Section 1 SERVICE CALL PROCEDURES This section contains the following e Initial Actions System Checks e System Checkout e Final Action Initial Actions System Checks This diagram identifies how to collect the data necessary to decide how to proceed with the service call It classifies the problem and refers you to the appropriate Repair Analysis Procedure System Checkout The System Checkout procedure is used to verify that the printer is operating properly after a repair has been made Final Action The Final Action procedure identifies the steps that must be performed before finishing the repair Copyright 1997 Okidata Division of OKI America Inc All rights reserved See the OKIDATA Business Partner Exchange BPX for any updates to this material
24. com Page 32 te Service Manual OKIJET 2500 OKIDATA Chapter 2 Repair Analysis Procedures RAPs 9 1 Blank Print RAP Initial Action Ensure that the Printhead latch is positioned towards the rear Unlatch the Printhead reset the Printhead and latch it back into position If problem still exists e Replace the Printhead e Goto Flag 1 and check the ribbon cable for being damaged e Check the terminals of J11 on the Carriage Assembly and J12 on the Ink Cartridge for being contaminated or damaged Clean or repair as necessary e fthe problem still exists replace the Printhead Ribbon Cable PL 2 1 see Chatper 5 Wain Dimis Brews FLii 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 33 FY Service Manual OKIJET 2500 OKIDATA Chapter 3 Image Quality RAPs IQ 1 Image Defect Entry RAP 1 Print the Test Print a Load paper into the Paper Tray b Press and hold the Power on Reset button for approximately 2 seconds and then release to switch the Printer power off c While pressing and holding the Resume FF button press and release the Power on Reset button The printer prints the test print shown in Figure 1 When the test print is complete the printer initializes and returns to the Ready status d If the test print fails to print repeat steps a through c 2
25. e 1 CAUTION While removing the Top Cover from the printer take care not to damage the ribbon cable that is connected to the Control Panel Assembly which is located inside the Top Cover NOTE The rear of the Top Cover has three locator tabs and two latch tabs 6 Return the printer to its normal operating position Lift and hold the front of the cover slightly while releasing the two rear latch tabs Then lift the rear of the cover and pivot towards the FRONT of the printer to remove Replacement 1 Ensure the ribbon cable is properly routed and not twisted during Top Cover installation 2 If previously disconnected reconnect ribbon cable to the Control Panel Assembly 3 Position the Top Cover on the printer Align and latch the rear latches then the front latches 4 Reinstall the following a Cartridge Cover REP 1 2 b Paper Tray Assembly REP 1 1 c Output Tray PL 1 1 d Printhead REP 1 0 m a latch tabs a P Figure 1 Caco 21A LAT 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 39 DATA Service Manual OKIJET 2500 OKI in ta Chapter 4 Repair Adjustment Procedures REP 1 4 Exit Guide Parts List on PL 2 2 Removal CAUTION Store the Printhead in the Storage Box Leaving the Printhead removed for long periods of time will cause the ink nozzles to dry out
26. econds the reinstall it The Power LED blinks Y N Printer is OK Go to 2 1 Selection Indication RAP Copyright 1997 Okidata Division of OKI America Inc All rights reserved See the OKIDATA Business Partner Exchange BPX for any updates to this material http bpx okidata com Page 25 te Service Manual OKIJET 2500 OKIDATA Chapter 2 Repair Analysis Procedures RAPs Low Ink LED s On RAP Initial Action Ensure all the ink cartridges are full and properly seated Go to Flags 1 and 2 Check the wires and connections for an open circuit The wires are good Y N Repair the wires or connections if possible Replace the main control board If the problem still exists replace the Printer Replace the Ink Level Sensor PL 2 1 located in Chapter 5 Replace the main control board If the problem still exists replace the printer BAA ath AL ETAD 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 26 DATA Service Manual OKIJET 2500 OKI Chapter 2 Repair Analysis Procedures RAPs Error LED Flashing RAP Note This procedure will work only when the Error LED is flashing Note In the following procedure the Error LED and Power LED will be used to display an 8 bit binary error code The LEDs will flash in 1 2 second intervals The code will be displayed 4 bits at a
27. either pivot to release the Cartridge Cover pivot from the Top Cover Figure 1 3 Lift the Cartridge Cover from the printer Replacement 1 Insert either Cartridge Cover pivot into the corresponding Top Cover pivot hole 2 Utilizing a screwdriver or similar tool slightly separate the Cartridge Cover and Top Cover at the opposite pivot 3 Position the Cartridge Cover pivot to engage with the pivot hole of the Top Cover 4 Close the Cartridge Cover am oe _ a me 4 HOH A LAT Figure 1 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 DATA Service Manual OKIJET 2500 OKI da la Chapter 4 Repair Adjustment Procedures REP 1 3 Top Cover Parts List on PL 1 1 Removal CAUTION Store the Printhead in the Storage Box Leaving the cartridge removed for long periods of time will cause the ink nozzles to dry out Image quality defects or a blank page could result If necessary prime the printhead after reinstallation REP 1 0 1 Remove the Printhead REP 1 0 Store the Printhead in the Storage Box WARNING Switch off the power Disconnect the power cord from the wall outlet 2 Remove the Output Tray PL 1 1 3 Remove the Paper Tray Assembly REP 1 1 4 Remove the Cartridge Cover REP 1 2 5 Lay the printer on it s back release the three front latch tabs Figur
28. ersonnel to an operating or maintenance procedure practice or condition that if not strictly observed could result in damage to or destruction of equipment Copyright 1997 Okidata Division of OKI America Inc All rights reserved See the OKIDATA Business Partner Exchange BPX for any updates to this material http bpx okidata com Page 15 OKIDATA a iia Signal Nomenclature The signal is named to imply the condition of the machine when the signal is available For example DOCUMENT JAM SENSED L 12 VDC ee vg mhen the signal is Hi Logic state when the signal is available in its named state In this case the signal is LOW when a document jam is sensed Copyright 1997 Okidata Division of OKI America Inc All rights reserved See the OKIDATA Business Partner Exchange BPX for any updates to this material http bpx okidata com Page 16 OKIDATA a ia DC Voltage Levels DC voltages should be measured between the test point and machine GND unless instructed otherwise The table below shows the values of the voltages Nominal Voltage ogic State Actual Voltage Ranges 4 8 to 5 2 VDC 0 0 to 1 0 VDC 39 0 to 44 0 VDC 0 0 to 3 0 VDC Copyright 1997 Okidata Division of OKI America Inc All rights reserved See the OKIDATA Business Partner Exchange BPX for any updates to this material http bpx okidata com Page 17 OKIDATA a ia Switches and Relay Contacts OF Safet
29. eted at the end of every repair call to ensure that the printer is operating properly Copyright 1997 Okidata Division of OKI America Inc All rights reserved See the OKIDATA Business Partner Exchange BPX for any updates to this material http opx okidata com Page 20 OKIDATA Service Manual OKIJET 2500 X Chapter 1 Service Call Procedures Printer Maintenance Introduction When the printer is being serviced the following maintenance procedure should be performed Procedure Clean the following parts every time the printer is serviced Description Cover Clean using a Lint Free Tissue and water Paper Feed Roller Clean using a Lint Free Tissue and water Paper Feed Pinch rollers and Paper Feed Guide Clean using a Lint Free Tissue and water Maintenance Station Clean using a Lint Free Tissue and water Copyright 1997 Okidata Division of OKI America Inc All rights reserved See the OKIDATA Business Partner Exchange BPX for any updates to this material http bpx okidata com Page 21 OKIDATA Service Manual OKIJET 2500 wr Chapter 1 Service Call Procedures Initial Actions 1 QUESTION THE OPERATOR 2 VERIFY CLASSIFY AND REPAIR THE PROBLEM STATUS INDICATOR PRINT QUALITY OTHER FAULTS ERROR LED ON IMAGE QUALITY PROBLEMS DEAD MACHINE Geo to Error LED On RAP Go to 12 1 Image Defect Entry RAP Go to 1 1 Power On RAP i Saction 3 LOW INK LED s ON SELECTION INDICATION Go to Low Ink LED
30. her side of frame to ensure tube exits onto Waste Ink Pad 5 Reinstall the following a Paper Feed Carriage Assembly REP 1 5 b Top Cover REP 1 3 c Cartridge Cover REP 1 2 d Paper Tray Assembly REP 1 1 e Output Tray PL 1 1 f Printhead REP 1 0 inlet tube anneta Figure 1 meuning _ screw mounting Screw wiri A LAT Figure 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 bpx okidata com Page 45 DATA Service Manual OKIJET 2500 OKI in le Chapter 4 Repair Adjustment Procedures REP 1 10 Maintenance Station Parts List on PL 2 1 Removal CAUTION Store the Printhead in the Storage Box Leaving the Printhead removed for long periods of time will cause the ink nozzles to dry out Image quality problems or a blank page could result If necessary prime the printhead after reinstallation REP 1 0 1 Remove the Printhead REP 1 0 Store the Printhead in the Storage Box WARNING Switch off the power Disconnect the power cord at the wall outlet 2 Remove the following a Output Tray PL 1 1 b Paper Tray Assembly REP 1 1 c Cartridge Cover REP 1 2 d Top Cover REP 1 3 3 Observe the routing of the tube from the Maintenance Station to the connector located below the Maintenance Station Disconnect this tube at the tube connector 4 Move the P
31. http bpx okidata com Page 6 OKIDATA a iia Section 2 REPAIR ANALYSIS PROCEDURES RAPs This section contains the Repair Analysis Procedures RAPs necessary to repair faults When using a RAP always exit the procedure when the fault is fixed Do not perform the remaining steps Copyright 1997 Okidata Division of OKI America Inc All rights reserved See the OKIDATA Business Partner Exchange BPX for any updates to this material http bpx okidata com Page 7 OKIDATA a ia Section 3 IMAGE QUALITY REPAIR ANALYSIS PROCEDURES RAPs This section contains the Repair Analysis Procedures RAPs necessary to repair print quality faults The first RAP IQ 1 Image Defect Entry RAP is used to classify a print quality problem and will reference the RAP to be used to repair the problem When using a RAP exit the procedure when the fault is fixed Do not perform the remaining steps Copyright 1997 Okidata Division of OKI America Inc All rights reserved See the OKIDATA Business Partner Exchange BPX for any updates to this material http opx okidata com Page 8 OKIDATA a iia Section 4 REPAIR ADJUSTMENT PROCEDURES This section contains the repair and adjustment procedures for the printer Copyright 1997 Okidata Division of OKI America Inc All rights reserved See the OKIDATA Business Partner Exchange BPX for any updates to this material http bpx okidata com Page 9 OKIDATA sean
32. idata com Page 23 D AT A Service Manual OKIJET 2500 OKI Chapter 2 Repair Analysis Procedures RAPs Error LED On RAP Initial Action Ensure a color printhead is installed Remove the power cord from the printer for 10 seconds then reinstall it Press the Power switch The Error LED is on steady Y N The Error LED is flashing Y N Press and hold the Resume FF button for 2 seconds to print the demo print The Error LED is steady Y N The Error LED is flashing Y N Check the interface cable and connectors for an open wire or bad connection If OK replace the Main Control Board Go to Error LED Flashing RAP Remove the power cord from the printer for 10 seconds then reinstall it Press and hold the Power switch for about 2 seconds The carriage was noisy Y N The printhead stopped at each ink cartridge during the power on cycle Y N Go to 6 2 Encoder RAP A B C D I Go to 8 1 Paper Feed RAP Go to 6 1 Carriage RAP Go to Error LED Flashing RAP One or more low ink LED s are blinking Y N Go to 6 1 Carriage RAP Go to Low Ink LED s on RAP Copyright 1997 Okidata Division of OKI America Inc All rights reserved See the OKIDATA Business Partner Exchange BPX for any updates to this material http bpx okidata com Page 24 Service Manual OKIJET 2500 ie OKIDATA Chapter 2 Repair Analysis Procedures RAPs Power LED Blinking RAP Remove the power cord from the printer for 10 s
33. ink supply may Press and hold the Cartridge Change be nearly empty Clean button for 2 seconds to clean and The Printhead restore the Printhead nozzles may be Runa Test Print If the print is still faint blocked repeat the process up to 2 more times If the problem is still not corrected replace the Printhead Blurry or jagged vertical Printhead Perform ADJ 2 0 Printhead Alignment lines Alignment Procedure If the problem still exists switch the printer to the High Quality print mode in the printer driver side Print image is clipped or e Print off edge of Ensure that the Print Driver setup has the off edge of media media correct selection of media size and type e Document margins Adjust margins in the application as necessary may exceed printer margins 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 DATA Service Manual OKIJET 2500 OKI in le Chapter 4 Repair Adjustment Procedures REP 1 0 Printhead Parts List on PL 2 2 Removal 1 Open the Cartridge Cover PL 1 1 2 Center the carriage using either of the following procedures e Press the Cartridge Change Clean button WARNING Switch off the power Disconnect the power cord from the wall outlet e Grasp and manually move the belt PL 2 1 in order to center the Printhead Figure 1 CAUTION Store the Pri
34. nce when removing carriage end cams from printer side frames CAUTION Ensure no portion of carriage is beneath ink level sensor during carriage removal Simultaneously slide both cams from their respective slots Figure 2 Ink level sensor 4071 A4 LAT Figure 2 CAUTION Take care not to damage ribbon cable while removing the carriage 6 Remove the carriage from printer side frames Figure 2 7 Position the Paper Feed Carriage Assembly as shown in Figure 3 8 Disconnect the Encoder connector J4 from the Relay BOARD Figure 3 Encoder 04071 71354 LAT Figure 3 NOTE Observe Encoder harness routing before removing Encoder 9 Release the Encoder harness from the carriage tabs 10 Return the Paper Feed Carriage Assembly to its upright position 11 Remove the screw and ground strap Figure 4 ground strap Encoder plate mounting 4011 ALAT Figure 4 12 Remove the two Encoder plate mounting screws remove the Encoder plate and Encoder Figure 4 13 Disconnect harness from Encoder 14 Remove the screw securing Encoder to Encoder plate remove Encoder retain spring Replacement 1 Position and hold the spring on the plate install Encoder on the plate reinstall the screw securing Encoder to the plate but DO NOT tighten 2 Route the Encoder harness through Paper Feed Carriage Assembly 3 Reinstall Encoder on Paper Feed Carriage Assembly install two mounting screws and the ground s
35. nly used graphic symbols are included in order to aid in troubleshooting when using the RAPs Interrupt Horizontal Signal i This indicates the continuation of a signal line which is interrupted in a horizontal direction Standby Power Input L This indicates the continuation of a standby power line which is interrupted in the vertical direction 4 YOC Left to Right Flow This indicates the direction of signal flow Feedback ae This indicates a feedback signal Flag E gt This is used to identify an area of a Circuit Diagram that you should check Ground Al This indicates a machine ground LED Phototransistor Sensor Oe This type of sensor is used in the paper path It uses reflected light to switch the sensor off and on Without Tag Change This signal indicates that the area the triangle points to has not been modified by the tag number in the circle This symbol indicates that the entire page has not been modified by the tag number in the circle With Tag Change O This symbol indicates that the area the triangle points to has been modified by the tag number in the circle This symbol indicates that the entire page has been modified by the tag number in the circle WARNING A warning is used to alert the personnel to an operating or maintenance procedure A N practice or condition that if not strictly observed could result in injury or loss of life CAUTION A caution is used to alert the p
36. nthead in the Storage Box Leaving the Printhead removed for long periods of time will cause the ink nozzles to dry out Image quality defects or a blank page could result If necessary prime the printhead after reinstallation See below to Refer to the Replacement Priming section of this procedure 3 Move the Printhead lock lever toward the front of the printer 4 Lift and remove the Printhead Store it in the Storage Box Replacement Priming 1 Install the Printhead onto the Printhead vertical guide 2 Move the Printhead lock lever toward the rear of the printer 3 Close the Cartridge Cover 4 Press the Resume FF button to prime the Printhead NOTE The optional high capacity printhead is shown Refer to the User s Documentation for illustrations of the standard printhead Cartridge Change Clean Printhead Resume FF lock lever C401 A LAT Figure 1 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 36 DATA Service Manual OKIJET 2500 OKI im la Chapter 4 Repair Adjustment Procedures REP 1 1 Paper Tray Assembly Parts List on PL 1 1 Removal 1 Remove the Output Tray PL 1 1 2 Press the two handles toward the rear of the printer to release the latches Figure 1 3 Pivot the Paper Tray Assembly toward the back of the printer to disengage the three tabs at
37. ntrol Board Parts List on PL 1 1 Removal CAUTION Store the Printhead in the Storage Box Leaving the Printhead removed for long periods of time will cause the ink nozzles to dry out Image quality defects or a blank page could result If necessary prime the printhead after reinstallation REP 1 0 1 Remove the Printhead REP 1 0 Store the cartridge in the Storage Box WARNING Switch off the power Disconnect the power cord at the wall outlet 2 Remove the Output Tray PL 1 1 3 Remove the Paper Tray Assembly REP 1 1 4 Remove the Cartridge Cover REP 1 2 5 Remove the Top Cover REP 1 3 6 Remove the Paper Feed Carriage Assembly REP 1 5 7 Remove the Power Supply REP 1 6 8 Disconnect Main Control Board connector CN2 from the Main Control Board Figure 1 NOTE The two screws securing the PC interface cable connector to the Main Control Board are longer than the others Ensure to replace them in their correct positions 9 Remove the eight mounting screws and ground wire Figure 1 NOTE It may be necessary to detach the ribbon cable and ferrite from the printer base before removing the Main Control Board NOTE Exercise care not to deform the two PC interface cable connector wire form locks during Main Control Board removal 10 Remove the Main Control Board Screws 3 O400071 A LAT Figure 1 Main Control Replacement NOTE There are 2 different length screws securing the Main Contr
38. ol Board Be sure to reinstall the two longer screws through the PC interface cable connector 1 Position the Main Control Board into the printer base 2 Reinstall the ground wire as per Figure 1 3 Reinstall mounting screws 4 Reconnect connector CN2 to the Main Control Board 5 If previously detached reattach the ribbon cable and ferrite to the printer base 6 Replace the following a Power Supply REP 1 6 b Paper Feed Carriage Assembly REP 1 5 c Top Cover REP 1 3 d Cartridge Cover REP 1 2 e Paper Tray Assembly REP 1 1 f Output Tray PL 1 1 g Printhead REP 1 0 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 43 DATA Service Manual OKIJET 2500 OKI in la Chapter 4 Repair Adjustment Procedures REP 1 8 Waste Ink Pad Parts List on PL 1 1 Replacement NOTE There are 2 different length screws securing the Main Control Board Be sure to reinstall the two longer screws through the PC interface cable connector J 2 e Position the Main Control Board into the printer base Reinstall the ground wire as per Figure 1 Reinstall mounting screws Reconnect connector CN2 to the Main Control Board If previously detached reattach the ribbon cable and ferrite to the printer base Replace the following Power Supply REP 1 6
39. orm the IQ 1 Image Defect Entry RAP to classify the print quality problem You will then be directed to the proper RAP to begin your troubleshooting From these RAPs you may be referenced to other sections of the manual to make checks adjustments or to replace parts When you have made a repair return to the System Checkout Final Action to complete the call Copyright 1997 Okidata Division of OKI America Inc All rights reserved See the OKIDATA Business Partner Exchange BPX for any updates to this material http bpx okidata com Page 13 OKIDATA ia Reference Symbology Notes adjustments and parts lists support the checklists and the RAP information The symbols that refer to this supportive data are shown below Note T This symbol is used to refer to notes found on the same page Adjustments wa ADJ 4 1 This symbol refers to an adjustment procedure located in Section 4 of this Service Manual The number adjacent to the symbol indicates the number that is assigned to that adjustment Parts List PL 10 6 Refers to the parts list located in Section 5 of this Service Manual The number after the PL designation indicates the number that is assigned to that part Copyright 1997 Okidata Division of OKI America Inc All rights reserved See the OKIDATA Business Partner Exchange BPX for any updates to this material http bpx okidata com Page 14 OKIDATA ai iiaa Special Symbols Descriptions of all commo
40. rinthead carriage to the extreme right side of the printer 5 Remove the mounting screw Figure 1 6 Lift and hold the left side of the paper pressure baffle approximately six millimeters away from the Maintenance Station NOTE Observe the tube routing during Maintenance Station removal 7 Slide the Maintenance Station toward the front of the printer to disengage the mounting tabs then lift upward to remove Maintenance Station from the printer mounting a l r Sscraw I i SAN a a g paper K 5 pressure battle MWainieananns Station O40 LOLA LAT Figure 7 Replacement CAUTION Ensure the Printhead carriage is positioned to the extreme right side of the printer 1 2 Route the Maintenance Station tube as observed during removal Lift and hold the left side of the paper pressure baffle approximately six millimeters away from the Maintenance Station 3 4 Lower the Maintenance Station into position to insert the mounting tabs Slide the Maintenance Station toward the rear of the printer to engage the mounting tabs Secure with mounting screw machine threads Connect tube to its mating connector Ensure tube is routed between the pinch arm and the Maintenance Station body Figure 2 Reinstall the following Top Cover REP 1 3 Cartridge Cover REP 1 2 Paper Tray Assembly REP 1 1 Output Tray PL 1 1 Printhead REP 1 0 tubs pinch arm Figure 2 1 VO
41. s On AAP PROBLEM Go to 2 1 Selection lndication HAP POWER LED BLINKING Go to Power LED Blinking RAP ALL OTHER PROBLEMS Go to Section 2 contents NO LEDs ON Go to the 1 1 Power On RAP Copyright 1997 Okidata Division of OKI America Inc All rights reserved See the OKIDATA Business Partner Exchange BPX for any updates to this material http opx okidata com Page 22 i Service Manual OKIJET 2500 OKIDATA Chapter 1 Service Call Procedures System Checkout Final Action Reset the Ink Level Sensing count to zero Perform the following e Install a Color Printhead with empty ink cartridges e Runa Test Print e Remove the Printhead and install a Color Printhead with full ink cartridges e Runa Test Print e The NVM counts are now set to zero Print a file The Printer prints the selected file Y N Refer to Initial Action System Checks to begin your repair Evaluate the print Is the image quality acceptable Y N Go to the image quality RAP identified by the IQ 1 Image Defect Entry RAP Section 3 Print and check the Printing Alignment Test pattern The alignment is good Y N Goto the Printhead Alignment Procedure Section Four Clean exterior of machine Use a lint free tissue and water Provide a sample of the Test Print Copyright 1997 Okidata Division of OKI America Inc All rights reserved See the OKIDATA Business Partner Exchange BPX for any updates to this material http bpx ok
42. stry Company Ltd marques deposee de Oki Electric Industry Company Ltd marca registrada Oki Electric Industry Company Ltd XEROX is a trademark of Xerox Corporation Notice All service documentation is supplied for informational purposes only Okidata service documentation is intended for use by certified product trained service personnel only Okidata does not warrant or represent that such documentation is complete nor does Okidata represent or warrant that it will notify or provide to such customer any future changes to this documentation Customer performed service of equipment or modules components or parts of such equipment may affect the warranty offered by Okidata with respect to such equipment You should consult the applicable warranty for its terms regarding customer or third party provided service If the customer services such equipment modules components or parts thereof the customer releases Okidata from any and all liability for the customer actions and the customer agrees to indemnify defend and hold Okidata harmless from any third party claims which arise directly or indirectly from such service Copyright 1997 Okidata Division of OKI America Inc All rights reserved See the OKIDATA Business Partner Exchange BPX for any updates to this material http opx okidata com Page 3 OKIDATA ia About This Manual This manual contains Repair Analysis Procedures Repair Procedures Adjustment Procedures P
43. t from the Encoder pulley left end 5 Rotate the carriage shaft cams so that their flats are aligned with the sides of the slot on each side frame Figure 1 side frame V cari 040115 144LaT Figure 1 NOTE Expect moderate to heavy resistance when removing carriage from printer side frames CAUTION Ensure no portion of carriage is beneath Ink Level Sensor during carriage removal During removal replacement it is necessary to simultaneously slide both cams from to their respective slots A ribbon cable is attached to the carriage board Do not damage the jack or connector lock while removing Carriage Figure 2 camage Ink Level Sensor 6 Remove the carriage from the Paper Feed Carriage Assembly 7 Remove the carriage shaft from carriage 8 Position the carriage upside down Figure 3 connector Da SS ALAT Figure 3 9 Slide the lock to the unlocked position 10 Disconnect the ribbon cable from the carriage board 11 Slide the ribbon cable from the carriage cable restraint 12 Note the installed position of the ribbon cable on the Paper Feed Carriage Assembly in the area shown in Figure 4c 13 Release the cable from the two cable edge restraints 14 Slide the cable to the left through the 45 slot then pull the cable upward and out through the slotted opening
44. the bottom of the Paper Tray Assembly from the tabs on the Paper Feed Carriage Assembly 4 Lift the Paper Assembly from the printer WNEI TREFI 11A LA Figure 1 Replacement 1 Retract the moveable face of the Paper Tray Assembly by pressing it toward the back of the Paper Tray Assembly 2 Insert the Paper Tray Assembly into the printer with bottom of tray touching the bottom of the tray opening on the printer ensuring the moveable face is behind the white cam near the bottom on the left See Figure 2 3 Engage the three tabs at the bottom of the Paper Tray Assembly with the tabs on the Paper Feed Carriage Assembly 4 Rotate the Paper Tray Assembly toward the front of the printer 5 Engage the two latches by gently pulling the handles downward and toward the front of the printer until the latches snap into position 6 Reinstall the Output Tray i Cam must be TH position d hara h me Figure 2 la 04001 12A LAT 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 37 DATA Service Manual OKIJET 2500 OKI s Chapter 4 Repair Adjustment Procedures REP 1 2 Cartridge Cover Parts List on PL 1 1 Removal 1 Open the Cartridge Cover PL 1 1 2 Utilizing a screwdriver or similar tool slightly separate the Cartridge Cover and Top Cover at
45. trap 4 Reconnect Encoder harness J4 to Relay Board secure harness to carriage tabs Caution It is physically possible to cross connect the Encoder Harness J4 and the Low ink Sensor J2 on the Relay Board since they use the same type of connector By doing so the Main Logic Board may be damaged 5 Reinstall Maintenance Station reinstall the machine screw 6 Reconnect Maintenance Station tube 7 Ensure tube is properly located behind the pinch arm Consult Maintenance Station Replacement REP 1 10 8 Reinstall carriage into Paper Feed Carriage Assembly Ensure carriage ribbon cable is properly secured and not twisted 9 Rotate both carriage shaft cams to align pointer with index mark Figure 5 C4117 54 LAT Figure 5 10 Reinstall carriage belt onto Encoder pulley left side 11 Reinstall carriage belt onto drive motor pulley 12 Tighten screw that secures Encoder to the plate 13 Ensure both ground straps left and right side are firmly contacting the carriage shaft Reform straps as required 14 Reinstall the following a Paper Feed Carriage Assembly REP 1 5 b Top Cover REP 1 3 c Cartridge Cover REP 1 2 d Paper Tray Assembly REP 1 1 e Output Tray PL 1 1 f Printhead REP 1 0 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 DAT
46. y interlock switch that is open Safety interlock switch that is closed E n Switch or relay contacts with momentary contacts shown normally open aa Switch or relay contacts with momentary contacts shown normally closed Copyright 1997 Okidata Division of OKI America Inc All rights reserved See the OKIDATA Business Partner Exchange BPX for any updates to this material http opx okidata com Page 18 OKIDATA ae Back Cover OKI OKIJET 2500 Service Manual P N 59228801 Printed in the U S A Copyright 1997 Okidata Division of OKI America Inc All rights reserved See the OKIDATA Business Partner Exchange BPX for any updates to this material http bpx okidata com Page 19 OKIDATA Service Manual OKIJET 2500 X Chapter 1 Service Call Procedures Introduction Use the Service Call Procedures as a maintenance guide when performing any service on the printer e Printer Maintenance This section contains a list of the printer subsystem components to be cleaned and or lubricated and the cleaning and lubricating materials to be used when that subsystem is accessed during a repair e Initial Actions System Checks This diagram identifies and classifies the printer problem and refers you to the appropriate RAP in order to repair the problem When the problem has been repaired perform the System Checkout Final Action e System Checkout Final Action This procedure should be compl
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