Oki PACEMARK 4410 User manual

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1
PACEMARK 4410
PRINTER
Service Manual

2 /
PREFACE
This maintenance manual describes how to maintain the Pacemark 4410 printer
in the field.
This manual is for customer engineers.
For further information, refer to the Users Manual for handling or operating the equipment.

3 /
CONTENTS
1.CONFIGURATION.....................................................................................5
1.1Basic System Configuration...............................................................5
1.2Printer Specifications.........................................................................6
1.3Option Specifications.........................................................................7
1.4Basic Specifications...........................................................................8
2.THEORY OF OPERATION........................................................................11
2.1Electrical Operation...........................................................................11
2.1.1 Summary.................................................................................................11
2.1.2 Microprocessor and the peripheral circuit...............................................11
2.1.3 Initialization..............................................................................................20
2.1.4 Interface control.......................................................................................21
2.1.5 Parallel Interface Control.........................................................................21
2.1.6 Serial Interface........................................................................................22
2.1.7 Printing operation....................................................................................23
2.1.8 Printhead control.....................................................................................24
2.1.9 Print Compensation Control....................................................................26
2.1.10 Space motor control................................................................................26
2.1.11 Line feed.................................................................................................. 27
2.1.12 Bail, tractor switching, AG, ribbon motor control.....................................28
2.1.13 Operation Panel......................................................................................29
2.1.14 Alarm circuits...........................................................................................31
2.1.15 Power supply circuit................................................................................33
2.2Mechanical Operation........................................................................34
2.2.1 Printhead mechanism and operation.......................................................34
2.2.2 Spacing operation...................................................................................36
2.2.3 Head gap adjusting.................................................................................37
2.2.4 Ribbon drive............................................................................................40
2.2.5 Paper Feed Mechanism..........................................................................41
2.2.6 Bail Feed Mechanism..............................................................................45
2.2.7 Paper End Detection Mechanism............................................................47
3.PARTS REPLACEMENT...........................................................................49
3.1Precautions for Parts Replacement...................................................49
3.2Parts Layout.......................................................................................52
3.3How to Change Parts.........................................................................53
3.3.1 Cover-Assy-Access / Cover-Assy-Side (R) / Cover-Assy-Side (L)
/Cover-Assy-Front / Frame-Assy-Rear / Plate-Front (stuck)................54
3.3.2 Printer Unit..............................................................................................55
3.3.3 Control Block [Control Board (PMA Printed Board),
Driver Board (PDA Printed Board)].......................................................56
3.3.4 Power Supply Assy.................................................................................57
3.3.5 PG Cooling Fan.......................................................................................58
3.3.6 I/F Board (PHA Printed Board)................................................................59
3.3.7 AG Board (PGA Printed Board) / Connector Cord..................................60
3.3.8 AG Motor Assy........................................................................................61
3.3.9 Mini Pitch Belt..........................................................................................62
3.3.10 Tractor Change Motor Assy....................................................................63
3.3.11 Bail Motor Assy.......................................................................................64
3.3.12 LF Motor Assy.........................................................................................65

4 /
3.3.13 Head Cooling Fan 1................................................................................66
3.3.14 Head Cooling Fan 2................................................................................67
3.3.15 Space Motor............................................................................................68
3.3.16 Operator Board (POA Printed Board)......................................................69
3.3.17 Ribbon Feed Assy...................................................................................70
3.3.18 Printing Head...........................................................................................71
3.3.19 Head Cable.............................................................................................72
3.3.20 Ribbon Protector.....................................................................................73
3.3.21 Space Motor Fan.....................................................................................74
3.3.22 Junction Board........................................................................................75
3.3.23 Cover Open Switch Assy / Ribbon Rotation Sensor...............................76
3.3.24 Interlock Switch / Interlock Switch Cord Assy.........................................77
3.3.25 Knob Bracket Assy..................................................................................78
3.3.26 Space Belt...............................................................................................79
3.3.27 AG Sensor Frame / Start Searching Sensor...........................................80
3.3.28 Paper Jam Sensor Assy / Bail PE Sensor Assy......................................81
3.3.29 Sprocket Assy (L) (R) (Front Tractor)......................................................82
3.3.30 Sheet Feeder Assy (L) Rear / Sheet Feeder Assy (R) Rear...................83
3.3.31 Bail Assy..................................................................................................86
4.ADJUSTMENTS........................................................................................87
5.CLEANIG AND LUBRICATION................................................................94
5.1Cleaning.............................................................................................94
5.2Lubrication.........................................................................................96
6.TROUBLESHOOTING AND REPAIR.......................................................104
6.1Items to Check Before Repair............................................................104
6.2Troubleshooting Table.......................................................................104
6.3Lamp and LCD Display......................................................................105
6.4Part Layout........................................................................................109
6.5Connection ........................................................................................111
7.PARTS LIST..............................................................................................112
APPENDIX A...................................................................................................XXX
APPENDIX B...................................................................................................XXX
APPENDIX.C...................................................................................................XXX

5
Ribbon
feed
motor
AG
motor
Power supply
FAN
FUSE holder
HEAD
FAN
Motor/Sensor PCB
Power supply unit
Paper width sensor
Print head
Bail PE sensor
Head driver PCB
Main control/
Motor driver PCB
Interface board
(Option)
Interface/Motor
/Sensor PCB
RS232C
I/F
IEEE 1284
I/F
Bail
motor
Tractor
change
motor
LF
motor
Head
FAN
Bail position SW
Tractor change SW
Front PE SW
Rear PE SW
Paper jam sensor
Paper top sensor
AG sensor coil
LCD
Operation panel PCB
AC source
SP
FAN
SP
motor
Cover open SW
Ribbon jam sensor
AG
sensor
PCB
Inter lock SW
1. CONFIGURATION
1.1 Basic System Configuration
The basic system configuration of Pacemark 4410 is illustrated in Figure 1.1.
Figure 1.1

6
1.2 Printer Specifications
This printer unit is composed with the following hardware.
•Printer mechanism
•Main control/Motor driver board
•Head driver board
•Interface/Motor/Sensor board (including IEEE 1284 bidirectional parallel interface and RS-
232C serial interface)
•Motor/Sensor and AG sensor boards
•Operation panel board
•Power supply unit
•Covers
Figure 1-2 show the printer unit configuration.
Figure 1.2

7
1.3 Option Specifications
Options available for the Pacemark 4410 are as follows.
(1) Interface boards
(a)Okilan 6100e Network card

8
1.4 Basic Specifications
(1) Dimensions
Width: 30.24inches (768mm) Length: 15.16inches (395mm) Height: 14.09inches (358mm)
(2) Weight
Approx. 92.6lbs (42kg)
(3) Form
Continuous Paper
One-part paper
Ream weight: 45 to 90g/m2(12 to 24 lb)
Multiple-part paper Max.0.79mm(0.031inches)total thickness(with front feed)
Max.0.36mm(0.014inches)total thickness(with rear feed)
Paper type Ream weight Number of sheet
Carbon-lined paper Ten sheet maximum including original
35 to 40 g/m2(with front feed)
Pressure-senstive (9 to 11 lbs) Six sheet maximum including original
paper (with rear feed)
Paper
35 to 52 g/m2Seven sheet maximum including original
Interleaf paper (9 to 14 lbs) (with front feed)
Carbon paper Four sheet maximum including original
34 g/m2(9 lbs) (with rear feed)
When 7p or more papers are used for the front tractor, "High Impact Copy" should be
selected in the menu mode to print these papers.
Continuous Envelope
Weight : Max. 90 g/m2(24lb)
Thickness : Max. 0.36mm (0.014 inch)
Width : 76.2 - 254mm (3 - 10 inches)
Media supply :Front paper feed only
Card Weight : Max. 375 g/m2(100lb)
Thickness : Max. 0.20mm (0.008 inch)
Size : 5 x 8 inches (separated)
Media supply :Front paper feed only
Label Thickness : Max 0.28mm (0.011 inch)
Size : Max. 381 x 83mm (15 x 3.25 inches)
Media supply :Front paper feed only
(4) Print speed
Print ModeCharacter Pitch
10 CPI 12 CPI 15 CPI 17.1 CPI 20 CPI
HSD 1066 CPS 1066 CPS 1066 CPS 1066 CPS 1066 CPS
NLQ 200 CPS 200 CPS 200 CPS 200 CPS 200 CPS
UTILITY 800 CPS 800 CPS 800 CPS 800 CPS 800 CPS

9
(5) Maximum Number of Dot Columns per Line
a)Graphics
Single Density Double Density Quadruple Density
816 1,632 3,264
b) Text
Print Mode Character Pitch (CP)
10 CPI 12 CPI 15 CPI 17.1 CPI20 CPI
ML, EPSON, IBM UTILITY 1,632 1,958 2,448 2,798 3,264
ML, EPSON, IBM NLQ 3,264 3,917 4,896 5,596 6,528
ML, EPSON, IBM HSD 1,224 1,468 1,836 2,098 2,448
(6) Maximun Number of Character per Line
Character Pitch (CPI) 567.5 8.5 10 12 15 17.1 20
ML EPSON IBM 68 81 102 116 136 163 204 233 272
(7) Printhead
Print method: Impact dot matrix
Number of dot wires: 9 wires x 2 rows
Dot wire diameter: 0.36mm(0.014inch)
(8) Line feed Speed
6 LPI spacing, one LF = 60 ms
8 LPI spacing, one LF = 52 ms
Continuous paper feed rate is 15 inches per second. (at head gap 1, 2)
(9) Line Feed Pitches
6 LPI 0.167 inch (4.23mm)
8 LPI 0.125 inch (3.175mm)
A variable line feed pitch of n/216 inch (integer n: 0 ≤n ≤255) can also be specified. Also,
7/72 inch and n/72 inch can be specified.
PROPRINTER n : 1 ≤n ≤255
EPSON n : 1 ≤n ≤255 (Cannot specify MSB : 1≤n ≤127)
(10)Power Requirements
a)Input power
Single-phase AC
Voltage : 120VAC +5.5%, -15%
230 VAC ±15%
Frequency :50/60Hz ±2%
b)Power consumption
Local Test :Max. 295 W (Rolling ASCII, Utility)
Idle : Max. 15W (Energy Star compliant)
c)AC power cable
Length : Approximately 5.9 It (1.8 m)
Cable conforms to the UL, CSA, and European Standards.
Note : AC power cable is not supplied.

10
(11)Ambient temperature and relative humidity
Operating Non-operating Storage Transportation Unit
Temperature 41 to 95 32 to 109.4 14 to 122 -40 to 158 °F
(5 to 35) (0 to 43) (-10 to 50) (-40 to 70) (°C)
Relative 20 to 80 10 to 90 5 to 95 5 to 95 %RH
Humidity
Avoid condensation at all times.
(12)Vibration
Operating : Max. 0.3G (5 to 150 Hz) (except at resonant frequency)
Non-operating : Max. 1G (5 to 150 Hz) (except at resonant frequency)
(13)Impact (Drop Test)
Packing : 12" Drop
(14)Noise
The 8-second average noise is Max. 55 dBA in quiet utility mode. (ISO 7779)
(15)Ribbon
Genuine OKI cartridge ribbon
Ink color : Black
Ribbon life : Approximately 15 million characters (Characters in Utility mode)
(16)Reliability
a)MTBF (mean time between failures)
12,000 hours of power-on time at 25% duty cycle and 35% page density.
b)Printhead life
400 million characters (average) in 10 CPI Utility print mode at 25% duty cycle and 35%
page density.
c)Printer life
12,000 hours of power-on time at 25% duty cycle and 35% page density, or 5 years.
d)MTTR
15 minutes, major Sub-assembly level.
Definition of terms
•Duty cycle : Actual operation rate
•Page density : the proportion in area of characters and spaces within print head
movable area.
•Power on Time : 8 hours/day, 25 days/month and 12 months/year.

11
2. THEORY OF OPERATION
2.1 Electrical Operation
The electrical operation of the printer circuit is described in this section.
2.1.1 Summary
Fig. 2-1 shows the block diagram of the printer.
Thecontrolboardismadeupofthemicroprocessors,peripheralcircuits,drivecircuits,sensorsand
interface connectors.
The power to the control board is supplied by the power board through the connector cord.
Thepowertootherelectricalpartsisalsodistributedthroughtheconnectorswithinthecontrolboard.
2.1.2 Microprocessor and the peripheral circuit
(1) Microprocessor (IC24: 80C186-16)
This processor is a CMOS single-chip computer with integrated peripheral device functions
and a 16 bit MPU core.
The processor has a 20 bit address bus and a 16 bit data bus.
It is capable of accessing up to 4M bit program memory and 4M bit of data memory.
The following characteristics are also provided:
•High-Speed DMA Channel x 2
•Programmable Interrupt Controller
•Programmable 16-bit Timer x 3
•Programmable Memory and Peripheral Chip-Select Logic
•Programmable Wait State Generator
•Local Bus Controller
And others.
The function of this microprocessor is to provide a central mechanism for the entire printer
by executing the control program through the LSI and driver circuits.

12
Figure 2.1
to ALM circuit
LF motor driver
Sub LSI #1 72V017 Sub LSI #2 72V017
AG motor driver
Sensor, SW DIP SW
Bail motor driver Paper path switching motor driver
to ALM circuit
to ALM circuit
to ALM circuit
to ALM circuit
ALM circuit
Head/ motor driver POWEROFF-P
SP motor
SP motor driver
FL ROM (8M)
+44V
Power Supply
Unit
CPU
80C186
32
MHz
+12V
Each part
+ 5V -12V 0V EP POWOFF-P POWDOWN-P AC DOWN-P POW ONRST-N POWALM-P
CG, ROM (4M) PRG, ROM (4M)
Slit sensor
IEEE1284
BUF
BUF
BUF
OPpanel
OPpanel LSI DRAM (4M)
RS232 LSI
D/R
EEPROM
LCD HEAD
Head driver
AG sensor
Ribbon motor driver
SRAM (1M)
NHDC LSI
2/2
NHDC LSI
1/2
Main LSI
BUF
MUPIS card (x1)
Extended slot <OPTION>
LAN
ML300's/ 500's OPTION RS232C, TWINAX, COAX, etc
to ALM circuit to ALM circuit
AG slit sensor
P/S FANP/S FAN DV.
HD FAN DV.1 HD FAN DV.2 SP FAN DV.
FAN ALM
HD FAN 1 HD FAN 2 SP FAN CB FAN
Continuous paper cutter (option)
Either of them
PM PM
PM
DC
PM PM
TFA. TFD.720S
ALE/ RD/ WR/ CS/ CLK AD0~AD15 A16~A19/ BHE

13
(2) PG ROM (IC46)
Thisisa256x16bits(4Mbit)EPROMwiththecontrolprogramfortheprinterstored.TheMPU
executes instructions under this program.
TheprogramROMisassignedtotheprogrammemoryareaoftheMPUandisfetchedbythe
RD signal of the MPU.
The following shows the operation of the memory access.
Figure 2.2
MPU CLOCK
ALE
A16~BHE
AD0~AD15
RD
CS
AD0~AD15
A16~BHE
MPU Main LSI CG ROM
NHDC LSI
A16-BHE
A0–A15 D0–D15
ALE
RD
WR
CS
CLK
BANK0
BANKS
CS
A17
A16
A0~A15
OE
CE
A1~A16

14
Figure 2.3
(3) DRAM(IC28)
TheRAMisCMOSdynamicRAMwith(256Kx16bit)configuration,andusedasbuffers(such
as receiving buffer, printing buffer, DLL buffer and working buffer).
The following shows the examples of the memory access operation.
MPU CLOCK
ALE
A16~BHE
AD0~AD15
RD
AD0~AD15
WR
CS
AD0~AD15
A16~BHE
DRAMD0~D15
DRAMA0~A9
MPU NHDC LSI DRAM
A16~BHE
A0–A15 D0–D15
A0–A15 D0–D15
ALE
RD
WR
CS
CLK
RAS
CASU
CASL
RD
WR

15
Figure 2.4
(4) CG ROM (IC48)
This is a 256K x 16 bits (4M bits) EPROM with the font data for the characters stored.
CGROMisassignedtotheprogrammemoryareaoftheMPUandisfetchedbytheRDsignal
of the MPU.
The following shows the memory access operation.
MPU CLOCK
ALE
A16~BHE
AD0~AD15
RD
CS
AD0~AD15
A16~BHE
MPU Main LSI CG ROM
NHDC LSI
A16-BHE
A0–A15 D0–D15
ALE
RD
WR
CS
CLK
BANK0
BANKS
CS
A17
A16
A0~A15
OE
CE
A1~A16

16
(5) EEPROM(IC40)
TheEEPROMisa CMOS serialI/Otypememorywhichiscapableofelectricallyerasing and
writing 1,024 bits.
The EEPROM contains menu data.
The following shows the memory access operation.
Figure 2.5
NHDC LSI EEPROM
EEPROMWR-P
EEPROMCS-P
EEPROMRD-P
EEPROMCLK-P
DI
CS
DO
SK
,
,
,
,
,
,
,























ReadyBus
twp
D0D15A0A5
110
Start
code Operation
code Address Data
t
CS
PRE = O
PE
Address
Start
code
Operation
code
EEPROMRD-P
EEPROMWR-P
EEPROMCLK-P
EEPROMCS-P
EEPROMRD-P
EEPROMWR-P
EEPROMCLK-P
EEPROMCS-P
D15 D0 D15 D0 D15
0
A0A5
0
11
t
CS
PRE = O
PE = X
Read cycle timing (READ)
Write cycle timing (WRITE)

17
(6) Main LSI (IC38: MSM91U036)
MSM91U036is controlLSIforheaddata, DCmotorandmodificationofprintdata,whichhas
the following functions.
(a) Head data control
Itdistributes print datastored in theDRAM over wirearrangements of theprint head and
outputs it as dot data in synchronism with print timing. In this time, the distribution
complies with each print mode which is specified by the MPU.
(b) Print timing control
It outputs the signals which control the print timing of ODD and EVEN pins on the print
head.
(c) Space motor speed control function
It controls the space motor with micro-programs to accelerate/decelerate it.
This LSI also controls the speed of the space motor in agreement with each print mode.
(d) I/O port
This printer has 8-bit output port which is used for controlling the SRAM.
(e) Head position count
It counts the outputs from slit sensors (SPPHASE A, B) located on the space motor to
keep monitoring the current position of the print head.
(f) Print data modifying function
It modifies the print data stored in the DRAM with command inputs from the MPU.
(g) DMA control function
It outputs a DMA request to the MPU, simultaneously controlling the DMA.
This LSI is connected in multiplex to the MPU.

18
Figure 2.6
MPU CLOCK
ALE
A16~BHE
AD0~AD15
RD
AD0~AD15
WR
CS
AD0~AD15
A16~BHE
MPU Main LSI
A16~BHE
A0–A15 D0–D15
A0–A15 D0–D15
ALE
RD
WR
CS
CLK

19
(7) NHDC LSI(IC27: TC190G08CF-7036)
This LSI controls timer, interruption, memories, printing, external interface, motor drive
interface.
(a) Timer control
It controls the watchdog timer for detecting any out-of-control program, baud rate
generator for setting the baud rate of the serial interface, and pulse generation timer for
AG plus count.
(b) Interruption control
It controls LSI inside interruptions, external interruptions and interruptions from an
external interface as outputs for the MPU.
(c)Memory control
DRAMand SRAM control, chip selectoutput control of ROM, flashmemory and MUPIS,
and bank switch control for expanding their memory spaces.
(d)Print control
It creates a print timing corresponding to the print DPI to control the position and print
correction for pins.
ThisalsocontrolstheprintMaskandDMACwhich readsprintdatafromthememoryand
transmits it to the print output buffer.
(e)External interface
It controls various interfaces for main LSI, IEEE1284, serial, MUPIS, OpePaneLSI,
EEPROM.
(f)Motor drive interface
Each control of OVDV pulse generation for AG motor, generation of pulse for switching
ribbon motor phase, and OVDV pulse generation for LF motor.
(8) Sub LSI (IC17, IC18: MSM72V017)
This LSI is the I/O port LSI which controls the input/output of various controlling signals with
command inputs from the MPU.
(a)Sub LSI #1 (IC17: MSM72V017)
Input/output control for controlling signals to various sensors, FAN controlling signals,
sensor slice level controlling signals, AG motor controlling signals, and LF motor
controlling signals.
(b)Sub LSI #2 (IC18: MSM72V017)
Input/output control for controlling signals to various sensors, SP motor current control-
lingsignals,externalinterfacecontrollingsignals,TRmotorcontrollingsignals,bailmotor
controlling signals, cutter motor (for optional connection) controlling signals.
(9) Serial I/F LSI (IC35: 85L30)
ThisLSIistheserialI/FLSIwhichcontrolstheinput/outputofserialI/Fcontrollingsignalswith
command inputs from the MPU.