OKIDATA OL400e Series User manual

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Page: 1
Service Manual for OL400e/OL410e/OL410e-PS
Chapter 0A Introduction
OL400e / OL410e / OL410e-PS Series
LED Page Printers
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://bpx.okidata.com)

Table of Contents Page
Service Manual for OL400e/OL410e/OL410e-PS
0A Introduction
Front Cover 1
Overview 2
Recommendations 3
Information Updates 4
Notices 5
Where To Send Testing Materials 6
Missing Items Or Missing Pages 7
Course Path 8
Service Training Requirements 9
....General Description 10
....Installation 11
....Principles Of Operation 12
....Failure Analysis 13
....Appendices A And B 14
....Maintenance 15
........Disassembly / Assembly 16
........Adjustments And Service Checks 17
........Cleaning 18
........Lubrication 19
........Shipping Instructions 20
Service Authorization 21
....Certification Test 22
....Course Critique 23
1 Product Specifications
1.1 General Description 24
1.2 Product Specifications 25
1.3 Paper Specifications 26
1.4 Physical Specifications 27
1.5 Power Requirements 28
1.6 Environmental Conditions 29
1.7 Agency Approvals 30
1.8 Options 31
1.9 Consumables 32
1.10 Memory Specifications 33
1.11 Reliability Specifications 34
2 Principles of Operation
2.1 Printer Overview 35
2.2 Control Process 36
....2.2.02 Block Diagrams 400E 37
....2.2.02 Block Diagrams 410E 38
....2.2.02 Block Diagrams 410E/PS 39

Table of Contents Page
2.2.03 Main Controller Board (OLCW) Overview 40
....Main Controller Board Functions 41
........Reception Control 42
........Command Analysis Processing 43
........Font Processing 44
........Main Controller Board Buffer Read Operation 45
........Engine Control Functions 46
............Operation Panel Control 47
............Operation Panel Functions 48
........Sensor Control & Location Diagrams 49
............Inlet Sensor 1 50
............Inlet Sensor 2 51
............Inlet Sensor 3 / Paper Sensor 52
............Outlet Sensor 53
............Paper Supply Sensor 54
............Toner Sensor 55
........Print Operation 56
2.2.04 Expanded Ram Board(410E Only) 57
2.2.05 Expansion Ram Board(400E) 58
2.2.06 Expansion Ram Board(410E) 59
2.2.07 Font Cards 60
2.2.08 Postscript Board 61
2.3.01 Basic Principals - Electrostatic Printing 62
....2.3.02 Engine Functions 63
....2.3.03 Eeprom Operation 64
....2.3.04 Power Supply Board 65
....2.3.05 Fusing Unit 66
....2.3.06 Registration Motor 67
....2.3.07 Drum Motor 68
....2.3.08 LED Head 69
2.4 Printing Process General Information 70
....2.4.02 Hopping 71
....2.4.03 Feeding 72
....2.4.04 Charging 73
....2.4.05 Exposing 74
....2.4.06 Developing 75
....2.4.07 Transfer 76
....2.4.08 Fusing 77
....2.4.09 Cleaning 78
....2.4.10 Printing 79
2.5 Sensors And Switches 80
....Sensor Location Diagram 81
....2.5.01 Paper Jam Detection 82
........Paper Inlet Jam 83

Table of Contents Page
........Paper Feed Jam 84
....2.5.02 Toner Low Sensor 85
....2.5.03 Paper Path 86
3 Maintenance & Disassembly
....3.1.01 Maintenance General Information 87
....3.1.02 Maintenance Items 88
....3.1.03 Maintenance Precautions 89
3.2 Disassembly/Assembly Procedures 90
....3.2.01 Preliminary Items 91
....3.2.02 Upper Cover Assembly 92
........Upper Cover Assembly Re-Installation 93
....3.2.03 Font Card Cover 94
....3.2.04 Face-Up Stacker Assembly 95
....3.2.05 Bias Springs And Exit Rollers 96
....3.2.06 Operator Panel Assembly 97
....3.2.07 LED Head Unit 98
....3.2.08 Eject Roller Assembly 99
....3.2.09 Main Stepper Motor 100
....3.2.10 Registration Stepper Motor 101
....3.2.11 Lower Base Unit 102
....3.2.12 Motor Assembly 103
....3.2.13 Hopping Roller Shaft Assembly 104
....3.2.14 Face-Down Stacker Assembly 105
....3.2.15 Registration Roller 106
....3.2.16 Transfer Roller 107
....3.2.17 Fusing Unit Assembly 108
....3.2.18 Pressure Roller 109
....3.2.19 Inlet Sensor Plate 110
....3.2.20 Toner Sensor Plate 111
....3.2.21 Outlet Sensor Plate 112
....3.2.22 Manual Feed Guide Assembly 113
....3.2.23 Paper Supply Sensor Plate 114
....3.2.24 Main Controller Board 115
........Main Controller Board Re-Installation 116
....3.2.25 Power Supply 117
....3.2.26 Transformer 118
....3.2.27 Cassette Guide (Left) 119
....3.2.28 Cassette Guide (Right) 120
....3.2.29 Base Plate 121
....3.2.30 Multi-Purpose Feeder Unit - Link 122
....3.2.31 Multi-Purpose Feeder Unit - Separator 123
....3.2.32 Multi-Purpose Feeder Unit - Board (OLEV) 124
....3.2.33 Multi-Purpose Feeder Unit - Stepping Motor 125
....3.2.34 Multi-Purpose Feeder Unit - Planet Gear 126

Table of Contents Page
....3.2.35 Multi-Purpose Feeder Unit - Rollers A And B 127
....3.2.36 Second Paper Feed Unit - Hopping Stepper Motor 128
....3.2.37 Second Paper Feed Unit - Board (OLEV) 129
....3.2.38 Second Paper Feed Unit - Hopping Roller Shaft 130
3.3 Adjustments And Service Settings 131
....3.3.01 User's Maintenance Mode 132
........Menu Reset / Menu Print 133
............Menu Settings - Level 1 134
............Menu Settings - Level 2 135
............Sample Menu - OL400E 136
............Sample Menu - OL410E 137
............Sample Menu - OL410E/PS 138
........Hex Dump 139
........Drum Counter Reset 140
........Operator Panel Menu Enable / Disable 141
........X Adjust 142
........Y Adjust 143
....3.3.02 System Maintenance Mode 144
........Page Count 145
........Page Count Printing Enable / Disable 146
........Continuous Print Test 147
........Serial Interface Loop Test 148
........EEPROM Reset (Printer Initializes) 149
........EEPROM Reset (Printer Does Not Initialize) 150
....3.3.03 Engine Maintenance Mode 151
........LED Head Drive Time 152
........Print Start Position 153
........Drum Count Total Display 154
........Drum Count 155
........T2 Tbl 1 156
........T2 Tbl 2 157
........EF Tbl 1 158
........EF Tbl 2 159
........Engine Reset 160
3.4 Cleaning General Information 161
....3.4.02 Printer Unit 162
....3.4.03 Covers 163
....3.4.04 LED Head Unit 164
....3.4.05 Cleaning Cycle Initialization 165
3.5 Lubrication General Information 166
3.6 Shipping Instructions - Return For Service 167
....3.6.02 All Other Returns 168
4 Failure & Repair Analysis
4.1.01 Troubleshooting Steps 169

Table of Contents Page
4.2 Reporting Problems - General Information 170
4.3 Troubleshooting Updates 171
4.4 Troubleshooting Tips - Preliminary Checks 172
....4.4.02 Tips For Preventing Image Problems 173
....4.4.03 Common Problems 174
....4.4.04 Audible Roller Noises 175
....4.4.05 Audible Noise / Input Jams From Paper Cassette 176
....4.4.06 Pinch Roller Clip Problems 177
....4.4.07 Paper Jams Under The Fuser Roller 178
....4.4.08 Dirty LED 179
4.5 Abnormal Output - Output Samples & Repair Procedures 180
4.6 Error Messages - Using The Error Message Charts 181
....Front Panel Messages: Normal Daily Status 182
....Front Panel Messages: Paper, Cover Open, Buffer Overflow 183
....Front Panel Messages: Buffer Overflow, Interface, Paper
Size 184
....Front Panel Messages: Jam, Cover Open, EEPROM, ROM,
Card 185
....Front Panel Messages: Controller Errors 186
....Front Panel Messages: Additional OL410E-PS 187
4.7 Repair Analysis Procedures (RAPS) - Index 188
....RAP 01: Printer Does Not Initialize 189
....RAP 02: Paper Input Jam 190
....RAP 03: Paper Feed Jam 191
....RAP 04: Paper Exit Jam 192
....RAP 05: Paper Size Error 193
....RAP 06: Fusing Unit Error (Error 71) 194
....RAP 07: Fan Error (Error 70) 195
....RAP 08: Light Or Blurred Output 196
....RAP 09: Dark Background 197
....RAP 10: Blank Output 198
....RAP 11: Vertical Black Streaks 199
....RAP 12: Evenly Spaced, Repeating Marks 200
....RAP 13: Missing Print 201
....RAP 14: Poor Fusing 202
....RAP 15: Vertical White Streaks 203
4.8 Printer Tests - Font Sample Test 204
........Font Sample Test: OL400E 205
........Font Sample Test: OL410E 206
........Font Sample Test: OL410E-PS 207
....4.8.02 Continuous Print Test 208
....4.8.03 Serial Interface Loopback Test 209
....4.8.04 Menu Print 210
........Sample Menu: OL400E 211

Table of Contents Page
........Sample Menu: OL410E 212
........Sample Menu: OL410E-PS 213
....4.8.05 Demo Page Print 214
........Demo Page Sample: OL400E 215
........Demo Page Sample: OL410E 216
........Demo Page Sample: OL410E-PS 217
4.9 Resistance Check Points - Registration Motor, Drum
Motor, And Fusing Unit 218
....4.9.02 Resistance Check Points - Transformer And Fan
Motor 219
A Reference Charts
A.1 Board Diagrams & General Information 220
A.2 Index To Charts 221
....A.2.01 Main Controller Board (OLCW) 222
....A.2.02 Postscript Board (OLPT) 223
....A.2.03 Ram Expansion Board (OLCB) 224
....A.2.04 Operator Panel Board 225
....A.2.05 Power Supply Board (OLAA) 226
A.3 Interconnect Diagram 227
B Illustrated Parts Listing
Illustrated Parts Listing - Overview & General Information 228
....B.1.02 Definition Of Terms 229
....B.1.03 Parts Ordering Information 230
B.2 Listing Of Illustrated Parts Breakdown Charts 231
....B.2.01 Lower Base Unit (1 Of 2) 232
....B.2.02 Lower Base Unit (2 Of 2) 233
....B.2.03 Upper Cover 234
....B.2.04 Base Unit (1 Of 2) 235
....B.2.05 Base Unit (2 Of 2) 236
....B.2.06 Options 237
....B.2.07 Multi-Purpose Feeder Unit 238
....B.2.08 Second Paper Feed Unit (Option) [ST-250] 239
....B.2.09 Second Paper Feed Unit (Option) Cabinet [ST-250] 240
....B.2.10 Packaging 241
....B.2.11 Consumables 242

Page: 2
Service Manual for OL400e/OL410e/OL410e-PS
Chapter 0A Introduction
OVERVIEW
Okidata developed this course in order to provide the information necessary to install
and maintain the OL400e, OL410e, and OL410e/PS LED Page Printers. Upon successful
completion of this training course, you will be able to do the following.
- Install and operate the printer
- Locate the major assemblies of the printer
- Identify fault indications
- Perform corrective and preventive maintenance
The Service Handbook is the primary reference manual for this course. You cannot, however,
successfully complete this course by referring only to this manual. Take the time to familiarize
yourself with all of the documentation in the training kit. This additional information will greatly
simplify working with the product.
NOTE: Whenever this manual references the OL400e, the information will also apply to the
OL410e and OL410e/PS. Information unique to the OL410e and OL410e/PS will be
listed as such!
Okidata's Technical Training Program is designed to build a knowledgeable and efficient
service and support group for Okidata products.
One step in becoming an Authorized Okidata Service Center is obtaining a training kit for the
appropriate product. This acquisition allows the Dealership to have reference materials available
during service jobs. Having, and using, these reference materials will minimize the time and money
spent on repairs.
Technicians complete Certification Tests as part of Okidata's Authorization process. Testing
familiarizes the technician with the product and reference materials.
This training course provides assembly level repair information to the field technician. No attempt
is made to provide basic training in being a technician. This kit strives to train a technician to service
the product. Okidata views service technicians as representatives of Okidata. Through this course,
Okidata seeks to provide the means and the motivation that will make good service a reality.
Remember
Component level servicing is provided only at Okidata Service Repair Depots!
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)