OKIDATA Pacemark 4410 User manual

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Service Guide for PM4410
Chapter 0 Introduction
Front Cover
Pacemark 4410
The PACEMARK® 4410 is simply the most reliable, powerful and durable forms printer in its class. Stand-alone or
shared by a workgroup, this heavy-duty impact printer can tackle your most demanding forms work-flow and then some.
Adobe Acrobat printable reference copy
of the OKIDATA Service Training Manual.
05/13/98
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.

Table of Contents Page
Service Guide for PM4410
0 Introduction
Preface 1
1 Specifications
1.1 Basic System Configuration 2
1.2 Printer Specifications 3
1.3 Option Specifications 4
1.4 Basic Specifications 5
2 Operation
2.1 Electrical Operation 6
....2.1.1 Summary 7
....2.1.2 Microprocessor and the peripheral circuit 8
....2.1.3 Initialization 9
....2.1.4 Interface Control 10
....2.1.5 Parallel Interface Control 11
....2.1.6 Serial Interface 12
....2.1.7 Printing Operation 13
....2.1.8 Printhead control 14
....2.1.9 Print Compensation Control 15
....2.1.10 Space motor control 16
....2.1.11 Line feed 17
....2.1.12 Bail, tractor, switching, AG, ribbon motor control 18
....2.1.13 Operation Panel 19
....2.1.14 Alarm circuit 20
....2.1.15 Power supply circuit 21
2.2 Mechanical Operation 22
....2.2.1 Printhead mechanism and operation 23
....2.2.2 Spacing operation 24
....2.2.3 Head gap adjusting 25
....2.2.4 Ribbon drive 26
....2.2.5 Paper Feed Mechanism 27
....2.2.6 Bail Feed Mechanism 28
....2.2.7 Paper End Detection Mechanism 29
3 Disassembly
3.1 Precautions for Parts Replacement 30
3.2 Parts Layout 31
3.3 How to Change Parts 32
....3.3.1 Cover-Assy-Access / Cover-Assy-Side (R) /
Cover-Assy-Side (L) / Cover-Assy-Front / Frame-Assy-Rear /
Plate-Front (stuck)
33
....3.3.2 Printer Unit 34
....3.3.3 Control Block [Control Board (PMA Printed Board),
Driver Board (PDA Printed Board)] 35
....3.3.4 Power Supply Unit 36
....3.3.5 PG Cooling Fan 37
....3.3.6 I/F Board (PHA Printed Board) 38
....3.3.7 AG Board (PGA Printed Board) / Connector Cord 39
....3.3.8 AG Motor Assy 40
....3.3.9 Mini Pitch Belt 41
....3.3.10 Tractor Change Motor Assy 42
....3.3.11 Bail Motor Assy 43
....3.3.12 LF Motor Assy 44
....3.3.13 Head Cooling Fan 1 45
....3.3.14 Head Cooling Fan 2 46
....3.3.15 Space Motor 47
....3.3.16 Operator Board (POA Printed Board) 48
....3.3.17 Ribbon Feed Assy 49
....3.3.18 Printing Head 50
....3.3.19 Head Cable 51
....3.3.20 Ribbon Protector 52
....3.3.21 Space Motor Fan 53
....3.3.22 Junction Board 54
....3.3.23 Cover Open Switch Assy / Ribbon Rotation Sensor 55
....3.3.24 Interlock Switch / Interlock Switch Cord Assy 56
....3.3.25 Knob Bracket Assy 57
....3.3.26 Space Belt 58
....3.3.27 AG Sensor Frame / Start Searching Sensor 59

Table of Contents Page
....3.3.28 Paper Jam Sensor Assy / Bail PE Sensor Assy 60
....3.3.29 Sprocket Assy (L) (R) (Front Tractor) 61
....3.3.30 Sheet Feeder Assy (L) Rear / Sheet Feeder Assy (R)
Rear 62
....3.3.31 Bail Assy 63
4 Adjustments
Adjustments 64
5 Maintenance
5.1 Cleaning 65
5.2 Lubrication 66
....(28) Option Interface 67
6 Maintenance
6.1 Items to Check Before Repair 68
6.2 Troubleshooting Table 69
6.3 Lamp and LCD Display 70
6.4 Part Layout 71
6.5 Connection 72
....(1) Printhead 73
....(2) Line feed motor 74
....(3) Space motor 75
....(4) Ribbon motor 76
....(5) Path-change motor 77
....(6) Auto-gap motor 78
....(7) Bail motor 79
....(8) Space Fan1 80
....(9) Space Fan2 81
....(10) Head Fan1 82
....(11) Head Fan2 83
....(12) Power Fan 84
....(13) Space slit sensor 85
....(14) Auto-gap sensor 86
....(15) Cover Open Switch / Ribbon Jam Sensor 87
....(16) Optical Sensor 88
....(17) Sheet Top Locating Sensor / Auto Gap Core 89
....(18) Paper Jam Sensor / Bail Paper End Sensor 90
....(19) Bail Open Switch / Front Tractor On Switch 91
....(20) Front Tractor Paper End Switch 92
....(21) Rear Tractor Paper End Switch 93
....(22) Power Supply Unit 94
....(23) Operation Panel 95
....(24) Standard Interface 96
....(25) Short Plug 97
....(26) Others 98
....(27) MUPIS Interface (Option) 99
....(29) Continuous-Form Paper Cutter (Option) 100
7 Troubleshooting
Troubleshooting 101
....(1) Printer is not powered on at all 102
....(2) Printer does not operate at all, while Power Lamp is on,
Alarm Lamp blinks and nothing is displayed on LCD 103
....(3) Printer does not operate at all, while Power Lamp is on,
Alarm Lamp is on/off and nothing is displayed on LCD 104
....(4) Spacing is abnormal, while Alarm Lamp is on and
"ERROR HOMING" or "ERROR SPACING" is displayed on LCD 105
....(5) Carriage does not operate at all, while the Alarm Lamp is
on and "ERROR AUTOGAP" is displayed on LCD 106
....(6) After Carriage works, Alarm Lamp goes on and "ERROR
(in the upper row, BAIL (in the lower)" is displayed on LCD 107
....(7) After Carriage operates, Alarm Lamp goes on and
"ERROR (in the upper row), PATH CHANGE (in the lower)" is
displayed on LCD
108
....(8) After initialization, Alarm Lamp goes on and "ERROR (in
the upper row), RIBBON JAM (in the lower)" is displayed on LCD 109
....(9) Paper is not line fed, while the Alarm Lamp is on and
"ERROR (in the upper row), FEED JAM (in the lower)" is
displayed on LCD
110
....(10) Papers line fed, but "FEED JAM" is displayed on LCD 111
....(11) Printer does not operate at all, while the Alarm Lamp is
on and "ERROR FUSE" is displayed on LCD 112

Table of Contents Page
....(12) Printer goes off during operation 113
....(13) Printer does not operate after being turned on, while
"INITIALIZING" is displayed on LCD 114
....(14) Wrong characters are printed or characters are omitted 115
....(15) Printer operates normally but characters are not printed 116
....(16) Printer operates normally but characters are not printed. 117
....(17) Printer operates normally but characters are not printed.
(With MUPIS Card used) 118
....(18) Dots are omitted 119
....(19) Images are faint 120
....(20) After Carriage works, the Alarm Lamp goes on and
"ERROR AUTOGAP" is displayed on LCD 121
....(21) Paper is set at Tractor, but printing is not conducted in the
state of "PAPER END" 122
....(22) "COVER OPEN" is displayed on LCD even though
Access Card is closed 123
....(23) Pressing Operation Panel Switches does not make
Printer operate (after normal initialization) 124
....(24) "ERROR, D-RAM" is displayed on LCD, while Alarm
Lamp blinks 125
....(25) "ERROR, PROGRAM-ROM" is displayed on LCD, while
Alarm Lamp blinks 126
....(26) "ERROR, EEPROM" is displayed on LCD, while Alarm
Lamp blinks 127
....(27) "ERROR, S-RAM" is displayed on LCD, while Alarm
Lamp blinks 128
....(28) "ERROR, CG-ROM" is displayed on LCD while Alarm
Lamp blinks 129
....(29) "ERROR, CENTERING" is displayed on LCD, while
Alarm Lamp blinks 130
8 Parts List
Total Assembling Diagram 131
Printer Unit (1 of 3) 132
Printer Unit (2 of 3) 133
Printer Unit (3 of 3) 134
Carriage Assembly 135
Knob Assembly 136
Ribbon Assembly 137
Sprocket Assembly (L) 138
Sprocket Assembly (R) 139
Sheet Feeder Assembly (L) Rear 140
Sheet Feeder Assembly (R) Rear 141
Bail Assembly 142
Lower Cover Assembly 143
Front Cover Assembly 144
Rear Cover Assembly 145
Access Cover 146
Frame Assembly - OpePane 147
PMA/PDA PCB Assembly 148
A PCB Layout
(1) Circuit board PMA (Control) 149
(2) Circuit board PDA (Driver) 150
(3) Circuit board POA (Operation Panel) 151
(4) Circuit board PHA (Interface) 152
(5) Circuit board PRA (Connection) 153
(6) Circuit board PGA (Sensor) 154
B RS-232C Serial Interface Board
1. General 155
2. Operation Description 156
....2.1 Element Description 157
....2.2 Circuit Description 158
........2.2.1 Operation at power on 159
........2.2.2. RS-232C interface 160
....2.3 Local Test 161
........2.3.1 Circuit test mode 162
............2.3.1.1 Setting 163
............2.3.1.2 Function 164
C Maintenance Support Function

Table of Contents Page
1. Normal mode 165
2. Maintenance mode 1 166
3. Maintenance mode 2 167
4. Maintenance function 168
....4.1 Auto gap test 169
....4.2 Gap close 170
....4.3 Sensor slice level learning function 171
....4.4 All sensors ON/OFF check function 172
....4.5 Print start position PE sensor aligning function 173
....4.6 FLASH memory loading function 174
....4.7 Head pin test 175
....4.8 AG correction function 176
....4.9 AG adjustment aid function 177
....4.10 Autogap Open/Close Test 178
....4.11 Aging Function 179

Page: 1
Service Guide for PM4410
Chapter 0 Introduction
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 User's Manual for handling or operating the equipment.
Copyright 1998, 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
Service Guide for PM4410
Chapter 1 Specifications
1.1 Basic System Configuration
The basic system configuration of Pacemark 4410 is illustrated below in Figure 1-1.
Copyright 1998, 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: 3
Service Guide for PM4410
Chapter 1 Specifications
1.2 Printer Specifications
This printer unit is composed with the following hardware.
Printer mechanisml
Main control/Motor driver boardl
Head driver boardl
Interface/Motor/Sensor board (including IEEE 1284 bi-directional parallel interface and RS-232C serial interface)l
Motor/Sensor and AG sensor boardsl
Operation panel boardl
Power supply unitl
Coversl
Figure 1-2 show the printer unit configuration.

Copyright 1998, 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
Service Guide for PM4410
Chapter 1 Specifications
1.3 Option Specifications
Options available for Pacemark 4410 are as follows.
(1) Interface boards
(a) 70034401 OkiLAN 6010e Pocket Printer Server
(b) 70034201 OkiLAN 6100e 10/100 Base-TX Ethernet Internal Print Server
(b) Okidata Microline 300/500 Series Serial/ HSP Adapter
RS422AlCurrent Loopl
Copyright 1998, 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: 5
Service Guide for PM4410
Chapter 1 Specifications
1.4 Basic Specifications
(1) Dimensions
Width: 768mm (30.24 inches) Length: 385mm (15.16 inches) Height: 358mm (14.09 inches)
(2) Weight
Approx. 42kg (92.6 lbs.)
(3) Form
Continuous Paper
One-part paper
Ream weight: 45 to 90g/m2(12 to 24 lbs.)
Multiple-part paper Max. 0.79mm 0.031 inches total thickness (with front feed)
Max. 0.36mm (0.014 inches) total thickness (with rear feed)
Paper type Ream weight Number of sheet
Carbon-lined paper
Pressure-sensitive paper
35 to 40 g/m2
(9 to 11 lbs.) Ten sheet maximum including original (with front feed)
Interleaf paper Paper 35 to 52 g/m2
(9 to 14 lbs.)
Carbon paper
34 g/m2(9 lbs.)
Seven sheets maximum including original (with front feed)
Four sheet maximum including original (with rear feed)
When 7 parts 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/m224 lbs
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/m2100 lbs.
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 Mode 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
(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 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
(6) Maximum Number of Characters per Line
Character pitch (CPI) 5 6 7.5 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 0.014 inch
(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.
(11) Ambient temperature and relative humidity
Operating Non-operating Storage Transportation Unit
Temperature 41 to 95
(5 to 35) 32 to 109.4 (0 to 43) 14 to 122 (-10 to 50) -40 to 158 (-40 to 70)
oF
(oC)
Relative Humidity 20 to 80 10 to 90 5 to 95 5 to 95 % RH
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 ratel
Page density : the proportion in area of characters and spaces within printhead movable area.l
Power on Time : 8 hours/day, 25 days/month and 12 months/year.l
Copyright 1998, 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: 6
Service Guide for PM4410
Chapter 2 Operation
2.1 Electrical Operation
The electrical operation of the printer circuit is described in this section.
2.1.1 Summary
2.1.2 Microprocessor and the peripheral circuit
2.1.3 Initialization
2.1.4 Interface control
2.1.5 Parallel Interface Control
2.1.6 Serial Interface
2.1.7 Printing operation
2.1.8 Printhead control
2.1.9 Print Compensation Control
2.1.10 Space motor control
2.1.11 Line feed
2.1.12 Bail, tractor switching, AG, ribbon motor control
2.1.13 Operation Panel
2.1.14 Alarm circuits
2.1.15 Power supply circuit
Copyright 1998, 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
Service Guide for PM4410
Chapter 2 Operation
2.1.1 Summary
Fig. 2-1 (shown in next section) shows the block diagram of the printer.
The control board is made up of the microprocessors, peripheral circuits, drive circuits, sensors and interface
connectors.
The power to the control board is supplied by the power board through the connector cord.
The power to other electrical parts is also distributed through the connectors within the control board.
Copyright 1998, 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: 8
Service Guide for PM4410
Chapter 2 Operation
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 2l
Programmable Interrupt Controllerl
Programmable 16-bit Timer x 3l
Programmable Memory and Peripheral Chip-Select Logicl
Programmable Wait State Generatorl
Local Bus Controllerl
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.

(2) PG ROM (IC46)
This is a 256 x16 bits (4M bit) EPROM with the control program for the printer stored. The MPU executes instructions
under this program.
The program ROM is assigned to the program memory area of the MPU and is fetched by the RD signal of the MPU.
The following shows the operation of the memory access.

(3) DRAM(IC28)
The RAM is CMOS dynamic RAM with (256K x 16 bit) configuration, and used as buffers (such as receiving buffer,
printing buffer, DLL buffer and working buffer).
The following shows the examples of the memory access operation.