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Service Guide DOC-IT3000/4000

Chapter 0 About This Manual

DOC-IT 3000/4000

Multifunctional Products

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.

Partner Exchange (BPX) for any updates to this material. (http://bpx.okidata.com)

Table of Contents Page

Service Guide DOC-IT3000/4000

0 About This Manual

Front Cover 1

Manual Revision & Copyright Information 2

1 Product Specifications

1.0 General Description 3

1.1 General Specifications 4

1.2 DOC-IT Controller Specifications 5

1.3 Printer Specifications 6

1.4 Facsimile Specifications 7

1.5 Scanner Specifications 8

1.6 Copier Specifications 9

1.7 Options 10

1.8 Consumables 11

1.9 Reliability Data 12

1.10 Agency Approvals 13

2 Principles of Operation

2.1 Electrical Principles Of Operation 14

....2.1.01 Main Control Board 15

........CPU (80C154) 16

........Memory Map (on Master CPU Side) 17

........Address Decoder 18

........Program ROM 19

........RAM 20

........WRITE 1 Waveforms (OE Clock) 21

........Image Control LSI 22

........Memory Configuration 23

........External RAM Access 24

........Scanner Control LSI 25

........Line Memory Read/Write Waveforms 26

........Peripheral Interface Controller 27

........Operator Panel 28

........Serial Video Interface 29

........Image Sensor Control Board 30

2.2 Printer Control - Principal Hardware Components 31

........Printer Unit Block Diagram 32

....2.2.02 Printer Control Board 33

....2.2.03 Fuser Unit 34

....2.2.04 Main Motor 35

....2.2.05 LED Array 36

....2.2.06 Sensor and Switch Control 37

....2.2.07 Resist Motor 38

....2.2.08 Fan 39

Table of Contents Page

....2.2.09 Main Control Board 40

........Video Interface 41

........Second Tray Interface 42

........Block Diagram of Serial Interface 43

....2.2.10 Power Supply Unit 44

........High-Voltage Generation 45

........RESET Control 46

........Power Supply Control Signals 47

2.3 DOC-IT Controller 48

....2.3.01 Doc-It Controller Block Diagram 49

....2.3.02 Doc-It Host Communication Controller 50

....2.3.03 Doc-It Integrated Peripheral Controller 51

2.4 Mechanical Operation 52

....2.4.02 Electrostatic Printing - Overview 53

........Printing Process Diagram 54

....2.4.03 Electrostatic Printing Process - Operational

Description 55

........Hopping 56

........Feeding 57

........Charging 58

........Exposure 59

........Developing 60

........Transfer 61

........Cleaning 62

........Fusing 63

........Paper Ejection 64

........Toner Recycling 65

....2.4.04 ADF Hopping and Feeding 66

....2.4.05 Sensors and Switches 67

....2.4.06 Alarm Detection 68

2.5 Software Configuration 69

....2.5.03 File Descriptions 70

....2.5.04 Software Power-up Sequence 71

....2.5.05 Software Functional Components 72

........The Kernel & TSR Primitives 73

3 Maintenance & Disassembly

3.1 Maintenance 74

....3.1.02 Maintenance Precautions 75

....3.1.03 Maintenance Tools 76

3.2 Disassembly/Assembly Procedures 77

........Flowchart Index 78

............Flowchart, Page 1 79

............Flowchart, Page 2 80

............Flowchart, Page 3 81

Table of Contents Page

............Flowchart, Page 4 82

............Flowchart, Page 5 83

............Flowchart, Page 7 84

............Flowchart, Pages 8 and 9 85

....3.2.01 Preliminary Items 86

....3.2.02 Ozone Filter 87

....3.2.03 Transfer Charger Assembly 88

....3.2.04 LED Head 89

....3.2.05 Operator Panel Assembly 90

....3.2.06 Upper Cover 91

....3.2.07 Stacker Open and Scanner Open Lever Assemblies 92

....3.2.08 Automatic Document Feed (ADF) Unit 93

....3.2.09 Mini-Pitch Belt (ADF) 94

....3.2.10 ADF Gears 95

....3.2.11 ADF Pulse Motor 96

....3.2.12 ADF Hopping Roller Assembly 97

....3.2.13 ADF Paper Set and Conveyor Frame Cover Support

Plates 98

....3.2.14 Brake Roller Assembly 99

....3.2.15 Inlet and Paper Sensor Levers 100

....3.2.16 SPAX Board (PS1 and PS2 Sensors) 101

....3.2.17 ADF Pulleys 102

....3.2.18 ADF Lower Base and Sequential Guide Assemblies 103

....3.2.19 ADF Left Side Frame 104

....3.2.20 ADF White, Exit, and Resist Rollers 105

....3.2.21 Timing Sensor Lever Assembly 106

....3.2.22 SPAX Board (PS3 and PS4 Sensors) 107

....3.2.23 Main Controller Board (SPSX) 108

....3.2.24 Paper Supply Unit 109

....3.2.25 Pulse (Resist) Motor 110

....3.2.26 Engine Connector Board, LLCC-2 111

....3.2.27 Hopping Roller A 112

....3.2.28 Separator 113

....3.2.29 Engine Controller Board (SPPY) 114

....3.2.30 Lower PCB Shield 115

....3.2.31 Main Motor 116

....3.2.32 Idle Gear A, Idle Gear B, and Speed Reduction Gear 117

....3.2.33 DC Fan Assembly 118

....3.2.34 Cover Open Microswitch Assembly 119

....3.2.35 High Voltage Power Board 120

....3.2.36 Power Supply Unit 121

....3.2.37 High Voltage Connector 122

....3.2.38 Exit Roller Assembly 123

....3.2.39 Paper Eject Sensor Lever and Rollers 124

Table of Contents Page

....3.2.40 Upper Unit 125

....3.2.41 Cover Open Switch Actuator 126

....3.2.42 Paper Eject Sensor Levers B and C 127

....3.2.43 Fusing Unit 128

....3.2.44 Metal Pressure Roller Assembly 129

....3.2.45 Resist Sensor Lever and Toner Sensor Lever 130

....3.2.46 Lock Lever Assembly 131

....3.2.47 LED Head Holder 132

....3.2.48 LED Holder Ground Plate 133

....3.2.49 Back-up Roller Assembly 134

....3.2.50 Idle Gear and Post 135

....3.2.51 Registration Roller Assembly 136

....3.2.52 Scanner Unit Assembly 137

....3.2.53 Scanner Upper Case 138

....3.2.54 Scanner Cable 139

....3.2.55 Scanner Board (SPHY) 140

....3.2.56 Base Frame 141

....3.2.57 Memory Expansion Board (DOC-IT Controller) 142

....3.2.58 Second Paper Feed Unit (Option) 143

....3.2.59 Second Paper Feed Unit Boards and Connectors 144

....3.2.60 Second Paper Supply Unit (Option) 145

....3.2.61 Cassette Spring (Second Paper Supply Unit) 146

....3.2.62 Resist Motor (Second Paper Supply Unit) 147

....3.2.63 Second Paper Supply Unit Control Board, LLFC 148

....3.2.64 Second Paper Supply Unit Hopping Roller 149

....3.2.65 Second Paper Supply Unit Separator 150

3.3 Adjustments And Service Settings 151

....Chart 3.3A Adjustments, Modes, and Service Checks Listed

by Adjustment 152

....Chart 3.3B Adjustments, Modes, and Service Checks Listed

by Mode 153

....3.3.01 Maintenance Mode 154

....Chart of Maintenance Mode Adjustments and Service

Checks 155

........LED Head Type Selection and Drive Time Setting 156

........ADF Slip Adjustment 157

........Scanner Shading Adjustment 158

....3.3.02 Administration Mode 159

....Chart of Administration Mode Adjustments and Service

Checks 160

........Buzzer Level 161

........Engine Version 162

........Keyclick Length 163

........Print Darkness Control 164

Table of Contents Page

........Print Start Position Adjustment 165

........Drum Counter Reset 166

........Scan Start Position Adjustment 167

........Software Version 168

........Time to Quiet 169

........Save Configuration Setting 170

........Restoring Factory Defaults 171

....3.3.03 Service Mode 172

....Chart of Service Mode Adjustments and Service Checks 173

........Automatic Document Feeder (ADF) Paper Feed Counter 174

........Drum Counter 175

........Fuser Counter 176

........Total Printed Page Counter 177

........Scan Counter 178

........Toner Counter 179

3.4 Cleaning 180

....3.4.02 Static Charger 181

....3.4.03 Transfer Charger 182

....3.4.04 LED Lens Array 183

....3.4.05 Hopping Roller 184

....3.4.06 Resist Roller 185

....3.4.07 Back-up Roller 186

....3.4.08 Printer Unit 187

....3.4.09 Covers 188

....3.4.10 Scanner Glass 189

....3.4.11 ADF White Roller 190

....3.4.12 ADF Resist Rollers 191

....3.4.13 ADF Hopping Roller 192

3.5 Lubrication 193

4 Failure & Repair Analysis

4.1 General Information 194

....4.1.02 OKILINK II 195

4.2 Troubleshooting Procedures - Using The RAPS 196

....4.2.02 Flowchart Page 1 "START HERE" Flowchart 197

....4.2.03 RAP Index 198

........RAP#1 - Paper Feed Error 199

........RAP#2 - Paper Jam Error Page 1 200

........RAP#3 - Paper Size Error Page 1 201

........RAP#4 - Fuser Unit Error Page 1 202

........RAP#5 - Engine Error 203

........RAP#6 - ADF Jam Error Page 1 204

........RAP#7 - Image Light or Blurred Page 1 205

........RAP#8 - Scanned Images Light or Blurred Page 1 206

........RAP#9 - Dark Background Density Page 1 207

Table of Contents Page

........RAP#10 - Scanned Image (Dark Backgrond Density)

Page 1 208

........RAP#11 - Blank Paper is Output Page 1 209

........RAP#12 - Scanned Image (Blank paper is Output) Page 1 210

........RAP#13 - Vertical Black Stripes on the Output Page 1 211

........RAP#14 - Printed Scanned Images with Vertical Black

Stripes 212

........RAP#15 - Repetitive Spaced Marks on printed Output

Page 1 213

........RAP#16 - Print Missing from Output Page 1 214

........RAP#17 - Poor Fusing Page 1 215

........RAP#18 - White Vertical Stripes on printed output Page 2 216

........RAP#19 - Scanned Image (Display) White Vertical Stripes 217

........RAP#20 - 2nd Paper Tray Cannot be Selected Page 1 218

........RAP#21 - No Operation Panel Functions Page 1 219

........RAP#22 - Facsimile Transmit Error Page 1 220

........RAP#23 - Facsimile Receive Error Page 1 221

........RAP#24 - Doc-It Does Not Initialize Page 1 222

........RAP 25: Black Page is Output 223

4.3 LCD Error Messages 224

....4.3.02 Index to Tables 225

....4.3.03 Immediate Error Message Displayed 226

....4.3.04 Maintenance Mode Error Messages 227

....4.3.05 Doc-It Engine Error Messages 228

....4.3.06 POWERON.EXE - Operational Error Messages 229

....4.3.07 POWERON.EXE - Diagnostic Error Messages 230

4.4 DOC-IT Controller - Diagnostic Tests 231

....4.4.02 Confidence Test 232

....4.4.03 Using the Poweron Test With /t and /d Commands 233

....4.4.04 Memory Test 234

....4.4.05 Controller Board Test 235

4.5 Maintenance Mode 236

....4.5.02 Maintenance Mode Selection 237

A Reference Charts

General Information Of The Printed Circuit Boards 238

A.2 Index To Charts 239

....A.2.01 Main Controller Board (SPSX) w/o ROM 240

....A.2.02 Engine Controller Board (SPPY) w/o ROM 241

....A.2.03 Operation Panel Board (RCDP) 242

....A.2.04 Engine Connection Board (LLCC-2) 243

....A.2.05 Scanner Board (SPHY) 244

....A.2.06 ADF Sensor Board (SPAX) 245

....A.2.07 Second Tray Controller Board (LLFC) 246

....A.2.08 Second Tray Connection Board (LLIF) 247

Table of Contents Page

....A.2.09 Power Connector Board (LLIE) 248

....A.2.11 Power Supply Assembly 249

....A.2.12 DOC-IT Controller Board (PPB) 250

....A.2.10 Second Tray Connection Board (LLIG) 251

B Illustrated Parts Listing

General Information 252

....B.1.02 Definition of Terms 253

....B.1.03 Parts Ordering Information 254

B.2 Charts 255

........Pictorial Overview 256

....B.2.01 Cabinet Assembly 257

....B.2.02 Cabinet Assembly 258

....B.2.03 Upper Unit 1-3 259

....B.2.04 Upper Unit 2-3 260

....B.2.05 Upper Unit 3-3 261

....B.2.06 Lower Unit 262

....B.2.07 Lower Unit 263

....B.2.08 Lower Unit 264

....B.2.09 Paper Exit Assembly 265

....B.2.10 Paper Supply Unit 266

....B.2.11 Automatic Document Feed (ADF) Unit 267

....B.2.12 Automatic Document Feed (ADF) Unit 268

....B.2.13 Scanner Unit 269

....B.2.14 Packing Materials 270

....B.2.15 Consumables 271

....B.2.16 Options 272

....B.2.17 Second Tray Unit 273

....B.2.18 Second Tray Unit Packing Materials 274

C Problem Reports

C.1 Problem Reports 275

....C.1.02 Reporting Problems 276

Page: 2

Service Guide DOC-IT3000/4000

Chapter 0 About This Manual

This document may not be reproduced without written permission of the Okidata® Technical

Training Group. Every effort has been made to ensure the accuracy of the information contained

in this training course. Okidata is not responsible for errors beyond our control.

Second Edition June, 1993

Written and produced by the Okidata® Technical Training Group

Okidata is a registered trademark of Oki Electric Industry Company, Ltd.; marque deposee de Oki

Electric Industry Company, Ltd.; Marca Registrada, Oki Electric Industry Company, Ltd.

DOC-IT is a trademark of Oki Electric Industry Company, Ltd.

Apple, AppleTalk, LaserWriter, LaserWriter II, LocalTalk, and Macintosh, are registered

trademarks of Apple Computer, Incorporated.

Microsoft and MS-DOS are registered trademarks and Microsoft Basic, Windows, TrueImage, and

TrueType are trademarks of Microsoft Corporation.

Hewlett-Packard, HP, LaserJet, LaserJet+, LaserJet Series II, LaserJet IIIp, and ScanJet are

registered trademarks of Hewlett-Packard Company.

IBM, PC, PC-DOS, and Proprinter XL are registered trademarks of International Business

Machines Corporation.

Intel is a trademark of Intel Corportation.

Okiport is a trademark of Oki Electric Industry Company, Ltd.

PostScript is a trademark of Adobe Systems, Incorporated, which may be registered in certain

jurisdictions.

Partner Exchange (BPX) for any updates to this material. (http://bpx.okidata.com)

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