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Oki ML520 User Manual

Oki ML520
269 pages
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Service Guide ML520/521
Chapter 0 About This Manual
ML520 // ML521
Dot Matrix 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

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Oki ML520 Specifications

General IconGeneral
Printer TypeDot Matrix Printer
EmulationEpson FX, IBM ProPrinter
Resolution240 x 216 dpi
Noise Level55 dB
InterfaceParallel, Serial
Paper SizeLetter, Legal, A4, Custom
Number of Pins9-pin

Summary

Chapter 0 About This Manual

Chapter 1 Product Specifications

General Information ML520/521

Overview of ML520/521 printers, OKISMART features, and warranty details.

Physical Specifications

Dimensions and weight specifications for ML520 and ML521 printers.

Power Requirements

Details on input power, power consumption, and power frequency.

Environmental Conditions

Acoustic ratings, altitude, and ambient temperature/humidity specifications.

Agency Approvals

Listings of UL, CSA, FCC, IEC, VDE, and BS agency approvals.

Operational Specifications

Character matrix sizes, print speeds, and characters per line for ML520/521.

Paper Specifications

Specifications for card stock, continuous form, cut sheet, envelopes, labels, and transparency.

Memory Specifications

Details on EEPROM, EPROM, and RAM specifications for the printer.

Consumables Information

Information about the printer ribbon, including material, type, and life.

Optional Features

Details on Cut Sheet Feeders, Pull Tractor Kit, Bottom Push Tractor Kit, and Serial Interface.

Reliability Specifications

Mean Time Before Failure (MTBF), To Repair (MTTR), Printer Life, and Printhead Life.

Chapter 2 Principles of Operation

Electrical Operation Overview

Lists the electrical components comprising the printer.

Main Control Board Functionality

Description of the main control board, its microprocessor, and memory access.

Printer Initialization Process

Describes the printer's initialization steps upon power-on.

Parallel Interface Control

Explains control signals and data flow for the parallel interface.

Print Control Mechanisms

How print data is transmitted and automatic head gap adjustment.

Motor Control Systems

Details on Space and Line Feed (SP/LF) motor control and operation.

Operation Panel Functionality

How the MPU reads switch data and the operator panel LED display.

Alarm Circuit and Processing

Details driver circuit alarm processing and overheating response.

Power Supply Circuit Details

Lists the voltages supplied by the switching power supply circuit.

Mechanical Operation Overview

Overview of the printhead mechanism and its components.

Head Gap Adjustment

Explains the three factors influencing printhead gap information.

Paper Handling Mechanisms

Details line feed, paper detection, automatic load, and paper park features.

Chapter 3 Maintenance & Disassembly

General Maintenance Information

Guidance on maintenance, adjustment, cleaning, lubrication, and shipping procedures.

Required Maintenance Tools

Lists the necessary tools for performing printer servicing.

Maintenance Precautions

Important safety and best practice guidelines for disassembly and assembly.

Disassembly/Assembly Procedures

General information and procedures for disassembling and assembling the printer.

Printhead Assembly Service

Steps for removing and installing the printhead assembly.

Ribbon Protector Service

Instructions for releasing and removing the ribbon protector.

Gear Case Assembly Service

Steps for removing and disassembling the gear case assembly.

Pull-up Roller Assembly Service

Procedure for removing the pull-up roller assembly.

Cover and Sheet Guide Assemblies Service

Steps to remove the upper cover, access cover, and sheet guide assemblies.

Control Board (FJIM) Service

Steps for removing and installing the control board (FJIM).

Power Supply Assembly Service

Procedures for removing the transformer and filter board assemblies.

Operator Panel PCB Service

Steps for removing and installing the operator panel PCB.

PC Connector Service

Procedure for removing and installing the PC connector.

Space Motor and Roller Guide Assemblies Service

Steps for removing the space motor and roller guide assemblies.

Carriage Cable Service

Procedure for removing and installing the carriage cable.

Space Rack Service

Steps for removing the space rack.

Roller/Holder Backup Assembly Service

Procedure for removing the roller/holder backup assembly.

Guide Rail and Adjust Cam Service

Steps for removing the guide rail and adjust cam.

Ground Plate Service

Procedures for removing the left and right ground plates.

Paper Feed Sensor Levers Service

Procedure for removing paper feed sensor levers.

Platen Assembly Service

Steps for removing the platen assembly.

Paper Chute Assembly Service

Procedure for removing the paper chute assembly.

Line Feed Motor Assembly Service

Steps for removing the line feed motor assembly.

Reset Spring Service

Procedure for removing the reset spring.

Idle Gear and Change Lever Service

Steps for removing the idle gear and change lever.

Pressure Spring Service

Procedure for removing the pressure spring.

Carriage Shaft Service

Steps for removing the carriage shaft.

Leaf Spring Service

Procedure for removing the leaf spring.

Bottom Paper Sensor Levers Service

Steps for removing bottom paper sensor levers.

Front Pressure Roller Assembly Service

Procedure for removing the front pressure roller assembly.

Tractor Assembly Service

Steps for removing the tractor assemblies.

Main Frame Disassembly

Procedure for disassembling the main frame.

Printer Adjustments Overview

Introduction to printer adjustment procedures.

Printhead Gap Adjustment Procedure

Detailed procedure for adjusting the printhead gap.

Key Combinations for Functions

Lists key combinations for accessing special functions and tests.

Menu Operation Guide

Guides on navigating and using the printer's menu system.

Top of Form Setting

Procedure for setting and resetting the Top of Form position.

Paper Park Feature

How to use the Paper Park feature for switching between paper types.

Tear Feature Operation

Manual activation of the tear feature for off-edge paper tearing.

Forms Tear Off and Spacing

Automatic tear-off and vertical spacing troubleshooting.

Printer Resets

Procedures for resetting menus to factory defaults.

Printer Cleaning Procedures

General information on cleaning the printer and its components.

Lubrication Procedures

General information on printer lubrication procedures and amounts.

Shipping Instructions

Instructions for returning the printer for service or other returns.

Chapter 4 Failure & Repair Analysis

Introduction to Failure Analysis

Overview of the failure analysis section and how to use it.

Printer Serial Number Identification

How to identify the printer's revision level using the serial number.

Firmware Revision Identification

How to identify firmware revision and part numbers by printing tests.

Reporting Problems

Encourages reporting of problems encountered with training materials.

Troubleshooting Updates

Information on how Okidata distributes updated troubleshooting information.

Troubleshooting Tips

Preliminary checks to perform before troubleshooting.

Printer Problem Categories

Categories of printer problems: fatal errors and operational errors.

Start Here Flowchart

A flowchart to help diagnose printer problems.

Preventing Image Problems

Advice on preventing image quality issues like faded print.

Common Printer Problems

Lists common problems and their potential causes and solutions.

Abnormal Output Samples

Visual examples of abnormal print outputs and their causes.

Fault Alarms and Troubleshooting

Guidelines for using troubleshooting tables for fault alarms.

Repair Analysis Procedures (RAPs)

Introduction to using Repair Analysis Procedures (RAPs).

RAP Index

Index of common printer problems and corresponding RAP numbers.

Specific RAP Troubleshooting

Procedures for diagnosing and fixing specific printer problems (RAPs 01-11).

Printer Tests Overview

Overview of printer tests for diagnostics.

Diagnostic Tests

Procedures and purposes of Rolling ASCII, Font, and Serial Loopback tests.

Serial Cable Information

Requirements for serial cables connecting the printer and computer.

Hexadecimal Dump Mode

Procedure to engage Hexadecimal Dump Mode for viewing data transfer.

Resistance Checks

General description of resistance checks for printer components.

Component Resistance Values

Interconnect diagrams and resistance values for key components.

A Reference Charts

Overview of reference charts for printed circuit boards.

PC Board Component Details

Details on Main Controller, Operator Panel, Power Supply, Space Motor, and Serial Interface boards.

B Illustrated Parts Listing

Introduction to the illustrated parts listing appendix.

Parts Information and Ordering

Guides on parts listing format, current numbers, ordering, and definitions.

Illustrated Parts Breakdown Charts

Index to illustrated parts breakdown charts for the printer and its components.

Specific Part Listings

Parts lists for printer units, assemblies, options, consumables, and packing materials.

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