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1. Mode LQ Utility High Speed Draft Speed 120 12 cpi 360 12 cpi 450 15 cpi Matrix H x V 29 x 18 9x17 7x17 Print Speed at Different CPI for the ML 590 Mode CPI CPS Horiz DPI Vert DPI IPS Utility 10 300 120 180 30 12 360 120 180 30 15 450 120 180 30 17 1 257 240 180 15 20 300 240 180 15 LQ 10 100 360 180 10 12 120 360 180 10 15 150 360 180 10 17 1 171 360 180 10 20 200 360 180 10 ML590 591 96 02 07 1 6 02 Characters Per Line 1 6 02 Characters Per Line Microline 590 Characters Per Characters Per Utility Letter Quality Line Inch 80 10 164 65 96 12 161 65 120 15 148 65 136 17 1 96 65 160 20 95 65 Microline 591 Characters Characters Utility Letter Per Line Per Inch Quality 136 10 105 40 163 12 96 40 204 Ld 88 40 233 7 1 59 40 272 20 59 40 ML590 591 96 02 07 1 6 03 Character Pitches 1 6 03 Character Pitches 5 6 8 5 10 12 15 17 1 20 ML590 591 96 02 07 1 6 04 Character Sets 1 6 04 Character Sets Standard ASCII EPSON Character Set amp Il IBM Character Set I II amp All Characters Foreign Character Substitution International Character Sets Code Page 850 860 863 and 865 Bar Code Code 39 UPC A UPC E EAN 8 EAN 13 Interleaved 2 of 5 Code 128 POSTNET ML590 591 96 02 07 1 6
2. ALARM UTIL PROP PRES ORATOR 10 12 15 17 20 SEL MENU Refere TIGE nce Number On F On On 1 On F On On 2 On F On On 3 On F On On On 4 On F On On On 5 On F On On 6 On F On On On 7 On F On On On 8 On F On On On 9 On F On 0 On F On 1 On F On 2 On F On On 3 On F On On 4 On F On 5 On F On On 6 On F On On 7 On F On On 8 On F On On 9 ML590 591 96 02 07 On F On On 20 On F On On 21 On On On On On 22 On On On 23 E On On On 24 E On On F 25 F On On F 26 F ML590 591 96 02 07 4 6 03 Alarm LED Display Troubleshooting Tables 4 6 03 ALARM LED Display Troubleshooting Tables Space Motor Driver Alarm temperature the TSD Signal has not changed Reference Failure Cause Recommended Action Number Description 1 Space Motor Space motor Refer to RAP 02 Alarm IPT does not occur in specified time 2 Printhead Printhead Refer to RAP 03 L Detection does not home Alarm 3 Printhead A D Thermistor is Check the printhead Alarm open or 5 connection then vdc shorted replace main control board carriage cable printhead 4 Printhead Gap Self Check the printhead Alarm adjustment connection then was not replace the main successful control board carria
3. ML590 591 96 02 07 Continuous Paper Feed Pull Tractor Mechanism Continuous Paper Feed Pull Tractor Mechanism Bottom feed of continuous sheets is possible only when an optional pull tractor unit is installed As the platen rotates power is transferred to the drive gear from the LF idler gear the platen gear idler gear B and idler gear A The drive gear turns the pull tractor assembly which feed the continuous paper Continuous torm PulvBotiom 0 Tractor assemb y A A Sheet feeder shaft NO 2 d Drive gear 7 i idle gear A i ce 1 idle gear Bx a N LF motor Platen gear LE idle gear ML590 591 96 02 07 Continuous Paper Feed Bottom Tractor Feed Mechanism Continuous Paper Feed Bottom Tractor Feed Mechanism As the platen rotates power is transferred to the drive gear from the platen gear the idle gear and the tractor change gear The drive gear turns the pin tractor belts on the bottom tractor feed unit to feed the continuous paper ML590 591 96 02 07 Continuous Paper Feed Push Pull Tractor Mechanism Continuous Paper Feed Push Pull Tractor Mechanism This mechanism consists of an optional pull tractor and a standard push tractor mechanism Continuous paper is fed by these two tractors at the same time Flaten gear ML590 591 96 02 07 2 2 06 Paper Detection Mechanism 2 2 06 Paper Detection Mechanism Top Feed Paper Detection
4. P N 53563101 Frame Main Narrow RSPL 590 B 2 03 4 5 P N 53563201 Frame Main Wide RSPL 591 B 2 03 4 5 ML590 591 96 02 07 3 3 Printer Adjustments 3 3 PRINTER ADJUSTMENTS This section contains the procedures for performing adjustments on the printer These procedures may be required when replacing either consumables or parts The disassembly assembly procedures list the required adjustments and refer you to this section Failure to perform these procedures may result in unnecessary service calls ML590 591 96 02 07 3 3 02 Printhead Gap Adjustment 3 3 02 Printhead Gap Adjustment General Information Before performing this adjustment always verify that the printhead is properly installed This adjustment should be performed when the following parts are replaced Printhead 3 2 02 Space Motor Assembly 3 2 11 Space Rack 3 2 13 Guide Rail 3 2 15 Platen Assembly 3 2 19 Carriage Shaft 3 2 25 NOTE Place a new ribbon cartridge in the printer before testing for parallelism If the density of the top portion of the characters differ from that of the bottom portion follow steps 10 12 This adjustment is comprised of four phases Setup Phase Steps 1 6 The cover is removed and the printhead is placed at a known reference point Printhead Gap Modification Phase Steps 7 9 The distance between the printhead and the platen at the left side of the platen is modified by turning the adjust screw
5. 6 LPI 8 LPI Bottom Margin Valid Invalid Page Width 13 6 8 Page Length 11 11 2 3 12 14 17 3 3042 4 5 36 BE e S Gap Control Auto Gap Semi Auto Gap 12345678 9 CSF Bin 2 Line Spacing 6 LPI 8 LPI kk k Kk Ok Bottom Margin Valid Invalid Page Width 13 6 8 Page Length 11 11 2 3 12 14 17 3 DED 4 Deo O T BRDN Gap Control Auto Gap Semi Auto Gap 1223 45 6e 7 8G k Model 591 only Appears only when optional Roll Paper Stand is installed Appears only when IBM Proprinter emulation is selected ML590 591 96 02 07 Le Optional color ribbon must be installed to print colors other than black te eS Appears only when Epson LQ emulation is selected BE eS Appears only when optional Serial Interface is installed Saas acca Appears only when optional Cut Sheet Feeder is installed Factory default settings are printed in Bold The tables show all possible menu settings available with the Microline 590 591 What you will actually see depends on the active emulation and the options installed ML590 591 96 02 07 3 3 05 Top of Form 3 3 05 Top of Form General Information Top of Form is the distance from the top edge of the paper to the first print position on the page The red line on the ribbon protector indicates the baseline of the Top of Form Setting Top of Form 1 Deselect the printer The SEL lamp must not be lit 2 To set the TOF further
6. When the cut sheet paper is inserted into the printer Point A of Paper Near EndLever B is pushed backward rotating Paper Near End Lever A As Paper Near End Lever A rotates it contacts the Rear Sensor Lever rotating it The Rear Sensor Lever rotates unblocking the Rear Top Paper End Sensor Rear Feed Detection When paper is fed from the rear push tractor Point B is pushed backward rotating Paper Near End Lever A As Paper Near End Lever A rotates it contacts the Rear Sensor Lever rotating it The Rear Sensor Lever rotates unblocking the Rear Top Paper End Sensor Paper near end lever B Rear and Top paper end sensor j Rear sensor lever i pi Fs ai j Paper near end lever A Bottom Feed Detection When the paper is fed from the bottom of the printer Point C is pushed rotating the Bottom Paper End Lever As the Bottom Paper End Lever rotates it contacts and rotates the Bottom Sensor Lever The Bottom Sensor Lever rotates unblocking the Bottom Paper End Sensor Note The method for detecting a paper end condition is in the reverse order that is paper end is detected when the Paper End Sensor is blocked Bottom paper end sensor Bottom sensor lever Point C ML590 591 96 02 07 2 2 07 Support Protector Mechanism 2 2 07 Support Protector Mechanism During printer initialization the support protector is latched in the stored position approximately 5 mm from th
7. m sP z i He uF ML590 591 BLOCK DIAGRAM ML590 591 96 02 07 Block Diagram ML590 591 96 02 07 Program ROM Program ROM Location 05D 2701024 This 64k x 16 bit Mbit EPROM contains the control program for the printer The MPU executes the instructions contained in this program The Program ROM is assigned to the program memory area of the MPU and instructions are fetched by the PSEN signal of the MPU wucox L Lf LS ISU LILI LSPs man DCO PE N 7 i ma Sinn oN os Ns a Pag Progam Program togram ML590 591 96 02 07 RAM RAM Location 05E 511664Z The RAM is CMOS dynamic RAM with 65 536 words x 16 bit configuration and is used as a receive buffer print buffer and work buffer COC Write omg ae EE a ____________Bbit bus byte instruction s6 5 us wortintruction Qockout is provided when the original excitation is selected ML590 591 96 02 07 Character Generator ROM CG ROM Character Generator ROM CG ROM Location 05C 27C4096 This 256k x 16 bits 4 Mbit masked EPROM contains the character data for the various fonts The CG ROM is assigned to the program memory area of the MPU The data is accessed by the PSEN signal of the MPU MPU ROM ML590 591 96 02 07 Electrically Erasable Programmable ROM EEPROM Electrically Erasable Programmable ROM EEPROM Location 03C 93CS46 The EEPROM is
8. Lubrication When lubricating refer to Section 3 5 of this Service Handbook P N 50805101 Lever Change RSPL Both B 2 04 P N 51228201 Gear Idle RSPL Both B 2 04 ML590 591 96 02 07 3 2 24 Pressure Spring 3 2 24 Pressure Spring 1 Perform these procedures 3 2 01 3 2 06 3 2 07 3 2 16 3 2 17 3 2 19 3 2 20 3 2 22 3 2 23 Turn the front release gear arm 1 until it is disengaged Remove the release cam 2 This is the medium size thick cam Work the end of the pressure spring 3 free and remove the spring Remove the front release gear arm This arm is long with a serrated edge Remove the switch lever 4 This is the small lever eee rer rey Do WP Front Release Gear Shaft NOTE Installation Install the release cam first Then install one end of the pressure spring into the release cam Slide the cam and spring away from the base frame until the opposite end of the spring can be installed into the frame Make sure that the front release gear arm is engaged as shown A ML590 591 96 02 07 3 2 25 Carriage Shaft 3 2 25 Carriage Shaft CAUTION The space motor assembly etc may be left in place when removing the carriage shaft However use extra care when doing so The carriage cable should be detached from the space motor before removing the carriage shaft 1 Perform these procedures 3 2 01 3 2 06 3 2 07 3
9. The Menu is made up of a number of Groups Each Group has a list of Items Each Item has several Settings Menu Mode To place the printer in the Menu Mode follow this procedure Verify that continuous feed paper is installed Verify that the ribbon is correctly installed Verify that the width of the installed paper matches the paper width menu setting CAUTION If the Menu is set for wide paper and narrow paper is used the printhead will print on the platen This could damage destroy the printhead platen and ribbon Press and hold the SHIFT switch while pressing the SEL switch The MENU lamp will light If the printer was selected the SELECT lamp will light When in Menu Mode the functions printed below the operator panel switches are active Press GROUP until the desired Group prints Press ITEM until the desired Item prints Press SET until the desired Setting prints Press EXIT to save the change and exit Menu Mode NOOR WD Platen Adjust screw j NY ie Adjust gear Press paper clip here IdiegearD Left Right t Mend Center end HL al lt SARASA O A P eee ye f H Print head B f Clockwise Gap Increases Carriage shaft f Adjust gear Q2 Counter clockwise Adjust screw Gap Decreases 1 Gap change gear Cc Figure 1 ML590 591 96 02 07 Print head 0 014 t 0 001 inch Counter clockwise Gap Decreases Clockwise
10. Automatically determines paper thickness of the first page During single sheet feed each page s thickness IS NOT checked while a job is printing 1 2 3 4 5 6 7 8 9 Used when the same paper is used ALL of the time Bypasses the automatic head gap adjustment 1 is the narrowest gap setting 9 is the widest gap setting ML590 591 96 02 07 sheets of Fensitve ted Pressure sensitive pape is SP or more Interlea paper is 4P or Pope Approniee gp a setting gap levels 6 Setting gap levels 1 ML590 591 96 02 07 1 6 19 Print Modes 1 6 19 Print Modes Letter Quality Utility High Speed Draft ML590 591 96 02 07 1 6 20 Print Speed 1 6 20 Print Speed Table of Print Speed and Character Matrix Mode LQ Utility High Speed Draft Speed 120 12 cpi 360 12 cpi 450 15 cpi Matrix H x V 29 x 18 9x17 7x17 ML590 591 96 02 07 1 7 Paper Specifications 1 7 PAPER SPECIFICATIONS CAUTION Use Bottom Feed and or optional Pull Tractor for card stock and labels 1 7 01 Types Card Stock Weight Width Length Thickness Paper Feed Path Printhead Gap Information Continuous Form Weight Single Part Multi Part Carbonless Multi Part Interleaf Paper Width Length Thickness 120 lbs 450 g m2 Maximum Microline 590 5 to 8 inches 12 7 to 20 3 centimeters Microline 591 5 to 14 inches 12 7 to 35 6
11. Gap Increases Adjustcam Adjust gear ML590 591 96 02 07 Printing the Menu Printing the Menu Printing the Menu provides a reference of current menu settings This will help you move through the menu Okidata STRONGLY RECOMMENDS printing the Menu before resetting the Menu to factory defaults Once the Menu is reset all customized settings are LOST To print the Menu follow this procedure 1 Verify that continuous feed paper is installed 2 Verify that the ribbon is correctly installed 3 Verify that the width of the installed paper matches the paper width menu setting CAUTION If the Menu is set for wide paper and narrow paper is used the printhead will print on the platen This could damage destroy the printhead platen and ribbon Press and hold the SHIFT switch while pressing the SEL switch The MENU lamp will light If the printer was selected the SELECT lamp will light When in Menu Mode the functions printed below the operator panel switches are active Press the PRINT switch The Menu will print Press EXIT to exit Menu Mode OONDOF For more information regarding the menu please refer to the Printer Handbook HARE ML590 591 96 02 07 Reset Menu to Factory Defaults Reset Menu to Factory Defaults CAUTION Once the menu has been reset all customized menu settings will be lost Always print the menu before resetting the printer to factory defaults To re
12. Move the paper lever to the REAR or BOT position as appropriate Lower the paper support Press FORM FEED to load the continuous forms paper into the printer TA NOTE When the printer is set to a different paper path the printhead will travel back and forth The pins are gently fired to sense paper thickness and set the printhead gap ML590 591 96 02 07 3 3 07 Tear Feature 3 3 07 Tear Feature NOTE Tear is activated by pressing TEAR It is a manual procedure FORMS TEAR OFF is activated by changing a setting in the Menu It is an automatic procedure General Information 1 This feature allows a printed page rear or bottom feed continuous form to be torn off without wasting paper or adjusting the printer 2 Tear Feature advances the paper from the initial printing position to the tear off position The top of the page perforation will be even with the tear bar The tear bar is located under the clear top of the access cover 3 Paper will remain in the tear off position until the printer receives data Then the paper is retracted to the initial print position 4 To activate the Tear Feature press TEAR ML590 591 96 02 07 3 3 08 Forms Tear Off 3 3 08 Forms Tear Off NOTE Tear is activated by pressing TEAR It is a manual procedure FORMS TEAR OFF is activated by changing a setting in the Menu It is an automatic procedure General Information 1 This feature allows a printed pa
13. SNS3 Bottom Feed Paper Out Sensor Switches BASW Paper Path Select Switch Test Points 5 vdc Logic LED Drive Voltage CN3 Pins 5 and 6 8 vdc Serial Interface Line Voltage CN3 Pin 11 8 vdc Serial Interface Line Voltage Comparator Voltage CNS Pin 10 12 vdc Printhead Analog Voltage CN3 Pin 9 40 vdc Printhead Space Motor Line Feed Motor Drive Voltage CN3 Pins 1 and 2 Frame Ground CNS Pins 3 and 4 Logic Ground CN3 Pins 7 and 8 ALM Alarm Signal to the Power Supply Board CN Pin 12 ML590 591 96 02 07 madd ao aba bola ml mbee bede me bebe SNS3 ML590 591 96 02 07 A 2 02 Operator Panel Board LEOP A 2 02 Operator Panel Board LEOP Firmware NONE Fuses NONE Jumpers NONE Sensors NONE Switches SEL Select SHIFT LF Line Feed FF Form Feed TEAR PARK QUIET PQ Print Quality CP Character Pitch Test Points NONE r T te lej ies 0 o amp o SEL SHIFT LF FF TEAR PARK QUIET ML590 591 96 02 07 A 2 03 Power Supply Assembly A 2 03 Power Supply Assembly Firmware NONE Fuses F1 125 250V 5 amp AC LINE Fuse F2 125 250V 2 5 amp Protects 5 vdc circuit Jumpers NONE Sensors NONE Switches SW Power Switch Test Points 5 vdc Logic LED Drive Voltage CN2 Pins 5 and 6 8 vde Serial Interface Line Voltage CN2 Pin 11 8 vdc Serial Interface Line Voltage Comparator
14. Sensor Control P C B Thermistor Print wire 2 W etnot printing ML590 591 96 02 07 2 2 02 Spacing Mechanism 2 2 02 Spacing Mechanism The spacing mechanism consists of a carriage shaft mounted parallel to the platen anda carriage frame which moves along the shaft The carriage frame is driven by a DC servo motor mounted on the carriage frame Items included in the spacing mechanism are listed below Space Motor Assembly DC Servo Motor Motor gear Sensor Encoder Disk Carriage Frame Carriage Shaft Space Rack Spacing Operation The carriage frame which contains the printhead and space motor moves along the carriage shaft parallel to the platen When the space motor rotates the driving force is transmitted to the motor gear As the motor gear rotates the carriage moves along the platen For every revolution of the DC servo motor the carriage frame moves 0 8 inch 20 32 mm As the DC servo motor rotates a slotted disk called the encoder disk passes between a light source and two photosensors The position of the carriage frame can be determined by counting the pulses generated by the photosensors In the same way the rotation of the space motor can be recognized and controlled by measuring the phase relationship and the pulse width of the signals generated by the photosensors Print Head Carriage frame Motor gear Slider Guide rail ML590 591 96 02 07 2 2 03 Head Gap
15. cable 9 If the problem continues check the parts listed below in the order given Replace the suspected part Be sure to test the printer after replacing each part OW N Carriage Frame Set Motor Space Rack Space Cable Printhead Board Main Control anon s 10 If the problem continues check all assemblies and connections Then contact Okidata Technical Information for further assistance ML590 591 96 02 07 4 6 Fault Alarms 4 6 FAULT ALARMS 4 6 01 General Information Follow these guidelines when using the Troubleshooting Tables Record the status OFF solidly ON Flashing of the Operator Panel LEDs Go to to the Troubleshooting Table Index Section 4 6 02 Look for the LED Indications you have observed The Reference Number in the column at the right side of the Troubleshooting Table Index directs you to the appropriate item in the Troubleshooting Tables Section4 6 03 5 The Troubleshooting Tables will provide a Failure Description Probable Cause and Recommended Action 6 The Recommended Action will direct you to the actions listed below Follow a specific RAP Replace items in a listed order ROD ML590 591 96 02 07 4 6 02 Alarm LED Display Troubleshooting Table Index 4 6 02 ALARM LED Display Troubleshooting Table Index NOTE Reference Numbers 25 and 26 use identical Operator Panel displays On F On Flashing
16. command OPTXD is transmitted from the MPU to the operation panel LSI in synchronization with the OPCLK signal Once the LSI decodes the command the command must pass a command code check and have no parity errors Then the specified I O control will return the two byte command response to the MPU Command gt LED Driver and Data latch Switch controlier 1 tih 2 1 2 a e PIE owe a e a meee FUL aun i he V N nanna Y H ontu Sa H if Nowe From the illustration above you can tee that the command and the command response are Output at the same sme This it because the bit O to bit 3 of OF RED are fined so that the reaporse can be returned before decoding the command ML590 591 96 02 07 2 1 08 Alarm Circuit 2 1 08 Alarm Circuit Driver Circuit Alarm Processing The printhead driver output the head gap magnet output and the color ribbon magnet drive signal are monitored at R670 and C15 and the POWER OFF P signal is output by the comparator Location 01A 1C2901 when driven for more than the specified time This signal becomes the ALM signal The ALM signal is sent to the power supply board and causes the DC voltages to be turned off 40V 133 GAP MDV Wb gt POWER OF F P c15 COR MDV HDALM P Low Motor Drive Voltage Alarm 40V is converted into the POWLEY signal 0 vde to 5 vde by the voltage divider network of R533 and R537 then input to the A D port of
17. 0 36 mm Maximum Thickness Rear Feed 0 017 inches 0 44 mm Maximum Thickness Bottom Feed Weight Note The recommended weight is specific to paper type Minimum 9 Ib 35 g m2 Maximum 24 Ib 90 g m2 Width Note The recommended width is specific to paper type Microline 590 ML590 591 96 02 07 Minimum Maximum Microline 591 Minimum Maximum Printing Area Microline 590 Microline 591 3 5 inches 8 8 centimeters 10 5 inches 26 6 centimeters 3 5 inches 8 8 centimeters 16 5 inches 41 9 centimeters 8 inches Maximum 13 6 inches Maximum ML590 591 96 02 07 1 8 Memory Specifications 1 8 1 8 01 1 8 02 1 8 03 MEMORY SPECIFICATIONS EEPROM 1 Kbit serial EEPROM used to store Menu data ROM Older Configuration 1 Mbit Character Generator ROM located on main control board 05C 1 Mbit Printer Control EPROM located on main control board 05D New Configuration 4 Mbit located on main control board 05D RAM Receive Buffer Size is selected through the Menu Settings are 64 K 32 K 1 line ML590 591 96 02 07 1 9 Consumables 1 9 CONSUMABLES 1 9 01 Ribbon CAUTION Using a non Okidata ribbon may damage the printhead and void any warranties Material Cartridge Fabric Types Black Ribbon Color Ribbon Magenta Yellow Cyan Black Life On average at 10 characters per inch Utility Mode Black Ribbon 4 million characters Color Ribbon Magenta 1
18. 1 5 million characters Magenta Approximately 1 5 million characters Yellow Approximately 0 8 million characters 1 11 06 Warranty Limited Two years parts and labor 1 11 07 Service Authorized Okidata Service Centers ML590 591 96 02 07 Chapter 2 2 1 Electrical Operation 2 1 ELECTRICAL OPERATION 2 1 01 General Information The printers is made of the following electrical components Main Control Board Power Supply Assembly Operator Panel Space Motor Line Feed Motor Printhead ML590 591 96 02 07 2 1 02 Main Control Board 2 1 02 Main Control Board The main control board is made up of the microprocessor peripheral circuits drive circuits sensors and interface connectors The power to the main control board is supplied by the power supply assembly through a wire harness The power to other electrical parts such as the line feed motor space motor and printhead is supplied by the power supply assembly through the connectors on the main control board Microprocessor MPU Location 04D 67X640 16 bit MPU using CMOS technology The MPU contains a 20 bit address bus a 16 bit data bus The MPU can access 1 Mbyte of program memory space and 1 Mbyte of data memory space The microprocessor controls the entire printer by executing the control program through the LSI and the driver circuit op ineiligent Head ef GaP e He MG ALAT Cole option 2P Encoder lt
19. 2 16 oH ae OO Push the end A of the carriage shaft 1 until it clears the base frame Pull the carriage shaft free of the base frame Remove the support protect reset spring 2 Remove the support protector assembly 3 Remove the frame set carriage 4 DRN NOTE Installation After installing the carriage shaft check the printhead gap adjustment Refer to Section 3 3 of this Service Handbook Cleaning ML590 591 96 02 07 3 2 26 Leaf Spring 3 2 26 Leaf Spring 1 Perform these procedures 3 2 01 3 2 06 3 2 07 3 2 16 3 2 25 0 2 Position the unit so you can access the top and bottom of the leaf spring 1 3 Start at one end of the spring 4 Use a straight slot screwdriver to release the bottom extension 2 from the claw of the base frame 5 Pull the spring up to release the top of the spring from the upper claw 6 Repeat the above two steps working towards the opposite end of the spring 7 Remove the spring OH ae Oe D A er P N 50923001 Spring Leaf Narrow RSPL 590 B 2 03 P N 50923101 Spring Leaf Wide RSPL 591 B 2 03 ML590 591 96 02 07 3 2 27 Bottom Paper Sensor Levers 3 2 27 Bottom Paper Sensor Levers 1 Perform these procedures 3 2 01 3 2 06 3 2 07 3 2 16 3 2 17 3 2 19 3 2 20 3 2 22 3 2 23 3 2 24 LAA A A A Oe OS ww a A A 2 W
20. 2 2 Mechanical Operation 2 2 MECHANICAL OPERATION The following section explains the mechanical operation of the printer Spacing Mechanism c ccccccseescsseseseees A Head Gap Mechanism ccccceeeeeeeees Ribbon Drive Mechanism cccccccccceeeeee Line Feed Mechanism ccccccccseesseeteeee Paper Detect Mechanism 0cceeee Support Protector Mechanism 05 Automatic Paper Load ccccccescseseeseeees PEDO ni a EE A A ARAE O ML590 591 96 02 07 2 2 01 Printhead Mechanism 2 2 01 Printhead Mechanism The printhead is a spring charged 24 pin printhead It is attached to the carriage which moves parallel to the platen Electrically the printhead is controlled by the main control board via the carriage cable and the space motor Arrangement of the head pins View from the tip of the printhead ML590 591 96 02 07 Interconnect Diagram Control Board to Printhead Interconnect Diagram Control Board to Printhead Note The printhead coil resistance values ARE NOT LISTED The individual print wire control lines CANNOT be accessed on this printhead Signal Connector pin number RST N ELS 10v 5v5 rosa HI TES HOSDATA N SSS ML590 591 96 02 07 Line Feed Motor Resistance Line Feed Motor Resistance The resistance of each coil should be approximately 13 ohms Pin
21. 3 5 of this Service Handbook P N 53343001 Holder Connector L RSPL Both B 2 06 P N 53343101 Holder Connector R RSPL Both B 2 06 P N 56510401 Motor Space Assembly RSPL Both B 2 06 P N 53343301 Guide Roller Assembly Both B 2 06 ML590 591 96 02 07 3 2 12 Carriage Cable 3 2 12 Carriage Cable 1 Perform these procedures 3 2 01 3 2 06 3 2 07 3 2 11 D gt os tt ee ee ee 2 Slightly bow the carriage cable 1 to release it from the claws 2 and the projection on the main frame 3 3 Remove the carriage cable NOTE Installation The contacts on the cable face up when the cable is positioned on the main frame The cable end with the 45 angled contacts connects to the gear case assembly DO NOT sharply bend the carriage cable You will slightly bow the cable to position it under the claws and over the projection P N 56627301 Cable Carriage Narrow RSPL 590 B 2 06 P N 56627302 Cable Carriage Wide RSPL 591 B 2 06 ML590 591 96 02 07 3 2 13 Space Rack 3 2 13 Space Rack 1 Perform these procedures 3 2 01 3 2 02 _ 3 2 04 3 2 10 3 2 11 AS a ae a ee 2 Remove the spring 1 3 Disengage the claws 2 on the both ends of the space rack 3 4 Pull the space rack straight up and remove it NOTE Installation After installing the space rack check the printhead gap adjustment Refer to S
22. 7 This is part of the upper cover and should not be removed No font cards are currently available NOTE When cleaning refer to Section 3 4 of this Service Handbook ML590 591 96 02 07 3 2 07 Control Board AKGI 3 2 07 Control Board AKGI 1 Perform these procedures 3 2 01 3 2 06 0 2 Remove the two screws 1 3 Release the control board AKGI 2 from the bracket 3 4 Tilt the board to access the connectors 5 Detach connectors CN7 operator panel 4 CN8 carriage cable 5 CN3 power supply 6 and CN6 line feed motor 7 6 Remove the board NOTE Installation The bottom sensor lever must be positioned in the SNS3 sensor 8 The rear sensor lever must be positioned in the SNS1 sensor 9 The cut sheet continuous sensor lever must be positioned below the BASW sensor 10 The lever should contact the sensor only when the change lever is in the top feed middle setting The IC EEPROM is soldered in on the board P N 55937401 PCB AKGI w o ROM RSPL Both B 2 02 P N 55938301 IC EEPROM BR93CC46A RSPL Both B 2 02 ML590 591 96 02 07 3 2 08 Power Supply Assembly 3 2 08 Power Supply Assembly Perform these procedures 3 2 01 0 3 2 06 1 Detach the cable from connector CN2 1 of the power supply board 2 2 Detach the cable from connector CN3 3 of the control board 4 3 Use a straight slot screwdriver t
23. Kit Includes Color mechanism Color Ribbon End user installable ML590 591 96 02 07 1 10 04 Bottom Push Tractor Kit 1 10 04 Bottom Push Tractor Kit Note The Bottom Push Tractor Kit P N 70022901 is a narrow feeder for the Microline 590 The Bottom Push Tractor Kit P N 70023101 is a wide feeder for the Microline 591 Bottom Feed Paper Type Continuous Feed Includes Stand and Metal Tear B ML590 591 96 02 07 1 10 05 Serial Interface 1 10 05 Serial Interface Super Speed 19 2K RS 232C Ready Busy X On X Off Protocols Can be configured through the Menu or OKISmart Utility Program ML590 591 96 02 07 1 10 06 Roll Paper Stand 1 10 06 Roll Paper Stand Adapts printer for use with roll type paper Model 590 only Includes Stand Support Cord and DIN plug for connection to printer ML590 591 96 02 07 1 11 Reliability 1 11 RELIABILITY 1 11 01 Mean Time Before Failure MTBF Approximately 6 000 hours 25 duty cycle 35 page density 1 11 02 Mean Time To Repair MTTR Approximately 15 minutes to major sub assembly level 1 11 03 Printer Life Approximately 16 000 hours of power on time 25 duty cycle 35 page density 1 11 04 Printhead Life Average 200 million characters in 10 cpi utility mode normal 25 duty 35 page density 1 11 05 Ribbon Life Black Approximately 4 million characters Color Black Approximately 1 5 million characters Cyan Approximately
24. Mechanism 2 2 03 Head Gap Mechanism The head gap is automatically set for the thickness of the medium loaded in the printer In the case of envelopes where the medium thickness varies as the printhead moves along the platen the head gap changes to compensate for the differences in thickness Head Gap Setting Operation Once printing starts the space motor rotates the ribbon gear causing idle gear C to turn the change gear When the MPU requests a change in the head gap setting the GAP P signal causes the armature which is holding the change gear to be attracted to the pranger magnet The gap reset spring can now push the change gear so it contacts the gap change gear The rotation of the gap change gear causes idle gear D to turn the adjust gear The adjust gear turns the adjusting screw resulting in a new head gap setting Note As the adjusting screw turns counter clockwise the gap narrows As the adjusting screw turns clockwise the gap widens Narrows Pr nihesd a Adjusting gear ee i NG ke i CCW Ki Met 5 _ oi y Platen There is a cam at each setting of the gap change gear When the change gear is at the top of the cam the change gear disengages from the gap change gear At this time the armature resets changing the head gap by one setting The head gap is modified in 06 mm units for each range setting ML590 591 96 02 07 idle gear C Ribbon gear ee Sen i Ribbon drive gea
25. NOTE The front pressure springs for the Microline 590 3A have three extensions The front pressure springs for the Microline 591 8B have one extension The Microline 591 uses both springs Lubrication When lubricating refer to Section 3 5 of this Service Handbook _ P N 50922901 Spring Front Pressure Narrow RSPL 590 B 2 05 P N 50922801 Spring Front Pressure Wide RSPL 591 B 2 05 P N 53341101 Holder Front Roller RSPL Both B 2 05 P N 53341202 Roller Front Pressure RSPL Both B 2 05 ML590 591 96 02 07 3 2 29 Tractor Assembly 3 2 29 Tractor Assembly 1 Perform these procedures 3 2 01 3 2 06 3 2 07 3 2 16 3 2 17 3 2 19 3 2 20 3 2 22 3 2 23 3 2 24 Use a needle nose pliers to release the claw of the tractor gear 1 and remove the gear Remove the change gear 2 Raise the lock levers 3 on the left 4 and right 5 tractor assemblies Slide the lower tractor feed shaft 6 in the direction of arrow A and remove the shaft This shaft is square 6 Slide the upper tractor feed shaft 7 in the direction of arrow A and remove the shaft This shaft is round 7 Remove the left tractor assembly the guide 8 and the right tractor assembly LA AAA dd dD Oe OO a S a a A A oR P ML590 591 96 02 07 3 2 30 Main Frame 3 2 30 Main Frame All disassembly procedures must be carried out to reach the base frame 1
26. No Replace the RS232C board Are 8 vdc 8 vdc present on the main control board Yes Replace the RS232C board Has the problem been resolved Yes End of procedure No Contact Technical Support No Replace the main control board Has the problem been resolved Yes End of procedure No Contact Technical Support ML590 591 96 02 07 4 8 Printer Tests 4 8 PRINTER TESTS 4 8 01 General Information This section covers the tests listed below Rolling ASCII Test Font Test Serial Interface Loopback Test Hexadecimal Dump Mode The Rolling ASCII and Font Tests check print operations The Serial Interface Loopback Test checks the operation of the serial interface board The Hexadecimal Dump Mode checks the data transfer between the computer and printer NOOR WOOD ML590 591 96 02 07 4 8 02 Rolling ASCII Test 4 8 02 Rolling ASCII Test General Information The rolling ASCII test is a continuous printout of all 96 ASCII characters Use this test to check the following items Print Quality Across the entire length of a line Down the entire page Line Spacing Left Margin Alignment NOORWND At the top of the test is the printer type 1 emulation 2 country 3 and firmware revision level 4 This information is often required while performing service or when contacting Okidata Have this test available during your service call CAUTION Before running this test
27. Perform this procedure 3 2 01 0 Open the access cover 1 Open the cover of the pull up roller assembly 2 Press at A while rotating the assembly towards the back of the printer Remove the assembly Adk Jj 4 r NOTE Lubrication When lubricating refer to Section 3 5 of this Service Handbook P N 53341501 Roller Pull Up Assembly Narrow RSPL 590 B 2 04 P N 53341601 Roller Pull Up Assembly Wide RSPL 591 B 2 04 ML590 591 96 02 07 3 2 06 Upper Cover Access Cover and Sheet Guide Assemblies 3 2 06 Upper Cover Access Cover and Sheet Guide Assemblies 1 Perform this procedure 3 2 01 0 2 Pull the platen knob 1 straight out and remove it 3 Set the change lever 2 to the bottom feed position toward the rear of the printer 4 Insert a flat blade screwdriver into the grooves 3 of the frame and pry the upper cover 4 away from the frame 5 Raise the front side of the upper cover assembly 6 Tilt the upper cover assembly toward the rear to disengage the claws not shown at the rear of the frame 7 Lift the upper cover assembly and remove it CAUTION Do not rotate the access cover past the vertical when removing it or you will break the tab extensions 8 Raise the access cover assembly 5 until it is vertical then lift it straight up to remove it 9 Remove the sheet guide assembly 6 10 Note the position of the cover B lt for card slot gt
28. Possible Causes 1 Power OFF the printer Move the carriage assembly The carriage should move smoothly If it does not remove the cause of the binding 2 Refer to the next section and or Technical Service Bulletin 3309 ae eee Drifting Margin ee ML590 591 96 02 07 Left Margin Drifting Problem Left Margin Drifting Problem NOTE This information is also provided in Technical Service Bulletin 3309 To correct a problem with the left margin drifting during print operations follow this procedure 1 Manually slide the carriage assembly back and forth along the full length of the carriage shaft Check for drag caused by the ribbon a dirty space rack or other obstructions If you suspect that the ribbon is causing movement problems check the movement of the carriage assembly with the ribbon removed OR with a new ribbon installed 4 Check the contact between the carriage frame and the space motor board assembly 5 Contact is made at the front edge of the board 6 Any gap will keep the space motor gear from fully engaging with the space rack This will result in slippage problems which will affect spacing operations 7 Check the printhead cable connections between the main control board and the space motor Solid contact MUST BE made at all connections or print problems will occur 8 Check the condition of the printhead cable If it is broken torn or sharply bent replace the
29. Printer RAP 01 No Power Supplied to Printer START The printer does not power On when the AC switch is turned ON Check the AC cable Is it correctly connected Yes Check the fuse on the power supply board and F1 of the main control board Are they open No Go to A Yes Replace the fuse s with fuse s of the same rating Is the problem resolved Yes End of procedure No Go to A No Remove the cable from CN3 on the main control board Refer to Appendix A of this Service Handbook for voltage check points on CN3 of the main control board Check the output voltages of the secondary of the transformer Replace the following in the order listed below Check operation before replacing next item in list 1 Operation Panel 2 Power Transformer Has the problem been resolved Yes End of procedure No Contact Technical Support A Remove the cable from CN7 of the main control board Then power ON the unit Do the operation panel LEDs light No Go to B Yes Power OFF the unit Remove the printhead Power ON the unit ML590 591 96 02 07 Has the problem been resolved Yes Replace the printhead Has the problem been resolved Yes End of procedure No Go to B No Replace the following in the order listed below Check operation before replacing next item in list 1 Ribbon Feed Mechanism 2 Carriage Cable 3 Main Control Board 4 PROM 05CA Has the problem been resolved Yes End of procedure No Contact
30. Roller Both 3 2 11 4PA4025 3719G1 Assembly 9 53341901 Roller Guide RSPL Both 3 2 11 4PP4025 3398P1 10 53342001 Holder Guide Roller RSPL Both 3 2 11 3PP4025 3399P1 11 N A N A Pin Both 3 2 11 12 N A Guide Roller Spring Both 3 2 11 4PP4025 3401P1 13 56627301 Cable Carriage RSPL 590 3 2 12 2PU4007 1193P1 Narrow 13 56627302 N A Cable Carriage RSPL 591 3 2 12 Wide 14 53343201 Assembly Both 3 2 14 4PA4025 3718G1 Roller Holder Backup 15 53341701 Roller Back Up RSPL Both 3 2 14 4PP4025 3392P1 16 53341801 Holder Back Up RSPL Both 3 2 14 3PP4025 3393P1 Roller 17 N A N A Pin Both 3 2 14 18 N A Backup Roller Both 3 2 14 4PP4025 3397P1 Holder Spring 19 50098901 Carriage Frame Set RSPL Both 3 2 25 4PP4025 3394G1 ML590 591 96 02 07 B 2 08 Options B 2 08 Options lems 9 10 441 12 and43 arenot shown Item Okidata P N Oki J Description Comments Disassembly P N Refer to B 1 02 Procedure 1 70022501 N A Kit Single Bin CSF Option 590 N A Narrow 1 70022701 N A Kit Single Bin CSF Option 591 N A Wide 2 70023001 N A Kit Pull Tractor Option 590 N A Narrow 2 70023201 N A Kit Pull Tractor Wide Option 591 N A 3 70022901 N A Kit Push Tractor Option 590 N A Bottom Narrow ML590 591 96 02 07 3 70023101 N A Kit Push Tractor Option 591 N A Bottom Wide 4 52106003 N A Color Kit Incl color
31. a CMOS serial I O type memory which is capable of electrically erasing and writing 1 024bits The EEPROM contains the menu data and the head drive time correction data MPU EEPROM AS 20 tp XO DOCX D15 DO DIS DO DIS Read cycle timing READ DO Bus Ready twp Write cycle timing WRITE ML590 591 96 02 07 LSI LSI Location 02D MSM 79V035 Detects the output of the two phase sensor on the DC space motor to control the motor drive phase Transmits and receives serial data to and from the printhead based on the dot timing which is derived from the space motor speed Controls the external interface The LSI is connected to the MPU aose LIL was XX BS a Clockout it provided when the original excitation is selected ML590 591 96 02 07 2 1 03 Initialization 2 1 03 Initialization This printer is initialized when the printer is powered on or when the I PRIME N signal is input from the host via the parallel interface Printer Initialization occurs as listed below The RST N signal is output from the Reset circuit to reset the MPU and LSls The program is executed and the LSls are reset by the MPU via lIORST N Note A Reset operation initiated by I PRIME does not reset the MPU The program sets the LSI 02D mode checks the memory ROM RAM then executes carriage homing and determines the phase of the line feed motor Finally the program establishes the inter
32. been resolved ML590 591 96 02 07 Yes End of procedure No Contact Technical Support ML590 591 96 02 07 RAP 09 Operation Panel Malfunction RAP 09 Operation Panel Malfunction START The operation panel does not function properly Do the operation panel LEDs light when power is applied Yes Make sure the cable from CN1 of the operation panel is properly connected to CN7 on the main control board GotoA No Check the F1 fuse on the main control board and the fuse on the power supply board Are they open Yes Replace the open fuse with one that has the proper rating GotoA No Replace the power supply unit GotoA A Has the problem been resolved Yes End of procedure No Replace the operation panel board Has the problem been resolved Yes End of procedure No Replace the main control board Has the problem been resolved Yes End of procedure No Contact Technical Support ML590 591 96 02 07 RAP 10 Parallel Interface Problem RAP 10 Parallel Interface Problem START No parallel port communication Is the SEL LED blinking Yes The printer is in the Print Suppress mode Disable the menu item Print Suppress if the function is not required End of procedure No Does the SEL LED light Yes GotoA No Press SEL key Has the problem been resolved No Disconnect the cable Does the SEL LED light Yes Change the menu item I prime to invalid No GotoA Yes Is data being received proper
33. ee m a PHASE B a Se ine eee wae FORWARD REVERSE ML590 591 96 02 07 Space Motor Control Space Motor Control The SP LF motor driver Location 5A MHM2025 drives the three phase brushless motor Motor movement is based on the phase signal SPU SPV and SPW and the speed instruction data from the LSI The MPU can identify the current speed of the space motor by measuring the pulse width of the output Phase A Phase B of the encoder disk sensor After comparing the target speed for each print mode with the actual speed the motor is accelerated or decelerated to maintain the desired speed for each print mode awa I Lit Ll ML590 591 96 02 07 Encoder Disk Encoder Disk As the space motor operates the encoder disk spins When the encoder disk interrupts the photo sensors the signals Phase A and Phase B are generated The LSI Location 02D MSM79V035 divides these edge pulse signals the frequency division is based on the selected print pitch to generate the signal IPT The IPT signal provides dot on timing and carriage position detection timing ML590 591 96 02 07 2 1 07 Operation Panel 2 1 07 Operation Panel The Serial I O Port Ports 20 23 of the MPU reads the operation panel switch data from the operation panel control LSI Location IC1 BUS148S The Serial I O Port also outputs LED data to the operation panel control LSI A two byte 15 bits 1 parity bit even parity
34. it is closed properly Go to A 3 Paper squeezed from either end Check around the pressure roller mechanism Check the front pressure springs to see that they are mounted properly There are three springs in the Microline 590 and five springs in the Microline 591 Check the tension of all the front pressure rollers to see if they are the same Top springs 250 g Rear Springs 90 g Make sure that the front release gear arm and the gear of the front release gear shaft are in the proper position Go to A A Has the problem been resolved Yes End of procedure No Check that the head gap is set properly Has the problem been resolved Yes End of procedure No Contact Technical Support ML590 591 96 02 07 RAP 05 Printhead Pins Not Firing RAP 05 Printhead Pins Not Firing START Missing dots on output Verify that the printhead gap is set correctly Ensure the carriage cable is making firm contact with CN7 on the main control board and the space motor assembly Inspect both ends of the carriage cable for worn edges Has the problem been resolved Yes End of procedure No Replace the printhead Has the problem been resolved Yes End of procedure No Replace the main control board Has the problem been resolved Yes End of procedure No Replace the carriage cable Has the problem been resolved Yes End of procedure No Replace the space motor assembly Has the problem been resolved Yes End of procedu
35. number of LeMoter anal Connector pin number 1 LFI 2 LFI 3 LFI 4 LF2 5 LF 6 LF2 7 LF3 8 tF3 9 LF3 10 LF LFA LFa ML590 591 96 02 07 Space Motor Resistance Space Motor Resistance The resistance of each coil should be approximately 5 ohms Pin number of SP Motor Signal Connector pin number SP U SP V SP W PHASE A PHASES s ML590 591 96 02 07 Printhead Operation Printhead Operation When the printhead is idle the armature is attracted to the permanent magnet The print wires which are attached to each armature are then concealed inside the wire guide When a signal to print a character is received current flows through a coil The magnetic field generated by the coil opposes the magnetic field between the armature and the permanent magnet The armature is then driven in the direction of the platen by the force of the armature spring The print wire which is attached to the armature protrudes from the tip of the wire guide strikes the paper through the ribbon and prints a dot on the paper As the armature gets closer to the electrode of the analog sensor the capacitance between them increases and a small amount of current flows This current is amplified and sent to the logic control LSI to indicate armature activity In order to attain optimum drive time this information is transferred to the MPU The MPU continually modifies the head gap t
36. printer from the computer 10 To exit Hexadecimal Dump Mode power OFF the printer ML590 591 96 02 07 4 9 Resistance Checks 4 9 RESISTANCE CHECKS 4 9 01 General Description The charts on the following pages provide information needed to determine if the printhead and motors used in the printer are defective NOTE The printhead coil resistance values ARE NOT LISTED The individual printwire control lines CANNOT be accessed on this printhead Operation pan l board _ Seatro comnector ACeonnector Print head Switch p Sparr motor ML590 591 96 02 07 4 9 02 Printhead Interconnect Diagram Control Board to Printhead 4 9 02 Printhead Interconnect Diagram Control Board to Printhead NOTE The printhead coil resistance values ARE NOT LISTED The individual printwire control lines CANNOT be accessed on this printhead Signal Connector pin number ALM O ALM E 40VFS 40v 40v 40v 40v EP EP EP EP TSD EL 5v RST N ELS 10v svs HDSLT N HOSDATA N HOSCLK N aK ERR ML590 591 96 02 07 4 9 03 Line Feed Motor Resistance 4 9 03 Line Feed Motor Resistance The resistance of each coil should be approximately 13 ohms Pin number of LF Motor Connector pin number woenoauweknbk wn ML590 591 96 02 07 4 9 04 Space Motor Resistance 4 9 04 Space Motor Resistance The resistance of each coil should be approximately 5 ohms Pin number o
37. the MPU The value of this voltage is used to control the drive time and the print speed pass number of the head 2 20 pex 40V R533 POWLEV R537 ML590 591 96 02 07 Head Drive Time Head Drive Time The head drive time is modified to compensate for the amount of the voltage drop of the POWLEV signal By monitoring the voltage drop every 500 microseconds the MPU is able to control and maintain the impact necessary for each printhead pin HARE ML590 591 96 02 07 Print Speed Print Speed Actual Voltage 40 vdc Passes Relative Print Speed Required 34 vdc or greater 1 100 32 vdc to 34 vdc 1 Approximately 85 30 vdc to 32 vdc 1 Approximately 50 30 vdc or less 2 Less than 50 ML590 591 96 02 07 Head Overheat Alarm Processing Head Overheat Alarm Processing Two thermistors are used to monitor the printhead temperature One is contained in the printhead and the other in the printhead driver The voltage of the TSD signal is monitored at the MPU A D port to control the pass number and print method unidirectional bi directional at each of seven levels If the printhead temperature exceeds 110 degrees Celsius the printer will switch to unidirectional print If the temperature exceeds 115 degrees Celsius printing will stop Once the printhead cools printing will resume i i u 3 PASS Unidirectiona 3 PASS Unidirectional 2 PASS
38. which varies the vertical position of the space motor Parallel Adjustment Phase Steps 10 11 The adjust cam lever is moved to ensure the printhead moves parallel to the platen Recheck Phase Steps 12 13 Verifies that the parallel adjustment phase did not affect the printhead gap modification phase Procedure Setup Phase 1 Remove the upper cover and pull roller assembly 2 Move the change lever to the rear paper feed position 3 Rotate the platen 4 Set the gap change gear Figure 1 A to Range 2 by turning the adjust screw using a small phillips screwdriver Turn this screw slowly while moving the carriage 1 to the left if turning the screw counter clockwise or 2 to the right if turning the screw clockwise This will allow easier rotation of the gears and prevent the gears from being stripped DO NOT DISENGAGE THE ADJUST GEAR Printhead Gap Modification Phase ML590 591 96 02 07 Slide the carriage assembly to the left side of the platen Check the printhead gap Use a 0 014 inch or 0 35 mm feeler gauge The printhead gap must measure 0 014 0 001 inch 0 35 0 03 mm 3 Use a large straightened paper clip Figure 1 B to push down on the adjust gear This will disengage the adjust gear from idle gear D Use a small phillips screwdriver to turn the adjust screw Figure 1 C Turning the screw CLOCKWISE will increase the printhead gap Turning the screw COUNTERCLOCKWISE will decrease the
39. 0 3 2 04 2 Remove the two screws 1 3 Remove the PC connector 2 NOTE Installation Do not touch the contacts of the PC connector Do not touch the contacts of the space motor 3 Cleaning When cleaning refer to Section 3 4 of this Service Handbook P N 56729601 Connector PC HD40 RSPL Both B 2 06 ML590 591 96 02 07 3 2 11 Space Motor and Roller Guide Assemblies 3 2 11 Space Motor and Roller Guide Assemblies 1 Perform these procedures 3 2 01 0 3 2 02 0 3 2 04 3 2 10 Remove the three screws 1 Lift the space motor assembly 2 Remove the left 3 and right connector holders 4 Remove the roller guide assembly 5 and guide roller spring 6 Use firm pressure to pull the carriage cable 7 out to detach the cable from the space motor assembly 7 Remove the space motor assembly DPP NOTE The guide roller assembly includes the guide roller 8 the guide roller holder 9 and the pin 10 Installation Position the guide roller assembly first The contact side of the cable faces down when the carriage cable is inserted into the connector on the space motor assembly Work the cable from side to side until it is fully seated in the connector No contacts should be visible After installing the space motor assembly check the printhead gap adjustment Refer to Section 3 3 of this Service Handbook When lubricating refer to Section
40. 0 degrees Celsius the printer stops bi directional printing Uni directional printing begins If the temperature exceeds 115 degrees Celsius printing stops Printing will resume when the printhead temperature drops below 115 degrees Celsius Note Refer to Section Two for more information on printhead operation ML590 591 96 02 07 Printhead Gap Information Printhead Gap Information Three items factor into printhead gap information 1 Printhead Gap Adjustment This is a SERVICE ADJUSTMENT made by a technician It is covered in Section 3 3 of this Service Handbook The Adjustment measures 0 014 0 001 inches 0 35 0 03 mm 2 Printhead Gap Adjust This is a MENU ITEM in the SET UP Group It fine tunes the automatic setting of the printhead gap The settings are 0 1 and 1 0 is the factory default Use 1 to darken print if output is consistently light Use 1 to lighten print if output is consistently dark 3 Gap Control This is a MENU ITEM in each Paper Feed Group The Groups are REAR FEED BOTTOM FEED and TOP FEED Gap Control determines how the printhead gap is set The settings are listed below Auto Gap Semi Auto Gap 1 2 3 4 5 6 7 8 9 An explanation of each setting follows Auto Gap This is the factory default Automatically determines paper thickness of the first page During single sheet feed each page s thickness is checked while a job is printing Semi Auto Gap Similar to Auto Gap
41. 05 Printer Emulations 1 6 05 Printer Emulations Note The emulations are co resident Epson LQ IBM XL 24E AGM IBM Proprinter ML590 591 96 02 07 1 6 06 Fonts 1 6 06 Fonts Letter Quality Courier Letter Gothic Prestige Orator Roman Swiss Draft Utility High Speed Draft 15 cpi Bar Code Code 39 UPC A UPC E EAN 8 EAN 13 Interleaved 2 of 5 Code 128 POSTNET ML590 591 96 02 07 1 6 07 Front Panel Switches 1 6 07 Front Panel Switches Select Menu Mode Line Feed Form Feed Top of Form Quiet Micro Feed Up Down Paper Park Pitch Selection Print Quality Selection Tear ML590 591 96 02 07 1 6 08 Graphics Resolution 1 6 08 Graphics Resolution Graphics Resolution 360 x 360 DPI maximum ML590 591 96 02 07 1 6 09 Interface 1 6 09 Interface Standard Parallel Optional RS232C Serial ML590 591 96 02 07 1 6 10 Line Feed Increments 1 6 10 Line Feed Increments Fixed 6 lines per inch Ipi 0 167 inch 4 23 millimeters 8 lines per inch Ipi 0 125 inch 3 175 millimeters Variable n 60 inch n 72 inch n 180 inch n 216 inch n 360 inch ML590 591 96 02 07 1 6 11 Line Feed Time 1 6 11 Line Feed Time 65 milliseconds 6 lines per inch lpi 6 milliseconds 8 lines per inch lpi 1 second 5 0 inches Continuous paper feed rate ML590 591 96 02 07 1 6 12 Menu Mode 1 6 12 Menu Mode Print Prints th
42. 1010201 Plate Right Ground RSPL Both 3 2 17 3PP4025 3386P1 9 50098301 Platen Assembly RSPL 590 3 2 19 3PA4025 3370G1 Narrow 9 50098302 N A Platen Assembly RSPL 591 3 2 19 Wide 10 53341501 Roller Pull Up RSPL 590 3 2 05 3PA4025 3440G2 Assembly Narrow 10 53341601 Roller Pull Up RSPL 591 3 2 05 3PA4025 3530G2 Assembly Wide ML590 591 96 02 07 B 2 06 Printer Unit 3 of 3 B 2 06 Printer Unit 3 of 3 b B205 Item Okidata P N Oki J Description Comments Refer Disassembly P N to B 1 02 Procedure 1 53563101 Frame Main Narrow RSPL 590 3 2 30 3PA4025 3720G1 1 53563201 Frame Main Wide RSPL 591 3 2 30 3PA4025 3721G1 2 50922901 Spring Front RSPL 590 3 2 28 4PP4025 3316P1 Pressure Narrow 3 50922801 Spring Front RSPL 591 3 2 28 4PP4025 3324P1 Pressure Wide 4 53341101 Holder Front Roller RSPL Both 3 2 28 4PP4025 3317P1 ML590 591 96 02 07 5 53341202 Roller Front Pressure RSPL Both 3 2 28 4PP4025 3327G1 6 51227801 Shaft Front Release RSPL 590 3 2 27 3PP4025 3318P1 Gear Narrow 6 51227901 Shaft Front Release RSPL 591 3 2 27 3PP4025 3505P1 Gear Wide 7 50097301 N A Pan Paper Narrow RSPL 590 3 2 27 7 50097401 Pan Paper Wide RSPL 591 3 2 27 1PP4025 3506P2 8 50923301 Spring Pressure RSPL 590 3 2 24 3PP4025 3346G1 Narrow 8 50923401 Spring Pressure RS
43. 1G1 12 50707501 Clamp Cord RSPL Both 3 2 08 4PP4025 3621P1 13 56305901 Fuse GGS 5 120V RSPL Both 3 2 08 540A2036M1502 13 56306001 Fuse 3 15 A for Option RSPL Both 3 2 08 4YB4021 1146P1 230 240V 14 56302901 Fuse 2 5A 120V RSPL Both 3 2 08 540A2036M1252 ML590 591 96 02 07 B 2 04 Printer Unit 1 of 3 B 2 04 Printer Unit 1 of 3 Item Okidata P N Oki J Description Comments Refer Disassembly P N to B 1 02 Procedure 1 53563101 Frame Main Narrow RSPL 590 3 2 30 3PA4025 3720G1 1 53563201 Frame Main Wide RSPL 591 3 2 30 3PA4025 3721G1 2 50804601 Lever Bottom Paper RSPL Both 3 2 27 3PP4025 3315P1 End 3 50804701 Lever Bottom Sensor RSPL Both 3 2 27 3PP4025 3322P1 4 50804801 Lever Rear Sensor RSPL Both 3 2 18 3PP4025 3321P1 5 50804902 Lever Sensor Cut RSPL Both 3 2 18 4PP4025 3323P2 Sheet Continuous 6 56627201 Cord Connection RSPL Both 3 2 21 3PB4025 3356P1 Line Feed 7 56510301 N A Motor Line Feed RSPL Both 3 2 21 Assembly ML590 591 96 02 07 4PB4025 3385P 1 Protect Reset 8 51228401 Gear Line Feed Idle RSPL Both 3 2 21 3PB4055 2887P1 9 51010301 Plate Left Ground RSPL Both 3 2 16 3PA4025 3387G1 10 50923001 Spring Leaf Narrow RSPL 590 3 2 26 3PP4025 3320P1 10 50923101 Spring Leaf Wide RSPL 591 3 2 26 3PP4025 3507P1 11 53067701 Cam
44. 5 million characters Yellow 0 8 million characters Cyan 1 5 million characters Black 1 5 million characters ML590 591 96 02 07 1 10 Options 1 10 OPTIONS Cut Sheet Feeders Pull Tractor Kit Color Ribbon Kit Bottom Push Tractor Serial Interface Roll Paper Stand Bitstream Facelift 2 0 OKlsmart Typer Utility OKlsmart Panel Utility ze EE G ML590 591 96 02 07 1 10 01 Cut Sheet Feeders 1 10 01 Cut Sheet Feeders The CSF 5000 is a narrow feeder for the Microline 590 Single Bin with envelope capability Paper Width 7 2 to 8 5 18 3 cm to 36 3 cm Paper Length 10 1 to 14 25 6 cm to 35 6 cm Capacity 170 sheets 16 lb 100 sheets 20 Ib The CSF 5001 is a wide feeder for the Microline 591 Single Bin with envelope capability Paper Width 7 2 to 14 3 18 3 cm to 36 3 cm Paper Length 10 1 to 14 25 6 cm to 35 6 cm Capacity 170 sheets 16 lb 100 sheets 20 Ib ML590 591 96 02 07 1 10 02 Pull Tractor Kit 1 10 02 Pull Tractor Kit Note The Pull Tractor Kit P N 70023001 is a narrow feeder for the Microline 590 The Pull Tractor Kit P N 70023201 is a wide feeder for the Microline 591 Bottom Feed Rear Feed For Push Pull Operation Paper Types Continuous Feed and Labels ML590 591 96 02 07 1 10 03 Color Ribbon Kit 1 10 03 Color Ribbon
45. 591 REPAIR ANALYSIS PROCEDURES RAPs RAP Number Description J No Power Supplied to Printer O 2 No Spacing Operation O 3 Printhead Homing Error O 4 Paper Jam During Paper Loading O 5 Printhead Not Firing Pins D 6 Poor Print Quality O 7 Ribbon Feed Problem 8 Line Feed Problem O 9 Operator Panel Malfunction 10 Parallel Interface Problem 11 Serial Interface Problem O ML590 591 96 02 07 4 7 01 Using the RAPs 4 7 01 Using the RAPs When using the Repair Analysis Procedures follow these steps 1 Go to the RAP Index 2 Find the RAP which is associated with the printer s problem 3 Go to the appropriate RAP 4 All RAPs begin with a START statement followed by questions or another type of statement ML590 591 96 02 07 4 7 02 RAP Index 4 7 02 RAP Index RAP Number Description 1 No Power Supplied to Printer O 2 No Spacing Operation O 3 Printhead Homing Error O 4 Paper Jam During Paper Loading O 5 Printhead Not Firing Pins O 6 Poor Print Quality O 7 Ribbon Feed Problem 8 Line Feed Problem O 9 Operator Panel Malfunction 10 Parallel Interface Problem 11 Serial Interface Problem A ML590 591 96 02 07 RAP 01 No Power Supplied to
46. Adjust RSPL Both 3 2 15 3PP4025 3380P1 12 53563301 Rack Space Narrow RSPL 590 3 2 13 3PP4025 3376P1 12 53563401 Rack Space Wide RSPL 591 3 2 13 3PP4025 3522P1 13 50923501 Spring Tension RSPL Both 3 2 13 4PB4025 3377P1 Space Rack 14 51009701 Guide Rail Ground RSPL Both 3 2 15 4PP4025 3378P1 Clip 15 51009801 Guide Rail Narrow RSPL 590 3 2 15 3PP4025 3379P1 15 51009901 Guide Rail Wide RSPL 591 3 2 15 3PP4025 3523P1 16 53563501 Shaft Carriage RSPL 590 3 2 25 4PP4025 3381P1 Narrow 16 53563502 Shaft Carriage RSPL 591 3 2 25 4PP4025 3381P2 Wide 17 53067601 Protector Support RSPL Both 3 2 25 4PA4025 3382G1 Assembly 18 50923601 Spring Support RSPL Both 3 2 25 ML590 591 96 02 07 B 2 05 Printer Unit 2 of 3 B 2 05 Printer Unit 2 of 3 Item Okidata P N Oki J Description Comments Refer Disassembly P N to B 1 02 Procedure 1 53563101 Frame Main RSPL 590 3 2 30 3PA4025 3720G1 Narrow 1 53563201 Frame Main Wide RSPL 591 3 2 30 3PA4025 3721G1 2 51228001 Gear Change RSPL Both 3 2 29 4PP4025 3340P1 3 51228101 Gear Tractor RSPL Both 3 2 29 3PP4025 3341P1 4 50805301 Cam Release RSPL Both 3 2 24 3PP4025 3352P1 5 51228201 Gear Idle RSPL Both 3 2 23 4PP4025 3353P 1 ML590 591 96 02 07 6 50805101 Lever Change RSPL Both 3 2 23 2PP4025 3354P3 7 50923201 Spring Reset RSPL Both 3 2 22 3PP4025 3355P1 8 5
47. CAUTION Running the test without paper loaded will allow the printhead to print on the platen This will dirty the platen cause excessive wear of the ribbon and may damage the platen ribbon and printhead Procedure Follow these steps to print the font test 1 Load the paper 2 Power off the printer 3 Press and hold the LF switch while powering on the printer You must hold the LF switch until the test starts to print 4 The one page test will print then stop ML590 591 96 02 07 4 8 04 Serial Interface Loopback Test 4 8 04 Serial Interface Loopback Test NOTE In order to run this test the serial interface board must be installed with a serial loopback test connector attached to it To perform the serial interface loopback test follow these steps Place the printer in the Serial Diagnostic mode Set the Diagnostic Test menu item to YES Power off the printer Attach the loopback connector to the serial port Install continuous feed paper Power on the printer e message LOOP TEST will be printed The size of the Message Buffer will be printed Three different messages may be printed next If the message OK is printed next the message buffer has been tested and no problems were found If the message BAD is printed next there is a problem with the message buffer f the message IF BAD is printed the signal logic was tested and a problem was found Hexadecimal characters 20 through 7F are t
48. Chapter 1 1 1 General Information 1 1 01 General Information The Microline 590 and Microline 591 are letter quality dot matrix printers which utilize OKISMART paper handling Patented Okidata technology does away with the manual head gap adjustment The Microline 590 591 actually reads and learns the media you feed in then automatically adjusts the head gap to the optimum distance This auto gapping process leads to longer printhead life An optional user installable Color Kit coupled with a customer provided color software package allows the printers to add impact to graphics charts transparencies and text presentations Additional options include the Bottom Feed Push Tractor Cut Sheet Feeder Pull Tractor and Serial Interface Board The Microline 590 is an 80 column printer The Microline 591 is a 132 column printer Okidata s extended two year limited warranty covers the parts labor and printhead on both printers The following items are included with the printer OKISMART Typer software which provides the flexibility for the Microline 590 591 to function like a typewriter on checks labels and envelopes OKISMART Panel a utility program that lets you control selected printer functions from your personal computer Scalable Fonts 14 scalable fonts available on diskette Note The OkiSmart software includes three programs 1 OkiSmart Control 2 OkiSmart Panel Emulator 3 OkiSmart Setup Refer to the Printer Handb
49. Feed for continuous feed paper When the continuous feed paper is used either with the rear tractor optional bottom tractor or optional pull tractor place the change lever in the Rear Bottom Feed position When the change lever is placed in this position the reset spring pushes the change gear In this position the idle gear is engaged with the bottom tractor unit drive gear and the tractor gear As the platen turns power is transferred from the platen gear to the idle gear to the change gear and to the push tractor shaft Cutsheet detection switch Main P C B Platen gear R idle gear __ TH Tractor gear Change gear Drive gear Bottom tractor unit a Reset spring ML590 591 96 02 07 Cut Sheet Paper Feed Operation Cut Sheet Paper Feed Operation As the line feed motor rotates power is transferred through decelerating gears line feed idler gear platen gear to the platen When using cut sheet paper the change lever must be in the TOP position so the platen and pressure rollers can feed the paper This also disengages the push tractor ML590 591 96 02 07 Continuous Paper Feed Rear Tractor Mechanism Continuous Paper Feed Rear Tractor Mechanism As the platen rotates power is transferred to the tractor gear from the platen gear the idler gear and the change gear The tractor gear drives the pin tractor belts which feed the continuous paper
50. Option Both N A ribbon and ribbon shift bracket 5 52106002 N A Ribbon Color Consumable N A Both 6 51709101 Bracket Ribbon Shift Option RSPL N A 3PA4025 3581G1 Color Both 7 70023301 N A Kit Roll Paper Stand Option 590 N A 8 70016301 N A Buffer Expansion Option Both N A Card 9 70000803 N A Kit Parallel Interface Option Both N A Plug n Play Accessory 10 70012801 N A Kit RS232 C Serial Option Both N A Interface 11 56412201 Power Supply Option RSPL 3 2 08 4YB4049 1708P1 230 240V 590 11 56412202 Power Supply Option RSPL 3 2 08 4YB4049 1708P2 230 240V 591 12 56624101 Cord AC 220V Option RSPL 3 2 01 3YS4011 1265P1 ML Right Ang Both 13 56624401 Cord AC 240V Option RSPL 3 2 01 3YS4011 1268P1 Both ML590 591 96 02 07 B 2 09 Option Parts B 2 09 Option Parts Item Okidata P N Oki J Description Comments Refer Disassembly P N to B 1 02 Procedure 1 50097901 N A Tractor Pull and Option RSPL Both N A Bottom Assembly Right 2 50098001 Tractor Pull and Option RSPL Both N A 4PA4025 3608G1 Bottom Assembly Left 3 50098501 Stand Bottom Push Option RSPL Both N A 2PA4094 6510G3 Right 4 50098502 Stand Bottom Push Option RSPL Both N A 2PA4094 6510G4 Left 5 50098701 Knife Paper N Option RSPL 590 N A 4PP4094 7385G1 Bottom Push Tractor 5 50098801 Knife Paper W Option RSPL 591 N A 4PP4094 7386G1 Bottom Push Tractor 6 50098101 Tractor Cover
51. Option RSPL 590 N A 2PP4094 7383G1 Assembly N Pull Tractor 6 50098201 Tractor Cover Option RSPL 591 N A 2PP4094 7384G1 Assembly W Pull Tractor 7 53067401 Cover Side Left Option RSPL Both N A 1PP4053 2574P1 Cut Sheet Feeder 8 53067501 Cover Side Right Option RSPL Both N A 1PP4053 2575P1 Cut Sheet Feeder 9 53563001 Shoe Brake Option RSPL Both N A 4PP4053 2547G1 Cut Sheet Feeder 10 55937301 PCB NCSF Option RSPL Both N A 4YA4050 3026G1 Cut Sheet Feeder ML590 591 96 02 07 11 56627501 Cable CSF Option RSPL Both N A 3YS4011 5120G1 Cut Sheet Feeder 12 51010001 Guide Front Sheet Option RSPL 590 N A 1PP4053 2570P2 N Cut Sheet Feeder 12 51010101 Guide Front Sheet Option RSPL 591 N A 1PP4053 2571P2 W Cut Sheet Feeder 13 56510501 Motor Pulse Option RSPL Both N A 3PB4053 2560P1 Cut Sheet Feeder 14 53562901 Supporter Front Option RSPL 590 N A 1PP4053 2576P1 Sheet N Cut Sheet Feeder 14 53480901 Supporter Front Option RSPL 591 N A 1PP4043 1891P4 Sheet W Cut Sheet Feeder 15 50062801 Roller Hopping L H Option RSPL Both N A 4PB4053 1705G1 Cut Sheet Feeder 16 50062802 Roller Hopping Option RSPL Both N A 4PB4053 1705G2 R H Cut Sheet Feeder 17 53321501 Support Rear Sheet Option RSPL Both N A 3PB4025 1941P1 Cut Sheet Feeder 18 53448501 Sheet Friction Option RSPL Both N A 4PB4025 1914P1 Cut Sheet Feeder 19 56306001 Fuse 3 15 A for Op
52. PL 591 3 2 24 3PP4025 3511G1 Wide 9 50805201 Lever Switch Cut RSPL Both 3 2 24 4PP4025 3351P1 Sheet Continuous 10 51228301 Arm Front Release RSPL Both 3 2 24 4PP4025 3350P1 Gear 11 50924701 Spring Lock RSPL Both 3 2 20 4PP4025 3365P1 12 50097701 Paper Chute RSPL 590 3 2 20 3PA4025 3360G2 Assembly Narrow 12 50097801 Paper Chute RSPL 591 3 2 20 3PA4025 3515G2 Assembly Wide 13 53341301 Roller Pressure Rear RSPL 590 3 2 20 3PB4025 3364P1 Narrow 13 53341401 Roller Pressure Rear RSPL 591 3 2 20 3PB4025 3517P1 Wide 14 50097501 Tractor Assembly RSPL 590 3 2 29 3PA4025 3330G1 Narrow 14 50097502 Tractor Assembly RSPL 591 3 2 29 3PA4025 3330G2 Wide ML590 591 96 02 07 B 2 07 Carriage Assembly B 2 07 Carriage Assembly Item Okidata P N Oki J Description Comments Refer Disassembly P N to B 1 02 Procedure 1 50707401 Clamp Head RSPL Both 3 2 03 3PP4025 3431P1 2 53562801 Protector Ribbon RSPL Both 3 2 03 3PP4025 3430P1 3 51228501 Gear Case RSPL Both 3 2 04 3PA4025 3406G1 Assembly 4 56729601 Connector PC RSPL Both 3 2 10 224A1285P0400 HD40 ML590 591 96 02 07 5 53343001 Holder Connector RSPL Both 3 2 11 4PP4025 3433P1 L 6 53343101 Holder Connector RSPL Both 3 2 11 4PP4025 3434P1 R 7 56510401 Motor Space RSPL Both 3 2 11 4YA4025 3250G1 Assembly 8 53343301 Guide
53. Preventing Image Problems 4 4 04 Tips for Preventing Image Problems Make sure that the ribbon is not dried out If the printer output is faded install a new ribbon then print another sample Make sure that the paper you are using is within specifications Paper specifications can be found in Section 1 of this Service Handbook ML590 591 96 02 07 4 4 05 Common Problems 4 4 05 Common Problems 1 Nothing happens when the unit is powered on The unit may not be plugged in Check the power cord connection to the outlet and to the printer If a power strip is being used make sure that it is powered ON Check to be sure that an external fuse hasn t blown or that a circuit breaker hasn t tripped 2 The printer does not print when the computer sends data The printer may be deselected If the SEL light is out press the SEL button to select the printer The printer cable may not be securely connected Check the cable to be sure that it is properly connected to both the PC and the printer If you have installed the serial interface board check to be sure that the board is firmly seated in the printer 3 A brand new ribbon has been installed and the printing is smeared and streaked The plastic shield on the ribbon is either loose or missing The shield must be left on the ribbon when you are installing the cartridge To remedy this situation move the printhead to the center of the platen careful the printh
54. Technical Support ML590 591 96 02 07 RAP 02 No Spacing Operation RAP 02 No Spacing Operation START The alarm LED blinks Is the carriage assembly binding or jammed No Make sure the carriage cable is properly connected to the space motor assembly and CN7 on the main control board Go to A Yes 1 Remove the ribbon to verify that the ribbon is not jammed 2 Remove the space motor assembly 3 Inspect the teeth on the space rack and the space motor gear 4 GotoA A Has the problem been resolved Yes End of procedure No Is the fuse F2 on the main control board open No Go to B Yes Replace the main control board Has the problem been resolved Yes End of procedure No Go to B Verify that 40 volts is present on CN7 main control board Refer to Appendix A of the Service Handbook Has the problem been resolved Yes End of procedure No Replace the carriage cable Has the problem been resolved Yes End of procedure ML590 591 96 02 07 No Replace the ribbon feed mechanism Has the problem been resolved Yes End of procedure No Replace the PROM O5CA Has the problem been resolved Yes End of procedure No Contact Technical Support ML590 591 96 02 07 RAP 03 Printhead Homing Error RAP 03 Printhead Homing Error START Printhead does not return to the home position Make sure the carriage cable is properly connected to the space motor assembly and CN8 on the main
55. Unidirectional PASS Unidirectiona print 1 PASS Bi directional print 110 C X ML590 591 96 02 07 2 1 09 Power Supply Circuit 2 1 09 Power Supply Circuit The switching type power supply circuit supplies the 5 vdc 8 vdc 12 vdc and 40 vdc 0S ee mr ee ee eee a nae ere T Hie teem ACIN SW 1 pes N ron Noise filter 40V primary i Rectification and 40V Fuse circuit j itching circuit smoothing circuit i i she Switching contro Alarm control ALM circuit circuit ecole cess Se i i i i i n 5V t 8V and Rectification and He 5V i 12V primary 7 i L switching circuit L regulating circuit 12V i eee i i i L Rectification and 8V i smoothing cir uit gv I ceniemneseenis eiepessbences es ineeh ome mom srrnsifen verververre mrmsemnminen ven ist E PEES Table of Output Voltages Voltage Signal Purpose 5 vdc IC logic levels LED drive voltages 8 vdc Serial interface line voltage comparator IC 8 vdc Serial interface line voltage 12 vdc Printhead analog circuit 40 vdc Printhead space motor and line feed motor drive voltage ALM Output from the main control board upon detection of an abnormality in the printhead head gap or color ribbon drive circuits This signal will cause all DC voltages to be turned off ML590 591 96 02 07
56. Voltage CN2 Pin 10 12 vdc Printhead Analog Voltage CN2 Pin 9 40 vdc Printhead Space Motor Line Feed Motor Drive Voltage CN2 Pins 1 and 2 Frame Ground CN2 Pins 3 and 4 Logic Ground CN2 Pins 7 and 8 ALM Alarm Signal from Main Control Board CN2 Pin 12 F1 tiiit Alli CN2 J ML590 591 96 02 07 A 2 04 Space Motor Board A 2 04 Space Motor Board Firmware NONE Fuses NONE Jumpers NONE Sensors SNS2 Encoder Disk Sensor Switches NONE Test Points NONE Connector Auto Gap Mechanism WA Encoder H 7 Disk Connector Color Ribbon Shift Mechanism Printhead Gap Adjusting Screw ML590 591 96 02 07 A 2 05 RS232 C Serial Interface Board LXHI Option A 2 05 RS232 C Serial Interface Board LXHI Option Firmware Masked to the MPU Socket is empty Fuses NONE Jumpers SP1 EPROM Address Select Jumper position as shown EPROM is masked to MPU Sensors NONE Switches NONE Test Points NONE Default Setting MPU ML590 591 96 02 07 B 2 02 Upper Cover Assembly B 2 02 Upper Cover Assembly Am ee Item Okidata P N Oki J Description Comments Refer Disassembly P N to B 1 02 Procedure 1 53066901 Cover Upper RSPL 590 3 2 06 1PP4094 6501P1 Narrow 1 53067001 Cover Upper Wide RSPL 591 3 2 06 1PP4094 7201P1 2 51009401 N A Guide Sheet RSPL 590 3 2 06 Narrow 2 51009501 N A Guid
57. boards directly on conductive surfaces 10 Follow the recommended procedures when replacing assemblies and units 1 D OTe Go N 1 Perform the printhead gap adjustment procedure Refer to Section 3 3 of this Service Handbook _ when the any of the following occur Print Quality is darker on one side of the document Parts are replaced Printhead 3 2 02 Space Motor Assembly 3 2 11 Space Rack 3 2 13 Guide Rail 3 2 15 Platen Assembly 3 2 19 Carriage Shaft 3 2 25 ML590 591 96 02 07 3 2 Disassembly Assembly Procedures 3 2 DISASSEMBLY ASSEMBLY PROCEDURES General Information This section contains the printer disassembly procedures Only the removal procedures are explained here Reverse the procedure for the installation At the bottom of each procedure is a listing of the parts covered in that procedure The Okidata part number item description comment RSPL Option Consumable and cross reference to Appendix B is provided for each part Items included in the Recommended Spare Parts List are indicated by the acronym RSPL N A will appear where a part number is not available 590 indicates that the item is specific to the Microline 590 591 indicates that the item is specific to the Microline 591 Both indicates that the item is common to both printers Part Description Item Comment Appendix B Number Reference This Service Handbook lists the disassembly procedures for major components of the unit Ok
58. button and change the I Prime item in the Parallel I F Group to Invalid ML590 591 96 02 07 4 5 Abnormal Output amp Output Samples 4 5 01 Output Samples Light Print on the Entire Page Possible Causes 1 Ribbon is dried out Replace the ribbon 2 Verify that the headgap menu setting is appropriate for the type of paper being used 3 Check perform the printhead gap adjustment 4 Paper is not within specification Refer to Section One for paper specification Light Print on the Entire Page Uneven Print Density Possible Causes 1 Printhead gap not within specification Perform the printhead gap adjustment 2 Defective platen Replace the platen Uneven Print Density Smeared Print Possible Causes Ribbon protector is missing or broken Replace the ribbon protector Verify that the headgap menu setting is appropriate for the type of paper being used Check perform the printhead gap adjustment Paper is not within specification Refer to Section One for paper specification ROD Smeared Print Inconsistent Line Feed Possible Causes 1 Power OFF the printer Turn the platen knob The platen should rotate smoothly If it does not remove the cause of the binding 2 Defective line feed motor Replace the line feed motor ML590 591 96 02 07 Aer errs Lene Oe eee Inconsistent MA een Line Feed pA wer Yn pee we pee ae Drifting Margin
59. centimeters 3 to 17 inches 7 62 to 43 18 centimeters 017 inches 0 44 millimeters Bottom Refer to the Printhead Gap Information Section 1 6 12 24 Ib 45 to 90 g m2 9 11 Ib 35 to 40 g m2 10 12 Ib 38 to 45 g m2 Carbon 9 Ib 35 g m2 Microline 590 3 5 to 10 5 inches 8 8 to 26 6 centimeters Microline 591 3 5 to 16 5 inches 8 8 to 41 9 centimeters 3 to 17 inches 7 62 to 43 18 centimeters 0 014 inches 0 36 millimeters Rear Feed 0 017 inches 0 44 millimeters Bottom Feed Paper Feed Path Printhead Gap Information Cut Sheet Weight Width Width Length Thickness Paper Feed Path Printhead Gap Information Envelopes Weight Size Single Feed Minimum Maximum Continuous Rear or Bottom Refer to the Printhead Gap Information Section 1 6 12 to 24 Ibs 45 to 90 g m2 7 2 to 14 3 inches 18 3 to 36 3 centimeters Microline 590 7 2 to 8 5 inches 18 2 to 21 5 centimeters Microline 591 7 2 to 14 3 inches 18 2 to 36 3 centimeters 3 to 17 inches 7 62 to 43 18 centimeters 0 014 inches 0 325 millimeters Maximum Top Refer to the Printhead Gap Information Section 1 6 A 24 Ibs 90 g m2 Maximum 6 5 x 3 6 inches 16 5 x 9 1 centimeters 9 5 x 4 1 inches 24 1 x 10 4 centimeters Non overlap type Thickness ML590 591 96 02 07 014 inches 325 millimeters Maximum Labels Paper Feed Path Bottom Printhead Gap Information Refe
60. ches are active 7 Press GROUP until the desired Group prints Rear Feed or Bottom Feed 8 Press ITEM until the desired Item prints Form Tear Off 9 Press SET until the desired setting prints Off 500 mS 1 sec 2 sec 10 Press EXIT to save the change and exit Menu Mode Using 1 Load paper 2 Press FORM FEED 3 The paper will advance past the start print position Top of Form to the tear bar position 4 The paper says in this position until the printer receives data Then the paper will be retracted to the appropriate Top of Form position 5 A few seconds after printing stops the paper advances to the tear bar position Checking Top of Form with Form Tear Off Activated 1 Load paper 2 Press and hold TEAR When you release TEAR the paper will return to the tear off position ML590 591 96 02 07 3 The paper will retract to the Top of Form position 4 Release TEAR 5 The paper advances to the tear bar position ML590 591 96 02 07 3 4 Cleaning 3 4 CLEANING An accumulation of paper dust is the most frequent cause of print quality problems in a dot matrix printer Small pieces of paper can cause paper jams A dirty platen will smudge paper It is important to clean the printer regularly paying particular attention to the printhead area and the paper paths If the lubrication procedures are not performed properly the printer will require more frequent cleaning Excessive lubricant attracts du
61. control board Make sure the power connector cable is properly connected to CN3 on the main control board Does the space motor assembly move manually No Remove the space motor assembly and inspect the space motor and space rack for dirt and worn teeth GotoA Yes Are there any breaks in the carriage cable Yes Replace the carriage cable assembly GotoA No Verify that ribbon feed mechanism is properly fastened to the space motor assembly GotoA A Does the carriage move slightly to the left after turning the power on No Replace the space motor assembly Has the problem been resolved Yes End of procedure No Contact Technical Support Yes Replace the ribbon feed assembly Has the problem been resolved Yes End of procedure No Replace the main control board Has the problem been resolved Yes End of procedure ML590 591 96 02 07 No Replace the space motor assembly Has the problem been resolved Yes End of procedure No Contact Technical Support ML590 591 96 02 07 RAP 04 Paper Jam During Paper Loading RAP 04 Paper Jam During Paper Loading START Check paper path release lever for proper position Make sure the paper path is clear Which of the following paper jams have occurred 1 Paper bent at top left corner Check the support protector to see if it covers the left side of the paper properly Go to A 2 Paper has torn ends Check the ribbon protector Check the pull up roller cover to see that
62. down the page press and hold the SHIFT switch while pressing the FF LOAD switch This will advance the paper in micro increments 3 To set the TOF higher on the page press and hold the SHIFT switch while pressing the LF switch This will retract the paper in micro increments 4 This setting will be kept in memory until you power off the printer or until you change the setting 5 To maintain this setting in the printer s memory even when the printer is powered off press and hold the SHIFT switch while pressing the QUIET TOF switch 6 Press the SEL switch Reset the Top of Form to Factory Default 1 Power off the printer 2 Press and hold the QUIET and FF LOAD switches while you power on the printer NOTE The factory default Top of Form Setting is 1 inch ML590 591 96 02 07 3 3 06 Paper Park 3 3 06 Paper Park General Information Paper Park allows the user to print using single cut sheet pages without removing continuous forms from the printer Procedure Continuous Feed to Single Sheet Remove any printed pages from the printer Press PARK to retract the continuous forms paper from the paper path Lift the paper separator to the upright position Move the paper lever to the TOP Single Sheet position Load the single sheet paper aorwons Procedure Single Sheet to Continuous Feed Remove any single sheet pages from the printer Lower the paper separator to the Continuous Forms position rear feed
63. dy to receive data ZO 25 Not Used ML590 591 96 02 07 Commonly Used Serial Cable Configurations Commonly Used Serial Cable Configurations IBM 25 Pin Cable Configuration ML590 591 96 02 07 4 8 05 Hexadecimal Dump Mode 4 8 05 Hexadecimal Dump Mode General Information The hexadecimal dump mode allows you to view the data sent from a computer to the printer When the printer is in hex dump mode all data received both printable characters and control codes will be printed in both hexadecimal and ASCII format NOTE In the ASCII format all non printable characters will be represented by a period Example Below is a line of BASIC code LPRINT CHR 27 0 CHR 30 This is an example of hexadecimal dump Below is the same line as it would appear in Hexadecimal Dump Mode 1B 30 1E 54 68 69 73 20 69 73 20 61 6E 20 65 78 0 61 6D 70 6C 65 20 66 20 61 20 68 65 78 61 64 65 63 69 6D 61 6C 20 64 75 6D 70 2E 0D OA Procedure Follow these steps to engage the Hexadecimal Dump Mode 1 Make sure the printer is connected to a computer 2 Verify that paper is loaded 3 Verify that the ribbon and printhead are correctly installed 4 Power OFF the printer 5 Press and hold the SEL and FF LOAD switches while powering on the printer 6 Hold the switches until the printer prints the line 7 Hex Data Dump 8 The printer is ready to receive data in the Hexadecimal Dump Mode 9 Send data to the
64. e Sheet Wide RSPL 591 3 2 06 ML590 591 96 02 07 3 53067101 Cover Access RSPL 590 3 2 06 2PA4094 7381G1 Narrow 3 53067201 Cover Access Wide RSPL 591 3 2 06 2PA4094 7382G1 ML590 591 96 02 07 B 2 03 Printer General Assembly B 2 03 Printer General Assembly Item Okidata P N Oki J Description Comments Refer Disassembly P N to B 1 02 Procedure 1 53562601 Knob Platen ML 500 RSPL Both 3 2 06 2PP4094 6507P3 Series 2 53067301 Cover B for card RSPL Both 3 2 06 2PP4094 6506P2 slot 3 55937401 PCB AKGI w o RSPL Both 3 2 07 4YA4042 1514G301 ROM 4 55938301 N A IC EEPROM RSPL Both 3 2 07 BR93LC46A ML590 591 96 02 07 5 55937501 PCB LEOP RSPL Both 3 2 09 4YA4042 1516G1 Operator Panel 6 53562701 Panel Operator RSPL Both 3 2 09 3PP4025 3670G1 7 56412101 Power Supply 120V RSPL 590 3 2 08 4YB4049 1707P1 7 56412102 N A Power Supply 120V RSPL 591 3 2 08 7 56412201 Power Supply Option RSPL 590 3 2 08 4YB4049 1708P1 230 240V 7 56412202 Power Supply Option RSPL 591 3 2 08 4YB4049 1708P2 230 240V 8 56609701 Cord AC RSPL Both 3 2 01 3YS4011 1315P1 9 56624101 Cord AC 220V Option RSPL Both 3 2 01 3YS4011 1265P1 ML Right Ang 10 56624401 Cord AC 240V Option RSPL Both 3 2 01 3YS4011 1268P1 11 50217201 Assembly Printhead RSPL Both 3 2 02 4YA4023 260
65. e entire menu Group Selects Group Function Item Selects Item Set Selects Item Value Exit Exits Menu Mode Enters Select ML590 591 96 02 07 1 6 13 Paper Feed Methods 1 6 13 Paper Feed Methods Standard Friction Feed Top Rear Push Tractor Rear Optional Pull Tractor Bottom Bottom Push Tractor Bottom Single Bin Cut Sheet Feeder Top CSF 5000 Narrow CSF 5001 Wide ML590 591 96 02 07 1 6 14 Paper Feed Paths 1 6 14 Paper Feed Paths Top Feed Standard Rear Feed Standard Bottom Feed by using an Optional feed mechanism Special Features Paper Park Automatic Paper Loading Forms Tear Off ML590 591 96 02 07 1 6 15 Paper Loading 1 6 15 Paper Loading Auto Loading Top Feed Press LOAD switch for Bottom Rear Feed ML590 591 96 02 07 1 6 16 Paper Out Detection 1 6 16 Paper Out Detection Distance from end of paper Rear Feed 0 5 inches 12 7 mm Bottom Feed 0 5 inches 12 7 mm Top Feed 0 5 inches 12 7 mm ML590 591 96 02 07 1 6 17 Paper Tear Capabilities 1 6 17 Paper Tear Capabilities Forms Tear Off sharp edge on access cover Metal Tear Bar with optional bottom tractor unit ML590 591 96 02 07 1 6 18 Print Method 1 6 18 Print Method Printhead Type General Information Impact Dot Matrix 24 pin printhead 0079 inch 20 millimeter diameter pins Overheat Protection When printhead temperature exceeds 11
66. e left bracket of the main frame Just before paper is loaded the printhead moves towards the left bracket and unlatches the support protector As the printhead moves to the right the support protector reset spring pushes the support protector toward the center of the platen With the support protector in this position the ribbon protector and the support protector prevent the leading edge of the paper from curling or folding Once the paper is ejected the printhead slowly moves towards the left bracket The support protector is latched in the stored position when it is pushed to approximately 5 mm from the left bracket a Ribbon protector a Platen Support protector Support protector reset spring ML590 591 96 02 07 2 2 08 Automatic Paper Load 2 2 08 Automatic Paper Load The Microline 590 591 printers will automatically detect cut sheet paper and feed the paper to the TOP OF FORM position Cut Sheet Paper Set the change lever to the TOP FEED position Note When the change lever is in the TOP FEED position the cut sheet detection lever contacts the cut sheet detection switch BASW which is located on the main control board Insert the sheet of paper between the platen and the paper chute Once paper is detected at the paper end sensor and the amount of time selected on the Wait Time setting of the menu has lapsed the line feed motor will feed the paper until the leading edge of the
67. ead may be HOT and lift off the ribbon cartridge Check the ribbon shield If it is loose secure it in place properly If it is missing locate it and install 4 Static electricity causes the paper to stick In cold dry weather static charges can build up on continuous form paper This can make the paper cling to the paper separator If you have this problem during high volume printing jobs try moving the single sheet paper guides on the separator together so that the paper rests on the guides rather than on the separator itself 5 The Print Quality and Character Pitch buttons on the front panel won t work The Operator Panel Function Item on the printer MENU can be used to disable these buttons If the printer is part of a customized system or if it is used by a number of people the system manager may have used this option to make sure the printer is always set properly NOTE This feature also prevents access to the Menu To access the Menu power OFF the printer then hold down the SEL key while powering ON 6 Strange symbols and incorrect fonts appear on the output when a document is printed The printer driver that is engaged does not agree with the emulation selected for the printer To check the emulation selected first make sure that paper is loaded Then press the SEL and SHIFT buttons simultaneously to enter the Menu Mode Next press the GROUP button This will print the emulation selected If the emulation is no
68. ection 3 3 of this Service Handbook Cleaning When cleaning refer to Section 3 4 of this Service Handbook CAUTION DO NOT lubricate the space rack Lubricating the space rack will attract dust If enough dust accumulates on the space rack printing problems will occur P N 50923501 Spring Tension Space Rack RSPL Both B 2 03 P N 53563301 Rack Space Narrow RSPL 590 B 2 03 P N 53563401 Rack Space Wide RSPL 591 B 2 03 ML590 591 96 02 07 3 2 14 Roller Holder Backup Assembly 3 2 14 Roller Holder Backup Assembly 1 Perform these procedures 3 2 01 3 2 02 _ 3 2 04 3 2 11 OH ae OO 2 Use a small straight slot screwdriver to disengage the claws of the backup roller holder spring 1 from the carriage frame 2 3 Remove the roller holder backup assembly 3 NOTE The roller holder backup assembly includes the backup roller 4 the backup roller holder 5 and the pin 6 P N 53343201 Assembly Roller Holder Backup Both B 2 06 P N 53341701 Roller Back Up RSPL Both B 2 06 P N 53341801 Holder Back Up Roller RSPL Both B 2 06 P N N A Pin Both B 2 06 P N N A Backup Roller Holder Spring Both B 2 06 ML590 591 96 02 07 3 2 15 Guide Rail and Adjust Cam 3 2 15 Guide Rail and Adjust Cam 1 Perform these procedures 3 2 01 3 2 02 3 2 04 _ 3 2 11 3 2 14 2 Rotate the adjust cam 1 in the direction of arrow A as far as po
69. eplace the main Alarm MPU kept low control board 17 BRK FFFF data Replace the ROM on the Instruction detected due main control board Alarm to MPU hang up 18 MPU Internal Read write Replace the interfac RAM Alarm error board 19 ROM alarm Check sum Replace th interfac error board 20 RAM on I F Read write Replace the interfac board alarm error board then the main control board 21 Interface not Serial Replace the interfac connected interface board replace the board not main control detected 22 Paper End From the cut Check paper supply Alarm sheet feed or Refer to RAP 04 O bottom feed paper end 23 Paper Change Change lever Set the lever to the specified position check the rear sensor lever replace th main control board ML590 591 96 02 07 24 Cut Sheet Jam Cut sheet could not be fed properly Remove the paper check the feed mechanism Press SEL 25 Printhead Printhead Wait until the Thermal Alarm temperature printhead cools The exceeds 115 printer should resume degrees printing If the problem persists replace the printhead replace the main board 26 Space Motor Temperature Wait until the Thermal Alarm of space printhead cools The motor exceeds printer should resume specified printing If the value problem persists replace the spac motor then replace th main control board ML590 591 96 02 07 4 7 Repair Analysis Procedures RAPs 4 7 ML590 ML
70. er is on a network do not reset this item without discussing the change with the network supervisor To access the menu when the printer is set to Limited Operation follow this procedure 1 Verify that continuous feed paper is installed 2 Verify that the ribbon is correctly installed 3 Verify that the width of the installed paper matches the paper width menu setting CAUTION If the Menu is set for wide paper and narrow paper is used the printhead will print on the platen This could damage destroy the printhead platen and ribbon Power off the printer Press and hold the SEL switch while powering on the printer The MENU lamp will light If the printer was selected the SELECT lamp will light When in Menu Mode the functions printed below the operator panel switches are active Press GROUP until Set Up prints Press ITEM until Operator Panel Function prints Press SET until FULL OPERATION prints Press EXIT to save the change and exit Menu Mode TSP ONDA O ML590 591 96 02 07 Menu Settings Menu Settings Factory default settings are printed in Bold The tables show all possible menu settings available with the Microline 590 591 What you will actually see depends on the active emulation and the options installed Group Item Setting Printer Emulation Mode IBM PPR IBM AGM Epson LQ Control Font Print Mode LQ Courier LQ Roman LQ Swiss Q Swiss Bold LQ Orator LQ Gothic LQ Pres
71. etimes darker change it to 1 Press SEL and SHIFT buttons simultaneously to exit Menu Mode 8 There are vertical spacing problems when using continuous forms and Forms Tear Off The Microline 590 591 does not have a bail arm so pages do not feed as high as printers with bail arms The first page does not line up correctly Enter Menu Mode and disable Form Tear Off Exit Menu Mode Deselect the printer and set the paper position using the Micro Feed buttons hold SHIFT while pressing MICRO FEED UP or DOWN Enter Menu Mode and enable Form Tear 9 The ALARM light is not on but paper needs to be loaded If the ALARM light is off the printer thinks that paper is loaded To correct this problem press and release the SEL button Then hold the SHIFT button and press the RESET Character Pitch button The ALARM light will come on and you will be able to load paper 10 The ALARM light is on and the Character Pitch 15 light is flashing This indicates a paper loading error To stop the flashing light press the SEL button Before trying to load paper check to be sure that you have the paper lever in the correct position BOT TOP REAR for the path that you are using CAUTION Always power OFF the printer before you turn the platen knob If the paper lever is in the correct position and you are using rear feed lift up the paper separator and check to be sure that the paper is properly on the tractors and has not jammed If the pape
72. ew gear must be installed P N 51228401 Gear Line Feed Idle RSPL Both B 2 03 P N 56510301 Motor Line Feed Assembly RSPL Both B 2 03 P N 56627201 Cord Connection Line Feed RSPL Both B 2 03 ML590 591 96 02 07 3 2 22 Reset Spring 3 2 22 Reset Spring CAUTION Please read through this entire procedure before performing it Do not press against the vertical extensions of the reset spring at any time during this procedure Firm pressure will release the spring not brute force 1 Perform these procedures 3 2 01 0 3 2 06 0 3 2 17 2 Place the right side of the unit over the edge of your work surface You must be able to access the bottom of the unit You will be working underneath and above the reset spring 1 at the same time 3 Reach from underneath the unit and press up at the extension A to free the spring from the claw 4 While pressing up slide the spring out in the direction of Arrow B and remove it P N 50923201 Spring Reset RSPL Both B 2 04 ML590 591 96 02 07 3 2 23 Idle Gear and Change Lever 3 2 23 Idle Gear and Change Lever 1 Perform these procedures 3 2 01 3 2 06 3 2 07 3 2 16 3 2 17 3 2 19 3 2 20 3 2 22 CN 2 Remove the idle gear 1 The idle gear is a large narrow gear 3 Release the claw 2 of the change lever 3 The claw is accessed from inside the unit 4 Remove the change lever NOTE
73. f SP Motor Connector pin number ML590 591 96 02 07 Appendix A General Information A 1 OVERVIEW A 1 01 General Information This section describes the characteristics of the printed circuit boards PCBs used in the printer The following areas are covered Firmware Fuses Jumpers Sensors Switches Test Points Where an item is not applicable the word NONE will be listed ML590 591 96 02 07 A 2 Index To Charts A 2 INDEX TO CHARTS Description Board Section Designation Main Controller Board AKGI A 2 01 0 Operator Panel Board EOP Aa 2 02 0 Power Supply Assembly N A A 2 03 Space Motor PCB A A 2 04 RS232 C Serial LXHI a 2 05 0 Interface Board ML590 591 96 02 07 Interconnect Diagram Interconnect Diagram ML590 591 96 02 07 A 2 01 Main Controller Board AKGI A 2 01 Main Controller Board AKGI Firmware 05C CG ROM Character Generator 05D EPROM Printer Control Program NOTE If a 4 Mbit Masked ROM is in location 05D there SHOULD NOT be a ROM in location 05C However make sure that jumper SP1 is placed on the A Side Fuses F1 soldered 1 amp protects the 40 vdc motor drive circuit Jumpers SP1 EPROM Address Select Jumper A Side 4 Mbit Masked ROM is in location 05D B Side CGROM Location 05C and EPROM Location 05D are installed Sensors SNS1 Rear Top Feed Paper Out Sensor
74. face signals P I F ACK P signal sending and S I F BUSY N signal off and lights the SELECT lamp to indicate that the printer is in the ON LINE state MPU LSI Resetting and Initial setting I F BUSY ON RAM Clear IF Motor Phase Initialization Parallel WF F BUSY OFF ML590 591 96 02 07 2 1 04 Parallel Interface Control 2 1 04 Parallel Interface Control The parallel data input from the host to the interface LSI is latched to the internal register by the falling edge of the STROBE N signal The LSI sets the BUSY N signal to inform the host that the data is being processed The LSI also outputs the RXD N signal to inform the MPU of data reception The data is read upon receiving the RD N signal from the MPU When the data processing is complete the BUSY N signal is disabled and the ACK N signal is sent to request the next data When the buffer is full and reception is not desired the BUSY signal is sent to request data transmission be stopped ML590 591 96 02 07 2 1 05 Print Control 2 1 05 Print Control The print data is transmitted as serial data from the LSI to the control circuit and the driver contained in the printhead After the data is printed the sensor analog circuit controlling each pin returns the pin stroke data to the MPU The MPU will make an automatic head gap adjustment This feedback system sets the optimum drive time for each pin in order to
75. ft the plate and remove it NOTE Installation The plate must be securely seated under the claws P N 51010201 Plate Right Ground RSPL Both B 2 04 ML590 591 96 02 07 3 2 18 Rear and Cut Sheet Paper Feed Sensor Levers 3 2 18 Rear and Cut Sheet Paper Feed Sensor Levers 1 Perform these procedures 3 2 01 3 2 06 3 2 07 3 2 16 OH ae OO 2 Turn the cut sheet continuous feed paper sensor lever 1 until the flag is at the top then work the lever free 3 Remove the lever 4 Turn the rear feed paper sensor lever 2 until the flag is at the top then work the lever free 5 Remove the lever P N 50804902 Lever Sensor RSPL Both B 2 03 Cut Sheet Continuous P N 50804801 Lever Rear Sensor RSPL Both B 2 03 ML590 591 96 02 07 3 2 19 Platen Assembly 3 2 19 Platen Assembly 1 Perform these procedures 3 2 01 0 3 2 06 0 2 Move the change lever 1 to the bottom feed position to the rear of the printer 3 Push the lock levers 2 in then rotate them towards the front to unlock them from the frame 4 The levers should be vertical 5 Lift the platen assembly 3 straight up and remove it ea NOTE Installation After installing the platen assembly check the printhead gap adjustment Refer to Section 3 3 of this Service Handbook Cleaning When cleaning refer to Section 3 4 of this Service Handbook Lubrication When
76. gap Slide the carriage assembly to the right side of the platen Parallel Adjustment Phase Check the printhead gap at the right side of the platen 10 If the gap measurements are different between the left and right positions turn the adjust cam as follows Figure 2 B 11 Turning the cam CLOCKWISE will increase the printhead gap 12 Turning the cam COUNTERCLOCKWISE will decrease the printhead gap po CONDOS Recheck Phase 1 Check the printhead gap adjustment at the left right and center of the platen 2 If the printhead gap is not the same at all three positions return to step 6 HAHAH ML590 591 96 02 07 3 3 03 Key Combinations 3 3 03 Key Combinations Key Combinations Description SEL LF lt R gt Hold during Power ON Reset Menu to Factory Defaults SEL lt R gt Hold during Power ON Access Menu if Menu set to LIMITED OPERATION QUIET FF LOAD lt R gt Hold during Reset Top of Form to Factory Default Power ON 1 inch QUIET lt R gt Hold during Power ON E Activa te Rolling ASCII Test LF lt R gt Hold during Power ON Activa te Font Test SEL FF LOAD lt R gt Hold during Power ON Activa te Hexadecimal Dump Test ML590 591 96 02 07 3 3 04 Menu Operation 3 3 04 Menu Operation General Information The menu is used to customize the printer s settings and features
77. ge rear or bottom feed continuous form to be torn off without wasting paper or adjusting the printer 2 Forms Tear Off automatically advances the paper from the initial printing position to the tear off position The top of the page perforation will be even with the tear bar The tear bar is located under the clear top of the access cover 3 Paper will remain in the tear off position until the printer receives data Then the paper is retracted to the initial print position 4 When printing stops the paper will advance to the tear off position NOTE If the software package being used pauses while sending data to the printer Forms Tear Off may be activated if it is enabled through the Menu The pause must be for two or more seconds No data is lost Uneven print registration will occur due to the paper movement If the problem occurs deactivate Forms Tear Off through the Menu DO NOT use Forms Tear Off with labels or multi part forms Remember to activate the Form Tear Off for the paper path you are using rear feed or bottom feed Setting Verify that continuous feed paper is installed Verify that the ribbon is correctly installed Verify that the width of the installed paper matches the paper width menu setting Power ON the printer Press and hold the SHIFT switch while pressing the SEL switch to place the printer in Menu Mode aorwoNn 6 When in Menu Mode the functions printed below the operator panels swit
78. ge cable printhead 5 Printhead Data Printhead Replace main control Transfer Alarm parity error board carriage cable printhead 6 Printhead Type 9 pin Replace the printhead Alarm printhead is with a 24 pin connected in printhead a 24 pin printer 7 Printhead Drive current Check the printhead Connection is detected connection then Alarm 1 during no replace main control overdrive board carriage cable signal printhead 8 Printhead Overdrive Check the printhead Connection signal is connection then Alarm 2 active but no replace main control current is board carriage cable detected printhead 9 Line Feed High driver Replace the following main control board linefeed motor space motor ML590 591 96 02 07 Lever Alarm is set for top feed while paper is inserted from rear or bottom 10 MPU Internal Read write Replace the main RAM Alarm error control board rH Program ROM Checksum Replace the ROM and Alarm error or main control board 12 RAM on Main Read write Replace the main Control Board error control board 13 CG ROM Alarm Checksum Replace the main error control board and or CG ROM 14 EEPROM Alarm No reaction Replace the main when the MPU control board reads data T5 watchdog MPU hung up Power OFF then ON Timeout Alarm 16 NMI Signal NMI port of R
79. holder up or down Here is a description of how the ribbon holder is shifted As the space motor moves idle gear C on the ribbon drive unit rotates Idle gear C rotates the color idle gear located in the color shift unit When the color P signal from the main control board activates the pranger magnet the magnet attracts the armature This causes the reset spring to force the change gear downward The color idle gear rotates the change gear which turns the color change gear The color change gear turns the color cam shaft The rotation of the color cam shaft moves the color ribbon holder up down to select the desired ribbon color There is a cam at each setting of the color change gear When the change gear is at the top of the cam the change gear disengages from the color change gear At this time the armature resets changing the color band selection by one setting HHH ML590 591 96 02 07 2 2 05 Line Feed Mechanism 2 2 05 Line Feed Mechanism The line feed operation is accomplished by activating the line feed motor which turns the platen The rotation of the platen is used to feed paper from the selected paper path Components of the paper feed mechanism are listed below Line Feed Motor pulse motor with Gears Line Feed Idler Gear Platen Rear Tractor Feed Unit Pressure Roller Change Lever Paper Path Selection Lever The change lever is used to select one of three different paper paths top rear or bo
80. ics Uni directional bi directional ML590 591 96 02 07 Receive Buffer Size 64K 1 line 32 K Paper Out Override No Yes Print Registration 0 0 05mm Left 0 10mm Left 0 15mm Left 0 20mm Left 0 25mm Left 0 25mm Right 0 20mm Right 0 15mm Right 0 10mm Right 0 05mm Right Qaar RE Function Full Operation Limited Operation Reset Inhibit No Yes Part IES Yes No Effective Auto LF No Yes Auto CR No Yes SI Select Pitch 10 17 1 15 cpi CPI SI Select Pitch 12 20 12 cpi CPI Time Out Print Valid Invalid Auto Select No Yes Smoothing Valid Invalid Ribbon Selection Black Ribbon Black Yellow Magenta Cyan Violet Orange Green Printhead Gap Adjust Oo 1 1 Graphics Speed High Low Group Item Setting Parallel I F I Prime Buffer Print Buffer Clear Invalid Pin 18 5v Open Auto Feed XT x x Invalid Valid ML590 591 96 02 07 Serial I F kK kK kK kK Ok Parity None Odd Even Serial Data 7 8 Bits 8 Bits 7 Bits Protocol Ready Busy X ON X OFF Diagnostic Test No Yes Busy Line SSD SSD DTR RTS Baud Rate 19200 9600 4800 2400 1200 600 300 bps DSR Signal Valid Invalid DTR Signal Ready on Power Up Ready on Select Busy Time 200 ms 1 sec CSF Bin 1 kK kK Kk Kk Ok Line Spacing
81. idata DOES NOT recommend disassembling a unit which is operating normally If you decide to perform disassembly during this training Okidata recommends that you perform only the disassembly procedures for RSPL items All other procedures are provided to assist you in identifying parts It is not likely that you will perform these procedures while servicing the unit Be sure to read all notes cautions and warnings as they contain important information regarding disassembly assembly ML590 591 96 02 07 3 2 01 Preliminary Items 3 2 01 Preliminary Items Press the AC switch 1 and power off the printer Remove the paper if installed 2 Detach the AC power cord 3 Detach the interface cable if installed 4 PON gt P N 56609701 Cord AC RSPL P N 56624101 Cord AC 220V ML Series Right Angle Option RSPL P N 56624401 Cord AC 240V P N 70000803 Kit Parallel Interface Plug n Play Accessory P N 70012801 Kit RS232 C Serial Interface Option RSPL Option Option Both Both Both Both Both B 2 02 B 2 02 B 2 07 B 2 07 B 2 07 ML590 591 96 02 07 3 2 02 Printhead Assembly 3 2 02 Printhead Assembly 1 Perform this procedure 3 2 01 2 Open the access cover 1 3 Lift and remove the ribbon Not shown 4 Pull the head clamp 2 towards the right and then rotate it up to release the printhead 3 5 Pull the printhead straight up to remove it NOTE Installa
82. ing 24 Grease Medium Bearing of Front Release Gear 24 Grease Medium Arm Carriage Shaft NOTE 220 Oil See lt _ gt lt _ gt Place a small amount on NOTE the surface then wipe clean Front Release Gear Shaft a2 Grease Medium Contact between Front Roller 28 Oil Small Holder and Front Pressure Roller Bearing of Tractor Gear 229 Grease Medium Contact between Lower Tractor 29 Grease Medium 3 5 06 Areas Not Lubricated Lubricant should never contact the parts listed below Ribbon Platen Assembly Rubber Face Pressure Roller Rubber Face Tractor Pins Head Cable Space Motor Printed Circuit Board Electrical Contacts and Connections Space Rack ML590 591 96 02 07 3 6 Shipping Instructions 3 6 SHIPPING INSTRUCTIONS 3 6 01 Return for Service CAUTION When shipping the printer use the original packaging to prevent damage Be sure to secure the printhead so it will not move during shipment 1 Locate the original packaging or order replacement packaging from Okidata Refer to Appendix B 2 Make sure the printhead is secured so it will not move during shipment 3 Remove the platen knob Be sure to place it in the shipping container 4 Pack the unit using the materials from Step 1 3 6 02 All Other Returns CAUTION The product MUST be returned in the original packaging The product MUST be returned with ALL originally supplied factory items Be sure to secure the printhead so it will not m
83. lubricating refer to Section 3 5 of this Service Handbook _ P N 50098301 Platen Assembly Narrow RSPL 590 B 2 04 P N 50098302 Platen Assembly Wide RSPL 591 B 2 04 ML590 591 96 02 07 3 2 20 Paper Chute Assembly 3 2 20 Paper Chute Assembly 1 Perform these procedures 3 2 01 3 2 06 0 3 2 19 0 2 Remove the rear pressure roller 1 3 Use a straight slot screwdriver to release the claws of the lock spring 2 and remove the spring 4 Remove the paper chute assembly 3 NOTE The paper chute assembly includes the levers for the rear and top paper feed paths P N 53341301 Roller Pressure Rear Narrow P N 53341401 Roller Pressure Rear Wide P N 50924701 Spring Lock P N 50097701 Paper Chute Assembly N P N 50097801 Paper Chute Assembly W RSPL RSPL RSPL RSPL 590 591 Both RSPL 591 B 2 05 B 2 05 B 2 05 590 B 2 05 B 2 05 ML590 591 96 02 07 3 2 21 Line Feed Motor Assembly 3 2 21 Line Feed Motor Assembly 1 Perform these procedures 3 2 01 3 2 06 3 2 07 3 2 16 3 2 20 0 2 Firmly press down on the line feed motor assembly 1 while tilting the assembly out 3 Remove the line feed motor assembly 4 Remove the line feed connection cord 2 OH ae OO CAUTION The line feed idle gear 3 should be removed only if it must be replaced The claws will break when the gear is removed A n
84. ly Yes End of procedure No Check that the cable is properly connected to the Host PC and the correct LPT port is selected Does the SEL LED light No GotoA Yes Change the menu item I prime to invalid End of procedure A Replace the interface cable Has the problem been resolved Yes End of procedure ML590 591 96 02 07 No Replace the main control board Has the problem been resolved Yes End of procedure No Contact Technical Support ML590 591 96 02 07 RAP 11 Serial Interface Problem RAP 11 Serial Interface Problem START Are you using a cable with proper number of pins No Change the interface cable Has the problem been resolved Yes End of procedure No GotoA Yes Is the ALARM LED blinking Yes Refer to Section 4 6 of the Service Handbook Has the problem been resolved Yes End of procedure No GotoA No Check the following parameters for the RS232C baud rate bit length parity protocol busy signal and parity Has the problem been resolved Yes End of procedure No Go to A A Check the voltages on the main control board Is 10 VAC being supplied to the main control board Yes Replace the RS232C board Has the problem been resolved Yes End of procedure No Replace the main control board Has the problem been resolved Yes End of procedure No Contact Technical Support No Replace the power supply unit ML590 591 96 02 07 Has the problem been resolved Yes End of procedure
85. maintain high print quality ML590 591 96 02 07 LSI Printhead Interface LSI Printhead Interface The connection between the LSI and the printhead is made with the bi directional serial data bus The LSI transmits the print data as serial data to the logic circuit of the printhead The printhead returns serial data from the printhead sensor analog circuit to the LSI This information is used to determine the optimum drive time for the next print request The logic circuit of the printhead signals the LSI if a parity error is detected in the print data ak JUUUUU UUUU UUU Le HOSDATA EOOD GX mee EE E a T HDSLT ee E E E ERR Normal 20 he a ERR parity error Fe a ee a a ML590 591 96 02 07 Gap Adjust Control Gap Adjust Control The Gap Adjust LSI receives stroke length information for all of the printhead pins from the sensor analog circuit The Gap Adjust LSI then sets the optimum printhead gap for the printing medium Note Refer to Section 2 2 03 for a description of the mechanical process All values in the chart are in millimeters Prelmanary printing Isgaprange at 6 of ebove Pressure sensitive pepe is SP or more intarleal paper is 4P or Sevens Appropriate gap setting gap level 6 7 Band 9 OK Appropriate gap setting gap levels 1 2 3 4and 5 ML590 591 96 02 07 Print Compensation Control Print Compensation Cont
86. make sure that continuous feed paper is loaded If you are running this test on a Microline 591 use wide paper or have the page width set for 8 5 x 11 in the printer menu Running the test without paper loaded or having the wrong width paper loaded will allow the printhead to print on the platen This will dirty the platen cause excessive wear on the ribbon and may damage the platen ribbon and printhead Procedure Follow these steps to print the Rolling ASCII Test 1 Load the correct size continuous feed paper 2 Power off the printer 3 Press and hold the QUIET switch while powering on the printer You must hold the QUIET switch until the test starts to print 4 The test will continue to print until you press the SEL switch or run out of paper ML590 591 96 02 07 4 8 03 Font Test 4 8 03 Font Test General Information The font test is a one page sample printout of each available typeface 10 cpi Letter Quality Courier 10 cpi Letter Quality Roman 10 cpi Letter Quality Swiss 10 cpi Letter Quality Orator 10 cpi Letter Quality Gothic 10 cpi Letter Quality Prestige 10 cpi Utility 18 point Letter Quality Swiss 12 cpi Letter Quality Superscript Subscript At the top of the test is the printer type 1 emulation 2 country 3 and firmware revision level 4 This information is often required while performing service or when contacting Okidata Have this test available during your service call
87. o maintain the optimum drive time condition The analog sensor element monitors all of the pins The difference in pin stroke due to the curvature of the platen is compensated for at the logic control section of the printhead and is not transferred to the MPU After the character has been printed the permanent magnet attracts the armature and the print wires are retracted into the wire guide Two thermistors are used to monitor the printhead temperature A thermistor in the printhead prevents over heating of the coil during periods of continuous bi directional printing If the printhead temperature exceeds 110 degrees Celsius the printer will switch to unidirectional print If the temperature exceeds 115 degrees Celsius printing will stop Once the printhead cools printing will resume When the temperature of the coil exceeds the pre determined limits the control circuit detects the thermistor signal TSD A thermistor in the printhead driver monitors the temperature of the driver If the temperature of the driver exceeds the pre determined limits 110 degrees Celsius unidirectional printing 115 degrees Celsius printing stops the control circuit detects the thermistor signal TSD The voltage of the TSD signal is monitored at the MPU A D port to control the pass number and print method unidirectional bi directional at each of seven levels printhead ML590 591 96 02 07 1 Wher printing Paper Armature assembly
88. o release the claws and remove the cable clamp 5 4 Remove the cable 6 5 Release the tab and remove the cover 7 6 Remove the screw 8 and detach the ground cable 9 7 Lift the AC inlet 10 and the AC switch 11 from the main frame 12 8 Remove the two screws 13 9 Slide the power supply in the direction of arrow A to clear the claws of the base frame 10 Lift and remove the power supply assembly NOTE The 5 amp fuse is on the end of the board facing the AC inlet and the AC switch The 2 5 amp fuse is near the middle of the board When installing verify that the AC inlet and AC switch are oriented correctly AC Inlet AC Switch oA P N 50707501 Clamp Cord RSPL Both B 2 02 P N 56302901 Fuse 2 5A 120V RSPL Both B 2 02 ML590 591 96 02 07 3 2 09 Operator Panel PCB LEOP 3 2 09 Operator Panel PCB LEOP Perform these procedures 3 2 01 0 3 2 06 0 3 2 07 0 1 Cut the nylon tie and release the cable Not shown 2 Disengage the claws 1 on both sides of the frame 3 Lift the operator panel assembly 2 straight up and remove it 4 Open eight claws 3 and remove the operator panel PCB LEOP 4 from the operator panel 5 P N 53562701 Panel Operator RSPL Both B 2 02 P N 55937501 PCB LEOP Operator Panel RSPL Both B 2 02 ML590 591 96 02 07 3 2 10 PC Connector 3 2 10 PC Connector 1 Perform these procedures 3 2 01 0 3 2 02
89. once a year or every 600 hours of operating time 3 5 03 Lubrication Types Machine Oil or equivalent Moly lube Grease or equivalent 3 5 04 Lubrication Amounts DO NOT over lubricate the printer Operational problems are caused by excess lubricant The excess lubricant causes dust to accumulate These accumulations can jam gears or cause print problems The Lubrication Table will direct you to use the following amounts of lubricant Medium Oil three to four drops Grease thin coating approximately 015 inch Small Oil one drop Grease extremely thin coating approximately 008 inch 3 5 05 Lubrication Table Area to be Lubricated Disassembly Lubricant Amount Procedure Visible Bearings of Gears in 3 2 04 Oil Small Gear Case Assembly Bearing of Pull up Roller S22 605 Grease Medium Shaft Contact between Idle Gear 32205 Grease Medium Bearing and Pull up Roller Shaft Contact of Space Motor SZ LT Oil Small Assembly Gear and Space Rack Contact between Platen Shaft Dae LI Grease Smal and Platen Ground Spring ML590 591 96 02 07 Feed Shaft and Main Frame Contact between Bias Gear and 19 Oil Small Platen Gear Bearing of Change Lever 223 Grease Medium Bearing and Pivot Point of 225 Grease Medium Change Lever Pivot Point of Release Cam 24 Grease Medium Holders on Pressure Spr
90. ook for more information ML590 591 96 02 07 1 2 Physical Specifications 1 2 PHYSICAL SPECIFICATIONS 1 2 01 Dimensions Note Dimensions INCLUDE the platen knob acoustic cover and paper separator Microline 590 Width 18 35 inches 466 millimeters Depth 17 24 inches 438 millimeters Height 6 52 inches 165 millimeters Microline 591 Width 24 41 inches 620 millimeters Depth 17 24 inches 438 millimeters Height 6 52 inches 165 millimeters 1 2 02 Printer Weight Microline 590 16 5 pounds 6 5 kilograms Microline 591 19 8 pounds 8 9 kilograms ML590 591 96 02 07 1 3 Power Requirements 1 3 POWER REQUIREMENTS 1 3 01 Input Power 120 VAC 5 5 15 230 240 VAC 10 14 1 3 02 Power Consumption Operating 110 VA Idle 40 VA 1 3 03 Power Frequency 120 VAC 60 Hz 2 230 240 VAC 50 60 Hz 2 ML590 591 96 02 07 1 4 Environmental Conditions 1 4 ENVIRONMENTAL CONDITIONS 1 4 01 Acoustic Rating Letter Quality Mode 53 dBA Quiet Mode 50 dBA 1 4 01 Altitude 10 000 feet 3 050 meters 1 4 03 Ambient Temperature and Relative Humidity RH While operating 41 to 104 F 5 to 40 C Operating humidity 20 to 80 RH While in storage 14 to 122 F 10 to 50 C Storage humidity 5 to 95 RH ML590 591 96 02 07 1 6 Operation Spec s Print Speed and Character Matrix 1 6 01 Character Matrix Sizes Table of Print Speed and Character Matrix
91. orking from the underside of the unit release the claws of the paper pan 1 When you release a claw push on the claw to move the paper pan away from the main frame 3 Remove the pan 4 Rotate the bottom sensor lever 2 until the flag is at the top Then lift the lever and work it free of the frame to remove it This lever has a box end 5 Remove the bottom paper end lever 3 6 Work the front release gear shaft 4 free of the tabs and remove it NOTE Lubrication When lubricating refer to Section 3 5 of this Service Handbook P N 50097301 Pan Paper Narrow RSPL 590 B 2 05 P N 50097401 Pan Paper Wide RSPL 591 B 2 05 P N 50804601 Lever Bottom Paper End RSPL Both B 2 03 P N 50804701 Lever Bottom Sensor RSPL Both B 2 03 P N 51227801 Shaft Front Release Gear Narrow RSPL 590 B 2 05 P N 51227901 Shaft Front Release Gear Wide RSPL 591 B 2 05 ML590 591 96 02 07 3 2 28 Front Pressure Roller Assembly 3 2 28 Front Pressure Roller Assembly 1 Perform these procedures 3 2 01 3 2 06 3 2 07 3 2 16 3 2 17 3 2 19 3 2 20 3 2 22 3 2 23 3 2 24 3 2 27 2 Separate the arms of the front roller holders 1 and remove the front pressure roller 2 3 Squeeze the extensions of the front roller holders together and remove the holders 4 Lift and remove the front pressure springs 3A and 3B Oe OO ww a a A A AA Add Jd Stl Leper
92. ove during shipment 1 Locate the original packaging or order replacement packaging from Okidata Refer to Appendix B 2 Locate the originally supplied factory items Refer to Setting Up in the Printer Handbook 3 Make sure the printhead is secured so it will not move during shipment 4 Pack the unit using the materials from Step 1 ML590 591 96 02 07 4 4 Troubleshooting Tips Preliminary Checks 4 4 TROUBLESHOOTING TIPS 4 4 01 Preliminary Checks Is the product being operated under the proper ambient conditions Does the paper being used meet the specifications for this product Has the ribbon been replaced as recommended Has the ribbon been installed properly Is an Okidata ribbon being used Is the printhead gap correctly set Is the firmware the latest current revision Are the printer drivers being used correct for the printer Is the printer driver being used the latest current release ML590 591 96 02 07 4 4 02 Problem Categories 4 4 02 Problem Categories There are three categories of problems that you might encounter when servicing the printer ALARM Lamp Blinks Fatal Errors The following can cause the ALARM lamp to blink Open Bail Arm Jammed Paper Printhead Cannot Move Other Fatal Error When the ALARM Lamp is blinking check the items listed below Close the bail arm Check for a paper jam Verify that the printhead moves freely Record
93. paper reaches the top of form position Sheet setting Va lt V Time out PE y Detection timer me eoe tme selected on the menu LF action Bottom Feed e ww BottomFeed RearFeed and Bottom Feed A N Change lever N sf Cut sheet Cut sheet Getection lever detection switch S ts Bey ae ov heet Lm detection lever Topreed Cut sheet detection switch Cut sheet detection lever Continuous Feed Paper Set the change lever to either the REAR FEED or BOTTOM FEED position NOTE When the change lever is in the REAR FEED or BOTTOM FEED position the cut sheet detection lever does not contact the cut sheet detection switch BASW which is located on the ML590 591 96 02 07 main control board Place continuous feed paper in the appropriate tractor Press the FF LOAD switch The line feed motor will feed the paper until the leading edge of the paper to the top of form position Push down the FF LOAD switch g Detection of the sheet supplied Line feed about 3 inches until the detection of the sheet supplied ML590 591 96 02 07 2 2 09 Paper Park 2 2 09 Paper Park If continuous feed paper is installed and printing on cut sheet paper is desired it is not necessary to unload the continuous feed paper The Paper Park feature provides a means of retracting the continuous feed paper from the paper path to allow feeding of the cut sheet paper Pa
94. per Park Operation Make sure the change lever is in the REAR FEED or BOTTOM FEED position Press the PARK switch on the operation panel A reverse line feed operation retracts the paper until paper end occurs or 19 inches of paper have been retracted Note Retracting 19 inches of paper without detecting a paper end condition causes the line feed operation to stop The line feed operation stops because the printer assumes a jam has occurred The operator can press the SEL switch to reset the ALARM LED and press the PARK switch to continue the park operation This operation may be useful when length of the paper to be parked is greater than 19 inches Paper end detection Reverse LF from P E Sensor to tri ee LF action a __ _ Reverse LF until paper end or 19 inches max ML590 591 96 02 07 Chapter 3 3 1 01 General Information 3 1 01 General Information This section lists the parts replacement adjustment cleaning lubrication and shipping procedures Disassembly should not be performed unless absolutely necessary NEVER perform disassembly on a malfunctioning printer until you have followed the failure analysis procedures in Section Four of this Service Handbook _ Follow the procedures listed in Adjustments and Service Settings Adjustments may be required when either consumable or parts are replaced Failure to perform these procedures could result in unnecessary service calls P
95. r Armature a Es 2 E 3 s z a gt o Eb o Es 4 s s mA A Armature cam ML590 591 96 02 07 2 2 04 Ribbon Drive Mechanism 2 2 04 Ribbon Drive Mechanism Black Ribbon Drive Operation The ribbon drive mechanism feeds the ribbon in synchronization with the spacing operation The force required to drive the ribbon is obtained from the space motor The ribbon drive mechanism is composed of the following items Ribbon drive gear assembly Ribbon gear located on the space motor assembly Ribbon cartridge Ribbon crive gear assembly Ribbon gear ff Space Motor Assembly A continuous loop ribbon with uni directional feed is used Ink is supplied from an ink tank which is built into the ribbon cartridge When the space motor turns the ribbon gear on the spacing motor shaft rotates The rotation is transmitted via a combination of gears from the ribbon drive gear assembly to the drive gear in the ribbon cartridge Although the space motor moves in both the forward and reverse directions during bi directional printing the gears in the ribbon drive assembly maintain uni directional ribbon feed by switching the rotation direction of the gears ML590 591 96 02 07 Color Ribbon Shift Mechanism Color Ribbon Shift Mechanism Items of the color ribbon unit option are listed below Color shift unit Color ribbon 4 colors Four colors can be selected by sliding the color ribbon
96. r lever is in the correct position and you are using the optional bottom feed push tractor check the bottom tractor unit to be sure that the paper is properly installed on the tractors and that the paper has not jammed Once the paper is correctly loaded press and release the SEL button then hold the SHIFT button and press the RESET Character Pitch button ML590 591 96 02 07 11 Word processor files do not print the way the MENU and front panel are set Before sending a file to the printer many word processors send either an initialization string or an Prime signal to the printer The initialization string contains codes that reset the printer to a default set of features Otherwise the printer might accidentally print using features set for a previous job These codes will override the panel or MENU settings To set your printer to ignore the reset codes enter the printer MENU hold down the SHIFT button while pressing SEL MENU button and change the Reset Inhibit item in the Setup Group to Yes Please note that while this will stop the reset code from resetting your printer other codes in the initialization string may still override the printer MENU and or front panel settings The I Prime signal is sent over the parallel interface pin31 and will automatically override any settings you have made using the front panel buttons To eliminate this problem enter the Menu Mode hold down the SHIFT button while pressing SEL MENU
97. r to the Printhead Gap Information Section 1 6 Weight N A Width Microline 590 3 5 to 10 5 inches 8 8 to 26 6 centimeters Microline 591 3 5 to 16 5 inches 8 8 to 41 9 centimeters Length 3 to 17 inches 7 62 to 43 18 centimeters Thickness 011 inches 0 28 mm Maximum including backing Paper Feed Path Bottom Printhead Gap Information Refer to the Printhead Gap Information Section 1 6 A CAUTION Use Bottom Feed and or optional Pull Tractor for card stock and labels Transparency 1 7 02 1 7 03 1 7 04 1 7 05 1 7 06 Paper Note Roller marks may mar the transparency under high temperature high humidity conditions Weight 12 to 24 Ibs 45 to 90 g m2 Width Microline 590 7 2 to 8 5 inches 18 2 to 21 5 centimeters Microline 591 7 2 to 14 3 inches 18 2 to 36 3 centimeters Length 3 to 17 inches 7 62 to 43 18 centimeters Thickness 0 14 inches 0 36 millimeters Paper Feed Path Top Printhead Gap Information Refer to the Printhead Gap Information Section 1 6 Length Note The recommended length is specific to paper type Rear Feed Minimum 3 inches 7 62 centimeters Maximum 17 inches 43 18 centimeters Bottom Feed Minimum 3 inches 7 62 centimeters Maximum 17 inches 43 18 centimeters Top Feed Minimum 3 inches 7 62 centimeters Maximum 17 inches 43 18 centimeters Number of Copies Original 4Interleaf Original 4Carbonless Original Cut Sheet Thickness 0 014 inches
98. ransmitted through the transmit data line The receive data line receives the characters The message buffer then stores the characters The data is then printed The test will run until the printer is powered off or the SELECT switch is pressed ML590 591 96 02 07 Serial Cable Information Serial Cable Information The information in this section will help you make a serial cable to connect between the printer and computer Refer to the computer documentation to determine the cable requirements on the computers end The printer has the following cable requirements Shielded RS 232C cable UL and CSA approved No more than 50 feet long Cannon DB 25P plug or equivalent with 25 pins Cannon DB C2 J9 or equivalent connector shell Serial Interface Signal Requirements 1 Protective PG Ground Connected to the Ground printer frame 2 Transmit Data TD From Printer Serial data transmitted to the system 3 Receive Data RD To Printer Serial data received by the printer 4 Request to RTS From Printer Always set to low Send mark 5 Not Used 6 Data Set DSR To Printer Indicates that data Ready can be sent 7 Signal Ground SG Ground Ground 8 to 10 Not Used 11 Supervisory SSD From Printer Indicates that the Send Data printer is not ready to receive data 12 to 19 Not Used 20 Data Terminal DTR From Printer Indicates that the Ready printer is not rea
99. re No Contact Technical Support ML590 591 96 02 07 RAP 06 Poor Print Quality RAP 06 Poor Print Quality START Is the print head gap properly set Yes GotoA No Go to B A Replace the printhead Has the problem been resolved Yes End of procedure No Go to C Cc Replace the main control board Has the problem been resolved Yes End of procedure No Check that the carriage cable is making good contact with the main control board and the carriage assembly Replace the cable if it is worn or bent Has the problem been resolved Yes End of procedure No Contact Technical Support B Adjust the print head gap See Section 3 of the Service Handbook Has the problem been resolved Yes End of procedure No Power ON the unit and view the head gap indicator Does the head gap indicator display a range of 9 Yes GotoA No Replace the ribbon feed mechanism Has the problem been resolved Yes End of procedure No Go to C ML590 591 96 02 07 RAP 07 Ribbon Feed Problem RAP 07 Ribbon Feed Problem START The ribbon feed does not function properly Verify that both ends of the carriage cable are connected correctly Make sure the ribbon shield is fastened properly Remove the ribbon cartridge Grasp the carriage Manually move the carriage left and right ROD Does the ribbon drive shaft rotate Yes Change the ribbon cartridge End of procedure No Remove the ribbon feed mechanism Man
100. rol The printhead compensates for the shape of the platen as shown below Note Refer to Section 2 1 08 Head Drive Time Platen As shown in the drawing left since the stroke length up to the platen is different for each pin the information of each pin within the print head is fed back to the logic circuit from the sensor analog circuit ta set the optimum drive time for each pin by controlling the pin coil current for each pin Print Head Pin 1 2 23 24 Pin coil er current t ML590 591 96 02 07 2 1 06 Space and Line Feed SP LF Motor Control 2 1 06 Space and Line Feed SP LF Motor Control The LSI Location 02D MSM79V035 generates the space motor and the line feed motor control signals according to commands received from the MPU These signals are sent to the SP LF motor driver MSM7SVO35 MM Z025 SPU uF overdrive register OA Bree Transmission of SP LF Motor Control Data spatan _ X 07 X gt s X os X oa X os KX pz X or X 00 SCLK N SLATCH N ML590 591 96 02 07 Line Feed Motor Control Line Feed Motor Control The SP LF motor driver Location 5A MHM2025 drives the line feed motor in two phase bipolar based on the phase changeover data output from the LSI The serial data from the LSI 02D MSM79V035 is processed by a register contained in the SP LF motor driver to measure the overdrive time and to change the phase amr a
101. roper performance of maintenance and cleaning will help to achieve the best possible print quality from the printer ML590 591 96 02 07 3 1 02 Maintenance Tools 3 1 02 Maintenance Tools The following tools are required to service the printer 2 Phillips Screwdriver with magnetic tip Straight slot Screwdriver Needle Nose Pliers 4 Inch Wire Cutters Digital Multimeter Feeler Gauge capable of measuring 014 inches Shop Vacuum Clean soft and lint free Cloth All Purpose Cleaner Contact Kleen Okidata P N 51802301 Platen Cleaner Machine Grease Machine Oil ML590 591 96 02 07 3 1 03 Maintenance Precautions 3 1 03 Maintenance Precautions 1 Do not disassemble the unit if it is operating normally N OO Pa OO N 9 Before starting disassembly and assembly always turn the AC power switch OFF and pull out the AC plug Detach the interface cable if installed Do not remove parts unnecessarily Try to keep disassembly to a minimum Use the recommended maintenance tools When disassembling follow the listed sequence Failure to follow the correct sequence may result in damaged parts Since screws collars and other small parts are easily lost they should be temporarily attached to the original positions When handling circuit boards use extreme care Integrated circuits microprocessors ROM and RAM can be destroyed by static electricity Do not place printed circuit
102. set the menu to factory default settings Before resetting the Menu Okidata STRONGLY RECOMMENDS printing the Menu Printing the Menu provides a reference of customized settings When the Menu is reset all customized settings are LOST Power off the printer Press and hold SEL and LF while powering ON the printer akRONM ML590 591 96 02 07 Limited Operation Limited Operation General Information 1 One of the menu selections that may be set by the end user is the operator panel function This is found in the Set up Group of the menu Operator Panel Function is an item in the Set up Group This item may be set to either Full Operation or Limited Operation 2 If the Operator Panel Function is set to Limited Operation the menu cannot be accessed and the operator panel switches listed below are not active Print Quality Character Pitch 3 The Operator Panel Function item is frequently set to Limited Operation on networks or other areas where many users share a printer Limited Operation prevents the printer settings from being changed 4 This item cannot be changed through the OKISMART software However the print quality and character pitch may be set through your software application packages ML590 591 96 02 07 Procedure Procedure To return the printer to Full Operation you must modify the menu CAUTION Determine the preference of the end user regarding this feature If the print
103. ssible 3 Pull the cam out and remove it 4 Carefully press the claw 2 location only in the base frame down to release the guide rail 3 Do not press too hard or the claw will break 5 Use a straight slot screwdriver to slide the guide rail in direction of arrow A 6 Lift the guide at position B and work the other end of the guide free to remove the guide rail 7 Remove the ground clip 4 OH ae OO NOTE Installation After installing the guide rail check the printhead gap adjustment Refer to Section 3 3 of this Service Handbook P N 51009701 Guide Rail Ground Clip RSPL Both B 2 03 P N 51009801 Guide Rail Narrow RSPL 590 B 2 03 P N 51009901 Guide Rail Wide RSPL 591 B 2 03 P N 53067701 Cam Adjust RSPL Both B 2 03 ML590 591 96 02 07 3 2 16 Left Ground Plate 3 2 16 Left Ground Plate 1 Perform these procedures 3 2 01 0 3 2 06 0 3 2 07 0 2 Cut the nylon tie and release the cable Not shown 3 Work the left ground plate 1 up and then out to remove it P N 51010301 Plate Left Ground RSPL Both B 2 03 ML590 591 96 02 07 3 2 17 Right Ground Plate 3 2 17 Right Ground Plate 1 Perform these procedures 3 2 01 0 3 2 06 0 2 Pull the top tabs 1 of the right ground plate 2 out to free the plate from the claws of the base frame You may have to use a screwdriver to work the plate tabs free 3 Li
104. st and accumulations build up quickly Keeping the covers in place and performing the cleaning procedures correctly will help ensure the highest quality printer output ML590 591 96 02 07 3 4 02 Cleaning Schedule 3 4 02 Cleaning Schedule Routine inspection and cleaning should be performed every six months or every 300 hours of operating time ML590 591 96 02 07 3 4 03 Cleaning Tools 3 4 03 Cleaning Tools Clean soft lint free cloth All purpose cleaner Vacuum cleaner Platen cleaner ML590 591 96 02 07 3 4 04 Areas to be Cleaned 3 4 04 Areas to be Cleaned Area Procedure Cleaning Tool s Carriage shaft 3 2425 Cloth and All purpose cleaner Area around BZ KZD Vacuum Cloth and carriage shaft All purpose cleaner Space Rack 352a 13 Vacuum Paper Paths N A Vacuum Cloth and All purpose cleaner Platen E RIR Cloth and Platen cleaner Covers 342 06 Cloth and All purpose cleaner ML590 591 96 02 07 3 5 Lubrication 3 5 LUBRICATION 3 5 01 General Information If the lubrication procedures are not performed properly the printer will require more frequent cleaning Excessive lubricant attracts dust and accumulations build up quickly An accumulation of paper dust is the most frequent cause of print quality problems in a dot matrix printer 3 5 02 Lubrication Schedule Routine inspection and lubricating should be performed
105. t the one you want to use press the SET button to change it to the one you want before exiting the Menu Mode To exit press the SEL and SHIFT buttons If the emulation is correct check your software documentation on how to select a printer driver Then check to be sure that you have selected one of the drivers listed for that emulation Refer ML590 591 96 02 07 to the Printer Handbook for emulation driver selections The closer the driver is to the top of the list in the Printer Handbook the more compatible it will be with your printer If your software does not have any of the indicated drivers available check with the software manufacturer to see if they have added any additional drivers since you purchased your software If you have embedded any printer commands in your software check to be sure that you have entered them correctly 7 Printing on the right side of the page is lighter or darker than the rest of the print on the page Although the printer automatically sets the head gap it sometimes may need a minor adjustment To make this adjustment enter the Menu Mode Press SEL and SHIFT buttons simultaneously To change the setting for the Printhead Gap Adjust under the Setup Group use the following procedure Press GROUP until Setup Group prints Press ITEM until Printhead Gap prints Press SEL to change the setting The default setting is 0 If the printing is sometimes lighter change the setting to 1 If it is som
106. the status of the ALARM PRINT QUALITY and CHARACTER PITCH Lamps Refer to the Alarm Lamp Codes Table Section 4 6 Locate the error Perform the designated corrective action Operational Errors An Operational Error is usually not accompanied by an ALARM Lamp Refer to the Start Here Flowchart Section 4 4 03 and perform the corrective action ALARM Lamp Lights Paper End Jam Conditions A solid ALARM Lamp usually indicates a cover open paper jam or paper end out of paper condition ML590 591 96 02 07 4 4 03 Start Here Flowchart 4 4 03 START HERE Flowchart START Power ON the unit Does the printer initialize No Is the ALARM Lamp Blinking No Refer to RAP 01 j Yes Refer to Section 4 6 of the Service Handbook Yes Load the printer with paper Does the paper load without jamming No Refer to Rap 04 Yes Perform the Rolling ASCII test Refer to Section 3 of the Service Handbook Is the output satisfactory No Refer to RAP 06 Yes Are all operator panel switches operating properly No Yes Yes No Yes No Refer to RAP 09 Has the problem been resolved End of procedure Does the parallel or serial interface port receive data from the host PC properly End of procedure Which port is not receiving data Parallel Refer to RAP 10 Serial Refer to RAP 11 ML590 591 96 02 07 4 4 04 Tips for
107. tige Utility Pitch 10 12 15 17 1 20 cpi Proportional No Yes Spacing Style Normal Italic Size Single Double Symbol Sets Character Set Set I Set II Language Set American French German British Danish I Swedish Italian Spanish I Japanese Norwegian Danish II Spanish II Latin American French Canadian Dutch Publisher zero Character Slashed Unslashed Code Page USA Canada French Multilingual Portugal Norway Group Item Setting Rear Feed Line Spacing 6 8 LPI Form Tear Off Off 500 ms 1 sec 2 sec ML590 591 96 02 07 Skip Over Perforation No Yes Page Width 13 6 8 Page Length 11 11 2 3 12 14 17 A320 e o F Gap Control Auto Gap Semi Auto 23 4596 78 9 Gap Bottom Feed Line Spacing 6 8 LPI Form Tear Off Off 500 ms 1 sec 2 sec Skip Over Perforation No Yes Page Width 13 6 8 Page Length 11 11 2 3 12 14 17 3 3 ADD 6 T 8865 Gap Control Auto Gap Semi Auto 2233 4 5 62 Te 8 9 Gap Top Feed Line Spacing 6 8 LPI Form Tear Off Off 500 ms 1 sec 2 sec Bottom Margin Valid Invalid Page Width 13 6 8 Page Length 11 11 2 3 12 14 17 3 3 ao re O T 8S BD T Gap Control Auto Gap Semi Auto Gap 23 4 5697 8 9 Wait Time 1 sec 2 sec 500 ms Page Length Control by MENU Setting by Actual Page Length Group Item Setting Set Up Graph
108. tion After installing the printhead check the printhead gap adjustment Refer to Section 3 3 of this Service Handbook P N 52106001 Ribbon Black Consumable Both B 2 09 P N 52106002 Ribbon Color Consumable Both B 2 09 P N 50707401 Clamp Head RSPL Both B 2 06 P N 50217201 Assembly Printhead RSPL Both B 2 02 ML590 591 96 02 07 3 2 03 Ribbon Protector 3 2 03 Ribbon Protector CAUTION You MUST use a straight slot screwdriver to release the ribbon protector If you attempt to lift the protector without releasing the tabs the protector will break 1 Perform these procedures 3 2 01 0 3 2 02 2 Open the pull up roller cover 1 3 Use a straight slot screwdriver to release the extensions 2 from the carriage frame set 3 4 Lift the ribbon protector 4 straight up and remove it P N 53562801 Protector Ribbon RSPL Both B 2 06 ML590 591 96 02 07 3 2 04 Gear Case Assembly 3 2 04 Gear Case Assembly 1 Perform these procedures 3 2 01 0 3 2 02 0 2 Use a straight slot screwdriver to release the four claws 1 of the gear case assembly 2 3 Lift and remove the gear case assembly NOTE Lubrication When lubricating refer to Section 3 5 of this Service Handbook P N 51228501 Gear Case Assembly RSPL Both B 2 06 ML590 591 96 02 07 3 2 05 Pull up Roller Assembly 3 2 05 Pull up Roller Assembly 1 aR oN
109. tion RSPL Both 3 2 08 4YB4021 1146P1 230 240V Power Supply 20 55038901 PCB LXHI Option RSPL Both N A 4YA4021 1050G1 RS232 C ML590 591 96 02 07
110. ttom Paper Clamp Mechanism Moving the Change Lever between the Bottom Top and Rear positions changes the positions of the Front Release Gear Arm and the Release Cam The movement of the Front Release Gear Arm changes the position of the Front Release Gear Shaft This causes the Front Pressure Roller to open or close The movement of the Release Cam causes the Rear Pressure Roller to open or close Position of Change Lever Status of Front Pressure Roller Tension of Front Pressure Roller Status of Rear Pressure Roller Tension of Rear Pressure Roller ML590 591 96 02 07 Bottom OPEN N A OPEN N A Top CLOSED 250 g CLOSED 700 g Rear CLOSED 90g OPEN N A ML590 591 96 02 07 Cut Sheet Continuous Sheet Switching Mechanism Cut Sheet Continuous Sheet Switching Mechanism Top Feed for cut sheet paper When cut sheet paper is used place the change lever in the Top Feed position As the platen turns the platen gear causes the idle gear to rotate At this time the rear and front pressure rollers press against the platen and feed the cut sheet The cut sheet detection lever enables the cut sheet detection switch which is located on the main control board This places the printer in the cut sheet mode When cut sheet paper is placed between the platen and the paper chute the printer automatically feeds the sheet to the print start position Rear Bottom
111. ually move the carriage left and right Does the space motor shaft rotate freely Yes Replace the ribbon feed mechanism End of procedure No Replace the space motor assembly Has the problem been resolved Yes End of procedure No Replace the main control board Has the problem been resolved Yes End of procedure No Contact Technical Support ML590 591 96 02 07 RAP 08 Line Feed Problem RAP 08Line Feed Problem START No line feed operation Make sure that the line feed cable is properly connected to the line feed motor and CN5 of the main control board Power OFF the printer Manually rotate the platen Does the platen rotate smoothly Yes GotoA No Is the left platen gear broken Yes Replace the platen assembly End of procedure No Is the line feed idle gear broken Yes Replace the line feed motor assembly or the line feed idle gear End of procedure No Are the right platen gear idle gear and or change gear broken Yes Replace the respective assembly End of procedure No Set the change lever to the rear position Does the platen rotate smoothly Yes Replace the tractor feed assembly End of procedure No Check the gears on the tractor feed assembly and platen assembly for broken or missing teeth Replace the defective assembly Go to A A Replace the line feed motor assembly Has the problem been resolved Yes End of procedure No Replace the main control board Has the problem

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