Olivetti d-Copia 3001MF User manual

d-Copia 3001MF
Digital Copier
SERVICE MANUAL
Code Y112040-6

PUBLICATION ISSUED BY:
Olivetti S.p.A.
77, Via Jervis - 10015 Ivrea (TO)
Italy
Copyright © 2010, Olivetti
All rights reserved

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Safety precautions
This booklet provides safety warnings and precautions for our service personnel to ensure the safety of
their customers, their machines as well as themselves during maintenance activities. Service personnel
are advised to read this booklet carefully to familiarize themselves with the warnings and precautions
described here before engaging in maintenance activities.

Safety warnings and precautions
Various symbols are used to protect our service personnel and customers from physical danger and
to prevent damage to their property. These symbols are described below:
DANGER: High risk of serious bodily injury or death may result from insufficient attention to or incorrect
compliance with warning messages using this symbol.
WARNING: Serious bodily injury or death may result from insufficient attention to or incorrect compliance
with warning messages using this symbol.
CAUTION: Bodily injury or damage to property may result from insufficient attention to or incorrect
compliance with warning messages using this symbol.
Symbols
The triangle ( ) symbol indicates a warning including danger and caution. The specific point
of attention is shown inside the symbol.
General warning.
Warning of risk of electric shock.
Warning of high temperature.
indicates a prohibited action. The specific prohibition is shown inside the symbol.
General prohibited action.
Disassembly prohibited.
indicates that action is required. The specific action required is shown inside the symbol.
General action required.
Remove the power plug from the wall outlet.
Always ground the copier.

1.Installation Precautions
WARNING
• Do not use a power supply with a voltage other than that specified. Avoid multiple connections to
one outlet: they may cause fire or electric shock. When using an extension cable, always check
that it is adequate for the rated current. .............................................................................................
• Connect the ground wire to a suitable grounding point. Not grounding the copier may cause fire or
electric shock. Connecting the earth wire to an object not approved for the purpose may cause
explosion or electric shock. Never connect the ground cable to any of the following: gas pipes,
lightning rods, ground cables for telephone lines and water pipes or faucets not approved by the
proper authorities. ............................................................................................................................
CAUTION:
• Do not place the copier on an infirm or angled surface: the copier may tip over, causing injury. .......
• Do not install the copier in a humid or dusty place. This may cause fire or electric shock. ................
• Do not install the copier near a radiator, heater, other heat source or near flammable material.
This may cause fire. .........................................................................................................................
• Allow sufficient space around the copier to allow the ventilation grills to keep the machine as cool
as possible. Insufficient ventilation may cause heat buildup and poor copying performance. ...........
• Always handle the machine by the correct locations when moving it. ...............................................
• Always use anti-toppling and locking devices on copiers so equipped. Failure to do this may cause
the copier to move unexpectedly or topple, leading to injury. ...........................................................
• Avoid inhaling toner or developer excessively. Protect the eyes. If toner or developer is acciden-
tally ingested, drink a lot of water to dilute it in the stomach and obtain medical attention immedi-
ately. If it gets into the eyes, rinse immediately with copious amounts of water and obtain medical
attention. ......................................................................................................................................
• Advice customers that they must always follow the safety warnings and precautions in the copier’s
instruction handbook. .....................................................................................................................

2.Precautions for Maintenance
WARNING
• Always remove the power plug from the wall outlet before starting machine disassembly. ...............
• Always follow the procedures for maintenance described in the service manual and other related
brochures. .......................................................................................................................................
• Under no circumstances attempt to bypass or disable safety features including safety mechanisms
and protective circuits. .....................................................................................................................
• Always use parts having the correct specifications. ..........................................................................
• Always use the thermostat or thermal fuse specified in the service manual or other related bro-
chure when replacing them. Using a piece of wire, for example, could lead to fire or other serious
accident. ..........................................................................................................................................
• When the service manual or other serious brochure specifies a distance or gap for installation of a
part, always use the correct scale and measure carefully. ................................................................
• Always check that the copier is correctly connected to an outlet with a ground connection. .............
• Check that the power cable covering is free of damage. Check that the power plug is dust-free. If it
is dirty, clean it to remove the risk of fire or electric shock. ..............................................................
• Never attempt to disassemble the optical unit in machines using lasers. Leaking laser light may
damage eyesight. ...........................................................................................................................
• Handle the charger sections with care. They are charged to high potentials and may cause electric
shock if handled improperly. ............................................................................................................
CAUTION
• Wear safe clothing. If wearing loose clothing or accessories such as ties, make sure they are
safely secured so they will not be caught in rotating sections. ..........................................................
• Use utmost caution when working on a powered machine. Keep away from chains and belts. ........
• Handle the fixing section with care to avoid burns as it can be extremely hot. ..................................
• Check that the fixing unit thermistor, heat and press rollers are clean. Dirt on them can cause
abnormally high temperatures. ........................................................................................................

• Do not remove the ozone filter, if any, from the copier except for routine replacement. ....................
• Do not pull on the AC power cord or connector wires on high-voltage components when removing
them; always hold the plug itself. .....................................................................................................
• Do not route the power cable where it may be stood on or trapped. If necessary, protect it with a
cable cover or other appropriate item. .............................................................................................
• Treat the ends of the wire carefully when installing a new charger wire to avoid electric leaks. ........
• Remove toner completely from electronic components. ...................................................................
• Run wire harnesses carefully so that wires will not be trapped or damaged. ....................................
• After maintenance, always check that all the parts, screws, connectors and wires that were
removed, have been refitted correctly. Special attention should be paid to any forgotten connector,
trapped wire and missing screws. ...................................................................................................
• Check that all the caution labels that should be present on the machine according to the instruction
handbook are clean and not peeling. Replace with new ones if necessary. ......................................
• Handle greases and solvents with care by following the instructions below: .....................................
· Use only a small amount of solvent at a time, being careful not to spill. Wipe spills off completely.
· Ventilate the room well while using grease or solvents.
· Allow applied solvents to evaporate completely before refitting the covers or turning the power
switch on.
· Always wash hands afterwards.
• Never dispose of toner or toner bottles in fire. Toner may cause sparks when exposed directly to
fire in a furnace, etc. .......................................................................................................................
• Should smoke be seen coming from the copier, remove the power plug from the wall outlet imme-
diately. ............................................................................................................................................
3.Miscellaneous
WARNING
• Never attempt to heat the drum or expose it to any organic solvents such as alcohol, other than the
specified refiner; it may generate toxic gas. .....................................................................................

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2K5
CONTENTS
1-1 Specifications
1-1-1 Specifications..........................................................................................................................................1-1-1
1-1-2 Parts names............................................................................................................................................1-1-3
(1) Machine.............................................................................................................................................1-1-3
(2) Operation panel.................................................................................................................................1-1-6
1-1-3 Machine cross section ............................................................................................................................1-1-7
1-2 Installation
1-2-1 Installation environment.........................................................................................................................1-2-1
1-2-2 Unpacking and installation......................................................................................................................1-2-2
(1) Installation procedure........................................................................................................................1-2-2
(2) Setting initial copy modes................................................................................................................1-2-11
1-2-3 Installing the key counter (option).........................................................................................................1-2-12
1-3 Maintenance Mode
1-3-1 Maintenance mode .................................................................................................................................1-3-1
(1) Executing a maintenance item..........................................................................................................1-3-1
(2) Maintenance modes item list.............................................................................................................1-3-2
(3) Contents of the maintenance mode items.........................................................................................1-3-6
1-3-2 Management mode...............................................................................................................................1-3-95
(1) Using the management mode.........................................................................................................1-3-95
(2) Common Settings............................................................................................................................1-3-96
(3) Copy Settings..................................................................................................................................1-3-99
(4) Sending Settings.............................................................................................................................1-3-99
(5) Document Box Settings...................................................................................................................1-3-99
(6) Printer Settings..............................................................................................................................1-3-100
(7) Printing Reports/Sending Notice...................................................................................................1-3-100
(8) Adjustment/Maintenance...............................................................................................................1-3-101
(9) Date/Timer.....................................................................................................................................1-3-101
(10) Editing Destination (Address Book/Adding One Touch Keys).......................................................1-3-102
(11) Internet Browser Setup..................................................................................................................1-3-103
(12) Applications...................................................................................................................................1-3-104
(13) System Settings ............................................................................................................................1-3-104
(14) User Login Administration.............................................................................................................1-3-106
(15) Job accounting..............................................................................................................................1-3-107
1-4 Troubleshooting
1-4-1 Paper misfeed detection.........................................................................................................................1-4-1
(1) Paper misfeed indication...................................................................................................................1-4-1
(2) Paper misfeed detection conditions ..................................................................................................1-4-2
(3) Paper misfeeds .................................................................................................................................1-4-9
1-4-2 Self-diagnosis .......................................................................................................................................1-4-18
(1) Self-diagnostic function...................................................................................................................1-4-18
(2) Self diagnostic codes ......................................................................................................................1-4-20
1-4-3 Image formation problems....................................................................................................................1-4-34
(1) No image appears (entirely white)...................................................................................................1-4-35
(2) No image appears (entirely black)...................................................................................................1-4-35
(3) Image is too light.............................................................................................................................1-4-36
(4) Background is visible.......................................................................................................................1-4-36
(5) A white line appears longitudinally..................................................................................................1-4-36
(6) A black line appears longitudinally..................................................................................................1-4-37
(7) A black line appears laterally...........................................................................................................1-4-37
(8) One side of the copy image is darker than the other.......................................................................1-4-37
(9) Black dots appear on the image......................................................................................................1-4-37
(10) Image is blurred...............................................................................................................................1-4-38
(11) The leading edge of the image is consistently misaligned with the original....................................1-4-38
(12) The leading edge of the image is sporadically misaligned with the original....................................1-4-38
(13) Paper creases.................................................................................................................................1-4-38
(14) Offset occurs...................................................................................................................................1-4-39
(15) Image is partly missing....................................................................................................................1-4-39

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(16) Fusing is poor..................................................................................................................................1-4-39
(17) Image is out of focus.......................................................................................................................1-4-39
(18) Image center does not align with the original center.......................................................................1-4-40
1-4-4 Electric problems ..................................................................................................................................1-4-41
1-4-5 Mechanical problems............................................................................................................................1-4-46
1-4-6 Send error code....................................................................................................................................1-4-48
(1) Scan to SMB error codes................................................................................................................1-4-48
(2) Scan to FTP error codes.................................................................................................................1-4-49
(3) Scan to E-mail error codes..............................................................................................................1-4-50
(4) Network Twain error codes .............................................................................................................1-4-51
(5) Software trouble error codes...........................................................................................................1-4-51
1-5 Assembly and Disassembly
1-5-1 Precautions for assembly and disassembly............................................................................................1-5-1
(1) Precautions .......................................................................................................................................1-5-1
(2) Drum..................................................................................................................................................1-5-1
(3) Toner.................................................................................................................................................1-5-1
(4) How to tell a genuine Olivetti toner container....................................................................................1-5-2
1-5-2 Paper feed section..................................................................................................................................1-5-3
(1) Detaching and refitting the forwarding, paper feed and separation pulleys ......................................1-5-3
(2) Detaching and refitting the MP separation, MP paper feed and MP forwarding pulleys...................1-5-6
1-5-3 Optical section ......................................................................................................................................1-5-15
(1) Detaching and refitting the exposure lamp......................................................................................1-5-15
(2) Detaching and refitting the scanner wires.......................................................................................1-5-19
(2-1) Detaching the scanner wires...................................................................................................1-5-19
(2-2) Fitting the scanner wires .........................................................................................................1-5-21
(3) Detaching and refitting the ISU (reference).....................................................................................1-5-24
(4) Detaching and refitting the laser scanner unit.................................................................................1-5-26
(5) Adjusting the position of the ISU (reference)...................................................................................1-5-30
1-5-4 Drum section.........................................................................................................................................1-5-31
(1) Detaching and refitting the drum unit ..............................................................................................1-5-31
(2) Detaching and refitting the main charger unit..................................................................................1-5-33
(3) Detaching and refitting the drum separation claws.........................................................................1-5-34
1-5-5 Developing section................................................................................................................................1-5-35
(1) Detaching and refitting the developing unit.....................................................................................1-5-35
1-5-6 Transfer section....................................................................................................................................1-5-36
(1) Detaching and refitting the transfer roller unit .................................................................................1-5-36
1-5-7 Fuser section ........................................................................................................................................1-5-37
(1) Detaching and refitting the fuser unit...............................................................................................1-5-37
(2) Detaching and refitting the heat roller separation claws..................................................................1-5-40
(3) Detaching and refitting the press roller............................................................................................1-5-41
(4) Detaching and refitting the fuser heater..........................................................................................1-5-43
(5) Detaching and refitting the heat roller .............................................................................................1-5-45
(6) Detaching and refitting the fuser thermistor 1 .................................................................................1-5-46
(7) Detaching and refitting the fuser thermistor 2 .................................................................................1-5-47
(8) Detaching and refitting the fuser thermostats 1 and 2.....................................................................1-5-48
(9) Adjusting front position of the fuser unit (adjusting lateral squareness)..........................................1-5-50
1-5-8 Others...................................................................................................................................................1-5-51
(1) Detaching and refitting the ozone filter 1.........................................................................................1-5-51
(2) Detaching and refitting the ozone filter 2.........................................................................................1-5-52
(3) Detaching and refitting the hard disk...............................................................................................1-5-53
(4) Direction of installing the principal fan motors.................................................................................1-5-55
1-6 Requirements on PWB Replacement
1-6-1 Upgrading the firmware...........................................................................................................................1-6-1
1-6-2 Adjustment-free variable resistors (VR)..................................................................................................1-6-2
1-6-3 Remarks on main and engine PWB replacement...................................................................................1-6-2
2-1 Mechanical construction
2-1-1 Paper feed section..................................................................................................................................2-1-1
(1) Cassette paper feed section..............................................................................................................2-1-1
(2) MP tray paper feed section ...............................................................................................................2-1-3
2-1-2 Main charging section.............................................................................................................................2-1-4

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2-1-3 Optical section ........................................................................................................................................2-1-5
(1) Image scanner section......................................................................................................................2-1-5
(2) Laser scanner section.......................................................................................................................2-1-7
2-1-4 Developing section..................................................................................................................................2-1-9
(1) Single component developing system.............................................................................................2-1-11
2-1-5 Transfer and separation sections..........................................................................................................2-1-12
2-1-6 Cleaning and charge erasing sections..................................................................................................2-1-13
2-1-7 Fuser section ........................................................................................................................................2-1-14
2-1-8 Eject and switchback sections..............................................................................................................2-1-16
2-1-9 Duplex section ......................................................................................................................................2-1-17
(1) Paper conveying operation in duplex copying.................................................................................2-1-19
2-2 Electrical Parts Layout
2-2-1 Electrical parts layout..............................................................................................................................2-2-1
(1) PWBs ................................................................................................................................................2-2-1
(2) Switches and sensors .......................................................................................................................2-2-3
(3) Motors ...............................................................................................................................................2-2-5
(4) Clutches and solenoids.....................................................................................................................2-2-7
(5) Other electrical components..............................................................................................................2-2-8
2-3 Operation of the PWBs
2-3-1 Power source PWB.................................................................................................................................2-3-1
2-3-2 Engine PWB............................................................................................................................................2-3-4
2-3-3 Main PWB.............................................................................................................................................2-3-13
2-3-4 Scanner PWB .......................................................................................................................................2-3-21
2-3-5 Main operation PWB.............................................................................................................................2-3-24
2-4 Appendixes
Maintenance parts list.............................................................................................................................2-4-1
Maintenance kits.....................................................................................................................................2-4-2
Periodic maintenance procedures ..........................................................................................................2-4-3
Chart of image adjustment procedures...................................................................................................2-4-7
Wiring diagram No.1...............................................................................................................................2-4-9
Wiring diagram No.2.............................................................................................................................2-4-10
Wiring diagram No.3.............................................................................................................................2-4-11
Wiring diagram No.4.............................................................................................................................2-4-12
Wiring diagram No.5.............................................................................................................................2-4-13
Wiring diagram No.6.............................................................................................................................2-4-14
INSTALLATION GUIDE
DOCUMENT PROCESSOR
PAPER FEEDER
DOCUMENT FINISHER
BUILT-IN FINISHER
JOB SEPARATOR
FAX System (S)

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2K5
1-1-1
1-1 Specifications
1-1-1 Specifications
Machine
Type................................................Desktop
Printing method...............................Electrophotography by semiconductor laser
Supported original types.................Sheets, books and three-dimensional objects
Maximum original size: A3/Ledger
Original feed system.......................Fixed
Paper weight...................................Cassette: 60 to 120 g/m2
MP tray : 45 to 200 g/m2
Paper type ......................................Cassette:Plain, Rough, Vellum, Recycled, Preprinted, Bond, Color (Colour),
Prepunched, Letterhead, Thick, High Quality, Custom 1 to 8
(Duplex: Same as Simplex)
MP tray: Plain, Transparency (OHP film), Rough, Vellum, Labels, Recycled,
Preprinted, Bond, Cardstock (Hagaki), Color (Colour), Prepunched,
Letterhead, Thick, Envelope, High Quality, Custom 1 to 8
Paper size.......................................Cassette:A3, B4, A4, A4R, B5, B5R, A5R, Ledger, Legal, Letter, LetterR, Statement,
Oficio II, 8.5 x 13.5", Folio, 8K, 16K, 16KR
MP tray: A3, B4, A4, A4R, B5, B5R, A5R, B6R, A6R, Ledger, Legal, Letter, LetterR,
ExecutiveR, Statement, Oficio II, 8.5 x 13.5", Folio, 8K, 16K, 16KR,
Postcards (100 x 148 mm), Return postcard (148 x 200 mm),
Envelope DL, Envelope C5, Envelope C4, Envelope #10 (Commercial #10),
Envelope #9 (Commercial #9), Envelope #6 (Commercial #6 3/4), Monarch,
ISO B5, Youkei 2, Youkei 4
Zoom level......................................Manual mode: 25 to 400%, 1% increments
Auto mode: Preset zoom
Printing speed.................................A4/Letter: 30 sheets/min.
A4R/LetterR: 22 sheets/min.
A3/Ledger: 15 sheets/min.
B4/Legal: 15 sheets/min.
B5: 30 sheets/min.
B5R: 20 sheets/min.
A5R: 14 sheets/min.
First copy time ................................5.1 s or less
Warm-up time .................................Room temperature 22°C/71.6°F, 60% RH
Power on: 29 s or less
Low power mode:10 s or less
Sleep mode: 15 s or less
Paper capacity................................Cassette: 500 sheets (80 g/m2)
MP tray : 200 sheets (80 g/m2)
Output tray capacity........................Top tray : 250 sheets (80 g/m2)
When built-in finisher installed: 100 sheets (80 g/m2)
When job separator installed: 150 sheets (80 g/m2)
Continuous copying........................1 to 999 sheets
Light source....................................Inert gas lamp
Scanning system ............................Flat bed scanning by CCD image sensor
Photoconductor...............................a-Si (drum diameter 30 mm)
Image write system.........................Semiconductor laser and electrophotography
Charging system.............................Single positive corona charging
Developing system .........................Dry, reverse developing (single component system)
Developer: 1-component, magnetism toner
Toner replenishing: automatic from a toner container
Transfer system..............................Transfer roller
Separation system..........................Curvature separation and separation electrode
Cleaning system.............................Cleaning blade and roller
Charge erasing system...................Exposure by cleaning lamp
Fusing system.................................Heat roller
Heat source: halogen heaters
Abnormally high temperature protection devices: thermostats
Main memory..................................Standard : 2048 MB
Maximum: 2048 MB
Hard disk.........................................160 GB
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2K5
1-1-2
Interface..........................................USB interface connector: 1 (USB Hi-speed)
USB memory slot: 2 (Full-speed USB)
Network interface: 1 (10 BASE-T/100 BASE-TX)
Optional interface: 2 (KUIO/W)
Resolution.......................................600 x 600 dpi
Operating environment...................Temperature: 10 to 32.5°C/50 to 90.5°F
Humidity: 15 to 80% RH
Altitude: 2500 m/8,202 ft maximum
Brightness: 1500 lux maximum
Dimensions.....................................570 (W) x 630 (D) x 767 (H) mm (main unit only)
22 7/16" (W) x 24 13/16" (D) x 30 3/16" (H) (main unit only)
Weight.............................................75 kg/165 lbs
Space required................................725 (W) x 630 (D) mm (using MP tray)
28 9/16" (W) x 24 13/16" (D) (using MP tray)
Power source..................................120 V AC, 60 Hz, 11.8 A
220 to 240 V AC, 50/60 Hz, 6.5 A
Options ...........................................Document processor, paper feeder, document finisher, built-in finisher, job separator,
key counter, fax kit, expansion memory, internet fax kit, data security kit and printed
document guard kit
Printer functions
Printing speed.................................Same as copying speed
First print time.................................5.8 s or less
Resolution.......................................600 dpi
Operating system............................Windows 2000 (Service Pack 2 or later), Windows XP, Windows Server 2003,
Windows Vista, Apple Macintosh OS 10.x
Interface..........................................USB interface connector: 1 (USB Hi-speed)
Network interface: 1 (10 BASE-T/100 BASE-TX)
Page description language .............PRESCRIBE
Scanner functions
Operating system............................Windows 2000 (Service Pack 2 or later), Windows XP, Windows Vista
System requirements......................CPU 600 MHz or higher
RAM 128 MB or more
Resolution.......................................600 dpi, 400 dpi, 300 dpi, 200 dpi, 200 x 100 dpi, 200 x 400 dpi
File format.......................................TIFF (MMR/JPEG compression), JPEG, XPS, PDF (MMR/JPEG compression),
PDF (high compression)
Scanning speed..............................A4, 300 dpi, Image quality: Text/Photo original
Single-sided: B/W: 50 images/min, Color: 15 images/min
Interface..........................................Ethernet (10 BASE-T/100 BASE-TX)
Network protocol.............................TCP/IP
Transmission system......................PC transmission SMB Scan to SMB
FTP Scan to FTP, FTP over SSL
E-mail transmission SMTP Scan to E-mail
Twain scan
WIA scan
NOTE: These specifications are subject to change without notice.
Service Manual Y112040-6

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1-1-3
1-1-2 Parts names
(1) Machine
Figure 1-1-1
1
2
4
5
3
6
78
910
11
12
13
14
15
1. Original cover (option)
2. Original size indicator plates
3. Clip holder
4. Slit glass
5. Attention indicator
6. Receive indicator
7. Left cover 1
8. Left cover 1 lever
9. Left cover 2
10. Left cover 2 handle
11. Contact glass
12. Operation panel
13. Cassette 1
14. Cassette 2
15. Duplex unit
Y112040-6Service Manual

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1-1-4
Figure 1-1-2
22
18
23
21
19
20
1617
16. Toner container stopper
17. Toner container
18. Waste toner box
19. Paper feed unit (A2)
20. Paper feed unit cover (A3)
21. Knob
22. Cleaner rod
23. Cleaning brush
Service Manual Y112040-6

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1-1-5
Figure 1-1-3
24
25
33
26 27
28
30
29
31
31
32
34
38
37
35
36
24. USB memory slot (A1)
25. Front cover
26. Paper width adjusting tab
27. Paper length guide
28. Top tray
29. Main power switch
30. Paper width guide
31. MP tray (multi purpose tray)
32. Output stopper
33. Filter (F1)
34. Optional interface slot (OPT2)
35. USB interface connector (A2)
36. USB interface connector (B1)
37. Network interface connector
38. Optional interface slot (OPT1)
Y112040-6Service Manual

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1-1-6
(2) Operation panel
Figure 1-1-4
1 2 3 4 5 6 7 8 9 10 11 12
13
14
15
18 2019 25
16 17 26
21 22 23 24 27
1. System menu key/indicator
2. Counter key/indicator
3. Print indicator
4. Send indicator
5. Receive indicator
6. Memory indicator
7. Attention indicator
8. Interrupt key/indicator
9. Logout key/indicator
10. Energy saver key/indicator
11. Power key/indicator
12. Main power indicator
13. Status/Job cancel key/indicator
14. Program key/indicator
15. Application key/indicator
16. Help key/indicator
17. Accessibility key/indicator
18. Document box key/indicator
19. Send key/indicator
20. Copy key/indicator
21. Numeric keys
22. Clear key
23. Quick No. search key
24. Enter key
25. Start key/indicator
26. Stop key
27. Reset key
Service Manual Y112040-6

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1-1-7
1-1-3 Machine cross section
Figure 1-1-5 Machine cross section
Paper path
Light path
3
8
9
76
2
5
41
1
1
3
1. Paper feed section
2. Main charging section
3. Optical section
4. Developing section
5. Transfer and separation section
6. Cleaning and charge erasing section
7. Fuser section
8. Eject and switchback section
9. Duplex section
Y112040-6Service Manual