Olivetti DF-650 User manual

Option Copier
SERVICE MANUAL
Code Y104371-8
DF-650
MT-1(A)
BF1(A)
PH-4A/PH-4C

PUBLICATION ISSUED BY:
Olivetti S.p.A.
77, Via Jervis - 10015 Ivrea (TO)
Italy
Copyright © 2008, 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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3H3-2.0
CONTENTS
1-1 Specifications
1-1-1 Specifications..........................................................................................................................................1-1-1
1-1-2 Parts names............................................................................................................................................1-1-2
1-1-3 Machine cross sectional view .................................................................................................................1-1-3
1-1-4 Machine drive system .............................................................................................................................1-1-4
(1) Finisher (paper feed and conveying section) ....................................................................................1-1-4
(2) Finisher (main tray driving section) ...................................................................................................1-1-5
(3) Multi job tray......................................................................................................................................1-1-6
(4) Centerfold unit...................................................................................................................................1-1-7
(5) Punch unit .........................................................................................................................................1-1-7
1-2 Installation
1-2-1 Unpacking and installation......................................................................................................................1-2-1
1-2-2 Installing the centerfold unit (option) .......................................................................................................1-2-3
1-2-3 Installing the multi job tray (option) .......................................................................................................1-2-11
1-2-4 Installing the punch unit (option) ...........................................................................................................1-2-17
1-2-5 Installing the stopper guide (option)......................................................................................................1-2-21
(1) Installing the stopper guide (To the finisher without the multi job tray) ...........................................1-2-21
(2) Installing the stopper guide (To the finisher with the multi job tray) ................................................1-2-22
1-3 Maintenance Mode
1-3-1 Maintenance mode .................................................................................................................................1-3-1
(1) Executing a maintenance item ..........................................................................................................1-3-1
(2) Contents of the maintenance mode items.........................................................................................1-3-2
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 .................................................................................................................................1-4-3
1-4-2 Self-diagnosis .........................................................................................................................................1-4-6
(1) Self-diagnostic function .....................................................................................................................1-4-6
(2) Self diagnostic codes ........................................................................................................................1-4-7
1-4-3 Electric problems ..................................................................................................................................1-4-14
1-4-4 Mechanical problems............................................................................................................................1-4-22
1-5 Assembly and Disassembly
1-5-1 Finisher ...................................................................................................................................................1-5-1
(1) Correcting paper curling....................................................................................................................1-5-1
(2) Correcting centerfold-stapling ...........................................................................................................1-5-3
(3) Adjusting the stapler unit mounting position......................................................................................1-5-4
(4) Centering stapling position................................................................................................................1-5-7
1-5-2 Centerfold unit.........................................................................................................................................1-5-9
(1) Detaching and refitting the centerfold blade......................................................................................1-5-9
(2) Adjusting the paper folding position ................................................................................................1-5-11
1-5-3 Punch unit.............................................................................................................................................1-5-12
(1) Centering punch-holes ....................................................................................................................1-5-12
(2) Setting margin from the leading edge to punch holes .....................................................................1-5-13
1-6 Requirements on PWB Replacement
1-6-1 Upgrading the version of the firmware of the finisher main PWB ...........................................................1-6-1
1-6-2 Requirements on finisher main PWB replacement .................................................................................1-6-2

3H3-2.0
2-1 Mechanical construction
2-1-1 Finisher ...................................................................................................................................................2-1-1
(1) Paper insertion section......................................................................................................................2-1-1
(2) Feedshift section ...............................................................................................................................2-1-2
(3) Intermediate tray section...................................................................................................................2-1-5
(4) Paper eject section..........................................................................................................................2-1-13
2-1-2 Multi job tray..........................................................................................................................................2-1-15
2-1-3 Centerfold unit.......................................................................................................................................2-1-17
2-1-4 Punch unit.............................................................................................................................................2-1-20
2-2 Electrical Parts Layout
2-2-1 Electrical parts layout..............................................................................................................................2-2-1
(1) PWBs (finisher) .................................................................................................................................2-2-1
(2) Switches and sensors (finisher) ........................................................................................................2-2-2
(3) Clutches and solenoids (finisher) ......................................................................................................2-2-4
(4) Motors and others (finisher) ..............................................................................................................2-2-5
(5) Stapler...............................................................................................................................................2-2-6
(6) PWBs (optional centerfold unit).........................................................................................................2-2-7
(7) Switches and sensors (optional centerfold unit)................................................................................2-2-8
(8) Motors and solenoids (optional centerfold unit).................................................................................2-2-9
(9) Switches and motors (optional multi job tray)..................................................................................2-2-10
(10) Switches and motors (optional punch unit) .....................................................................................2-2-11
2-3 Operation of the PWBs
2-3-1 Finisher main PWB .................................................................................................................................2-3-1
2-3-2 Finisher drive PWB ...............................................................................................................................2-3-10
2-3-3 Centerfold unit main PWB.....................................................................................................................2-3-14
2-4 Appendixes
Timing chart No.1....................................................................................................................................2-4-1
Timing chart No.2....................................................................................................................................2-4-2
Timing chart No.3....................................................................................................................................2-4-3
Timing chart No.4....................................................................................................................................2-4-4
Maintenance parts list.............................................................................................................................2-4-5
Periodic maintenance procedures ..........................................................................................................2-4-7
Optional devices supplied parts list.......................................................................................................2-4-11
Centerfold unit wiring diagram ..............................................................................................................2-4-13
General wiring diagram No.1 ................................................................................................................2-4-14
General wiring diagram No.2 ................................................................................................................2-4-15
General wiring diagram No.3 ................................................................................................................2-4-16
General wiring diagram No.4 ................................................................................................................2-4-17
General wiring diagram No.5 ................................................................................................................2-4-18
General wiring diagram No.6 ................................................................................................................2-4-19
General wiring diagram No.7 ................................................................................................................2-4-20

3H3
1-1-1
1-1 Specific ations
1-1-1 Specifications
Finisher
Type ................................................ Floor type
Number of trays .............................. 2 trays
Tray capacity ................................... Main tray (80 g/m
2
weight paper)
A3, B4 (257 x 364 mm), 11" x 17", 8 1/2 " x 14": 1500 sheets
A4 - A6R, Folio, 8
1/2 " x 11", 11" x 8 1/2 ", 5 1/2 " x 8 1/2 ": 3000 sheets
Sub tray (80 g/m2weight paper)
A3 - A6R, Folio, 11" x 17", 8 1/2" x 14", 8 1/2" x 11", 11" x 8 1/2", 5 1/2" x 8 1/2": 200
sheets
Stapling capacity.............................A3, B4 (257 x 364 mm), 11" x 17", 8 1/2" x 14": 30 sheets
A4, A4R, B5, 8 1/2" x 11", 11" x 8 1/2": 50 sheets
Storage capacity .............................A3, B4 (257 x 364 mm), 11" x 17", 8 1/2" x 14"
Stapling 2 - 4 sheets: 150 sets
Stapling 5 - 10 sheets: 100 sets
Stapling 11 - 30 sheets: 50 sets
A4, A4R, 8 1/2" x 11", 11" x 8 1/2", 5 1/2" x 8 1/2"
Stapling 2 - 4 sheets: 150 sets
Stapling 5 - 10 sheets: 100 sets
Stapling 11 - 30 sheets: 50 sets
Stapling 31 - 50 sheets: 3000 sheets
Power source.................................. Supplied via machine
Dimensions (W x D x H) ................ 796 x 640 x 1070 mm
31 5/16" x 25 3/16" x 42 1/8"
Weight............................................. Approx. 73 kg/160.6 lbs.
Multi job tray (option)
Number of trays .............................. Job tray: 5
Paper size.......................................A3, B4 (257 x 364 mm), A4, A4R, A5R, B6R, Folio, 11" x 17", 8 1/2" x 14", 8 1/2" x 11",
11" x 8 1/2", 5 1/2" x 8 1/2"
Tray capacity...................................A3, B4 (257 x 364 mm), 11" x 17", 8 1/2" x 14": 100 sheets (80 g/m2weight paper)
A4 - B6R, Folio, 8 1/2" x 11", 11" x 8 1/2", 5 1/2" x 8 1/2": 150 sheets (80 g/m2weight
paper)
Dimensions (W x D x H) .................368 x 392 x 573 mm
14 1/2" x 15 7/16" x 22 9/16"
Weight ............................................Approx.15 kg/33 lbs.
Centerfold unit (option)
Foldable sizes.................................A3, B4 (257 x 364 mm), A4R, 11" x 17", 8 1/2" x 11"
Foldable number of sheets .............1 - 16 (no stapling for 1 sheet)
Maximum number for storage......... 5 or less copies in a set: 30 sets
6 - 10 copies in a set: 20 sets
11 - 16 copies in a set: 10 sets
Paper thickness ..............................60 - 200 g/m2(only one cover for 81 g/m2or more)
Punch unit (option)
Available sizes ................................A3, B4 (257 x 364 mm), A4, A4R, B5, B5R, A5R, Folio, 11" x 17", 8 1/2" x 14",
81/2" x 11", 11" x 8 1/2", 5 1/2" x 8 1/2"
Y104371-8 Service Manual

3H3
1-1-2
1-1-2 Parts names
Figure 1-1-1
9
5
2
1
3
4
7
6
24
22
21
23
20
8
17
19
18
10
16
1312 15
14
11
Finisher
1. Main tray (Tray A)
2. Sub tray (Tray B)
3. Front cover
4. Front cover handle
5. Upper cover
6. Intermediate tray
7. Intermediate tray handle
8. Intermediate tray release lever
9. Lower lever
10. Conveyor knob
11. Coupling section lower guide lever
12. Stapler cartridge A
13. Stapler cartridge B
14. Coupling section upper guide lever
Punch unit (option)
15. Punch unit
16. Punch unit adjustment dial
17. Punch waste box
Centerfold unit (option)
18. Unit release lever
19. Unit transport handle
20. Unit release handle
21. Centerfold unit installation button
22. Conveyor guide lever
23. Storage tray
Multi job tray (option)
24. Job trays No.1 - 5
Service Manual Y104371-8

3H3
1-1-3
1-1-3 Machine cross sectional view
Figure 1-1-2
Paper path
1. Paper insertion section
2. Feedshift section
3. Intermediate tray section
4. Paper ejection section
5. Multi job tray (option)
6. Centerfold unit (option)
7. Punch unit (option)
Y104371-8 Service Manual

3H3
1-1-4
1-1-4 Machine drive system
(1) Finisher (paper feed and conveying section)
Figure 1-1-3
Viewed from the machine rea
r
1. Paper conveying motor
gear
2. Paper conveying gear Z54/
P50
3. Paper conveying drive belt
4. Paper conveying gear Z48/
P31
5. Drive tension pulley
6. Paper conveying roller pul-
ley 31
7. Intermediate tray drive gear
Z40/P30
8. Drive tension pulley
9. Paper entry motor gear
10. Paper entry gear 25
11. Paddle gear 22
12. Paddle gear 22
13. Siding drum motor gear
14. Drum gear Z50/Z20
15. Drum drive gear 53
16. Drum drive gear 46
17. Movable guide motor gear
18. Idle gear
19. Idle cam gear 75
20. Intermediate tray joint gear
34
21. Drive pulley 20
22. Pulley 16
23. Feed pulley belt
24. Forwarding roller gear
25. Feed pulley drive belt
26. Pulley 16
27. Drive pulley 20
28. Feed pulley belt
29. Forwarding roller gear
30. Paper conveying pulley belt
31. Paper conveying drive pul-
ley 27
32. Upper paper conveying belt
motor gear
33. Intermediate tray drive belt
34. Eject pulley 20
35. Pulley 20
36. Intermediate tray convey-
ing belt
37. Pulley 20
38. Eject pulley 20
39. Intermediate tray drive belt
40. Lower paper conveying belt
motor gear
41. Lower intermediate tray belt
42. Pulley 20
43. Timing belt pulley
44. Pulley 20
45. Eject motor gear
46. Eject gear Z60/Z32
47. Intermediate drive gear 40
48. Intermediate drive gear 40
49. Gear 16T
Service Manual Y104371-8

3H3
1-1-5
(2) Finisher (main tray driving section)
Figure 1-1-4
1. Main tray elevation motor pulley
2. Feed belt
3. Pulley 34
4. Worm gear
5. Gear 50
6. Gear 18
7. Gear 51
8. Pulley 20S
9. Tray drive belt
10. Pulley 20S
11. Gear 26
Y104371-8 Service Manual

3H3
1-1-6
(3) Multi job tray
1. Multi job tray elevation motor pulley
2. Feed belt
3. Pulley 34
4. Worm gear
5. Gear 50
6. Gear 18
7. Gear 51
8. Pulley 20S
9. Tray drive belt
10. Pulley 20S
11. Gear 26
Service Manual Y104371-8

3H3
1-1-7
(4) Centerfold unit
Figure 1-1-5
(5) Punch unit
Figure 1-1-6
1. Main motor pulley
2. Belt 118P2M6
3. Gear 22/40
4. Gear 33/15
5. Gear 51
6. Manual roller gear
(conveyor guide knob)
7. Gear 22
8. Gear 51
9. Gear 19
10. Gear 50/15
11. Gear 16/25
12. Gear 16/25
13. Bypass pulley gear
14. Gear 58
15. Pulley 28
16. Paper drive belt
17. Pulley 28
18. Idle pulley 15
19. Centering plate motor pul-
ley
20. Belt 124
21. Pulley 22
22. Pulley 20
23. Paper conveying belt
24. Pulley 20
25. Blade motor pulley
26. Belt 126P2M6
27. Gear 22/40
28. Gear 33/15
29. Gear 40
30. Gear 22
31. Gear 50
32. Manual roller gear
1. Punch motor gear
2. Idle gear 16/51
3. Drive cum gear 40
Y104371-8 Service Manual

3H3
1-2-1
1-2Installation
1-2-1 Unpacking and installation
Figure 1-2-1 Unpacking (Finisher)
1. Finisher
2. Main tray
3. Sub tray
4. Connecting plate
5. Sponge
6. Pins
7. Nuts
8. M4 x 20 TP tap tight S screws
9. Stapler cartridges
10. Outer case
11. Barcode labels
12. Inner frame
13. Skid
14. Hinge joint
15. Accessory case
16. Bottom cushion sheet
17. Front lower left pad
18. Rear lower left pad
19. Front lower right pad
20. Rear lower right pad
21. Upper pad
22. Machine cover
23. Air cap bag
24. Air cap bag
25. Air cap bag
26. Plastic bag
27. Plastic bag
28. Operation guide
29. Installation guide
30. Spacer
31. Spacer
32. Plastic sheet
33. Clamp
34. M3 x 14 tap tight S screws
35. M4 x 8 tap tight S screws
36. M3 x 10 tap tight S screw
37. Grounding plates A
38. Grounding plates B
Y104371-8 Service Manual

3H3
1-2-2
Removing tapes and spacers
Procedure
1. Remove the plastic sheet.
2. Remove two tapes and spacer.
Figure 1-2-2
3. Remove eight tapes.
Figure 1-2-3
4. Remove four tapes and two spacers.
Figure 1-2-4
Plastic sheet
Tape
Tape
Spacer
Tape
Tapes
Tapes
Tape
Tape
Tape
Tape
Tape Spacers
Service Manual Y104371-8