Olivetti FS-603 User manual

FS-603
Color Printer
SERVICE MANUAL
Code Y104710-1

PUBLICATIONISSUEDBY:
Olivetti S.p.A.
77, Via Jervis - 10015 Ivrea (TO)
Italy
Copyright © 2006, Olivetti
All rights reserved

After publication of this service manual, the parts and mechanism may be subject to change for
improvement of their performance.
Therefore, the descriptions given in this service manual may not coincide with the actual machine.
When any change has been made to the descriptions in the service manual, a revised version will be
issued with a revision mark added as required.
Revision mark:
• To indicate clearly a section revised, show to the left of the revised section.
A number within represents the number of times the revision has been made.
• To indicate clearly a section revised, show in the lower outside section of the correspond-
ing page.
A number within represents the number of times the revision has been made.
NOTE
Revision marks shown in a page are restricted only to the latest ones with the old ones deleted.
• When a page revised in Ver. 2.0 has been changed in Ver. 3.0:
The revision marks for Ver. 3.0 only are shown with those for Ver. 2.0 deleted.
• When a page revised in Ver. 2.0 has not been changed in Ver. 3.0:
The revision marks for Ver. 2.0 are left as they are.
1
1
1
1
2006/03 1.0—Issueof the firstedition
Date Service manual Ver. Revision mark Descriptions of revision

FS-603GeneralMaintenanceAdjustment / Setting
Troubleshooting
Field Service Ver.1.0 Mar.2006
i
CONTENTS
General
1. Product specification ............................................................................................... 1
1.1 Type ...................................................................................................................... 1
1.2 Functions .............................................................................................................. 1
1.3 Paper type ............................................................................................................ 1
1.3.1 Group, Group offset ...................................................................................... 1
1.3.2 Sort, Sort offset............................................................................................. 1
1.3.3 Sort staple..................................................................................................... 2
1.3.4 Center Staple & Fold..................................................................................... 2
1.4 Stapling................................................................................................................. 2
1.5 No. of sheets to be stapled (sort staple)............................................................... 3
1.6 Machine specifications.......................................................................................... 3
1.7 Operating environment ......................................................................................... 3
Maintenance
2. Other ....................................................................................................................... 5
2.1 Disassembly/Adjustment prohibited items ............................................................ 5
2.2 Disassembly/Assembly list (Other parts) .............................................................. 6
2.3 Disassembly/Assembly procedure........................................................................ 7
2.3.1 Exit Tray ........................................................................................................ 7
2.3.2 Front Cover ................................................................................................... 7
2.3.3 Rear Cover.................................................................................................... 7
2.3.4 Upper Door ................................................................................................... 8
2.3.5 Finisher Tray Upper Cover ............................................................................ 8
2.3.6 Upper Cover.................................................................................................. 9
2.3.7 Side Guide .................................................................................................... 9
2.3.8 Middle Transport Unit.................................................................................. 10
2.3.9 Stapler......................................................................................................... 10
2.3.10 Saddle Section............................................................................................ 11
2.3.11 Finisher Tray................................................................................................ 11
2.3.12 Paddle Section ........................................................................................... 12
2.3.13 Exit Roller (Upper) ...................................................................................... 14
2.3.14 Paddle......................................................................................................... 14
2.3.15 Exit Roller (Lower) and Paper Exit Belt....................................................... 15
2.3.16 Stapler/Folding Drive Unit ........................................................................... 17
2.3.17 Transport Roller........................................................................................... 18
Y104710-1 Service Manual

FS-603
GeneralMaintenanceAdjustment / Setting
Troubleshooting
Field Service Ver.1.0 Mar.2006
ii
2.3.18 Middle Transport Roller............................................................................... 19
2.3.19 Punch Unit .................................................................................................. 20
2.3.20 Finisher Control Board................................................................................ 21
2.3.21 Punch Control Board .................................................................................. 21
2.3.22 Transport Motor Unit ................................................................................... 22
2.3.23 Middle Transport Motor............................................................................... 22
2.3.24 Punch Motor ............................................................................................... 22
2.3.25 Side Registration Motor .............................................................................. 22
Adjustment/Setting
3. How to use the adjustment section ....................................................................... 23
4. Sensor check ........................................................................................................ 24
4.1 Check procedure ................................................................................................ 24
4.2 Sensor check list ................................................................................................ 24
4.2.1 Sensor check screen .................................................................................. 24
5. Mechanical adjustment ......................................................................................... 26
5.1 Adjustment of the stapling position..................................................................... 26
5.1.1 Adjustment procedure................................................................................. 26
5.2 Adjustment of the folding position....................................................................... 28
5.2.1 Adjustment procedure................................................................................. 28
5.3 Adjustment of height and inclination................................................................... 30
5.4 Adjustment of the Folding Position ..................................................................... 32
5.4.1 Adjustment procedure................................................................................. 32
5.5 Stapler Phase Adjustment.................................................................................. 36
5.5.1 Adjustment procedure................................................................................. 36
5.6 Saddle Gear Phase Adjustment ......................................................................... 39
6. Board switch ......................................................................................................... 40
6.1 PWB-A FN (Finisher Control Board) .................................................................. 40
6.1.1 Adjustment of the folding positions ............................................................. 41
6.1.2 Adjustment of the center stapling position.................................................. 42
6.1.3 Adjustment of the Alignment Plate position ................................................ 43
6.2 PWB-B PK (Punch Control Board) ..................................................................... 45
6.2.1 Adjustment of the sensor output ................................................................. 46
6.2.2 Registration of the number of punch holes ................................................. 46
6.2.3 Procedure after replacing the EEP-ROM (IC1002)..................................... 47
6.2.4 Punch center position adjustment............................................................... 47
Service Manual Y104710-1

FS-603GeneralMaintenanceAdjustment / Setting
Troubleshooting
Field Service Ver.1.0 Mar.2006
iii
Troubleshooting
7. Jam Display........................................................................................................... 51
7.1 Misfeed display ................................................................................................... 51
7.1.1 Misfeed display resetting procedure ........................................................... 51
7.2 Sensor layout...................................................................................................... 52
7.3 Solution............................................................................................................... 53
7.3.1 Initial check items........................................................................................ 53
7.3.2 Transport section misfeed ........................................................................... 53
7.3.3 Horizontal Transport section misfeed.......................................................... 54
7.3.4 Folding position section misfeed ................................................................. 54
7.3.5 Stapler section misfeed............................................................................... 55
8. Trouble code.......................................................................................................... 56
8.1 Trouble code display ........................................................................................... 56
8.2 Trouble code list.................................................................................................. 56
8.2.1 How to reset................................................................................................ 59
8.3 Solution............................................................................................................... 60
8.3.1 C1180: Transport System Drive malfunctions............................................. 60
8.3.2 C1181: Paddle Motor malfunctions............................................................. 60
8.3.3 C1183: Elevate Mechanism malfunctions ................................................... 61
8.3.4 C1192: Front Aligning Plate Motor malfunctions......................................... 61
8.3.5 C1193: Rear Aligning Plate Motor malfunctions ......................................... 62
8.3.6 C11A4: Booklet Exit Motor malfunctions..................................................... 62
8.3.7 C11B1: Stapler Unit Slide Motor malfunctions............................................ 63
8.3.8 C11B4: Stapler/Folding Motor malfunctions................................................ 63
8.3.9 C11C1: Punch Control Board malfunctions ................................................ 65
8.3.10 C11C2: Punch Side Registration Motor malfunctions................................. 66
8.3.11 C11C3: Punch Motor malfunctions ............................................................. 66
8.3.12 C11C5: Punch Sensor malfunctions ........................................................... 67
8.3.13 C1401: Backup RAM malfunction ............................................................... 68
Y104710-1 Service Manual

FS-603
GeneralMaintenanceAdjustment / Setting
Troubleshooting
Field Service Ver.1.0 Mar.2006
iv
Blank Page
Service Manual Y104710-1

Field Service Ver.1.0 Mar.20061. Product specification
1
FS-603General
General
1. Product specification
1.1 Type
1.2 Functions
1.3 Paper type
• Remove the finisher off the machine for feeding the long paper.
• The maximum loading capacity shown is for when loading the single type of paper (80g/
m2)
1.3.1 Group, Group offset
*1: Controlled by whichever reached earlier
1.3.2 Sort, Sort offset
Type Multi Staple Finisher with Saddle (Booklet)
Installation Freestanding
Document Alignment Center
Supplies Staple Cartridge
Modes Normal Group, Sort, Group Offset, Sort Offset, Sort Staple
Center Staple & Fold
Punch (Option) Group Punch, Sort Punch, Group Offset Punch,
Sort Offset Punch, Sort Staple Punch
Plain Paper Paper Size Weight Tray Capacity *1 Exit Tray No. of Sheets
to be Stapled
B5R/B5 to
A3 wide
5.5 × 8.5R/
5.5 × 8.5
to
12.25 × 18
60 to 90
g/m2
16 to 24 lb
No. of
Sheet
Height
A4R /
8.5×11R
or smaller
1000
150 mm
B4/
8.5×14 or
larger
500
75 mm
1st paper
exit tray
-
Envelop
OHP Film
Label Paper
Thick Paper
60 to 256
g/m2
16 to 68 lb
20 sheet
Paper Type Paper Size Weight Tray Capacity Exit Tray No. of Sheets
to be Stapled
Plain Paper A5,B5R/B5 to A3
8.5 × 11R/
8.5 × 11
to
11 × 17
60 to 90
g/m2
16 to 24 lb No. of
Sheets
Height
A4R /
8.5×11R
or smaller
1000
150 mm
B4/
8.5×14 or
larger
500
75 mm
1st paper
exit tray
-
Controlled by whichever
reached earlier
Y104710-1 Service Manual

1. Product specification Field Service Ver.1.0 Mar.2006
2
FS-603
General
1.3.3 Sort staple
* The number of Sheets to be Stapled is limited for high-density images.
(Color Wise: 20 sheets x 20 sets)
1.3.4 Center Staple & Fold
1.4 Stapling
Paper Type Paper Size Weight Tray Capacity Exit Tray No. of Sheets
to be Stapled
Plain Paper
Cardboard
B5R/B5 to A3
8.5 × 11R/
8.5 × 11
to
11×17
Normal
Mode
60 to 90
g/m2
16 to 24 lb
Cover Mode
60 to 209
g/m2
16 to 55.5 lb
No. of
Sheets
Height
No. of
Sets
A4R /
8.5×11R
or smaller
1000
150 mm
30
B4/
8.5×14 or
larger
500
75 mm
30
Normal Mode *1
1st paper
exit tray
A4R/
8.5×
11R or
smaller
2 to 50
B4/
8.5×14
or larger
2 to 25
Controlled by whichever
reached earlier
Paper Type Paper Size Weight Tray Capacity Exit Tray No. of Sheets to
be Stapled
Plain Paper A4R, B4, A3
8.5 × 11R/
11 × 17
60 to 90
g/m2
16 to 24 lb
10 sets
(No. of Sheets to be
Stapled: 6 to 15 sheets)
20 sets
(No. of Sheets to be
Stapled: 2 to 5 sheets)
2nd paper
exit tray
Black copy
2 to 15 sheets
(Max. 60 pages)
Other copy
2 to 10 sheets
(Max. 40 pages)
Staple Filling Mode Dedicated Staple Cartridge Mode (5000 staples)
Staple Detection Available (Nearly Empty: 40 remaining staples)
Stapling Position
Rear: Parallel 1 point B5R/B5 to A3,
8.5× 11R / 8.5× 11 to 11 × 17
Front: Parallel 1 point
Side: Parallel 2 points
Center: Parallel 2 points
Manual Staple None
Folding Mode Roller Pressure Folding
Folding Position Center of Paper
Service Manual Y104710-1

Field Service Ver.1.0 Mar.20061. Product specification
3
FS-603General
1.5 No. of sheets to be stapled (sort staple)
A. A4R, 8.5× 11R or smaller
B. B4, 8.5× 14 or larger
1.6 Machine specifications
1.7 Operating environment
Conforms to the operating environment of the main unit.
NOTE
• These specifications are subject to change without notice.
No. of Sheets to
be Stapled
No. of Sets
Rear: Parallel Center: Parallel Front: Parallel
2 100 40 40
3 to 5 80 40 40
6 to 10 60 40 40
11 to 20 30 30 30
21 to 30 30 30 30
31 to 50 30 sets or 1000 sheets
No. of Sheets to
be Stapled
No. of Sets
Rear: Parallel Center: Parallel Front: Parallel
2 100 50 50
3 to 5 80 40 40
6 to 10 40 40 40
11 to 20 30 sets or 1000 sheets
21 to 25
Power Requirements DC 24 V (supplied from the main unit)
DC 5 V (generated by Finisher)
Max. Power
Consumption 65 W or less
Dimensions 601 mm (W) × 933 mm (H) × 603 mm (D)
23.75 inch (W) × 36.75 inch (H) × 23.75 inch (D)
Weight 41.6 kg (91.75 lb)
Y104710-1 Service Manual

1. Product specification Field Service Ver.1.0 Mar.2006
4
FS-603
General
Blank Page
Service Manual Y104710-1

Field Service Ver.1.0 Mar.20062. Other
5
FS-603Maintenance
Maintenance
2. Other
2.1 Disassembly/Adjustment prohibited items
A. Paint-locked Screws
NOTE
• Paint-locked screws show that the assembly or unit secured can only be adjusted
or set at the factory and should not be adjusted, set, or removed in the field.
B. Red Painted Screws
NOTES
• When the screws are removed, the red paint is coated on the points where read-
justment is required.
• Once the red painted screw is removed or loosened, you should make adjustment.
Accordingly check the adjustment items in operation manual and make necessary
adjustment.Note that when two or more screws are used on the part in questions,
only one representative screw may be marked with red paint.
C. Variable Resistors on Board
NOTE
• Do not turn the variable resistors on boards for which no adjusting instructions
are given in Adjustment/Setting.
D. Removal of PWBs
NOTES
• When removing a circuit board or other electrical component, refer to “Handling of
PWBs” and follow the corresponding removal procedures.
• The removal procedures given in the following omit the removal of connectors and
screws securing the circuit board support or circuit board.
• When it is absolutely necessary to touch the ICs and other electrical components
on the board, be sure to ground your body.
Y104710-1 Service Manual

2. Other Field Service Ver.1.0 Mar.2006
6
FS-603
Maintenance
2.2 Disassembly/Assembly list (Other parts)
No Section Part name Ref. page
1
Exterior Parts
Exit Tray ☞7
2FrontCover ☞7
3RearCover ☞7
4 Upper Door ☞8
5 Finisher Tray Upper Cover ☞8
6 Upper Cover ☞9
7
Unit
Side Guide ☞9
8 Middle Transport Unit ☞10
9Stapler ☞10
10 Saddle Section ☞11
11 Finisher Tray ☞11
12 Paddle Section ☞12
13 Exit Roller (Upper) ☞14
14 Paddle ☞14
15 Exit Roller (Lower) and Paper Exit Belt ☞15
16 Stapler/Folding Drive Unit ☞17
17 Transport Roller ☞18
18 Middle Transport Roller ☞19
19 Punch Unit ☞20
20
Electrical Parts
Finisher Control Board ☞21
21 Punch Control Board ☞21
22 Transport Motor Unit ☞22
23 Middle Transport Motor ☞22
24 Punch Motor ☞22
25 Side Registration Motor ☞22
Service Manual Y104710-1

Field Service Ver.1.0 Mar.20062. Other
7
FS-603Maintenance
2.3 Disassembly/Assembly procedure
2.3.1 Exit Tray
1. Remove four screws [1], and remove
the Exit Tray [2].
2.3.2 Front Cover
1. Remove the Middle Transport Unit.
☞10
2. Open the Front Door [1].
3. While pinching the claws [2], remove
the Folding Jam Release Dial [3].
4. Remove two screws [4].
5. Remove the screw [5], and remove
the Front Cover [6].
2.3.3 Rear Cover
1. Remove the Middle Transport Unit.
☞10
2. Remove two screws [1], and remove
the Rear Cover [2].
[2]
[1] [1]
4583fs2526c0
[1]
[4]
[4] [3]
[2]
4583fs2527c0
[5]
[6]
4583fs2528c0
[1]
4583fs2529c0
[1]
[2]
4583fs2530c0
Y104710-1 Service Manual

2. Other Field Service Ver.1.0 Mar.2006
8
FS-603
Maintenance
2.3.4 Upper Door
1. Open the Upper Door [1], and
remove the Door Band Holder [2] by
turning it clockwise.
2. Remove the Door Band [3].
3. Remove the screw [4], and remove
the grounding wire.
4. Remove the screw [5], remove the
Finisher Tray Rear Cover [6], and
remove the Upper Door [7].
2.3.5 Finisher Tray Upper Cover
1. Remove the Front Cover.
☞7
2. Remove the Rear Cover.
☞7
3. Remove the Upper Door.
☞8
4. Unplug the connector [1].
5. Unplug the connector [3] while hold-
ing up the Finisher Tray Upper Cover
[2], and remove the Finisher Tray
Upper Cover [2].
[1]
[4]
4583fs2531c0
[2]
[3]
[5]
[6]
4583fs2532c0
[7]
[1]
4583fs2533c0
[2]
[3]
4583fs2534c0
Service Manual Y104710-1

Field Service Ver.1.0 Mar.20062. Other
9
FS-603Maintenance
2.3.6 Upper Cover
1. Remove the Front Cover.
☞7
2. Remove the Rear Cover.
☞7
3. Remove two screws [1].
4. Open the Upper Door[2],and remove
the Upper Cover [3].
2.3.7 Side Guide
1. Remove the Exit Tray.
☞7
2. Remove the Front Cover.
☞7
3. Remove the Rear Cover.
☞7
4. Derail the Exit Tray Support Plate
(Front) [1] and the Exit Tray Support
Plate (Rear) [2] to the outside off the
respective rail grooves.
5. Remove four screws [3].
6. Pull down the Side Guide [4] lightly,
disengage the Exit Tray Home Posi-
tion Detecting Lever (Rear) [5], and
then remove the Side Guide [4].
NOTE
• In reassembling, ensure of exact
installation with the Exit Tray Home
Position Detecting Lever (Rear) [5]
set in the slot of the Exit Tray Home
Position Detecting Lever (Center)
[6].
• After reassembly, press each of
these levers for several times to
make sure of exact installation.
[1]
4583fs2535c0
[1]
[2]
[3]
4583fs2536c0
[3]
[3]
[2]
[3]
4583fs2537c0
[1]
[3]
[5]
[4]
4583fs2538c0
[6]
[5]
[5]
[6]
4583fs2539c0
Y104710-1 Service Manual

2. Other Field Service Ver.1.0 Mar.2006
10
FS-603
Maintenance
2.3.8 Middle Transport Unit
1. Remove four screws [1].
2. Hold up the Middle Front Cover [2]
and the Middle Rear Cover [3], and
remove them while shifting them
back and forth.
3. Unplug two connectors [4].
4. Pinch the tie band [5], and remove it
from the sheet metal.
5. Remove two screws [6].
6. Loosen two screws [7].
7. Remove the Middle Transport Unit by
sliding it upwards.
2.3.9 Stapler
1. Open the Front Door [1].
2. Pull out the Stapler [3] while pressing
the Stop Lever [2].
NOTES
• Do not remove the Stapler from the
shaft of the stapler frame, or dis-
placement will be caused between
the position to which the Staple
Driver [4] (the lower unit of the Sta-
pler) feeds staples and the position
from which the Staple Clincher [5]
(the upper unit of the Stapler)
receives them.
[1]
[1]
4583fs2540c0
[2] [3]
[5]
[4]
4583fs2541c0
[6]
[7]
[7]
4583fs2542c0
[3]
[1]
4583fs2502c0
[2]
4583fs2503c0
[5]
[4]
Service Manual Y104710-1

Field Service Ver.1.0 Mar.20062. Other
11
FS-603Maintenance
2.3.10 Saddle Section
1. Remove the Front Cover.
☞7
2. Remove the Rear Cover.
☞7
3. Remove the Punch Dust Box.
4. Open the Jam Access Cover [1],
remove two screws [2], and remove
the Right Stay [3].
5. Remove two screws [4], and remove
the Lever [5].
6. Turn the Folding Jam Release Dial
[6] to move the Paper Pressure [7]
inside.
7. Remove the C-clip [8], and remove
the Belt [9].
8. Unplug two connectors [10].
9. Remove the Stapler[11].
☞10
10. Remove three screws [12], and pull
out and remove the Saddle [13].
2.3.11 Finisher Tray
1. Remove the Finisher Tray Upper
Cover.
☞8
2. Remove the Side Guide.
☞9
3. Remove two screws [1],and unplug
six connectors [2].
[1]
[2]
[5]
[3]
[4]
[2]
4583fs2544c0
[7]
[6]
4583fs2518c0
[8]
[9]
[10]
4583fs2519c0
[11]
[12]
[12]
[13]
4583fs2520c0
[1]
[2]
[2] 4583fs2546c0
[1]
[2]
[2]
Y104710-1 Service Manual

2. Other Field Service Ver.1.0 Mar.2006
12
FS-603
Maintenance
4. Pull out the Finisher Stopper Base
[3], and disengage the front claw [5]
and the rear claw [6] of the Finisher
Stopper [4].
5. Remove the Motor Harness [8] from
two Harness Saddles [7].
6. Unplug three connectors [9].
7. Remove the C-clip [10], and remove
the spacer [11], and remove the Belt
[13] from the Gear [12].
8. Unplug the connector [14], and
remove the Harness [16] from the
Wire Saddle [15].
9. Remove two screws [17], and
remove the Finisher Tray [18] by slid-
ing it to the far side and lifting it.
2.3.12 Paddle Section
1. Remove the Finisher Tray.
☞11
2. Place the Finisher Tray [1] as shown
in the figure.
NOTE
• Be careful not to damage the Align-
ing Plate [2].
[6]
[4]
[5]
[4]
[3]
4583fs2522c0
[8]
[7]
[9]
4583fs2523c0
[6] 4583fs2547c0
[10]
[11]
[13]
[12] [14]
[16]
[15]
[18]
[17]
4583fs2525c0
[1]
[2]
[2]
4583fs2548c0
Service Manual Y104710-1