Olivetti PI-503 User manual

PI-503
Option Printer
SERVICE MANUAL
Code Y107982-5

PUBLICATION ISSUED BY:
Olivetti S.p.A.
77, Via Jervis - 10015 Ivrea (TO)
Italy
Copyright © 2008, Olivetti
All rights reserved

Revision history
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, is shown at the left margin of the revised section.
The number inside represents the number of times the revision has been made.
• To indicate clearly a page that contains the revision, is shown near the page number of the
corresponding page.
The number inside 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.
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PI-503
Outline
MaintenanceAdjustment / Setting
Troubleshooting
Field Service Ver. 2.0 Aug. 2007
i
CONTENTS
PI-503
Outline
1. Product specification ............................................................................................... 1
Maintenance
2. Periodical check ...................................................................................................... 3
2.1 Maintenance procedure (Periodical check parts) ................................................ 3
2.1.1 Replacing the pick-up roller /Up and the feed roller /Up ............................... 3
2.1.2 Replacing the pick-up roller /Lw and the feed roller /Lw ............................... 5
2.1.3 Replacing the separation roller /Up and the torque limiter /Up ..................... 6
2.1.4 Replacing the separation roller /Lw and the torque limiter /Lw ..................... 7
3. Other ....................................................................................................................... 8
3.1 Disassembly/Adjustment prohibited items ............................................................ 8
3.2 Disassembly/Assembly/Cleaning list (Other parts)............................................... 9
3.2.1 Disassembly/Assembly parts list................................................................... 9
3.2.2 Cleaning parts list ......................................................................................... 9
3.3 Disassembly/Assembly procedure........................................................................ 9
3.3.1 Upper cover................................................................................................... 9
3.3.2 Rear cover................................................................................................... 10
3.3.3 Operation panel cover assy ........................................................................ 10
3.3.4 Post inserter ................................................................................................ 11
3.3.5 PI drive board (PIDB).................................................................................. 12
3.3.6 PI control board (PIOB)............................................................................... 13
3.4 Cleaning procedure ............................................................................................ 13
3.4.1 Pick-up roller /Up, feed roller /Up, separationroller /Up ............................... 13
3.4.2 Pick-up roller /Lw, feed roller /Lw, separationroller /Lw ............................... 14
3.4.3 Transport roller /Up ..................................................................................... 16
3.4.4 Transport roller /Lw ..................................................................................... 16
Adjustment/Setting
4. How to use the adjustment section ....................................................................... 17
5. Utility Mode ........................................................................................................... 18
5.1 Utility Mode function tree .................................................................................... 18
5.2 User Settings ...................................................................................................... 18
5.2.1 System Settings .......................................................................................... 18

PI-503
Outline
MaintenanceAdjustment / Setting
Troubleshooting
Field Service Ver. 2.0 Aug. 2007
ii
6. Sensor Check ....................................................................................................... 19
6.1 Check procedure ................................................................................................ 19
6.1.1 Sensor check screens ................................................................................ 19
6.1.2 Sensor check list......................................................................................... 20
7. Finisher ................................................................................................................. 21
7.1 FS-FN adjustment .............................................................................................. 21
7.1.1 Punch Resist Loop Size (PI)....................................................................... 21
7.1.2 Cover Sheet Tray Size Detection ................................................................ 21
7.1.3 Cover Sheet Feeder Adj. ............................................................................ 22
8. Mechanical adjustment ......................................................................................... 23
8.1 PI displacement adjustment (with PK-512/PK-513 installed) ............................. 23
8.2 PI tilt adjustment (with PK-512/PK-513 installed)............................................... 25
Troubleshooting
9. Jam display ........................................................................................................... 27
9.1 Misfeed display................................................................................................... 27
9.1.1 Misfeed display resetting procedure ........................................................... 27
9.2 Sensor layout...................................................................................................... 28
9.3 Solution .............................................................................................................. 28
9.3.1 Initial check items ....................................................................................... 28
9.3.2 Code: 7235 ................................................................................................. 29
9.3.3 Code: 7249 ................................................................................................. 29
9.3.4 Code: 7250 ................................................................................................. 30
9.3.5 Code: 7251 ................................................................................................. 30
10. Malfunction code................................................................................................... 31
10.1 Trouble code ....................................................................................................... 31
10.2 Solution .............................................................................................................. 32
10.2.1 C1124: Sheet feeder up/down drive failure (lower)..................................... 32
10.2.2 C1125: Sheet feeder up/down drive failure (upper) .................................... 32
10.2.3 C1126: Sheet feeder transportation drive failure ........................................ 33
10.2.4 C1132: Output OP punch driving motor malfunction .................................. 33

Field Service Ver. 2.0 Aug. 2007 1. Product specification
11
PI-503
Outline
Outline
1. Product specification
A. Type
B. Functions
C. Paper type
D. Machine specifications
E. Operating environment
• Conforms to the operating environment of the main body.
NOTE
• These specifications are subject to change without notice.
Name Post inserter unit
Type Torque limiter separation type seat feeding device
Auto sheet feeding
(online operation)
Feeds the sheet to finisher automatically under the instruction from the main
body.
Manual sheet feeding
(offline operation)
Feeds the sheet to finisher under the instruction from the operation panel of PI.
You can select the following 5 post processing modes:
• 1 staple/back mode
• 2 staples (flat-stapling) mode
• Punch mode (when PK-512/PK-513 is installed on finisher)
• Saddle stitching mode (when installed on FS-608)
• Tri-folding mode (when installed on FS-608)
Size Tray /Up A4/A4S, B5/B5S, A5
81/2x 11, 8 1/2x 11S, 5 1/2x 8 1/2, 7 1/4x 10 1/2S, 16K, 16KS
Custom paper (Max. 311.1 x 297 mm, Min. 182 x 139 mm)
Tray /Lw A3, B4, A4/A4S, B5/B5S, A5
8 x 13S, 8 1/4x 13S, 8 1/2x 13S, 8 1/8x 13 1/4S, 12 x 18, 11 x 17,
81/2x 14, 8 1/2x 11, 8 1/2x 11S, 5 1/2x 8 1/2, 8K, 16K, 16KS,
71/4x 10 1/2, 7 1/4x 10 1/2S
Custom paper (Max. 311.1 x 457.2 mm, Min. 182 x 139 mm)
Type Plain paper, recycle paper, color paper, special paper, coated paper,
high-quality paper
Weight 64 g/m2to 209 g/m2
Capacity Tray /Up 200 sheets (80 g/m2) or 30 mm or less in height
Tray /Lw 200 sheets (80 g/m2) or 30 mm or less in height
Power requirements DC 24 V, DC 5 V (supplied from the main body)
Max. power
consumption 30 W or less
Dimensions 511 mm (W) x 635 mm (D) x 220 mm (H)
20 inch (W) x 25 inch (D) x 8.75 inch (H)
Weight 10.5 kg (23.25 lb)
1
Y107982-5 Service Manual

1. Product specification Field Service Ver. 2.0 Aug. 2007
2
Outline
Blank Page
PI-503
Service Manual Y107982-5

Field Service Ver. 2.0 Aug. 2007 2. Periodical check
3
PI-503Maintenance
Maintenance
2. Periodical check
2.1 Maintenance procedure (Periodical check parts)
2.1.1 Replacing the pick-up roller /Up and the feed roller /Up
A. Periodically replaced parts/cycle
• Pick-up roller /Up: Every 200,000 prints
• Feed roller /Up: Every 100,000 prints
B. Replacing procedure
1. Remove the upper cover.
See P.9
2. Remove two C-clips [1], and then
slide two bearings [2] at the both
sides and remove the feed roller
assy /Up [3].
3. Remove the bearing [1] and remove
the actuator [2].
A07VF2C500DA
[3]
[1] [2] [1]
[2]
A07VF2C501DA
[1]
[2]
Y107982-5 Service Manual

2. Periodical check Field Service Ver. 2.0 Aug. 2007
4
PI-503
Maintenance
4. Remove two C-clips [1] and remove
two bearings [2].
5. Remove the C-clip [1].
6. Slide two roller shafts [2] to the
arrow-marked direction to remove
the pick-up roller /Up [3] and the feed
roller /Up [4].
NOTE
• Reinstalling the pick-up roller and
the feed roller with the blue faces of
the one-way clutches of the pick-up
roller and the feed roller face to the
front.
7. Remove the pick-up roller [1] and the
feed roller [2] from the one-way
clutches [3] and [4].
NOTE
• When reinstalling the pick-up roller
[1], be sure to insert its cutout [5]
over the protrusion [6] of the one-
way clutch [3].
• When reinstalling the feed roller [2],
be sure to insert its cutout [7] over
the protrusion [8] of the one-way
clutch [4].
8. To reinstall, reverse the order of removal.
A07VF2C502DA
[1]
[2]
A07VF2C503DA
[1][4]
[3]
[2]
A07VF2C504DA
[3]
[1]
[5][7][2]
[8] [6]
[4]
Service Manual Y107982-5

Field Service Ver. 2.0 Aug. 2007 2. Periodical check
5
PI-503Maintenance
2.1.2 Replacing the pick-up roller /Lw and the feed roller /Lw
A. Periodically replaced parts/cycle
• Pick-up roller /Lw: Every 200,000 prints
• Feed roller /Lw: Every 100,000 prints
B. Replacing procedure
1. Pull the release lever [1] and open
the upper door [2].
2. Take steps 2 to 7 in the replacement procedure of the pick-up roller /Up and feed roller
/Up.
See P.3
3. To reinstall, reverse the order of removal.
A07VF2C505DA
[2]
[1]
Y107982-5 Service Manual

2. Periodical check Field Service Ver. 2.0 Aug. 2007
6
PI-503
Maintenance
2.1.3 Replacing the separation roller /Up and the torque limiter /Up
A. Periodically replaced parts/cycle
• Separation roller /Up: Every 100,000 prints
• Torque limiter /Up: Every 600,000 prints
B. Replacing procedure
1. Remove the upper cover.
See P.9
2. Remove two C-clips [1], and then
slide two bearings [2] at the both
sides and remove the feed roller
assy /Up [3].
3. Release hooks [1] at the both sides,
and then lift up and remove the sep-
aration roller assy /Up [2].
A07VF2C500DA
[3]
[1] [2] [1]
[2]
A07VF2C506DA
[1]
[2]
Service Manual Y107982-5

Field Service Ver. 2.0 Aug. 2007 2. Periodical check
7
PI-503Maintenance
4. Remove the C-clip [1] and remove
the separation roller /Up [2] and the
torque limiter /Up [3].
NOTE
• Install the separation roller with two
notches [4] face to the front and be
aligned with the prong [5].
5. To reinstall, reverse the order of removal.
2.1.4 Replacing the separation roller /Lw and the torque limiter /Lw
A. Periodically replaced parts/cycle
• Separation roller /Lw: Every 100,000 prints
• Torque limiter /Lw: Every 600,000 prints
B. Replacing procedure
1. Pull the release lever [1] and open
the upper door [2].
2. Take steps 2 to 4 in the replacement procedure of the separation roller /Up and torque
limiter /Up.
See P.6
3. To reinstall, reverse the order of removal.
A07VF2C507DA
[5]
[3]
[4]
[2]
[1]
A07VF2C505DA
[2]
[1]
Y107982-5 Service Manual

3. Other Field Service Ver. 2.0 Aug. 2007
8
PI-503
Maintenance
3. Other
3.1 Disassembly/Adjustment prohibited items
A. Paint-locked screws
NOTE
• To prevent loose screws, a screw lock in blue or green series color is applied to
the screws.
• The screw lock is applied to the screws that may get loose due to the vibrations
and loads created by the use of machine or due to the vibrations created during
transportation.
• If the screw lock coated screws are loosened or removed, be sure to apply a screw
lock after the screws are tightened.
B. Red-painted screws
NOTE
• The screws which are difficult to be adjusted in the field are painted in red in order
to prevent them from being removed by mistake.
• Do not remove or loosen any of the red-painted screws in the field. It should also
be noted that, when two or more screws are used for a single part, only one repre-
sentative screw may be marked with the 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
CAUTION
• 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.
• Where it is absolutely necessary to touch the ICs and other electrical components
on the board, be sure to ground your body.
Service Manual Y107982-5

Field Service Ver. 2.0 Aug. 2007 3. Other
9
PI-503Maintenance
3.2 Disassembly/Assembly/Cleaning list (Other parts)
3.2.1 Disassembly/Assembly parts list
3.2.2 Cleaning parts list
3.3 Disassembly/Assembly procedure
3.3.1 Upper cover
1. Remove the cap [1].
2. Remove four screws [2] and remove
the upper cover [3].
No Section Part name Ref. page
1
Exterior parts
Upper cover P. 9
2Rearcover P. 1 0
3 Operation panel cover assy P. 1 0
4 Unit Post inserter P. 1 1
5Board and etc. PI drive board (PIDB) P. 1 2
6 PI control board (PIOB) P. 1 3
No Section Part name Ref. page
1
Feed section
Pick-up roller /Up P. 1 3
2 Pick-up roller /Lw P. 1 4
3 Feed roller /Up P. 1 3
4 Feed roller /Lw P. 1 4
5 Separation roller /Up P. 1 3
6 Separation roller /Lw P. 1 4
7Transport section Transport roller /Up P. 1 6
8 Transport roller /Lw P. 1 6
A07VF2C508DA
[1]
[2]
[3]
Y107982-5 Service Manual

3. Other Field Service Ver. 2.0 Aug. 2007
10
PI-503
Maintenance
3.3.2 Rear cover
1. Remove the upper cover.
See P.9
2. Remove the screw [1] and remove
the connector cover [2].
3. Remove three screws [3] and
remove the rear cover [4].
3.3.3 Operation panel cover assy
1. Remove the upper cover.
See P.9
2. Remove two screws [1], disconnect
the connector [2] and remove the
operation panel assy [3].
A07VF2C509DA
[1]
[2]
[3]
[4]
A07VF2C510DA
[3]
[2]
[1]
Service Manual Y107982-5

Field Service Ver. 2.0 Aug. 2007 3. Other
11
PI-503Maintenance
3.3.4 Post inserter
1. Remove the screw [1] and remove
the connector cover [2].
2. Open the front door of the finisher.
3. Remove three screws [1].
4. Disconnect the connector [1].
A07VF2C511DA
[1]
[2]
A07VF2C512DA
[1]
[1]
A07VF2C513DA
[1]
Y107982-5 Service Manual

3. Other Field Service Ver. 2.0 Aug. 2007
12
PI-503
Maintenance
5. Slide the post inserter [1] in the
direction of arrow and remove it.
3.3.5 PI drive board (PIDB)
1. Remove the rear cover.
See P.10
2. Disconnect seven connectors [1]
from the PI drive board.
3. Remove four board supports [1] and
remove the PI drive board [2].
A07VF2C514DB
[1]
A07VF2C515DA
[1]
[1]
A07VF2C516DA
[1]
[1]
[2]
Service Manual Y107982-5

Field Service Ver. 2.0 Aug. 2007 3. Other
13
PI-503Maintenance
3.3.6 PI control board (PIOB)
1. Remove the operation panel cover assy.
See P.10
2. Remove two screws [1] and remove
the PI control board [2].
3.4 Cleaning procedure
NOTE
• The alcohol described in the cleaning procedure of maintenance represents the
isopropyl alcohol.
3.4.1 Pick-up roller /Up, feed roller /Up, separationroller /Up
1. Remove the upper cover.
See P.9
2. Using a cleaning pad dampened with
alcohol, wipe the pick-up roller /Up
[1] clean of dirt.
A07VF2C517DA
[1]
[2]
A07VF2C518DA
[1]
Y107982-5 Service Manual

3. Other Field Service Ver. 2.0 Aug. 2007
14
PI-503
Maintenance
3. Using a cleaning pad dampened with
alcohol, wipe the feed roller /Up [1]
clean of dirt.
4. Remove the separation roller assy /Up.
See P.6
5. Using a cleaning pad dampened with
alcohol, wipe the separation roller /
Up [1] clean of dirt.
3.4.2 Pick-up roller /Lw, feed roller /Lw, separationroller /Lw
1. Pull the release lever [1] and open
the upper door [2].
A07VF2C519DA
[1]
A07VF2C520DA
[1]
A07VF2C505DA
[2]
[1]
Service Manual Y107982-5

Field Service Ver. 2.0 Aug. 2007 3. Other
15
PI-503Maintenance
2. Using a cleaning pad dampened with
alcohol, wipe the pick-up roller /Lw
[1] clean of dirt.
3. Using a cleaning pad dampened with
alcohol, wipe the feed roller /Lw [1]
clean of dirt.
4. Remove the separation roller assy /Lw.
See P.6
5. Using a cleaning pad dampened with
alcohol, wipe the separation roller /
Lw [1] clean of dirt.
A07VF2C521DA
[1]
A07VF2C522DA
[1]
A07VF2C523DA
[1]
Y107982-5 Service Manual