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)
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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