Olivetti ZU-603 User manual

ZU-603
Option Printer
SERVICE MANUAL
Code Y107910-0

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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ZU-603Outline
MaintenanceAdjustment / Setting
Troubleshooting
Field Service Ver. 2.0 May 2008
i
CONTENTS
ZU-603
Outline
1. Product specification ............................................................................................... 1
Maintenance
2. Other ....................................................................................................................... 7
2.1 Disassembly/adjustment prohibited items ............................................................ 7
2.2 Disassembly/Assembly list (Other parts) .............................................................. 9
2.2.1 Disassembly/Assembly parts list................................................................... 9
2.3 Disassembly/Assembly procedure...................................................................... 10
2.3.1 Rear cover................................................................................................... 10
2.3.2 Upper cover................................................................................................. 11
2.3.3 Right cover .................................................................................................. 11
2.3.4 Front cover .................................................................................................. 12
2.3.5 Z folding unit................................................................................................ 13
2.3.6 Punch unit ................................................................................................... 16
2.3.7 Z folding/conveyance unit............................................................................ 17
2.3.8Punch scraps conveyance motor (M7)........................................................ 19
2.3.9 Punch motor (M4) ....................................................................................... 20
2.3.10 Main motor (M6).......................................................................................... 21
2.3.11 Registration motor (M1) .............................................................................. 23
2.3.12 Punch shift motor (M5)................................................................................ 24
2.3.13 Punch clutch (CL1) ..................................................................................... 25
2.3.14 Main motor cooling fan (FM1) ..................................................................... 26
2.3.15 ZU control board (ZUCB) ............................................................................ 27
2.3.16 Paper size detect board (PSDTB)............................................................... 27
Adjustment/Setting
3. Howto use the adjustment section ....................................................................... 29
4. Sensor check......................................................................................................... 30
4.1 Check procedure ................................................................................................ 30
4.1.1 Sensor check screen................................................................................... 30
4.1.2 Sensor check list......................................................................................... 30
5. Finisher ................................................................................................................. 32
5.1 FS-FN adjustment............................................................................................... 32

ZU-603
Outline
MaintenanceAdjustment / Setting
Troubleshooting
Field Service Ver. 2.0 May 2008
ii
5.1.1 Punch Unit Vert. Position ............................................................................ 32
5.1.2 Punch Unit Hor. Position ............................................................................. 33
5.1.3 Punch unit edge detection .......................................................................... 33
5.1.4 1st Z-fold Position/2nd Z-fold Position......................................................... 34
5.1.5 Finisher check............................................................................................. 35
5.2 Punch option setting........................................................................................... 36
5.3 Fold power of pages restrict. .............................................................................. 37
6. Mechanical adjustment ......................................................................................... 38
6.1 Gate solenoid/Lwadjustment ............................................................................. 38
6.2 1st folding skewadjustment ............................................................................... 39
6.3 2nd folding skewadjustment .............................................................................. 41
6.4 2nd stopper position adjustment ........................................................................ 42
Tr o ubleshooting
7. Jam display ........................................................................................................... 45
7.1 Misfeed display................................................................................................... 45
7.1.1 Misfeed display resetting procedure ........................................................... 45
7.2 Sensor layout...................................................................................................... 46
7.3 Solution .............................................................................................................. 47
7.3.1 Initial check items ....................................................................................... 47
7.3.2 Code: 7238................................................................................................. 48
7.3.3 Code: 7239 ................................................................................................. 48
7.3.4 Code: 7240 ................................................................................................. 49
7.3.5 Code: 7241 ................................................................................................. 49
7.3.6 Code: 7242 ................................................................................................. 50
7.3.7 Code: 7244 ................................................................................................. 50
7.3.8Code: 7245 ................................................................................................. 51
7.3.9 Code: 7246 ................................................................................................. 51
7.3.10 Code: 7247 ................................................................................................. 52
7.3.11 Code: 7260 ................................................................................................. 52
7.3.12 Code: 7261 ................................................................................................. 53
7.3.13 Code: 7262 ................................................................................................. 53
7.3.14 Code: 7264 ................................................................................................. 54
8.Malfunction code................................................................................................... 55
8.1 Trouble code ....................................................................................................... 55
8.2 Solution .............................................................................................................. 56
8.2.1 C1005: ZU communication error................................................................. 56
8.2.2 C1130: 1st stopper motor drive failure........................................................ 56

ZU-603Outline
MaintenanceAdjustment / Setting
Troubleshooting
Field Service Ver. 2.0 May 2008
iii
8.2.3 C1131: 2nd stopper motor drive failure....................................................... 57
8.2.4 C1133: Punch shift motor drive failure ........................................................ 57
8.2.5 C1134: Main motor cooling fan drive failure................................................ 58
8.2.6 C1135: Punch motor drive failure................................................................ 58
8.2.7 C1136: Punch switchover motor drive failure.............................................. 59
8.2.8CC158: Finisher ROM failure (ZU).............................................................. 59

ZU-603
Outline
MaintenanceAdjustment / Setting
Troubleshooting
Field Service Ver. 2.0 May 2008
iv
Blank Page

Field Service Ver. 2.0 May 20081. Product specification
1
ZU-603Outline
Outline
1. Product specification
A. Type
B. Functions
Type Z-folding multi punching device
Punch Punching method Reciprocal punching method (punching each paper)
No. of holes Metric area : 2 holes/4 holes (switched automatically)
Inch area : 2 holes/3 holes (switched automatically)
Hole diameter Metric area : 6.5 mm
Inch area : 8.0 mm
Hole position
Folding method Buckle folding method with the roller pair
A07TT1C012AA
Hole pitch
Metric area : 80 mm
Inch area : 70 mm
Metric area : 10.5 mm
Inch area : 9.5 mm
Center of the
paper
Inch area : 9.5 mm
Metric area : 10.5 mm
Center of the
paper
Center of the
paper
Hole pitch 108mm
Hole pitch 80 mm
Hole pitch 80 mm
Hole pitch 80 mm
Hole pitch 108mm
Y107910-0 Service Manual

1
1. Product specification Field Service Ver. 2.0 May 2008
2
ZU-603
Outline
Z-folding Folding length
Folding precision
Folding Folding length
Folding precision
A07TT1C010AA
a
L
Paper size L (mm) a (mm)
A3 209 or less
4 ± 2
B4 181 or less
11 x 17 215 or less
8K *1 194 or less
A07TT1C011AA
1st folding 2nd folding
2 mm or less 2 mm or less
A07TT1C003AA
L
Paper size L (mm)
8-1/2x 14 241.7 or less
A07TT1C004AA
2 mm or less
Service Manual Y107910-0

Field Service Ver. 2.0 May 20081. Product specification
3
ZU-603Outline
*1: Only for the Taiwan market
Maximum tray capacity (80 g/m2) The maximum number of sheets for the FS main tray at
the Z-folding operation
• Z-folding continuous: Max. 30 sheets
• Z-folding/stapling: See the table below
No. of sheets per staple No. of set on
the main tray
No. of fold sheets No. of unfold
sheets
1 sheet 1 to 40 sheets 20 set
2 sheets 0 to 30 sheets 10 set
3 sheets 0 to 20 sheets 4 set
4 sheets 0 to 10 sheets 3 set
5 sheets 0 sheet 2 set
6 to 30 sheets Stapling not available
Y107910-0 Service Manual

1
1. Product specification Field Service Ver. 2.0 May 2008
4
ZU-603
Outline
C. Type of paper
*1: Only for the Taiwan market
No punch mode Same as the main body.
Punch mode Paper size
• Combination with the folding/saddle stitching mode is not available.
Metric area 2holes:
A3, B4, A4, A4S, B5, B5S, A5, A5S,
8K *1, 16K *1, 16KS *1,
8x 13, 8-1/2x 13, 8-1/4x 13, 8-1/8x 13-1/4
4holes:
A3, B4, A4, B5, 8K *1, 16K *1
Inch area 2holes:
11 x 17, 8-1/2x 14, 8-1/2x 11, 8-1/2x 11S,
5-1/2x 8-1/2, 5-1/2x 8-1/2S, 7-1/4x 10-1/2, 7-1/4x 10-1/2S
3holes:
11 x 17, 8-1/2x 11
Type of paper 64 to 90 g/m2of the high-quality paper and the plain paper
• Special paper is not guaranteed. The punching of label
paper, tab paper, OHP paper, blueprint master and bind-
ing-holed paper are not allowed.
Z-folding mode Paper size A3, B4, 11 x 7, 8K
• For B4 paper (including the mix of the paper), the com-
bination with the stapling mode is not available.
Type of paper 64 to 90 g/m2of the high-quality paper and the plain paper
• Special paper is not supported. Label paper, tab paper,
transparency film, paper, holed paper, and lowstiffness
paper are not supported in Z-folding mode.
Folding mode Paper size 8-1/2x 14
Type of paper 64 to 90 g/m2of the high-quality paper and the plain paper
• Special paper is not supported. Label paper, tab paper,
transparency film, paper, holed paper, and lowstiffness
paper are not supported in folding mode.
Paper curling
a : Excluding the OHP paper : Amount of curl: 15 mm or less
OHP paper : Amount of curl: 10 mm or less
A07TT1C006AA
5 sheets of paper immediately after the printing
a
Service Manual Y107910-0

Field Service Ver. 2.0 May 20081. Product specification
5
ZU-603Outline
D. Maintenance
E. Machine specifications
F. Operating environment
NOTE
• These specifications are subject to change without notice.
Maintenance Same as the main body.
Machine service life Same as the main body.
Power requirements 100 to 240 VAC (automatic switching)
DC5 V(supplied from the main body)
Max. power
consumption
120 W or less
Dimensions 169 mm (W) x 660 mm (D) x 1027.5 mm (H)
6.75 inch (W) x 26 inch (D) x 40.5 inch (H)
Weight 45 kg (99 lb)
Temperature 10 to 30 °C
Humidity 15 to 85 % RH (with no condensation)
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1. Product specification Field Service Ver. 2.0 May 2008
6
ZU-603
Outline
Blank Page
Service Manual Y107910-0

Field Service Ver. 2.0 May 20082. Other
7
ZU-603
Maintenance
Maintenance
2. Other
2.1 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.
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2. Other Field Service Ver. 2.0 May 2008
8
ZU-603
Maintenance
E. Parts not allowed to be removed
(1) Punch section
• The precision of the punch edges is ensured in the punch unit. The normal punch opera-
tion may be affected if it is disassembled. Never loosen or remove these screws and
retaining rings.
(2) Z-folding section
• The screws position the clearance of the conveyance guide plate. The precision of the Z-
folding may be affected if it is disassembled. Never loosen or remove these screws.
[1] Screws not allowed to be removed
[1]
A07TF2C510DA
[1] Screws not allowed to be removed [2] Conveyance guide plate
A07TF2C513DA
[1]
[1]
[2]
Service Manual Y107910-0

Field Service Ver. 2.0 May 20082. Other
9
ZU-603
Maintenance
2.2 Disassembly/Assembly list (Other parts)
2.2.1 Disassembly/Assembly parts list
No. Section Part name Ref. page
1
Exterior parts
Rear cover P. 1 0
2 Upper cover P. 1 1
3 Right cover P. 1 1
4Frontcover P. 1 2
5
Units
Z folding unit P. 1 3
6Punch unit P. 1 6
7 Z folding/conveyance unit P. 1 7
8
Electrical parts
Punch scraps conveyance motor (M7) P. 1 9
9Punch motor (M4) P. 2 0
10 Main motor (M6) P. 2 1
11 Registration motor (M1) P. 2 3
12 Punch shift motor (M5) P. 2 4
13 Punch clutch (CL1) P. 2 5
14 Main motor cooling fan (FM1) P. 2 6
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2. Other Field Service Ver. 2.0 May 2008
10
ZU-603
Maintenance
2.3 Disassembly/Assembly procedure
2.3.1 Rear cover
1. Remove the screw[1] and the clamp
[2], and remove the power cord [3].
2. Loosen the screw[1], and remove
two screws [2], and remove the rear
cover [3].
3. To reinstall, reverse the order of removal.
A07TF2C508DA
[2] [3]
[1]
A07TF2C509DA
[1]
[3]
[2]
Service Manual Y107910-0

Field Service Ver. 2.0 May 20082. Other
11
ZU-603
Maintenance
2.3.2 Upper cover
1. Remove the Z folding unit.
See P.13
2. Remove four screws [1], and remove
the upper cover [2].
2.3.3 Right cover
1. Remove the Z folding unit.
See P.13
2. Remove three screws [1], and
remove the right cover [2].
A07TF2C001DA
[1]
[1]
[2]
A07TF2C002DA
[1]
[2]
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2. Other Field Service Ver. 2.0 May 2008
12
ZU-603
Maintenance
2.3.4 Front cover
1. Remove the Z folding unit.
See P.13
2. Remove three screws [1], and
remove the front cover [2].
A07TF2C003DA
[1]
[2]
Service Manual Y107910-0

Field Service Ver. 2.0 May 20082. Other
13
ZU-603
Maintenance
2.3.5 Z folding unit
A. Removal from the finisher
1. Open the front door of finisher [1].
2. Remove two screws [2] and slide the
finisher as shown in the illustration.
NOTE
• To mount the finisher, align the
hook portions of the mounting
bracket [1] and [2] with the upper
and lower holes [3] in the finisher.
Then, push the finisher toward the
rear.
3. Disconnect three connectors [1] and
remove the finisher.
A07TF2C500DA
[2]
[1]
A07TF2C501DA
[1]
[3]
[2]
A07TF2C502DA
[1]
[1]
Y107910-0 Service Manual