Olivetti ZU-606 User manual

ZU-606
Option Printer
SERVICE MANUAL
Code Y111420-1

PUBLICATION ISSUED BY:
Olivetti S.p.A.
77, Via Jervis - 10015 Ivrea (TO)
Italy
Copyright © 2009, Olivetti
All rights reserved

ZU-606OUTLINEMAINTENANCEADJUSTMENT / SETTING
Field Service Ver. 1.0 Jul. 2009
i
CONTENTS
ZU-606
OUTLINE
1. PRODUCT SPECIFICATIONS ................................................................................ 1
MAINTENANCE
2. PERIODICAL MAINTENANCE PROCEDURE ....................................................... 5
2.1 Punch section ....................................................................................................... 5
2.1.1 Replacing the punch scraps conveyance motor (M7) ................................... 5
2.1.2 Replacing the punch clutch (CL1)................................................................. 6
3. OTHER MAINTENANCE ITEM ............................................................................... 8
3.1 Items not allowed to be disassembled and adjusted ............................................ 8
3.2 Disassembly/reassembly parts list...................................................................... 10
3.3 Disassembly/reassembly procedure................................................................... 11
3.3.1 Rear cover................................................................................................... 11
3.3.2 Upper cover................................................................................................. 12
3.3.3 Right cover .................................................................................................. 12
3.3.4 Front cover .................................................................................................. 13
3.3.5 Z folding unit................................................................................................ 14
3.3.6 Punch unit ................................................................................................... 17
3.3.7 Z folding/conveyance unit............................................................................ 18
3.3.8 Punch motor (M4) ....................................................................................... 20
3.3.9 Main motor (M6).......................................................................................... 21
3.3.10 Registration motor (M1) .............................................................................. 23
3.3.11 Punch shift motor (M5)................................................................................ 24
3.3.12 Main motor cooling fan (FM1) ..................................................................... 25
3.3.13 ZU control board (ZUCB) ............................................................................ 26
3.3.14 Paper size detect board (PSDTB)............................................................... 26
ADJUSTMENT/SETTING
4. HOW TO USE THE ADJUSTMENT SECTION..................................................... 27
5. MECHANICAL ADJUSTMENT ............................................................................. 28
5.1 Gate solenoid/Lw adjustment ............................................................................. 28
5.2 1st folding skew adjustment................................................................................ 29
5.3 2nd folding skew adjustment............................................................................... 31
5.4 2nd stopper position adjustment......................................................................... 32

ZU-606
OUTLINEMAINTENANCEADJUSTMENT / SETTING
Field Service Ver. 1.0 Jul. 2009
ii
Blank Page

Field Service Ver. 1.0 Jul. 2009 1. PRODUCT SPECIFICATIONS
1
ZU-606OUTLINE
OUTLINE
1. PRODUCT SPECIFICATIONS
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± 0.5 mm
Inch area : 8.0 mm± 0.5 mm
Hole position
Folding method Buckle folding method with the roller pair
A07TT1C012AA
Hole pitch Metric area :
80 mm± 0.5 mm
Inch area :
108 mm± 0.5 mm
Metric area : 11.0 mm± 5 mm
Inch area : 9.5 mm± 5 mm
Center of the
paper
Inch area : 9.5 mm± 5 mm
Metric area : 11.0 mm± 5 mm
Center of the
paper
Center of the
paper
Hole pitch 108 mm± 0.5 mm
Hole pitch 21 mm± 0.5 mm
Hole pitch 70 mm± 0.5 mm
Hole pitch 21 mm± 0.5 mm
Hole pitch 108 mm± 0.5 mm
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1. PRODUCT SPECIFICATIONS Field Service Ver. 1.0 Jul. 2009
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ZU-606
OUTLINE
Z-folding Folding length
*1: Only for the Taiwan market
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 14 263 or less
A07TT1C004AA
2 mm or less
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Field Service Ver. 1.0 Jul. 2009 1. PRODUCT SPECIFICATIONS
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ZU-606OUTLINE
C. Type of paper
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
41 to 90 sheets 10 set
2 sheets 1 to 80 sheets 10 set
3 sheets 1 to 70 sheets 4 set
4 sheets 1 to 60 sheets 3 set
5 sheets 1 to 50 sheets 2 set
6 sheets or greater Not guaranteed
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,
8 x 13, 8-1/2x 13, 8-1/4x 13, 8-1/8x 13-1/4
4holes:
A3, B4, A4, B5, 8K *1, 16K *1
*1: Only for the Taiwan market
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 17, 8-1/2x 14, 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 low stiffness
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 low stiffness
paper are not supported in folding mode.
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1. PRODUCT SPECIFICATIONS Field Service Ver. 1.0 Jul. 2009
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ZU-606
OUTLINE
D. Maintenance
E. Machine specifications
F. Operating environment
NOTE
• These specifications are subject to change without notice.
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
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)
6.65 inch (W) x 25.98 inch (D) x 40.45 inch (H)
Weight 45 kg (99.21 lb)
Temperature 10 to 30 °C
Humidity 15 to 85 % RH (with no condensation)
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Field Service Ver. 1.0 Jul. 2009 2. PERIODICAL MAINTENANCE PROCEDURE
5
ZU-606MAINTENANCE
MAINTENANCE
2. PERIODICAL MAINTENANCE PROCEDURE
2.1 Punch section
2.1.1 Replacing the punch scraps conveyance motor (M7)
A. Periodical replaced parts/cycle
• Punch scraps conveyance motor: Every 1,000,000 counts
B. Procedure
1. Remove the Z folding unit.
See P.14
2. Disconnect the connector [1] and
remove two screws [2], and remove
the punch scraps conveyance motor
assy [3].
3. Remove two screws [1], and remove
the punch scraps conveyance motor
[2].
4. Reinstall the above parts following the removal steps in reverse.
A07TF2C511DA
[3]
[1]
[2]
A07TF2C011DA
[1]
[2]
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2. PERIODICAL MAINTENANCE PROCEDURE Field Service Ver. 1.0 Jul. 2009
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ZU-606
MAINTENANCE
2.1.2 Replacing the punch clutch (CL1)
A. Periodical replaced parts/cycle
• Punch clutch: Every 1,000,000 counts
B. Procedure
1. Remove the Z folding unit.
See P.14
2. Remove the punch unit.
See P.17
3. Cut three wiring harness bands [1].
NOTE
• When bind the wiring harness band
[1], face them to the arrow-marked
direction [2] to avoid the contact
with the conveyance section of the
main body.
4. Remove two screws [1], and remove
the punch motor assy [2].
NOTE
• When reinstalling the punch motor
assy [2], press the punch motor
gear [3] to the gear [4]. Be sure to
check that the gears rotate
smoothly and there is appropriate
backlash.
A07TF2C023DA
[1]
A07TF2C024DA
[1]
[1]
[2]
[2]
[2]
A07TF2C012DA
[2][1][4]
[3] [1]
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Field Service Ver. 1.0 Jul. 2009 2. PERIODICAL MAINTENANCE PROCEDURE
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ZU-606MAINTENANCE
5. Remove the C-clip [1], and remove
the punch clutch [2].
NOTE
• When reinstalling punch clutch [2],
be sure to check the stopper [3] is
engaged with a projection [4] of
metal plate.
6. Reinstall the above parts following the removal steps in reverse.
A07TF2C512DA
[3]
[4]
[1]
[2]
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3. OTHER MAINTENANCE ITEM Field Service Ver. 1.0 Jul. 2009
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ZU-606
MAINTENANCE
3. OTHER MAINTENANCE ITEM
3.1 Items not allowed to be disassembled and adjusted
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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Field Service Ver. 1.0 Jul. 2009 3. OTHER MAINTENANCE ITEM
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ZU-606MAINTENANCE
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]
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3. OTHER MAINTENANCE ITEM Field Service Ver. 1.0 Jul. 2009
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ZU-606
MAINTENANCE
3.2 Disassembly/reassembly parts list
Section Part name Ref. page
Exterior parts
Rear cover P. 1 1
Upper cover P. 1 2
Right cover P. 1 2
Front cover P. 1 3
Units
Z folding unit P. 1 4
Punch unit P. 1 7
Z folding/conveyance unit P. 1 8
Electrical parts
Punch motor (M4) P. 2 0
Main motor (M6) P. 2 1
Registration motor (M1) P. 2 3
Punch shift motor (M5) P. 2 4
Main motor cooling fan (FM1) P. 2 5
ZU control board (ZUCB) P. 2 6
Paper size detect board (PSDTB) P. 2 6
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Field Service Ver. 1.0 Jul. 2009 3. OTHER MAINTENANCE ITEM
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ZU-606MAINTENANCE
3.3 Disassembly/reassembly procedure
3.3.1 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. Reinstall the above parts following the removal steps in reverse.
A109F2C500DA
[3]
[1]
[2]
A07TF2C509DA
[1]
[3]
[2]
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3. OTHER MAINTENANCE ITEM Field Service Ver. 1.0 Jul. 2009
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ZU-606
MAINTENANCE
3.3.2 Upper cover
1. Remove the Z folding unit.
See P.14
2. Remove four screws [1], and remove
the upper cover [2].
3. Reinstall the above parts following the removal steps in reverse.
3.3.3 Right cover
1. Remove the Z folding unit.
See P.14
2. Remove three screws [1], and
remove the right cover [2].
3. Reinstall the above parts following the removal steps in reverse.
A07TF2C001DA
[1]
[1]
[2]
A07TF2C002DA
[1]
[2]
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Field Service Ver. 1.0 Jul. 2009 3. OTHER MAINTENANCE ITEM
13
ZU-606MAINTENANCE
3.3.4 Front cover
1. Remove the Z folding unit.
See P.14
2. Remove three screws [1], and
remove the front cover [2].
3. Reinstall the above parts following the removal steps in reverse.
A07TF2C003DA
[1]
[2]
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3. OTHER MAINTENANCE ITEM Field Service Ver. 1.0 Jul. 2009
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ZU-606
MAINTENANCE
3.3.5 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.
4. Reinstall the above parts following the removal steps in reverse.
A109F2C501DA
[1]
A07TF2C501DA
[1]
[3]
[2]
A07TF2C502DA
[1]
[1]
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Field Service Ver. 1.0 Jul. 2009 3. OTHER MAINTENANCE ITEM
15
ZU-606MAINTENANCE
B. Removal from the main body
1. Remove the finisher.
See P.14
2. Remove the punch waste box [1].
3. Remove three screws [1] and two
washers [2].
4. Disconnect three connectors [1].
NOTE
• When reconnecting the connectors,
make sure that the harness of the Z
folding unit is placed below the
cable [2] of the horizontal transport
unit.
A07TF2C503DA
[1]
A07TF2C504DA
[2]
[1]
[2]
[1]
A07TF2C505DA
[1]
[2] [2]
[1] [1]
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3. OTHER MAINTENANCE ITEM Field Service Ver. 1.0 Jul. 2009
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ZU-606
MAINTENANCE
5. Remove the Z folding unit [1].
CAUTION
• Make available collective manpower
of an appropriate size for transport-
ing the machine.
NOTE
• When reinstalling the Z folding unit,
use the upper/lower brackets [1] as
a guide for positioning the Z folding
unit.
6. Reinstall the above parts following the removal steps in reverse.
A07TF2C506DA
[1]
A07TF2C507DA
[1]
[1]
Service Manual Y111420-1