Olivetti ZU-603 Service Manual
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Olivetti ZU-603 Service Manual

Olivetti ZU-603 Service Manual

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ZU-603
SERVICE MANUAL
Code Y107910-0

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  • Page 1 Option Printer ZU-603 SERVICE MANUAL Code Y107910-0...
  • Page 2 PUBLICATION ISSUED BY: Olivetti S.p.A. 77, Via Jervis - 10015 Ivrea (TO) Italy Copyright © 2008, Olivetti All rights reserved...

  • Page 3: Revision History

    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.

  • Page 4: Table Of Contents

    Field Service Ver. 2.0 May 2008 CONTENTS ZU-603 Outline Product specification ....................1 Maintenance Other ........................7 Disassembly/adjustment prohibited items ............7 Disassembly/Assembly list (Other parts) .............. 9 2.2.1 Disassembly/Assembly parts list..............9 Disassembly/Assembly procedure..............10 2.3.1 Rear cover....................10 2.3.2...
  • Page 5 Field Service Ver. 2.0 May 2008 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 Punch option setting................... 36 Fold power of pages restrict.
  • Page 6 Field Service Ver. 2.0 May 2008 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 ..........

  • Page 7: Field Service Ver. 2.0 May

    Field Service Ver. 2.0 May 2008 Blank Page...

  • Page 8: Outline

    Field Service Ver. 2.0 May 2008 1. Product specification Outline Product specification A. Type Type Z-folding multi punching device B. Functions 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...
  • Page 9 1. Product specification Field Service Ver. 2.0 May 2008 Z-folding Folding length A07TT1C010AA Paper size L (mm) a (mm) 209 or less 181 or less 4 ± 2 11 x 17 215 or less 8K *1 194 or less Folding precision 2 mm or less 2 mm or less 1st folding...
  • Page 10 Field Service Ver. 2.0 May 2008 1. Product specification Maximum tray capacity (80 g/m 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.
  • Page 11 1. Product specification Field Service Ver. 2.0 May 2008 C. Type of paper 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- x 13, 8-...
  • Page 12 Field Service Ver. 2.0 May 2008 1. Product specification D. Maintenance Maintenance Same as the main body. Machine service life Same as the main body. E. Machine specifications Power requirements 100 to 240 VAC (automatic switching) DC5 V (supplied from the main body) Max.
  • Page 13 1. Product specification Field Service Ver. 2.0 May 2008 Blank Page Service Manual Y107910-0...

  • Page 14: Maintenance

    Field Service Ver. 2.0 May 2008 2. Other Maintenance Other 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.
  • Page 15 2. Other Field Service Ver. 2.0 May 2008 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.

  • Page 16: Disassembly/Assembly List (Other Parts)

    Field Service Ver. 2.0 May 2008 2. Other Disassembly/Assembly list (Other parts) 2.2.1 Disassembly/Assembly parts list Section Part name Ref. page Rear cover P.10 Upper cover P.11 Exterior parts Right cover P.11 Front cover P.12 Z folding unit P.13 Units Punch unit P.16 Z folding/conveyance unit...

  • Page 17: Disassembly/Assembly Procedure

    2. Other Field Service Ver. 2.0 May 2008 Disassembly/Assembly procedure 2.3.1 Rear cover 1. Remove the screw [1] and the clamp [2], and remove the power cord [3]. A07TF2C508DA 2. Loosen the screw [1], and remove two screws [2], and remove the rear cover [3].

  • Page 18: Upper Cover

    Field Service Ver. 2.0 May 2008 2. Other 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]. A07TF2C001DA 2.3.3 Right cover 1. Remove the Z folding unit. See P.13 2.

  • Page 19: Front Cover

    2. Other Field Service Ver. 2.0 May 2008 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 Service Manual Y107910-0...

  • Page 20: Z Folding Unit

    Field Service Ver. 2.0 May 2008 2. Other 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. A07TF2C500DA NOTE •...
  • Page 21 2. Other Field Service Ver. 2.0 May 2008 B. Removal from the main body 1. Remove the finisher. See P.13 2. Remove the punch waste box [1]. A07TF2C503DA 3. Remove three screws [1] and two washers [2]. A07TF2C504DA 4. Disconnect three connectors [1]. NOTE •...
  • Page 22 Field Service Ver. 2.0 May 2008 2. Other 5. Remove the Z folding unit [1]. CAUTION • Make available collective manpower of an appropriate size for transport- ing the machine. A07TF2C506DA NOTE • When reinstalling the Z folding unit, use the upper/lower brackets [1] as a guide for positioning the Z folding unit.

  • Page 23: Punch Unit

    2. Other Field Service Ver. 2.0 May 2008 2.3.6 Punch unit 1. Remove the Z folding unit. See P.13 2. Remove the rear cover. See P.10 3. Remove the right cover. See P.11 4. Pull out the Z folding/conveyance unit [1]. A07TF2C004DA 5.

  • Page 24: Z Folding/Conveyance Unit

    Field Service Ver. 2.0 May 2008 2. Other 2.3.7 Z folding/conveyance unit 1. Remove the Z folding unit. See P.13 2. Remove the upper cover. See P.11 3. Pull out the Z folding/conveyance unit [1]. A07TF2C007DA 4. Disconnect three connectors [1]and remove two screws [2], and remove the arm [3].
  • Page 25 2. Other Field Service Ver. 2.0 May 2008 6. Remove four screws [1], and remove Z-folding/conveyance unit [3] to the front [4] by holding the rails [2] at the both sides. A07TF2C009DA NOTE • When placing the Z-folding/convey- ance unit, place it on the flat sur- face with its top or left side down.

  • Page 26: Punch Scraps Conveyance Motor (M7)

    Field Service Ver. 2.0 May 2008 2. Other 2.3.8 Punch scraps conveyance motor (M7) 1. Remove the Z folding unit. See P.13 2. Disconnect the connector [1] and remove two screws [2], and remove the punch scraps conveyance motor assy [3]. A07TF2C511DA 3.

  • Page 27: Punch Motor (M4)

    2. Other Field Service Ver. 2.0 May 2008 2.3.9 Punch motor (M4) 1. Remove the Z folding unit. See P.13 2. Remove the punch unit. See P.16 3. Remove two screws [1], and remove the punch motor assy [2]. NOTE •...

  • Page 28: Main Motor (M6)

    Field Service Ver. 2.0 May 2008 2. Other 2.3.10 Main motor (M6) 1. Remove the Z folding unit. See P.13 2. Remove the upper cover. See P.11 3. Remove four screws [1], and remove the conveyance upper cover [2]. A07TF2C014DA 4.
  • Page 29 2. Other Field Service Ver. 2.0 May 2008 7. Remove the screw [1], the slit circu- lar disc [2] and the belt [3], and remove the main motor assy [4] A07TF2C017DA 8. Remove four screws [1], and remove the main motor [2]. A07TF2C018DA Service Manual Y107910-0...

  • Page 30: Registration Motor (M1)

    Field Service Ver. 2.0 May 2008 2. Other 2.3.11 Registration motor (M1) 1. Remove the Z folding unit. See P.13 2. Disconnect the connector [1], and remove three screws [2], and remove the registration motor assy [3]. A07TF2C019DA 3. Remove the screw [1]. 4.

  • Page 31: Punch Shift Motor (M5)

    2. Other Field Service Ver. 2.0 May 2008 2.3.12 Punch shift motor (M5) 1. Remove the Z folding unit. See P.13 2. Remove the rear cover. See P.10 3. Disconnect two connectors [1] and remove three screws [2], and remove the punch shift motor assy [3].

  • Page 32: Punch Clutch (Cl1)

    Field Service Ver. 2.0 May 2008 2. Other 2.3.13 Punch clutch (CL1) 1. Remove the Z folding unit. See P.13 2. Remove the punch unit. See P.16 3. Cut three wiring harness bands [1]. A07TF2C023DA 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...

  • Page 33: Main Motor Cooling Fan (Fm1)

    2. Other Field Service Ver. 2.0 May 2008 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.

  • Page 34: Zu Control Board (Zucb)

    Field Service Ver. 2.0 May 2008 2. Other 2.3.15 ZU control board (ZUCB) 1. Remove the Z folding unit. See P.13 2. Remove the punch unit. See P.16 3. Disconnect all thirteen connectors from the ZU control board. 4. Remove seven board supports [1], and remove the ZU control board [2].
  • Page 35 2. Other Field Service Ver. 2.0 May 2008 Blank Page Service Manual Y107910-0...

  • Page 36: Adjustment/Setting

    Field Service Ver. 2.0 May 2008 3. How to use the adjustment section Adjustment/Setting How to use the adjustment section • “Adjustment/Setting” contains detailed information on the adjustment items and proce- dures for this machine. • Throughout this “Adjustment/Setting,” the default settings are indicated by “ ”. Advance checks Before attempting to solve the customer problem, the following advance checks must be made.

  • Page 37: Sensor Check

    4. Sensor check Field Service Ver. 2.0 May 2008 Sensor check Check procedure A. Procedure 1. Call the Service Mode to the screen. See P.434 of the main body service manual. 2. Touch [State Confirmation]. 3. Touch [Sensor Check]. 4. Touch seven times [ ]. 4.1.1 Sensor check screen •...
  • Page 38 Field Service Ver. 2.0 May 2008 4. Sensor check Operation characteristics/ panel display Symbol Panel display Part/Signal name Other than Punch rubbish full detection L: Full Punch scraps full sensor Full full Other than Punch rubbing box set H: Set Punch scraps box set sensor Z transportation motor lock detec- Other than...

  • Page 39: Finisher

    • To adjust the position of the punch hole in the sub-scanning direction when ZU is in Functions use. • Make the adjustment upon setup of ZU-603. • Make copies in the punch mode and adjust so that width A falls within the range of the following specifications.

  • Page 40: Punch Unit Hor. Position

    • To adjust the position of the punch hole in the main scanning direction when ZU is in Functions use. • Make the adjustment upon setup of ZU-603. • Make copies in the punch mode and adjust so that width B falls within the range of the following specifications.

  • Page 41: 1St Z-Fold Position/2Nd Z-Fold Position

    • To adjust the positions of the 1st Z-fold and 2nd Z-fold for the Z-fold mode. • Make the adjustment upon setup of ZU-603. • Make copies in the Z-fold mode and adjust so that length a falls within the range of the following specifications.

  • Page 42: Finisher Check

    Field Service Ver. 2.0 May 2008 5. Finisher 5.1.5 Finisher check 1. Call the Service Mode to the screen. See P.434 of the main body service manual. 2. Touch [Finisher]. 3. Touch [FS-FN adjustment]. 4. Touch [finisher check]. 5. Touch [4] or [5] and select the specific function. A07TF3E515DA 6.

  • Page 43: Punch Option Setting

    Punch option setting Functions • To make each of the various settings for the punch option. • This setting is necessary when ZU-603 is mounted. • An individual punch setting needs to be made according to the type of the punch option.

  • Page 44: Fold Power Of Pages Restrict

    • Set the maximum number of sheets that can be folded together in each folding mode. Functions • This function is available only when FS517/FS-518/FS-608 + ZU-603 is installed. • To change the maximum number of sheets that can be folded together in each folding mode.

  • Page 45: Mechanical Adjustment

    6. Mechanical adjustment Field Service Ver. 2.0 May 2008 Mechanical adjustment Gate solenoid/Lw adjustment • Make this adjustment when the gate solenoid/Lw (SD1) is replaced with a new one. 1. Remove the Z folding unit. See P.13 2. Remove the front cover. See P.12 3.

  • Page 46: 1St Folding Skew Adjustment

    Field Service Ver. 2.0 May 2008 6. Mechanical adjustment 1st folding skew adjustment • Conduct the 1st folding skew adjustment when the skew of the 1st folding is not within the standard value. NOTE • This adjustment affects the 1st Z-fold position. Be sure therefore to perform [1st Z- fold Position] of the service mode whenever this adjustment has been completed.
  • Page 47 6. Mechanical adjustment Field Service Ver. 2.0 May 2008 5. Loosen four screws [1]. 6. Adjust the 1st stopper assembly [2] by moving the front side of the assembly to right and left by referring to the markings [3], and then tighten the four screws [1].

  • Page 48: 2Nd Folding Skew Adjustment

    Field Service Ver. 2.0 May 2008 6. Mechanical adjustment 2nd folding skew adjustment • Conduct the 2nd folding skew adjustment when the skew of the 2nd folding is not within the standard value. NOTE • This adjustment affects the 2nd Z-fold position. Be sure therefore to perform [2nd Z-fold Position] of the service mode whenever this adjustment has been com- pleted.

  • Page 49: 2Nd Stopper Position Adjustment

    6. Mechanical adjustment Field Service Ver. 2.0 May 2008 2nd stopper position adjustment • Conduct this adjustment when the 2nd folding position cannot be adjusted from the ser- vice mode or the skew of the 2nd folding cannot be adjusted by the procedure in “6.3 2nd folding skew adjustment.”...
  • Page 50 Field Service Ver. 2.0 May 2008 6. Mechanical adjustment 6. Rotate the shaft [2] so that you can reach to two screws [1] with the hex wrench. 7. Loosen two screws [1]. 8. Rotate the shaft [2] so that the actua- tor [3] is roughly positioned to the home position [5] of the 2nd stopper home sensor [4].
  • Page 51 6. Mechanical adjustment Field Service Ver. 2.0 May 2008 Blank Page Service Manual Y107910-0...

  • Page 52: Troubleshooting

    Field Service Ver. 2.0 May 2008 7. Jam display Troubleshooting Jam display Misfeed display • When misfeed occurs, message, misfeed location “Blinking” and paper location “Light- ing” are displayed on the touch panel of the main body. A07TF4C502DA Display Code Misfeed access location Action 7238...

  • Page 53: Sensor Layout

    7. Jam display Field Service Ver. 2.0 May 2008 Sensor layout A07TF4C500DA [1] Paper size detect board (PSDTB) [2] Paper pass sensor (SP202) [3] Exit sensor (PS9) [4] Conveyance sensor (PS1) Service Manual Y107910-0...

  • Page 54: Solution

    Field Service Ver. 2.0 May 2008 7. Jam display Solution 7.3.1 Initial check items • When a paper misfeed occurs, first perform the following initial check items. Check Item Action Does the paper meet product specifications? Change the paper. Change the paper. Is paper curled, wavy, or damp? Instruct the user in correct paper storage.

  • Page 55: Code: 7238

    7. Jam display Field Service Ver. 2.0 May 2008 7.3.2 Code: 7238 A. Detection timing Description The leading, trailing, and side edge sensors on the paper size detect board (PSDTB) are not turned ON even after the set period of time has elapsed after the paper pass sensor (PS202) of the horizontal transport unit is turned ON by the paper.

  • Page 56: Code: 7240

    Field Service Ver. 2.0 May 2008 7. Jam display 7.3.4 Code: 7240 A. Detection timing Description The conveyance sensor (PS1) is not turned ON even after the set period of time has elapsed after the leading, trailing, and side edge sensors on the paper size detect board (PSDTB) are turned ON by the paper.

  • Page 57: Code: 7242

    7. Jam display Field Service Ver. 2.0 May 2008 7.3.6 Code: 7242 A. Detection timing Description The conveyance sensor (PS1) is not turned OFF from the ON state by the paper even after the set period of time has elapsed at the end of the 2nd folding in the Z-fold mode. B.

  • Page 58: Code: 7245

    Field Service Ver. 2.0 May 2008 7. Jam display 7.3.8 Code: 7245 A. Detection timing Description The exit sensor (PS9) is not turned ON even after the set period of time has elapsed after the paper pass sensor (PS202) of the horizontal transport unit is turned ON by the paper. B.

  • Page 59: Code: 7247

    7. Jam display Field Service Ver. 2.0 May 2008 7.3.10 Code: 7247 A. Detection timing Description Paper is left in the Z-folding unit even after the set period of time has elapsed after the main body trans- mits an operation stop signal to the Z-folding unit. B.

  • Page 60: Code: 7261

    Field Service Ver. 2.0 May 2008 7. Jam display 7.3.12 Code: 7261 A. Detection timing Description The conveyance sensor (PS1) is not turned ON even after the set period of time has elapsed after the leading, trailing, and side edge sensors on the paper size detect board (PSDTB) are turned ON by the paper.

  • Page 61: Code: 7264

    7. Jam display Field Service Ver. 2.0 May 2008 7.3.14 Code: 7264 A. Detection timing Description The conveyance encoder sensor (PS10) is not turned OFF from the ON position, or not turned ON from the OFF position, even after the set period of time has elapsed after the main motor (M6) is turned ON. B.

  • Page 62: Malfunction Code

    Field Service Ver. 2.0 May 2008 8. Malfunction code Malfunction code Trouble code • The machine’s CPU performs a self-diagnostics function that, on detecting a malfunction, gives the corresponding malfunction code and maintenance call mark on the touch panel. Trouble isolation Code Item Detection timing...

  • Page 63: Solution

    8. Malfunction code Field Service Ver. 2.0 May 2008 Solution 8.2.1 C1005: ZU communication error Relevant electrical parts ZU control board (ZUCB) WIRING DIAGRAM Location Step Action Control signal (Electrical component) Disconnect and then connect the power cord. Turn OFF the main power switch, wait —...

  • Page 64: C1131: 2Nd Stopper Motor Drive Failure

    Field Service Ver. 2.0 May 2008 8. Malfunction code 8.2.3 C1131: 2nd stopper motor drive failure Relevant electrical parts 2nd stopper motor (M3) ZU control board (ZUCB) 2nd stopper home sensor (PS4) WIRING DIAGRAM Location Step Action Control signal (Electrical component) Check the motor and sensor connectors for proper connection, and correct as...

  • Page 65: C1134: Main Motor Cooling Fan Drive Failure

    8. Malfunction code Field Service Ver. 2.0 May 2008 8.2.5 C1134: Main motor cooling fan drive failure Relevant electrical parts Main motor cooling fan (FM1) ZU control board (ZUCB) WIRING DIAGRAM Location Step Action Control signal (Electrical component) Check the FM1 connector for proper con- —...

  • Page 66: C1136: Punch Switchover Motor Drive Failure

    Field Service Ver. 2.0 May 2008 8. Malfunction code 8.2.7 C1136: Punch switchover motor drive failure Relevant electrical parts Punch switchover motor (M8) ZU control board (ZUCB) Punch switchover switch (MS2) WIRING DIAGRAM Location Step Action Control signal (Electrical component) Check the motor and switch connectors for proper connection, and correct as —...
  • Page 67 8. Malfunction code Field Service Ver. 2.0 May 2008 Blank Page Service Manual Y107910-0...
  • Page 68 UPDATING STATUS DATE UPDATED PAGES PAGES CODE 10/2008 EDITION Y107910-0...

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