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PI-505

Option Printer

SERVICE MANUAL

Code Y111440-1

PUBLICATION ISSUED BY:

Olivetti S.p.A.77, Via Jervis - 10015 Ivrea (TO)Italy

Copyright © 2009, OlivettiAll rights reserved

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Field Service Ver. 1.0 Jul. 2009

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CONTENTS

PI-505

OUTLINE1. PRODUCT SPECIFICATIONS................................................................................ 1

MAINTENANCE2. PERIODICAL MAINTENANCE PROCEDURE ....................................................... 3

2.1 Paper feed section ................................................................................................ 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 MAINTENANCE ITEM ............................................................................... 8

3.1 Items not allowed to be disassembled and adjusted ............................................ 8

3.2 Disassembly/reassembly parts list........................................................................ 9

3.3 Cleaning parts list ................................................................................................. 9

3.4 Disassembly/reassembly procedure..................................................................... 9

3.4.1 Upper cover................................................................................................... 9

3.4.2 Rear cover................................................................................................... 10

3.4.3 Operation panel cover assy ........................................................................ 10

3.4.4 Post inserter ................................................................................................ 11

3.4.5 PI drive board (PIDB).................................................................................. 12

3.4.6 PI control board (PIOB)............................................................................... 13

3.5 Cleaning point..................................................................................................... 13

3.5.1 Pick-up roller /Up, feed roller /Up, separationroller /Up ............................... 13

3.5.2 Pick-up roller /Lw, feed roller /Lw, separationroller /Lw ............................... 14

3.5.3 Transport roller /Up ..................................................................................... 16

3.5.4 Transport roller /Lw ..................................................................................... 16

ADJUSTMENT/SETTING4. HOW TO USE THE ADJUSTMENT SECTION..................................................... 17

5. MECHANICAL ADJUSTMENT ............................................................................. 18

5.1 PI displacement adjustment (with PK-516 installed)........................................... 18

5.2 PI tilt adjustment (with PK-516 installed) ............................................................ 20

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Field Service Ver. 1.0 Jul. 2009

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Field Service Ver. 1.0 Jul. 2009 1. PRODUCT SPECIFICATIONS

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OUTLINE1. PRODUCT SPECIFICATIONSA. 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-516 is installed on finisher)• Saddle stitching mode (when installed on SD-508)• Tri-folding mode (when installed on SD-508)

Size Tray /Up A4/A4S, B5/B5S, A58 1/2 x 11, 8 1/2 x 11S, 5 1/2 x 8 1/2, 7 1/4 x 10 1/2S, 16K, 16KSCustom paper (Max. 311.1 x 297 mm, Min. 182 x 139 mm)

Tray /Lw A3, B4, A4/A4S, B5/B5S, A58 x 13S, 8 1/4 x 13S, 8 1/2 x 13S, 8 1/8 x 13 1/4S, SRA4S, 12 x 18, 11 x 17, 8 1/2 x 14, 8 1/2 x 11, 8 1/2 x 11S, 5 1/2 x 8 1/2, 8K, 16K, 16KS, 7 1/4 x 10 1/2, 7 1/4 x 10 1/2SCustom 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/m2 to 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

Dimensions511 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)

Y111440-1 Service Manual

1. PRODUCT SPECIFICATIONS Field Service Ver. 1.0 Jul. 2009

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Service Manual Y111440-1

Field Service Ver. 1.0 Jul. 2009 2. PERIODICAL MAINTENANCE PROCEDURE

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MAINTENANCE2. PERIODICAL MAINTENANCE PROCEDURE

2.1 Paper feed section

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 counts• Feed roller /Up: Every 100,000 counts

B. Replacing procedure1. 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 removethe actuator [2].

A07VF2C500DA

[3]

[1][2] [1]

[2]

A07VF2C501DA

[1]

[2]


2. PERIODICAL MAINTENANCE PROCEDURE Field Service Ver. 1.0 Jul. 2009

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4. Remove two C-clips [1] and removetwo bearings [2].

5. Remove the C-clip [1].6. Slide two roller shafts [2] to the

arrow-marked direction to removethe 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]

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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 counts• Feed roller /Lw: Every 100,000 counts

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


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2.1.3 Replacing the separation roller /Up and the torque limiter /Up

A. Periodically replaced parts/cycle• Separation roller /Up: Every 100,000 counts• Torque limiter /Up: Every 600,000 counts

B. Replacing procedure1. 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].

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4. Remove the C-clip [1] and removethe 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].


2.1.4 Replacing the separation roller /Lw and the torque limiter /Lw

A. Periodically replaced parts/cycle• Separation roller /Lw: Every 100,000 counts• Torque limiter /Lw: Every 600,000 counts

B. Replacing procedure


2. Take steps 2 to 4 in the replacement procedure of the separation roller /Up and torquelimiter /Up. See P.6


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3. OTHER MAINTENANCE ITEM Field Service Ver. 1.0 Jul. 2009

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3. OTHER MAINTENANCE ITEM

3.1 Items not allowed to be disassembled and adjusted

A. Paint-locked screwsNOTE• 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 screwsNOTE• 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.


Field Service Ver. 1.0 Jul. 2009 3. OTHER MAINTENANCE ITEM

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3.2 Disassembly/reassembly parts list

3.3 Cleaning parts list

3.4 Disassembly/reassembly procedure

3.4.1 Upper cover

1. Remove the cap [1].2. Remove four screws [2] and remove

the upper cover [3].

3. Reinstall the above parts following the removal steps in reverse.

Section Part name Ref. page

Exterior parts

Upper cover P.9

Rear cover P.10

Operation panel cover assy P.10

Unit Post inserter P.11

Board and etc.PI drive board (PIDB) P.12

PI control board (PIOB) P.13

Section Part name Ref. page

Feed section

Pick-up roller /Up P.13

Pick-up roller /Lw P.14

Feed roller /Up P.13

Feed roller /Lw P.14

Separation roller /Up P.13

Separation roller /Lw P.14

Transport sectionTransport roller /Up P.16

Transport roller /Lw P.16

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3.4.2 Rear cover

1. Remove the upper cover.See P.9

2. Remove the screw [1] and removethe connector cover [2].

3. Remove three screws [3] and remove the rear cover [4].


3.4.3 Operation panel cover assy


2. Remove two screws [1], disconnect the connector [2] and remove the operation panel assy [3].


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3.4.4 Post inserter

1. Remove the screw [1] and removethe connector cover [2].

2. Open the front door of the finisher.3. Remove three screws [1].

4. Disconnect the connector [1].

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5. Slide the post inserter [1] in the direction of arrow and remove it.


3.4.5 PI drive board (PIDB)

1. Remove the rear cover.See P.10

2. Disconnect eight connectors [1] from the PI drive board.

3. Remove four board supports [1] and remove the PI drive board [2].


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3.4.6 PI control board (PIOB)

1. Remove the operation panel cover assy.See P.10

2. Remove two screws [1] and removethe PI control board [2].


3.5 Cleaning point

NOTE• The alcohol described in the cleaning procedure of maintenance represents the

isopropyl alcohol.

3.5.1 Pick-up roller /Up, feed roller /Up, separationroller /Up


2. Using a cleaning pad dampened with alcohol, wipe the pick-up roller /Up [1] clean of dirt.

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3. Using a cleaning pad dampened withalcohol, 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 withalcohol, wipe the separation roller /Up [1] clean of dirt.

3.5.2 Pick-up roller /Lw, feed roller /Lw, separationroller /Lw


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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.

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3.5.3 Transport roller /Up


2. Using a cleaning pad dampened withalcohol, wipe the transport roller /Up [1] clean of dirt.

3.5.4 Transport roller /Lw

1. Remove the post inserter.See P.11

2. Using a cleaning pad dampened withalcohol, wipe the transport roller /Lw[1] clean of dirt.

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Field Service Ver. 1.0 Jul. 2009 4. HOW TO USE THE ADJUSTMENT SECTION

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ADJUSTMENT/SETTING4. 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. Check to see if:

• The power supply voltage meets the specifications.• The power supply is properly grounded.• The machine shares the power supply with any other machine that draws large current

intermittently (e.g., elevator and air conditioner that generate electric noise).• The installation site is environmentally appropriate: high temperature, high humidity,

direct sunlight, ventilation, etc.; levelness of the installation site.• The original has a problem that may cause a defective image.• The density is properly selected.• The original glass, slit glass, or related part is dirty.• Correct paper is being used for printing.• The units, parts, and supplies used for printing (developer, PC drum, etc.) are properly

replenished and replaced when they reach the end of their useful service life.• Toner is not running out.

CAUTION• To unplug the power cord of the machine before starting the service job proce-

dures.• If it is unavoidably necessary to service the machine with its power turned ON, use

utmost care not to be caught in the scanner cables or gears of the exposure unit.• Special care should be used when handling the fusing unit which can be

extremely hot.• The developing unit has a strong magnetic field. Keep watches and measuring

instruments away from it.• Take care not to damage the PC drum with a tool or similar device.• Do not touch IC pins with bare hands.


5. MECHANICAL ADJUSTMENT Field Service Ver. 1.0 Jul. 2009

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5. MECHANICAL ADJUSTMENT

5.1 PI displacement adjustment (with PK-516 installed)

• Conduct this adjustment when the punch position is displaced when feeding from PI.

NOTE• Punch hole deviation correction must be completed before making this adjust-

ment.See P.12 of the PK-516 service manual.

• Centering adjustment of the tray 1/2/3/4 must be completed before making this adjustment.

See P.649 of the main body service manual.See P.650 of the main body service manual.

• In the PI displacement adjustment, adjust the tray /Up, and then adjust the tray /Lw.

1. Set three sheets of paper in the tray of the PI, and then feed them in the punch mode as samples.

2. Fold the sheets in half at the center and check the misalignment of the punch holes.

<In the upper tray case>3. Release the hook [1], and remove

the adjustment cover [2].

<In the lower tray case>3. Remove the adjustment cover in the

same way as the upper tray case.Remove two screws [1], slide the side guide plate /Rr [2] to the front, and remove it.

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4. Loosen two adjustment screws [1] on the side guide plate /Rr [2] and slide the side guide plate /Rr twice as long as the misalignment of the punchhole position (for example, if the mis-alignment is 1.5 mm to the rear, slide 3 mm to the rear).1 index: 2 mm

5. Fully tighten the adjustment screws to secure the side guide plate /Rr.6. For the tray /Lw, reinstall the side guide plate /Rr with two screws.7. Repeat step 1 to 6 until the misalignment of the punch holes is corrected.8. Reinstall the adjustment cover.9. In the service mode, perform [Post Inserter Adjustment.].

See P.608 of the main body service manual.

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5.2 PI tilt adjustment (with PK-516 installed)

• Conduct this adjustment if the edge of the paper and the punch hole position of the paper fed from PI is not in parallel.

1. Set three sheets of paper in the tray of the PI, and then feed them in the punch mode as samples.

2. Fold the sheets in half and check the tilt of the punch holes.[1]: The front is wider[2]: The back is wider

3. Open the front door of finisher, and then loosen the screw [2] of the guide plate [1].

4. Adjust the guide plate [1] in accor-dance with the misalignment of the punch holes by referring to the mark [3].The back is wider: Move to [4]The front is wider: Move to [5]

5. Tighten the screw [2].

6. Repeat step 1 to 5 until the tilt of the punch holes is corrected.

A07VF3C501DA

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UPDATING STATUS

DATE UPDATED PAGES PAGES CODE

10/2009 1ST EDITION 25 Y111440-1

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