Option

AD-503
SERVICE MANUAL

Code Y104701-3
PUBLICATION ISSUED BY:

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

Copyright © 2006, Olivetti

All rights reserved
Field Service Ver. 1.0 Mar. 2006

CONTENTS

Duplex unit
Duplex Unit (AD-503)

General
1. Product specifications ............................................................................................. 1

Maintenance

General
2. Periodical check ...................................................................................................... 3
2.1 Maintenance procedure (Periodical check parts) ................................................. 3
2.1.1 Cleaning transport roller/roll 1, 2................................................................... 3
2.1.2 Cleaning transport roller/roll 3....................................................................... 3
2.1.3 Cleaning ventilation section .......................................................................... 4
3. Other ....................................................................................................................... 5

Maintenance
3.1 Disassembly/Adjustment prohibited items ............................................................ 5
3.2 Disassembly/Assembly list (Other parts) .............................................................. 6
3.3 Disassembly/Assembly procedure........................................................................ 6
3.3.1 Duplex unit .................................................................................................... 6

Adjustment/Setting

Adjustment / Setting
4. How to use the adjustment section ......................................................................... 7
5. Sensor check........................................................................................................... 8
5.1 Check procedure .................................................................................................. 8
5.2 Sensor check list................................................................................................... 8
5.2.1 Sensor check screen..................................................................................... 8
5.2.2 Sensor check list ........................................................................................... 8
6. Mechanical adjustment ........................................................................................... 9
6.1 Adjusting the paper reference position ................................................................. 9 Troubleshooting

Troubleshooting
7. Jam display ........................................................................................................... 11
7.1 Misfeed display ................................................................................................... 11
7.1.1 Misfeed display resetting procedure ........................................................... 11
7.2 Sensor layout ...................................................................................................... 12
7.3 Solution............................................................................................................... 13
7.3.1 Initial check items........................................................................................ 13
7.3.2 Duplex unit pre-registration section misfeed (AD-503)................................ 13
7.3.3 Duplex unit transport section misfeed (AD-503) ......................................... 14

i
 Troubleshooting Adjustment / Setting Maintenance General Duplex unit

ii
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Field Service Ver. 1.0 Mar. 2006
 Field Service Ver. 1.0 Mar. 2006 1. Product specifications

General

Duplex unit
1. Product specifications
A. Type

Name Duplex unit (AD-503)

Type Switchback and circulating duplex unit
Installation Mounted on the right side door of main unit
Document alignment Center

General
B. Paper type

Plain paper 64 to 90 g/m2 (17 to 24 lb)

Thick paper 1 91 to 150 g/m2 (24.25 to 40 lb)
Type
Thick paper 2 151 to 209 g/m2 (40.25 to 55.5 lb)
Thick paper 3 *1 210 to 256 g/m2 (55.75 to 68 lb)
A5/A5S to A3, A3Wide (12 x 18),
Size
5 1/2 x 8 1/2 to 11 x 17, 8 x 13 to 8 1/2 x 13, 8K, 16K/16KS
Width 139.7 to 311.1 mm (5.5 x 12.25 inch)
Print paper size
Length 148.0 to 457.2 mm (5.75 x 18 inch)

*1: Image is not guaranteed when thick paper 3 is used.

C. Machine specifications

Power requirements DC 24 V ± 10% (supplied from the main unit)

DC 5 V ± 5% (supplied from the main unit)
Max. power
17 W or less
consumption
Dimensions 110 mm (W) x 440 mm (D) x 345 mm (H)
4.25 inch (W) x 17.25 inch (D) x 13.5 inch (H)
Weight 3.0 kg (6.5 lb)

D. Operating environment
Conforms to the operating environment of the main unit.

NOTE
• These specifications are subject to change without notice.

Y104701-3 Sevice Manual 1

 1. Product specifications Field Service Ver. 1.0 Mar. 2006
Duplex unit
General

Blank Page

2 Service Manual Y104701-3

 Field Service Ver. 1.0 Mar. 2006 2. Periodical check

Maintenance

Duplex unit
2. Periodical check
2.1 Maintenance procedure (Periodical check parts)
NOTE
• The alcohol described in the cleaning procedure of maintenance represents the
isopropyl alcohol.

2.1.1 Cleaning transport roller/roll 1, 2

1. Open the duplex unit door [1].
[2] 2. Using a soft cloth dampened with
alcohol, wipe the transport roller/roll
1 [2], 2 [3] clean of dirt.

[1]

Maintenance
[3]
4066F2C006DA

2.1.2 Cleaning transport roller/roll 3

1. Remove the duplex unit.

[1] See P.6
2. Using a soft cloth dampened with
alcohol, wipe the transport roller/roll
3 [1] clean of dirt.

4066F2C504DA

Y104701-3 Sevice Manual 3

 2. Periodical check Field Service Ver. 1.0 Mar. 2006

2.1.3 Cleaning ventilation section

1. Using a soft cloth dampened with
Duplex unit

alcohol, wipe the outside of the venti-

lation section [1] clean of dirt.

[1]
4066F2C007DA

2. Open the duplex unit door [1].

3. Using a soft cloth dampened with
alcohol, wipe the inside of the venti-
lation section [2] clean of dirt.
Maintenance

[2]

[1]

4066F2C008DA

4 Service Manual Y104701-3

 Field Service Ver. 1.0 Mar. 2006 3. Other

3. Other

Duplex unit
3.1 Disassembly/Adjustment prohibited items
A. Paint-locked screws
NOTE
• Paint-locked screws show that the assembly or unit secured can only be adjusted
or set at the factory and should not be adjusted, set, or removed in the field.
B. Red painted screws

NOTE
• When the screws are removed, the red paint is coated on the points where read-
justment is required.
• Once the red painted screw is removed or loosened, you should make adjustment.
Accordingly check the adjustment items in this manual and make necessary
adjustment. Note that when two or more screws are used on the part in questions,
only one representative screw may be marked with red paint.

C. Variable resistors on board

Maintenance
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 “SAFETY
AND IMPORTANT WARNING ITEMS” and follow the corresponding removal proce-
dures.
• The removal procedures given in the following omit the removal of connectors and
screws securing the circuit board support or circuit board.
• When it is absolutely necessary to touch the ICs and other electrical components
on the board, be sure to ground your body.

Y104701-3 Sevice Manual 5

 3. Other Field Service Ver. 1.0 Mar. 2006

3.2 Disassembly/Assembly list (Other parts)

Duplex unit

No. Section Part name Ref. page

1 Unit Duplex unit P.6

3.3 Disassembly/Assembly procedure

3.3.1 Duplex unit

1. Release the tab, and remove the

connector cover [1].

[1]

4066F2C507DA

2. Disconnect the connector [1].

Maintenance

[1]
4066F2C508DA

3. Open the duplex unit door [1].

[2]
4. Remove two shoulder screws [2],
and remove the duplex unit [3].

[3]

[1]
4066F2C509DA

6 Service Manual Y104701-3

 Field Service Ver. 1.0 Mar. 2006 4. How to use the adjustment section

Adjustment/Setting

Duplex unit
4. 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
• Be sure to unplug the power cord of the machine before starting the service job

Adjustment / Setting
procedures.
• 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.

Y104701-3 Sevice Manual 7

 5. Sensor check Field Service Ver. 1.0 Mar. 2006

5. Sensor check
Duplex unit

5.1 Check procedure

• To allow sensors to be checked for operation easily and safely, data applied to the IC on
the board can be checked on the panel with the main unit in the standby state (including
a misfeed, malfunction, and closure failure condition).

A. Procedure
1. Call the Service Mode to the screen.
See P.286 of the main unit service manual.
2. Touch [State Confirmation].
3. Touch [Sensor Check].
4. Touch [2].

5.2 Sensor check list

5.2.1 Sensor check screen
• This is only typical screen which may be different from what are shown on each individ-
ual main unit.
Adjustment / Setting

4066F3E505DA

5.2.2 Sensor check list

A. Sensors 2

Operation characteristics/
Symbol Panel display Part/Signal name Panel display
1 0
PCI DU Set Duplex unit door set sensor Open Close
Paper Paper Paper not
PC1 DU Duplex unit transport sensor1
Duplex Passage1 present present
Paper Paper Paper not
PC2 DU Duplex unit transport sensor2
Passage2 present present

8 Service Manual Y104701-3

 Field Service Ver. 1.0 Mar. 2006 6. Mechanical adjustment

6. Mechanical adjustment

Duplex unit
6.1 Adjusting the paper reference position
1. Call the Service Mode to the screen.
See P.286 of the main unit service man-
ual.
2. Touch [Machine] o[Printer Area]o
[Dup Print Positioning: Side Edge].

4066F3E503DA

3. Touch [1st.] and then press the Start

key. A test print will then be pro-
duced.

Adjustment / Setting
4066F3E504DA

4. Measure the width of printed refer-

ence line A.
Specifications: 3.0 mm ± 2.0 mm
A
5. If the measured width A falls outside
the specified range, enter the correc-
tion value.
6. Produce another test print and check
for width A.

4061F3C809DA

7. Touch [END].
8. Touch [Exit] on the Service Mode screen.
9. Turn OFF the main power switch. then, wait for 10 sec. or more and turn ON the main
power switch.

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 6. Mechanical adjustment Field Service Ver. 1.0 Mar. 2006
Duplex unit

Blank Page
Adjustment / Setting

10 Service Manual Y104701-3

 Field Service Ver. 1.0 Mar. 2006 7. Jam display

Troubleshooting

Duplex unit
7. Jam display
7.1 Misfeed display
• When misfeed occurs, message, misfeed location “Blinking” and paper location “Light-
ing” are displayed on the touch panel of the main unit.

[1]

4066F4C501DA

No. Code Misfeed location Misfeed access location Action

9201 Duplex unit pre-registration section misfeed P.13
[1] Duplex unit door
9301 Duplex unit transport section misfeed P.14

7.1.1 Misfeed display resetting procedure

• Open the corresponding door, clear the sheet of paper misfed, and close the door.

Troubleshooting

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 7. Jam display Field Service Ver. 1.0 Mar. 2006

7.2 Sensor layout

Duplex unit

[1]

[2]

[3]
Troubleshooting

4066F4C502DA

[1] Duplex unit transport sensor 1 PC1 DU [3] Registration roller sensor PC1
[2] Duplex unit transport sensor 2 PC2 DU

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 Field Service Ver. 1.0 Mar. 2006 7. Jam display

7.3 Solution
7.3.1 Initial check items

Duplex unit
• When a paper misfeed occurs, first perform the following initial check items.

Check item Action

Does paper meet product specifications? Replace paper.
Replace paper.
Is the paper curled, wavy, or damp? Instruct the user on the correct paper storage
procedures.
Is a foreign object present along the paper path, or is
Clean the paper path and replace if necessary.
the paper path deformed or worn?
Are rolls/rollers dirty, deformed, or worn? Clean or replace the defective roll/roller.
Are the edge guide and trailing edge stop at the cor-
Set as necessary.
rect position to accommodate the paper?
Are the actuators operating correctly? Correct or replace the defective actuator.

7.3.2 Duplex unit pre-registration section misfeed (AD-503)

A. Detection timing

Type Description
Detection of The registration roller sensor (PC1) is not blocked even after the lapse of a given
misfeed at duplex period of time after the duplex paper take-up sequence started.
pre-registration
section
Duplex unit pre-reg- Rise timing of load for registration is earlier than the one for making the loop at
istration section front of the registration roller at pre-registration take-up.
loop registration
reversing jam
detection

B. Action

Relevant electrical parts

Registration roller sensor (PC1) Duplex control board (PWB-A DU)
Mechanical control board (MFPB)

Troubleshooting
Wiring diagram

Step Action Location

Control signal (Electrical
components)
1 Initial check items — —
d-Color MF30/35
2 PC1 sensor check MFPB CNSEN-3 (ON)
C-3
3 PWB-A DU replacement — —
4 MFPB replacement — —

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 7. Jam display Field Service Ver. 1.0 Mar. 2006

7.3.3 Duplex unit transport section misfeed (AD-503)

A. Detection timing
Duplex unit

Type Description
The duplex unit transport sensor 2 (PC2 DU) is not blocked even after the set
period of time has elapsed after the duplex unit transport sensor 1 (PC1 DU) is
blocked by the paper.
Detection of The duplex unit transport sensor 1 (PC1 DU) is not unblocked even after the set
misfeed at duplex period of time has elapsed after the duplex unit transport sensor 1 (PC1 DU) is
Transport section blocked by the paper.
The duplex unit transport sensor 2 (PC2 DU) is not unblocked even after the set
period of time has elapsed after the duplex unit transport sensor 2 (PC2 DU) is
blocked by the paper.
Detection of paper
The duplex unit transport sensor 1 (PC1 DU) or duplex unit transport sensor 2
remaining in the
(PC2 DU) are blocked when the main power switch is set to on, a door or cover is
duplex unit
opened and closed, or a misfeed or malfunction is reset.
transport section

B. Action

Relevant electrical parts

Registration roller sensor (PC1) Duplex control board (PWB-A DU)
Duplex unit transport sensor 1 (PC1 DU) Mechanical control board (MFPB)
Duplex unit transport sensor 2 (PC2 DU)
Duplex unit switchback motor (M1 DU)
Duplex unit transport motor (M2 DU)

Wiring diagram

Step Action Location

Control signal (Electrical
components)
1 Initial check items — —
d-Color MF30/35
2 PC1 sensor check MFPB CNSEN-3 (ON)
C-3
d-Color MF30/35
3 PC1 DU sensor check —
Q-21
d-Color MF30/35
Troubleshooting

4 PC2 DU sensor check —

Q-22
d-Color MF30/35
5 M1 DU operation check PWB-A DU PJ4A DU-1 to 4
S-22
d-Color MF30/35
6 M2 DU operation check PWB-A DU PJ5A DU-1 to 4
S-22 to 23
7 PWB-A DU replacement — —
8 MFPB replacement — —

14 Service Manual Y104701-3

 UPDATING STATUS

DATE UPDATED PAGES PAGES CODE

06/2006 1ST EDITION 19 Y104701-3