Olivetti PK-512, PK-513 Service Manual

PK-512
PK-513

Option Printer

SERVICE MANUAL

Code Y108421-6

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.

1

1

1

1

PK-512/513

Outline

MaintenanceAdjustment / Setting

Troubleshooting

Field Service Ver. 1.0 Feb. 2007

i

CONTENTS

PK-512/513

Outline

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

Maintenance

2. Periodical check ...................................................................................................... 3

2.1 Maintenance procedure (Periodical check parts) ................................................. 3

3. Other ....................................................................................................................... 4

3.1 Disassembly/Adjustment prohibited items ............................................................ 4

3.2 Disassembly/Assembly/Cleaning list (Other parts)............................................... 5

3.2.1 Disassembly/Assembly parts list................................................................... 5

3.3 Disassembly/Assembly procedure........................................................................ 5

3.3.1 Punch kit ....................................................................................................... 5

Adjustment/Setting

4. How to use the adjustment section ......................................................................... 9

5. Sensor Check........................................................................................................ 10

5.1 Check procedure ................................................................................................ 10

6. Finisher ................................................................................................................. 12

6.1 FS-FN adjustment............................................................................................... 12

6.1.1 Punch Vertical Position ............................................................................... 12

6.1.2 Punch Horizontal Position ........................................................................... 13

6.1.3 Punch edge detection ................................................................................. 13

6.1.4 Punch Resist Loop Size (Body) .................................................................. 14

6.2 Punch option setting ........................................................................................... 14

7. Mechanical adjustment ......................................................................................... 15

7.1 Punch hole deviation correction.......................................................................... 15

Troubleshooting

8. Jam display ........................................................................................................... 17

8.1 Misfeed display................................................................................................... 17

8.1.1 Misfeed display resetting procedure ........................................................... 17

8.2 Sensor layout...................................................................................................... 17

8.3 Solution............................................................................................................... 18

8.3.1 Initial check items........................................................................................ 18

PK-512/513

Outline

MaintenanceAdjustment / Setting

Troubleshooting

Field Service Ver. 1.0 Feb. 2007

ii

8.3.2 Code: 7243 ................................................................................................. 18

9. Malfunction code................................................................................................... 19

9.1 Trouble code ....................................................................................................... 19

9.2 Solution .............................................................................................................. 19

9.2.1 C1127: Punch kit movement motor drive failure ......................................... 19

Field Service Ver. 1.0 Feb. 2007 1. Product specifications

1

PK-512/513

Outline

Outline

1. Product specifications

A. 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 Punch unit

Type FS-integrated type punching operation device

Punching method Stops and punches every paper

No. of holes

PK-512 2-3 holes / 2-4 holes

PK-513 4 holes

Hole diameter I 8.0 mm (2-3 holes), I 6.5 mm (2-4 holes)

Supported mode Punch mode, through mode

Applicable post processing
mode

Sort, group, staple

Size

2 hole punch setting:
A3, B4, A4/A4S, B5/B5S, A5/A5S

8 x 13, 8

1

/4 x 13, 81/2 x 13, 81/8 x 13 1/4, 11 x 17, 81/2 x 14,

8

1

/2 x 11/81/2 x 11S, 5 1/2 x 81/2S, 8K, 16K/16KS

7

1

/4 x 10 1/2, 7 1/4 x 10 1/2S

3 hole/4 hole punch setting:
A3, B4, A4, B5

11 x 17, 8

1

/2 x 11, 7 1/4 x 10 1/2, 8K, 16K

Supported paper

Plain paper, bond paper, colored paper, coated paper
(Main unit specifications prioritized)

Weight

64 to 128 g/m

2

Punch prohibited paper

Label paper, tab paper, transparency film, 2nd base paper, holed paper,
and the other paper that may interfere with the operation of the punch unit
or the punch blade

Power requirements

DC 24 V (supplied from the main body)

DC 5 V (supplied from the main body)

Max. power consumption 40 W or less

Dimensions

130 mm (W) x 470 mm (D) x 115 mm (H)
5 inch (W) x 18.5 inch (D) x 4.5 inch (H)

Weight 3.0 kg (6.5 lb)

Y108421-6 Service Manual

1. Product specifications Field Service Ver. 1.0 Feb. 2007

2

PK-512/513

Outline

Blank Page

Service Manual Y108421-6

Field Service Ver. 1.0 Feb. 2007 2. Periodical check

3

PK-512/513Maintenance

Maintenance

2. Periodical check

2.1 Maintenance procedure (Periodical check parts)

• Periodically replaced parts are not employed.

Y108421-6 Service Manual

3. Other Field Service Ver. 1.0 Feb. 2007

4

PK-512/513

Maintenance

3. Other

3.1 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 repre­sentative 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.

Service Manual Y108421-6

Field Service Ver. 1.0 Feb. 2007 3. Other

5

PK-512/513Maintenance

3.2 Disassembly/Assembly/Cleaning list (Other parts)

3.2.1 Disassembly/Assembly parts list

3.3 Disassembly/Assembly procedure

3.3.1 Punch kit

1. Remove the finisher from the main body.

See P.31 of the FS-517/518/608 service manual.

2. Open the front door.

3. Slide the punch scraps box [1] out

and remove it.

4. Loosen the screw [1] and remove the
board cover [2].

No Section Part name Ref. page

1 Punch kit Punch kit P. 5

[1]

A04EF2C001DA

[1] [2]

A04EF2C002DA

Y108421-6 Service Manual

3. Other Field Service Ver. 1.0 Feb. 2007

6

PK-512/513

Maintenance

5. Remove the harness from four wire
saddles [1].

6. Remove seven connectors [1] from
the board.

7. Remove four board supports [1] and
remove the punch drive board [2].

A04EF2C500DA

[1]

[1]

[1]

[1]

A04EF2C003DA

[1]

[1]

[2]

A04EF2C004DA

Service Manual Y108421-6

Field Service Ver. 1.0 Feb. 2007 3. Other

7

PK-512/513Maintenance

8. Remove three screws [1] and
remove the punch kit cover [2].

9. Remove two connectors [1] from the
front side of the punch kit.
Remove the harness from two wire
saddles [2].

10. Remove four screws [1] and remove
the punch kit [2].

NOTE

• When reinstalling the punch kit,

align the mark [3] of the punch kit
with the center of the markings on
the housing.

• When removing the punch kit, take

care not to get the wire bundles
damaged or broken.

[1]

[2]

A04EF2C005DA

[1]

[2]

A04EF2C006DA

[1]

[2]

A04EF2C007DA

[3]

Y108421-6 Service Manual

3. Other Field Service Ver. 1.0 Feb. 2007

8

PK-512/513

Maintenance

11. Loosen the screw [1] and remove the
sensor [2].

12. Bring the front side two connectors
[1] inside through the hole [2].

13. Remove the harness from eight wire
saddles [3].

A04EF2C501DA

[1]

[2]

A04EF2C502DA

[3]

[3]

[2]

[1]

Service Manual Y108421-6

Field Service Ver. 1.0 Feb. 2007 4. How to use the adjustment section

9

PK-512/513Adjustment / Setting

Adjustment/Setting

4. How to use the adjustment section

• “Adjustment/Setting” contains detailed information on the adjustment items and proce­dures 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 serv

ice life.

• Toner is not running out.

CAUTION

• To unplug the power cord of the machine before starting the service job 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.

Y108421-6 Service Manual

5. Sensor Check Field Service Ver. 1.0 Feb. 2007

10

PK-512/513

Adjustment / Setting

5. Sensor Check

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.434 of the main body service manual.

2. Touch [State Confirmation].

3. Touch [Sensor Check].

4. Touch [z] four times.

B. Sensor check screen

• This is only typical screen which may be different from what are shown on each individ­ual main unit.

A04FF3E500DA

Service Manual Y108421-6

Field Service Ver. 1.0 Feb. 2007 5. Sensor Check

11

PK-512/513Adjustment / Setting

C. Sensor check list

Symbol Panel display Part/signal name

Operation characteristics/

panel display

10

PS301 PK punch drive motor HP detecti Punch home sensor

Other than

HP

HP

PS306 PK punch encoder



PS302 PK punch rubbish box full detection Scraps box full sensor Other than full Full

PS304

PK punch rubbish box existence
detection

Scraps box set sensor Set

Other than

set

PS303

PK punch swing drive M HP detec­tion

Punch shift home sensor HP

Other than

HP

PS305

Edge detection sensor signal 1

Paper size detect board

Paper not

present

Paper

present

Edge detection sensor signal 2

Edge detection sensor signal 3

Edge detection sensor signal 4

Edge detection sensor signal 5

- PK connection recognition 1
PK connection signal

0

Connection

1

No con­nection

- PK connection recognition 2 1 1

Y108421-6 Service Manual

6. Finisher Field Service Ver. 1.0 Feb. 2007

12

PK-512/513

Adjustment / Setting

6. Finisher

6.1 FS-FN adjustment

6.1.1 Punch Vertical Position

Functions • Adjusts the vertical position of the punch holes

Use • To change the vertical position of the punch holes

Adjustment
Specifica­tion

• Make a copy in the punch mode and make an adjustment so that 1/2 of the length A is
within the following standard range.

• Specifications: A=80 r 0.5 mm (Interval between the holes unadjustable), 1/2 of the
vertical length A r 1.0 mm

• Adjustment range: -5.0 mm to +5.0 mm (1 step=0.1 mm)

Adjustment
instructions

• To move the hole position upward: Enter a positive value.

• To move the hole position downward: Enter a negative value.

Setting/
procedure

1. Call the Service Mode to the screen.

2. Touch [Finisher].

3. Touch [FS-FN adjustment].

4. To

uch [Punch Vertical Position].

5. Touch [ALL].

NOTE

• To make an adjustment separately for each paper size, select the paper size the
adjustment will affect.

6. Set the correction value using the [+]/[-] keys.

7. Touch [OK] twice to return.

8. Touch [Exit] on the Service Mode screen.

9. Turn OFF the main power switch, wait for 10 sec., then turn the switch ON.

10.Make a copy and check the punch hole positions again.

A04EF3C502DA

A

Service Manual Y108421-6

Field Service Ver. 1.0 Feb. 2007 6. Finisher

13

PK-512/513Adjustment / Setting

6.1.2 Punch Horizontal Position

6.1.3 Punch edge detection

Functions • Adjusts the horizontal position of the punch holes.

Use • To change the horizontal position of the punch holes.

Adjustment
Specifica­tion

• Make a copy in the punch mode and make an adjustment so that the width B is within
the following range.

• Specifications: B=10.5 mm

• Adjustment range: -5.0 mm to +5.0 mm (1 step=0.1 mm)

Adjustment
instructions

• To make width B greater : Enter the value of [+]

• To make width a smaller : Enter the value of [-]

Setting/
procedure

1. Call the Service Mode to the screen.

2. Touch [Finisher].

3. Touch [FS-FN adjustment].

4. Touch [Punch Horizontal Position].

5. Touch [Main body].

6. Set the correction value using the [+]/[-] keys.

7. Touch [OK] twice to return.

8. Touch [Exit] on the Service Mode screen.

9.

Turn OFF the main power switch, wait for 10 sec., then turn the switch ON.

10.Make a copy and check the punch hole positions again.

B

A04EF3C501DA

Functions • Adjusts the sensitivity (light intensity) of the paper size detect board of the punch kit.

Use • This adjustment is made at the time of setup.

Adjustment
Specifica­tion

1. Call the Service Mode to the screen.

2. Touch [Finisher].

3. Touch [FS-FN adjustment].

4. Touch [Punch edge detection].

5. Touch Start key.

6. Confirm that the result is OK.

NOTE

• When NG appears, check whether the punch kit is properly installed.

7. Touch [OK] twice to return.

8. Touch [Exit] on the Service Mode screen.

9. Turn OFF the main power switch, wait for 10 sec., then turn the switch ON.

Y108421-6 Service Manual

6. Finisher Field Service Ver. 1.0 Feb. 2007

14

PK-512/513

Adjustment / Setting

6.1.4 Punch Resist Loop Size (Body)

6.2 Punch option setting

Functions • Adjusts the punch loop size used for paper exited from the main unit.

Use

• To address problems such as misaligned punch holes, wrinkled paper, and jam at the
punch registration section.

Adjustment
instructions

• Misaligned punched holes: Enter a positive value.

• Wrinkled paper: Enter a negative value.

Setting/
procedure

1. Call the Service Mode to the screen.

2. Touch [Finisher].

3. Touch [FS-FN adjustment].

4. Touch [Punch Resist Loop Size (Body)].

5. Set the correction value using the [+]/[-] keys.

6. Touch [OK] twice to return.

7. Touch [Exit] on the Service Mode screen.

8. Turn OFF the main power switch, wait for 10 sec., then tu

rn the switch ON.

9. Make a copy again and check the deviation of punch hole position.

10.If the above adjustment does not resolve the problems, perform the punch hole devia-

tion correction.

P. 1 5

Functions • Specifies punch settings depending on the optional punch kit attached to the finisher.

Use

• An individual punch setting needs to be made according to the type of the punch
option.

Adjustment
instructions

• The default setting is Non-installat.

1. Call the Service Mode to the screen.

2. Touch [Finisher].

3. Touch [Punch option setting].

4. Touch [PK-512] or [PK-513].

5. Touch [2-Holes/3-Holes] or [2-Holes/4-Holes] or [SWE4 holes].

6. Touch [decision].

7. Touch [END].

8. Touch [Exit] on the Service Mode screen.

9. Turn OFF the main power switch, wait for 10 sec., then turn the switch ON.

Service Manual Y108421-6

Field Service Ver. 1.0 Feb. 2007 7. Mechanical adjustment

15

PK-512/513Adjustment / Setting

7. Mechanical adjustment

7.1 Punch hole deviation correction

1. Insert a piece of paper [1] into the
finisher’s interlock to turn it ON.

2. Turn ON the Main and Sub power
switches of the machine, and make
sample copies for both the single­side and double-side with any tray in
Punch mode.

NOTE

• ADF cannot be used to produce the

samples.

3. Fold the output paper in half and
check whether the punch holes are
aligned. If the punch holes are mis­aligned, make the following adjust­ment.

4. Remove three screws [1] and
remove the punch kit cover [2].

5. Loosen four screws [1] and move the
punch kit to the left or right by the
amount that needs to be corrected
referring to the mark [2].

• Wider at the rear [3]: Move the punch

kit to the left.

• Wider at the front [4]: Move the punch

kit to the right.

A04EF3C505DA

[1]

A04EF3C503DA

[1]

[2]

[1]

A04EF3C504DA

[1]

[1]

[2][3] [4]

Y108421-6 Service Manual

7. Mechanical adjustment Field Service Ver. 1.0 Feb. 2007

16

PK-512/513

Adjustment / Setting

6. Make another copy in the punch
mode. During the punch operation,
check the punch position is within
the range that can be detected by
the sensor [1].

7. After the adjustment, if the punch
holes are still misaligned, check the
partiality of the tray.

See P.569 of the main body service
manual.
See P.570 of the main body service
manual.

8. Install the punch kit cover.

9. Remove the sheet of paper inserted in the interlock section and close the front door of

the finisher.

A04EF3C506DA

[1]

[1]

Service Manual Y108421-6

Field Service Ver. 1.0 Feb. 2007 8. Jam display

17

PK-512/513

Troubleshooting

Troubleshooting

8. Jam display

8.1 Misfeed display

• When a paper misfeed occurs, the misfeed message, misfeed location, and paper loca­tion are displayed on the touch panel of the machine.

8.1.1 Misfeed display resetting procedure

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

8.2 Sensor layout

Display Code Misfeed processing location Action

[1] 7243 Front door P. 1 8

A04EF4C500DA

[1]

[1] Punch home sensor PS301

A04EF4C501DA

[1]

Y108421-6 Service Manual

8. Jam display Field Service Ver. 1.0 Feb. 2007

18

PK-512/513

Troubleshooting

8.3 Solution

8.3.1 Initial check items

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

8.3.2 Code: 7243

A. Detection timing

B. Action

Check Item Action

Does the paper meet product specifications? Change the paper.

Is paper curled, wavy, or damp?

Change the paper.
Instruct the user in correct paper storage.

Is a foreign object present along the paper path, or is the
paper path deformed or worn?

Clean or change the paper path.

Are the rolls/rollers dirty, deformed, or worn? Clean or change the defective roll/roller.

Are the edge guide and trailing edge stop at the correct
position to accommodate the paper?

Set as necessary.

Are the actuators found operational when checked for
correct operation?

Correct or change the defective actuator.

Type Description

Punch kit misfeed
detection

The after punch home sensor (PS301) is not turned ON after a lapse of a
given time after the punch motor (M301) is turned ON.

Relevant electrical parts

Punch motor (M301)
Punch home sensor (PS301)

Punch drive board (PDB)
FNS control board (FSCB)

Step Action

WIRING DIAGRAM

Control signal

Location

(Electrical

component)

1 Initial check items — —

2 M301 operation check

PDB CN45PDB-1 (DRV1)
PDB CN45PDB-3 (DRV2)

PK-511/512/513

C-2 to 3

3 PS301 I/O, sensor check PDB CN46PDB-5 (ON)

PK-511/512/513

C-3

4 Change PDB — —

5 Change FSCB — —

Service Manual Y108421-6

Field Service Ver. 1.0 Feb. 2007 9. Malfunction code

19

PK-512/513

Troubleshooting

9. Malfunction code

9.1 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.

9.2 Solution

9.2.1 C1127: Punch kit movement motor drive failure

Code Description Detection timing

Trouble isolation

compliant unit

Rank

C1127

Punch kit movement
motor drive failure

• The after punch shift home sensor
(PS303) is not turned ON after a lapse of
a given time after the punch shift motor
(M302) is turned ON.

Punch B

Relevant electrical parts

Punch shift motor (M302)
Punch shift home sensor (PS303)

Punch drive board (PDB)
FNS control board (FSCB)

Step Action

WIRING DIAGRAM

Control signal

Location

(Electrical

component)

1

Check the M302 connector for proper
connection and correct as necessary.

——

2

Check M302 for proper drive coupling
and correct as necessary.

——

3 M302 operation check PDB CN44PDB-1 to 6

PK-511/512/513

C-5

4 PS303 I/O, sensor check PDB CN47PDB-2 (ON)

PK-511/512/513

C-5

5 Change PDB — —

6 Change FSCB — —

Y108421-6 Service Manual

9. Malfunction code Field Service Ver. 1.0 Feb. 2007

20

PK-512/513

Troubleshooting

Blank Page

Service Manual Y108421-6

UPDATING STATUS

DATE UPDATED PAGES PAGES CODE

10/2008 1

ST

EDITION 26 Y108421-6