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Safety precautions

This booklet provides safety warnings and precautions for our service personnel to ensure the safety of
their customers, their machines as well as themselves during maintenance activities. Service personnel
are advised to read this booklet carefully to familiarize themselves with the warnings and precautions
described here before engaging in maintenance activities.

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Summary of Contents for DU-61

Page 1: ...SERVICE MANUAL Published in Jan 04 3DS70761 Revision 1 DU 61 ...

Page 2: ...Revision history Version Data Replaced pages Remarks 1 0 1 1 9 Jan 2004 19 Jan 2004 1 1 1 1 4 1 1 4 4 1 4 5 2 1 1 2 1 3 2 1 4 2 2 1 ...

Page 3: ...rsonnel to ensure the safety of their customers their machines as well as themselves during maintenance activities Service personnel are advised to read this booklet carefully to familiarize themselves with the warnings and precautions described here before engaging in maintenance activities ...

Page 4: ...ompliance with warning messages using this symbol WARNING Serious bodily injury or death may result from insufficient attention to or incorrect compliance with warning messages using this symbol CAUTION Bodily injury or damage to property may result from insufficient attention to or incorrect compliance with warning messages using this symbol Symbols The triangle symbol indicates a warning includi...

Page 5: ...d or dusty place This may cause fire or electric shock Do not install the copier near a radiator heater other heat source or near flammable material This may cause fire Allow sufficient space around the copier to allow the ventilation grills to keep the machine as cool as possible Insufficient ventilation may cause heat buildup and poor copying performance Always handle the machine by the correct ...

Page 6: ...e clean Dirt on them can cause abnormally high temperatures Do not remove the ozone filter if any from the copier except for routine replacement 2 Precautions for Maintenance WARNING Always remove the power plug from the wall outlet before starting machine disassembly Always follow the procedures for maintenance described in the service manual and other related brochures Under no circumstances att...

Page 7: ...at all the caution labels that should be present on the machine according to the instruction handbook are clean and not peeling Replace with new ones if necessary Handle greases and solvents with care by following the instructions below Use only a small amount of solvent at a time being careful not to spill Wipe spills off completely Ventilate the room well while using grease or solvents Allow app...

Page 8: ...This page is intentionally left blank ...

Page 9: ...ostic codes 1 4 4 1 4 3 Electrical problems 1 4 5 1 False Duplexer rear cover open 1 4 5 2 False Missing duplex drawer 1 4 5 1 5 Assembly and Disassembly 1 5 1 Precautions for assembly and disassembly 1 5 1 1 Precautions 1 5 1 1 5 2 Removing the vertical path assembly 1 5 2 1 5 3 Removing the right and left cover 1 5 3 1 5 4 Removing the duplexer board 1 5 4 2 1 Mechanical Construction 2 1 1 Paper...

Page 10: ...3DS This page is intentionally left blank This page is intentionally left blank ...

Page 11: ...s FS 1800 1800N 3800N 1920 3820N 3830N Paper size A4 210 297 mm B5 182 257 mm A5 148 210 mm Letter 81 2 11 Legal 81 2 14 Folio 210 330 mm Oficio II 216 330 mm Dimensions 345 W 520 D 105 H 139 16 W 201 2 D 41 8 H Weight Approx 4 6 kg 101 8 lbs Power source Supplied from printer ...

Page 12: ...3DS 1 1 2 Figure 1 1 1 1 1 2 Name of parts 1 Overall 1 Interface connector 2 Positioning pins 3 Duplex drawer 4 Rear cover 5 Right cover 6 Left cover 7 Vertical path assembly 1 6 2 3 2 5 4 7 ...

Page 13: ...3DS 1 1 3 1 1 3 Machine cross section Figure 1 1 2 Switchback section Vertical path assembly Paper refeed section Duplexer Printer face up output tray Paper path Printer ...

Page 14: ...3DS 1 1 4 This page is intentionally left blank ...

Page 15: ...1 2 1 3DS 1 Remove the nine tape and pad from the duplexer Figure 1 2 1 Tape Tape Pad Tape Tape Duplexer Tape Tape 1 2 1 Unpacking and installation 1 Installation procedure Removing the tape and pad ...

Page 16: ...wer cord and printer cable Gently place the printer on top of the duplexer Figure 1 2 3 Placing the printer Figure 1 2 2 Printer Duplexer 1 While pushing the release levers inward remove the vertical path assembly Release levers Vertical path assembly ...

Page 17: ...l or Network according to operation environment Connecting the printer cable and power cord Printer cable Power cord Figure 1 2 4 2 Connect the power cord to the printer Pass the connected cable and power cord through the opening in the duplexer Figure 1 2 5 ...

Page 18: ...1 2 4 3DS 3 Install the vertical path assembly Vertical path assembly Completion of machine installation Figure 1 2 6 ...

Page 19: ... 3 1 1 3 1 Cleaning the switchback roller 1 Cleaning the switchback roller Remove the vertical path assembly See page 1 5 2 Using the cleaning cloth wipe the switchback roller Figure 1 3 1 Switchback roller ...

Page 20: ...3DS 1 3 2 This page is intentionally left blank ...

Page 21: ...ing and displays the paper misfeed message on the printer s operator panel To remove paper misfeed in the duplexer pull out the duplex drawer or rear cover Figure 1 4 1 2 Paper misfeed detection Figure 1 4 2 Paper jam Duplexer Paper misfeed location Paper misfeed message Duplex refeed sensor Switchback sensor Vertical path sensor ...

Page 22: ... paper as described below After you have removed the jammed paper open and close the printer s top cover to clear the error message from the message display Jam in the rear cover 1 Open the rear cover of the duplexer and remove the jammed paper Figure 1 4 3 Figure 1 4 4 Rear cover Rear cover ...

Page 23: ...3DS 1 4 3 Jam in the duplex drawer 1 Pull out the duplex drawer Remove the jammed paper Duplex drawer Duplex drawer Figure 1 4 5 Figure 1 4 6 ...

Page 24: ... 1210 is displayed The message is categorized as follows 2 Self diagnostic codes Code Contents Remarks Causes Check procedures corrective measures Figure 1 4 7 Duplexer communication error Communication error between printer s engine board KP 1081 and duplexer Side registration error Side registration home position error of duplexer Defective duplexer board Defective gate array U7 on the engine bo...

Page 25: ...ch switch If there is no continuity when the rear cover interlock switch is on replase it Reinsert the connector Also chek for continuity within the connector cable If none remedy or replace the cable Replace the duplexer board see page 1 5 4 Draw the duplex drawer of duplexer then install tightly Replace the drawer detection sensor Reinsert the connector Also chek for continuity within the connec...

Page 26: ...3DS 1 4 6 This page is intentionally left blank ...

Page 27: ... charge Do not touch any PWB containing ICs with bare hands or any object prone to static charge Use only the specified parts to replace the fixing unit thermal cutout Never substitute electric wires as the printer may be seriously damaged Use the following circuit testers when measuring voltages Hioki 3200 Sanwa MD 180C Sanwa YX 360TR Beckman TECH300 Beckman DM45 Beckman 330 Beckman 3030 Beckman ...

Page 28: ...5 2 Release levers Vertical path assembly 1 5 2 Removing the vertical path assembly 1 While pushing the release levers inward remove the vertical path assembly Figure 1 5 1 Removing the vertical path assembly ...

Page 29: ...Screw 1 5 3 Removing the right and left cover 1 Remove the vertical path assembly See page 1 5 2 2 Pull out the duplex drawer 3 Remove three screws To remove the right cover and grounding plate 4 Remove four screws To remove the left cover Figure 1 5 2 Removing the right and left cover ...

Page 30: ... board 1 Remove the vertical path assembly See page 1 5 2 2 Pull out the duplex drawer 3 Remove the right cover See page 1 5 3 4 Remove nine connectors from duplexer board Remove three screws To remove the duplexer board Figure 1 5 3 Removing the duplexer board ...

Page 31: ... sensors solenoid motors etc are described in the following pages Figure 2 1 1 Paper feeding path 1 Vertical path roller 2 Switchback roller 3 Conveying roller 1 4 Conveying roller 2 5 Duplex refeed roller 6 Face up roller Switchback section Vertical path assembly Printer Paper refeed section Duplexer Printer face up output tray Paper path 1 6 2 3 4 5 ...

Page 32: ...ranch guide 3 Switchback motor 4 Vertical path roller 5 Face up roller 6 Switchback roller 7 Paper refeed motor 8 Conveying roller 1 9 Conveying roller 2 10 Duplex refeed roller 11 Vertical path sensor 12 Switchback sensor 13 Duplex refeed sensor OPRDY OPSDI OPSDO OPSCLK OPSEL0 OPSEL1 OPSEL2 GND OP24 V OP5 V GND Power train YC6 11 YC6 7 YC6 9 YC6 5 YC6 6 YC6 8 YC6 10 YC6 2 YC6 1 YC6 3 YC6 2 CN6 1 ...

Page 33: ...orward to drive the vertical path roller and switchback roller to convey the paper to the switchback section The switchback motor then rotates in the reverse direction reversing the switchback roller to convey paper to the paper refeed section The vertical path sensor and switchback sensor detect the paper conveying status and paper jams in the switchback section Printer paper exiting Paper refeed...

Page 34: ...r refeed motor moves the side registration guide to the size of the paper by rotating in the reverse direction as support to the paper conveying operation The duplex refeed sensor detects the paper conveying status and paper jams in the paper refeed section Figure 2 1 4 Paper refeed section Duplexer paper refeed Conveying roller 1 Conveying roller 2 Duplex refeed roller Duplex refeed sensor Side r...

Page 35: ...etects the opening and closing of the duplex drawer 4 Vertical path sensor Detects a paper jam in the vertical path 5 Switchback sensor Detects a paper jam in the switchback section 6 Duplex refeed sensor Detects a paper jam in the refeed section 7 Side registration sensor Detects the side registration guide home position 8 Branch solenoid Operates the branch guide 9 Switchback motor Drives paper ...

Page 36: ...3DS 2 2 2 This page is intentionally left blank ...

Page 37: ...feed motor based on the control signals SBM PRM from CPU IC4 The reset circuit consists mainly of reset IC7 It monitors the 5 V DC supply voltage When the power is turned on or when the power supply becomes low it outputs a RESET signal to CPU IC4 to prevent system malfunction or runaway SEL 2 0 OPSDI OPSDO OPSCLK OPREADY Serial communication VPS DDS SBS SRS DRS 5 V PB BRSOL 5 V 5 V 24 V 24 V CFM ...

Page 38: ...ensor On Off 2 GND Signal ground 3 5V O 5 V DC 5 V DC power supply 4 5V O 5 V DC 5 V DC power supply 5 5V O 5 V DC 5 V DC power supply 6 GND Signal ground 7 SRS I 5 0 V DC Side registration sensor On Off 1 OPRDY O 0 5 V DC Duplexer Ready Not ready 2 OPSDI O 5 0 V DC Serial communication data signal with printer 3 OPSDO I 5 0 V DC Serial communication data signal with printer 4 OPSCLK I 5 0 V DC Pu...

Page 39: ...3DS 2 3 3 Connector Pin No Signal I O Voltage Description CN9 Connected to the cooling fan motor 1 and 2 1 24V PB O 24 V DC 24 V DC power supply 2 CFM O 0 24 V DC Cooling fan motor 1 and 2 On Off ...

Page 40: ...3DS 2 3 4 This page is intentionally left blank ...

Page 41: ... fan motor 2 Switchback motor Paper refeeed motor Duplexer board VPS GND 5 V 5 V BE BE BE BE 1 2 3 4 4 3 2 1 K E A C SBS GND 5 V 5 V DDS GND 5 V 5 V BE BE BE BE BE BE BE BE BE BE BE BE BE BE BE BE BE BE BE BE BE BE BE BE BE BE BE BE BE BE BE RD BK RD RD RD RD BE BE BE E K C A J21 J22 J11 J12 1 2 3 4 5 6 7 8 9 10 11 12 1 2 3 4 5 6 7 8 9 10 11 12 J13 J14 Duplex refeed sensor Side registration sensor...

Page 42: ...aper refeed motor 1 4 8 m m s L e a d i n g e d g e o f 1 s t s h e e t L e a d in g e d g e o f 1 s t s h e e t L e a d i n g e d g e o f 2 n d s h e e t L e a d in g e d g e o f 2 n d s h e e t 1 4 8 m m s 3 5 0 m m s T ra il in g e d g e o f 1 s t s h e e t T r a i l i n g e d g e o f 1 s t s h e e t T ra il in g e d g e o f 2 n d s h e e t T ra il in g e d g e o f 3 rd s h e e t T r a i l i n ...

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