Utax DF 420 User manual

Service
Manual
Document Finisher
DF 420
First Edition
Date: 04-08-2009
3MJSM060

Service
Manual
Document Finisher
DF 420
First Edition
Date: 04-08-2009
3MJSM060

CAUTION
RISK OF EXPLOSION IF BATTERY IS REPLACED BY AN INCORRECT TYPE. DISPOSE OF
USED BATTERIES ACCORDING TO THE INSTRUCTIONS.
It may be illegal to dispose of this battery into the municipal waste stream. Check with your local
solid waste officials for details in your area for proper disposal.
ATTENTION
IL Y A UN RISQUE D’EXPLOSION SI LA BATTERIE EST REMPLACEE PAR UN MODELE DE
TYPE INCORRECT. METTRE AU REBUT LES BATTERIES UTILISEES SELON LES INSTRUC-
TIONS DONNEES.
Il peut être illégal de jeter les batteries dans des eaux d’égout municipales. Vérifiez avec les fonc-
tionnaires municipaux de votre région pour les détails concernant des déchets solides et une mise
au rebut appropriée.

Revision history
Revision Date Replaced pages Remarks

This page is intentionally left blank.

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.

Safety warnings and precautions
Various symbols are used to protect our service personnel and customers from physical danger and
to prevent damage to their property. These symbols are described below:
DANGER: High risk of serious bodily injury or death may result from insufficient attention to or incorrect
compliance 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 including danger and caution. The specific point
of attention is shown inside the symbol.
General warning.
Warning of risk of electric shock.
Warning of high temperature.
indicates a prohibited action. The specific prohibition is shown inside the symbol.
General prohibited action.
Disassembly prohibited.
indicates that action is required. The specific action required is shown inside the symbol.
General action required.
Remove the power plug from the wall outlet.
Always ground the copier.

1.Installation Precautions
WARNING
• Do not use a power supply with a voltage other than that specified. Avoid multiple connections to
one outlet: they may cause fire or electric shock. When using an extension cable, always check
that it is adequate for the rated current. .............................................................................................
• Connect the ground wire to a suitable grounding point. Not grounding the copier may cause fire or
electric shock. Connecting the earth wire to an object not approved for the purpose may cause
explosion or electric shock. Never connect the ground cable to any of the following: gas pipes,
lightning rods, ground cables for telephone lines and water pipes or faucets not approved by the
proper authorities. ............................................................................................................................
CAUTION:
• Do not place the copier on an infirm or angled surface: the copier may tip over, causing injury. .......
• Do not install the copier in a humid 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 locations when moving it. ...............................................
• Always use anti-toppling and locking devices on copiers so equipped. Failure to do this may cause
the copier to move unexpectedly or topple, leading to injury. ...........................................................
• Avoid inhaling toner or developer excessively. Protect the eyes. If toner or developer is acciden-
tally ingested, drink a lot of water to dilute it in the stomach and obtain medical attention immedi-
ately. If it gets into the eyes, rinse immediately with copious amounts of water and obtain medical
attention. ......................................................................................................................................
• Advice customers that they must always follow the safety warnings and precautions in the copier’s
instruction handbook. .....................................................................................................................

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 attempt to bypass or disable safety features including safety mechanisms
and protective circuits. .....................................................................................................................
• Always use parts having the correct specifications. ..........................................................................
• Always use the thermostat or thermal fuse specified in the service manual or other related bro-
chure when replacing them. Using a piece of wire, for example, could lead to fire or other serious
accident. ..........................................................................................................................................
• When the service manual or other serious brochure specifies a distance or gap for installation of a
part, always use the correct scale and measure carefully. ................................................................
• Always check that the copier is correctly connected to an outlet with a ground connection. .............
• Check that the power cable covering is free of damage. Check that the power plug is dust-free. If it
is dirty, clean it to remove the risk of fire or electric shock. ..............................................................
• Never attempt to disassemble the optical unit in machines using lasers. Leaking laser light may
damage eyesight. ...........................................................................................................................
• Handle the charger sections with care. They are charged to high potentials and may cause electric
shock if handled improperly. ............................................................................................................
CAUTION
• Wear safe clothing. If wearing loose clothing or accessories such as ties, make sure they are
safely secured so they will not be caught in rotating sections. ..........................................................
• Use utmost caution when working on a powered machine. Keep away from chains and belts. ........
• Handle the fixing section with care to avoid burns as it can be extremely hot. ..................................
• Check that the fixing unit thermistor, heat and press rollers are clean. Dirt on them can cause
abnormally high temperatures. ........................................................................................................

• Do not remove the ozone filter, if any, from the copier except for routine replacement. ....................
• Do not pull on the AC power cord or connector wires on high-voltage components when removing
them; always hold the plug itself. .....................................................................................................
• Do not route the power cable where it may be stood on or trapped. If necessary, protect it with a
cable cover or other appropriate item. .............................................................................................
• Treat the ends of the wire carefully when installing a new charger wire to avoid electric leaks. ........
• Remove toner completely from electronic components. ...................................................................
• Run wire harnesses carefully so that wires will not be trapped or damaged. ....................................
• After maintenance, always check that all the parts, screws, connectors and wires that were
removed, have been refitted correctly. Special attention should be paid to any forgotten connector,
trapped wire and missing screws. ...................................................................................................
• Check that 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 applied solvents to evaporate completely before refitting the covers or turning the power
switch on.
· Always wash hands afterwards.
• Never dispose of toner or toner bottles in fire. Toner may cause sparks when exposed directly to
fire in a furnace, etc. .......................................................................................................................
• Should smoke be seen coming from the copier, remove the power plug from the wall outlet imme-
diately. ............................................................................................................................................
3.Miscellaneous
WARNING
• Never attempt to heat the drum or expose it to any organic solvents such as alcohol, other than the
specified refiner; it may generate toxic gas. .....................................................................................

This page is intentionally left blank.

3MJ
CONTENTS
1-1 Specifications
1-1-1 Specifications..........................................................................................................................................1-1-1
1-1-2 Parts names............................................................................................................................................1-1-2
1-1-3 Machine cross section ............................................................................................................................1-1-3
1-2 Installation
1-2-1 Installation environment ..........................................................................................................................1-2-1
1-2-2 Unpacking ...............................................................................................................................................1-2-2
(1) Unpacking .........................................................................................................................................1-2-2
(2) Remove the tapes .............................................................................................................................1-2-3
1-3 Maintenance Mode
1-3-1 Maintenance mode .................................................................................................................................1-3-1
(1) Executing a maintenance item ..........................................................................................................1-3-1
(2) Maintenance mode item list...............................................................................................................1-3-2
(3) Contents of the maintenance mode items.........................................................................................1-3-3
1-4 Troubleshooting
1-4-1 Paper misfeed detection .........................................................................................................................1-4-1
(1) Paper misfeed indication...................................................................................................................1-4-1
(2) Paper misfeed detection conditions ..................................................................................................1-4-1
(3) Paper misfeeds .................................................................................................................................1-4-2
1-4-2 Self-diagnosis .........................................................................................................................................1-4-3
(1) Self-diagnostic function .....................................................................................................................1-4-3
(2) Self diagnostic codes ........................................................................................................................1-4-3
1-4-3 Electric problems ....................................................................................................................................1-4-5
1-4-4 Mechanical problems ..............................................................................................................................1-4-6
1-5 Assembly and Disassembly
1-5-1 Precautions for assembly and disassembly............................................................................................1-5-1
(1) Precautions .......................................................................................................................................1-5-1
(2) Adjusting the positions of the front side registration cursor, rear side registration cursor and
trailing edge registration cursor (reference) ......................................................................................1-5-2
(3) Adjusting the pressure of curl eliminator mechanism........................................................................1-5-3
2-1 Mechanical construction
2-1-1 Construction of each section...................................................................................................................2-1-1
(1) Paper conveying operation in sort mode...........................................................................................2-1-2
2-1-2 Process table section..............................................................................................................................2-1-3
(1) Paper registration on the process table.............................................................................................2-1-4
2-1-3 Stapler section ........................................................................................................................................2-1-5
2-2 Electrical Parts Layout
2-2-1 Electrical parts layout..............................................................................................................................2-2-1
(1) Paper conveying section ...................................................................................................................2-2-1
(2) Process table section ........................................................................................................................2-2-2
(3) Stapler section...................................................................................................................................2-2-3
2-3 Operation of the PWBs
2-3-1 Finisher control PWB ..............................................................................................................................2-3-1
2-4 Appendixes
Maintenance parts list .............................................................................................................................2-4-1
Periodic maintenance procedures ..........................................................................................................2-4-1
Wiring diagram........................................................................................................................................2-4-2

3MJ
This page is intentionally left blank.

3MJ
1-1-1
1-1 Specific ations
1-1-1 Specifications
Type ................................................Built-in
Number of trays ..............................1 tray
Paper weight................................... 60 to 105 g/m2
Maximum sheets (Not stapling) ......A3, B4, Ledger, Legal, Folio, OfficioII, 8K: 250 sheets
A4, A4R, B5, Letter, LetterR, 16K: 500 sheets
Muximum sheets for stapling .......... A3, B4, Ledger, Legal, Folio, OfficioII, 8K: 20 sheets
A4, A4R, B5, Letter, LetterR, 16K: 30 sheets
Power source.................................. Electrically connected to the machine
Dimension.......................................325 (W) x 450 (D) x 165 (H) mm
12 13/16" (W) x 17 11/16" (D) x 6 1/2" (H)
Weight.............................................8 kg/17.6 lbs or less
NOTE: These specifications are subject to change without notice.

3MJ
1-1-2
1-1-2 Parts names
Figure 1-1-1
75
6
2
4
1
3
1. Ejected paper guide extension
2. Finisher tray
3. Ejected paper guide
4. Process table
5. Finisher tray extension
6. JAM release lever
7. Staple

3MJ
1-1-3
1-1-3 Machine cross section
Figure 1-1-2 Machine cross section
Paper path
21
3
1. Paper conveying section
2. Process table section
3. Eject section

3MJ
1-1-4
This page is intentionally left blank.

3MJ
1-2-1
1-2 Installation
1-2-1 Installation environment
Installation location (Be based on the machine establishment place.)
Avoid direct sunlight or bright lighting. Ensure that the photoconductor will not be exposed to direct sunlight or other strong
light when removing paper jams.
Avoid locations subject to high temperature and high humidity or low temperature and low humidity; an abrupt change in
the environmental temperature; and cool or hot, direct air.
Avoid places subject to dust and vibrations.
Choose a surface capable of supporting the weight of the machine.
Place the machine on a level surface (maximum allowance inclination: 1°).
Avoid air-borne substances that may adversely affect the machine or degrade the photoconductor, such as mercury, acidic
of alkaline vapors, inorganic gasses, NOx, SOx gases and chlorine-based organic solvents.
Select a well-ventilated location.

3MJ
1-2-2
1-2-2 Unpacking
(1) Unpacking
Figure 1-2-1 Unpacking
Caution: See the Installation Guide for installation.
1. Paper conveying unit
2. Outer case
3. Finisher bottom pad
4. Spacer A
5. Accessory case
6. Finisher tray
7. Left upper cover
8. Inner cover
9. Spacer B
10. Sub staple cover
11. Front eject cover
12. Rear eject cover
13. M3 x 6 screws
14. Small pin
15. Large pin
16. Hook holder
17. Staple cartridge
18. Process table
19. Tray left pad
20. Tray right pad
21. Plastic sheet
22. Paper
23. Spacer C
24. Staple cover
25. Tray top pad
26. Installation guide
27. Barcode labels

3MJ
1-2-3
(2) Remove the tapes
Procedure
1. Remove two tapes from the finisher tray.
Figure 1-2-2
2. Remove the tape from the paper conveying
unit.
Figure 1-2-3
Tape
Finisher tray
Tape
Tape
Paper conveying unit