Konica Minolta Magicolor 5450 User manual

SERVICE MANUAL
2005.042005.04
Ver. 3.0Ver. 3.0
FIELD SERVICE
magicolor 5430 DL
magicolor 5440 DL
magicolor 5450
magicolor 5430 DL
magicolor 5440 DL
magicolor 5450
®
®
®
®
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SAFETY AND IMPORTANT WARNING ITEMS
S-11
[5] Laser Safety
• This is a digital machine certified as a class 1 laser product. There is no possibility of
danger from a laser, provided the machine is serviced according to the instruction in this
manual.
5.1 Internal Laser Radiation
*:at laser aperture of the Print Head Unit
• This product employs a Class 3b laser diode that emits an invisible laser beam. The laser
diode and the scanning polygon mirror are incorporated in the print head unit.
• The print head unit is NOT A FIELD SERVICEABLE ITEM. Therefore, the print head unit
should not be opened under any circumstances.
semiconductor laser
Maximum power of the laser diode 15 mW
Maximum average radiation power (*) 7.2 µW
Wavelength 770-800 nm
4138safe002c0
This figure shows the view
inside the Front Door.
Laser Aperture of
the Print Head Unit
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SERVICE MANUAL
2005.04
Ver. 3.0
FIELD SERVICE
magicolor 5430 DL
magicolor 5440 DL
magicolor 5450
®
®
®
Main Unit
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Main Unit Field Service
i
I OutlineII MaintenanceIII Adjustment/SettingIV TroublshootingV Appendix
CONTENTS
I Outline
1. System configuration............................................................................................1-1
2. Product Specifications..........................................................................................1-2
2.1 Type...................................................................................................................1-2
2.2 Functions...........................................................................................................1-3
2.3 Maintenance......................................................................................................1-5
2.4 Machine Specifications......................................................................................1-5
2.5 Operating Environment......................................................................................1-6
II Maintenance
1. Periodic Check .....................................................................................................2-1
1.1 Service schedule...............................................................................................2-1
1.2 Maintenance Items ............................................................................................2-2
1.2.1 Parts to be replaced by users (CRU)............................................................2-2
1.2.2 Parts to be Replaced by a Service Engineer (FRU).....................................2-3
1.3 Maintenance parts.............................................................................................2-3
1.4 Concept of parts life...........................................................................................2-4
1.5 Maintenance Procedure (Periodic Parts Check)................................................2-6
1.5.1 Feed Roller (Tray 1)......................................................................................2-6
1.5.2 Feed Roller (Manual Feed Tray) (magicolor 5440 DL/5450 only).................2-7
1.5.3 Ozone Filter................................................................................................2-10
1.5.4 Toner Cartridge (C/M/Y/Bk)........................................................................2-10
1.5.5 Waste Toner Bottle .....................................................................................2-13
1.5.6 Cleaning the Laser Irradiation Section .......................................................2-14
1.6 Replacing Units................................................................................................2-15
1.6.1 Replacing the Transfer Roller .....................................................................2-15
1.6.2 Replacing the Transfer Belt Unit.................................................................2-16
.....................2-19
2 .....................2-20
.....................2-20
2.2 Consumable Parts...........................................................................................2-20
2.2.1 Toner Cartridge (TC) (as an individual part)...............................................2-20
2.2.2 Waste Toner Bottle .....................................................................................2-20
2.2.3 Maintenance Kit..........................................................................................2-20
3. Firmware Upgrade .............................................................................................2-21
3.1 Print Control Board (PWB-P) Firmware Upgrading .........................................2-21
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3.1.1 Upgrade procedure (magicolor 5430 DL/5440 DL)....................................2-21
3.1.2 Upgrade procedure (magicolor 5450) ........................................................2-23
4. Other..................................................................................................................2-28
4.1 Disassembly/Adjustment-Prohibited Items......................................................2-28
4.2 Names of Feed Trays.......................................................................................2-28
4.3 Disassembly/Assembly list (Other parts).........................................................2-29
4.4 Disassembly/Assembly Procedure..................................................................2-30
4.4.1 Front Door, Upper Front Cover, and Right Front Cover..............................2-30
4.4.2 Left Cover...................................................................................................2-31
4.4.3 Rear Cover................................................................................................. 2-31
4.4.4 Exit Tray......................................................................................................2-32
4.4.5 Rear Right Cover........................................................................................2-32
4.4.6 Tray 1..........................................................................................................2-33
4.4.7 Manual Feed Tray (magicolor 5440 DL/5450 only).....................................2-33
4.4.8 Control Panel (PWB-OP)............................................................................2-34
4.4.9 Hard Disk Unit (HDD) (magicolor 5450 only) .............................................2-34
4.4.10 Print Control Board (PWB-P) (magicolor 5430 DL/5440 DL) .....................2-35
4.4.11 Print Control Board (PWB-P) (magicolor 5450)..........................................2-36
4.4.12 Backup Battery (magicolor 5450 only) ....................................................... 2-37
4.4.13 Mechanical Control Board (PWB-A)...........................................................2-38
4.4.14 Low Voltage Unit (LV).................................................................................2-41
4.4.15 High Voltage Unit /1 (HV1).........................................................................2-42
4.4.16 High Voltage Unit /2 (HV2).........................................................................2-43
4.4.17 Toner Level Sensor Board (PWB-D)...........................................................2-44
4.4.18 PH Unit.......................................................................................................2-46
4.4.19 PWB Box/1................................................................................................. 2-47
4.4.20 PWB Box/2................................................................................................. 2-48
4.4.21 Developing Motor /Y, M, C (M1) .................................................................2-48
4.4.22 Color PC Drum Motor (M2) ........................................................................2-48
.................................2-49
.................................2-49
.................................2-49
4.4.26 Fusing Motor (M4)......................................................................................2-50
4.4.27 Intermediate Transport Motor (M3).............................................................2-50
4.4.28 Synchronizing Roller Clutch (CL2).............................................................2-50
4.4.29 Pressure/Retraction Clutch /2nd Image Transfer (CL5)..............................2-51
4.4.30 Pressure/Retraction Clutch /1st Image Transfer (CL4)............................... 2-53
4.4.31 Tray 1 Paper Feed Clutch (CL1).................................................................2-54
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4.4.32 Manual Feed Tray Paper Feed Clutch (CL3)
(magicolor 5440 DL/5450 only) ..................................................................2-58
4.4.33 Temperature/ Humidity Sensor (HS1).........................................................2-63
4.4.34 AIDC Sensor/Rt, AIDC Sensor/Lt (AIDC R, AIDC L)..................................2-64
4.4.35 Camera Direct Photo Print Card (magicolor 5440 DL only)........................2-65
III Adjustment/Setting
1. How to Use the Adjustment Section.....................................................................3-1
2. Adjustment Item List.............................................................................................3-2
2.1 magicolor 5430 DL/5440 DL..............................................................................3-2
2.2 magicolor 5450..................................................................................................3-3
3. Description of the Control Panel
(magicolor 5430 DL /5440 DL).............................................................................3-4
3.1 Control Panel Display ........................................................................................3-4
3.1.1 Basic screen.................................................................................................3-4
3.1.2 Warning screen ............................................................................................3-4
3.1.3 Error display..................................................................................................3-4
3.1.4 Caution display.............................................................................................3-5
3.2 List of Control Panel Messages.........................................................................3-6
3.2.1 Normal state messages................................................................................3-6
3.2.2 Caution messages........................................................................................3-6
3.2.3 Minor error messages...................................................................................3-7
3.2.4 Error messages............................................................................................3-7
3.2.5 Serious error messages ...............................................................................3-8
3.2.6 Malfunction messages..................................................................................3-9
3.2.7 Message Priority for Consumables/Periodic Replacement Parts (Units)....3-10
3.3 Canceling a Print Job ......................................................................................3-11
4. Menu (magicolor 5430 DL /5440 DL).................................................................3-12
4.1 List of Menu Functions.....................................................................................3-12
4.2 SPECIAL PAGES.............................................................................................3-13
..........................................................................3-13
..........................................................................3-13
..........................................................................3-13
4.3 LANGUAGE.....................................................................................................3-13
4.4 ENGINE...........................................................................................................3-14
4.4.1 ENGINE TONER EMPTY...........................................................................3-14
4.4.2 ENERGY SAVER .......................................................................................3-14
4.4.3 AUTO CONTINUE......................................................................................3-14
4.4.4 TRAY CHAINING........................................................................................3-14
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4.4.5 ENGINE SERVICE.....................................................................................3-15
4.5 NETWORK......................................................................................................3-17
4.5.1 DHCP:XX / BOOTP:XX..............................................................................3-17
4.5.2 IP ADDRESS.................................................................... ......3-17
4.5.3 SUBNET MASK................................................................ ......3-17
4.5.4 GATEWAY ........................................................................ ......3-18
4.5.5 MAC ADDRESS............................................................... ......3-18
4.5.6 HTTP................................................................................ ......3-18
4.5.7 SNMP............................................................................... ......3-18
4.5.8 FORCED MODES............................................................ ......3-18
4.6 CONSUMABLE USAGE........................................................ ......3-19
4.6.1 BLACK TONER ................................................................ ......3-19
4.6.2 CYAN TONER .................................................................. ......3-19
4.6.3 MAGENTA TONER........................................................... ......3-19
4.6.4 YELLOW TONER............................................................. ......3-19
4.7 DIRECT PRINT..................................................................... ......3-19
4.7.1 IMAGE QUALITY.............................................................. ......3-19
4.7.2 PAPER SIZE..................................................................... ......3-20
4.7.3 MEDIA TYPE.................................................................... ......3-20
4.7.4 LAYOUT............................................................................ ......3-20
4.7.5 BRIGHTNESS.................................................................. ......3-20
4.7.6 SHARPNESS.............................................................................................3-20
4.7.7 AUTO ROTATE...........................................................................................3-20
5. Service Mode (magicolor 5430 DL/5440 DL).....................................................3-21
5.1 Service Mode Entry Procedure.......................................................................3-21
5.2 Service Mode Function Tree............................................................................3-21
5.3 Settings/Adjustments in Service/Service Person Mode Functions..................3-22
5.3.1 RESTORE FACTORY DEFAULT................................................................3-22
5.3.2 SERVICE PERSON SRU USAGE..............................................................3-24
5.3.3 RESET CONTROLLER..............................................................................3-24
5.3.4 RESET COUNTER FUSER UNIT..............................................................3-25
6. Description of the Control Panel (magicolor 5450) ............................................3-26
6.1 Control Panel Display......................................................................................3-26
6.1.1 Parts of the Control Panel Display..............................................................3-26
6.1.2 Message structure......................................................................................3-27
6.1.3 Normal messages ......................................................................................3-28
6.1.4 Menu ..........................................................................................................3-32
6.1.5 Operator Call messages.............................................................................3-33
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6.1.6 Service Call messages...............................................................................3-34
6.1.7 Help screen ................................................................................................3-35
6.2 List of Control Panel Messages.......................................................................3-36
6.2.1 Normal messages.......................................................................................3-36
6.2.2 Operator Call messages.............................................................................3-38
6.2.3 Service Call messages...............................................................................3-40
6.3 Canceling a Print Job ......................................................................................3-41
7. Menu (magicolor 5450) ......................................................................................3-42
7.1 List of Menu Functions.....................................................................................3-42
7.1.1 Outline........................................................................................................3-42
7.1.2 Detail ..........................................................................................................3-43
7.2 PROOF/PRINT MENU..................................................... ............3-45
7.3 PRINT MENU .................................................................. ............3-45
7.3.1 CONFIGURATION PG................................................ ............3-45
7.3.2 DEMO PAGE .............................................................. ............3-45
7.3.3 STATISTICS PAGE..................................................... ............3-46
7.3.4 FONT LIST................................................................. ............3-46
7.3.5 MENU MAP................................................................ ............3-46
7.3.6 DIRECTORY LIST...................................................... ............3-46
7.4 PAPER MENU ................................................................. ............3-47
7.4.1 PAPER SOURCE ....................................................... ............3-47
7.4.2 DUPLEX..................................................................... ............3-50
7.4.3 COPIES...................................................................... ............3-50
7.4.4 COLLATE.................................................................... ............3-50
7.4.5 UNIT OF MEASURE .................................................. ............3-51
7.5 QUALITY MENU.............................................................. ............3-52
7.5.1 COLOR MODE........................................................... ............3-52
7.5.2 BRIGHTNESS ............................................................ ............3-52
7.5.3 PCL CONTRAST........................................................ ............3-52
7.5.4 PS PROFILE ..............................................................................................3-52
7.5.5 IMAGE PRINTING......................................................................................3-54
7.5.6 TEXT PRINTING ........................................................................................3-55
7.5.7 GRAPHICS PRINTING...............................................................................3-56
7.5.8 CALIBRATION............................................................................................3-57
7.5.9 COLOR SEPARATION ...............................................................................3-57
7.5.10 SUPPLIES..................................................................................................3-58
7.6 INTERFACE MENU.........................................................................................3-59
7.6.1 JOB TIMEOUT ...........................................................................................3-59
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7.6.2 ETHERNET................................................................................................ 3-59
7.7 SYS DEFAULT MENU.....................................................................................3-63
7.7.1 LANGUAGE...................................................................... ......3-63
7.7.2 EMULATION..................................................................... ......3-63
7.7.3 DEFAULT PAPER............................................................. ......3-67
7.7.4 STARTUP OPTIONS /DO STARTUP PAGE..................... ......3-68
7.7.5 AUTO CONTINUE............................................................ ......3-69
7.7.6 HOLD JOB TIMEOUT...................................................... ......3-69
7.7.7 ENERGY SAVER............................................................. ......3-69
7.7.8 ENERGY SAVER TIME.................................................... ......3-70
7.7.9 MENU TIMEOUT.............................................................. ......3-70
7.7.10 LCD BRIGHTNESS.......................................................... ......3-70
7.7.11 SECURITY....................................................................... ......3-71
7.7.12 CLOCK............................................................................. ......3-72
7.7.13 HDD FORMAT.................................................................. ......3-72
7.7.14 RESTORE DEFAULTS..................................................... ......3-73
7.7.15 ENABLE WARNING......................................................... ......3-77
7.7.16 TONER EMPTY ............................................................... ......3-78
8. Service Menu (magicolor 5450)............................................... ......3-79
8.1 How to Enter the Service Menu............................................. ......3-79
8.2 Service mode function tree..............................................................................3-79
8.3 Service Menu Setting/Adjustment...................................................................3-80
8.3.1 SERIAL NUMBER......................................................................................3-80
8.3.2 FIRMWARE VERSION...............................................................................3-80
8.3.3 ALIGNMENT ..............................................................................................3-80
8.3.4 TRANSFER POWER /IMAGE ADJ PARAM...............................................3-83
8.3.5 RESTORE PASSWARD.............................................................................3-84
IV Troubleshooting
........................................................................4-1
0 DL / 5440 DL)...............................................4-1
0) .....................................................................4-2
1.3 Misfeed Display Resetting Procedure ...............................................................4-2
1.4 Sensor Layout ...................................................................................................4-3
1.5 Solutions............................................................................................................4-4
1.5.1 Initial Check Items........................................................................................4-4
1.5.2 Misfeed at Tray 1 media feed section
(Misfeed at Tray 2 media feed section).........................................................4-5
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Main Unit Field Service
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I OutlineII MaintenanceIII Adjustment/SettingIV TroublshootingV Appendix
1.5.3 Misfeed at Manual Feed Tray media feed section
(Misfeed at Tray 1 media feed section).........................................................4-6
1.5.4 Misfeed at transfer section............................................................................4-7
1.5.5 Misfeed at fusing/exit section........................................................................4-8
1.5.6 Undefined misfeed........................................................................................4-8
2. Malfunction code..................................................................................................4-9
2.1 Trouble Codes (magicolor 5430 DL/5440 DL) ...................................................4-9
2.1.1 Trouble code list............................................................................................4-9
2.2 Trouble Codes (magicolor 5450)......................................................................4-12
2.2.1 Trouble code list..........................................................................................4-12
2.3 Resetting a Malfunction...................................................................................4-15
2.4 Solutions..........................................................................................................4-15
2.4.1 0010H: Color PC Drum Motor malfunction.................................................4-15
2.4.2 001BH: Developing Motor/Y,M,C malfunction.............................................4-16
2.4.3 0017H: Intermediate Transport Motor malfunction.....................................4-16
2.4.4 0018H: Developing Motor/K malfunction....................................................4-17
2.4.5 0046H: Fusing Cooling Fan Motor malfunction ..........................................4-17
2.4.6 004CH: Ozone Ventilation Fan Motor malfunction......................................4-18
2.4.7 004EH: LV Cooling Fan Motor malfunction.................................................4-18
2.4.8 0060H: Fusing Motor malfunction...............................................................4-19
2.4.9 0094H: 2nd image transfer pressure/retraction failure................................4-19
2.4.10 0096H: 1st image transfer pressure/retraction failure.................................4-20
2.4.11 0300H: Polygon Motor malfunction.............................................................4-20
2.4.12 0310H: Laser malfunction...........................................................................4-21
2.4.13 0500H: Heating Roller warm-up failure ......................................................4-21
2.4.14 0501H: Fusing Pressure Roller warm-up failure.........................................4-21
2.4.15 0510H: Abnormally low Heating Roller temperature ..................................4-21
2.4.16 0511H: Abnormally low Fusing Pressure Roller temperature.....................4-21
2.4.17 0520H: Abnormally high Heating Roller temperature.................................4-21
e Roller temperature...................4-21
....................................................4-22
13E3H: Flash ROM device fault..................................................................4-22
2.4.21 C002, C003: RAM error (Only for magicolor 5450) ....................................4-22
2.4.22 C013: MAC address error (Only for magicolor 5450)
C015: BOOT ROM error (Only for magicolor 5450)
C022: NVRAM error (Only for magicolor 5450)..........................................4-23
2.4.23 C025, C026, C027: Controller ROM error (Only for magicolor 5450).........4-23
2.4.24 C050: Hard disk access error (Only for magicolor 5450)............................4-24
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