Konica Minolta Magicolor 5650EN User manual

SERVICE MANUAL
2008.042008.04
Ver. 1.0Ver. 1.0
FIELD SERVICE
magicolor
5650EN/5670EN

FIELD SERVICE TOTAL CONTENTS
SAFETY AND IMPORTANT WARNING ITEMS ..............................................................S-1
IMPORTANT NOTICE ................................................................................................S-1
DESCRIPTION ITEMS FOR DANGER, WARNING AND CAUTION .........................S-1
SAFETY WARNINGS .................................................................................................S-2
WARNING INDICATIONS ON THE MACHINE ........................................................S-18
MEASURES TO TAKE IN CASE OF AN ACCIDENT ....................................................S-21
Composition of the service manual ................................................................................. C-1
Notation of the service manual ....................................................................................... C-2
magicolor 5650EN/5670EN Main body
General...........................................................................................................................1
Maintenance ...................................................................................................................7
Adjustment/Setting........................................................................................................97
Troubleshooting...........................................................................................................199
Appendix.....................................................................................................................243
Lower feeder unit
General...........................................................................................................................1
Maintenance ...................................................................................................................3
Adjustment/Setting........................................................................................................13
Troubleshooting.............................................................................................................15
Duplex option
General...........................................................................................................................1
Maintenance ...................................................................................................................3
Troubleshooting...............................................................................................................9
Staple finisher
General...........................................................................................................................1
Maintenance ...................................................................................................................5
Troubleshooting.............................................................................................................23

Composition of the service manual
This service manual consists of Theory of Operation section and Field Service section to
explain the main machine and its corresponding options.
Theory of Operation section gives, as information for the CE to get a full understanding of
the product, a rough outline of the object and role of each function, the relationship
between the electrical system and the mechanical system, and the timing of operation of
each part.
Field Service section gives, as information required by the CE at the site (or at the cus-
tomer’s premise), a rough outline of the service schedule and its details, maintenance
steps, the object and role of each adjustment, error codes and supplementary information.
The basic configuration of each section is as follows. However some options may not be
applied to the following configuration.
<Theory of Operation section>
<Field service section>
OUTLINE: Explanation of system configuration,
product specifications, unit configuration, and paper path
COMPOSITION/OPERATION: Explanation of configuration of each unit,
operating system, and control system
GENERAL: Explanation of system configuration, and product
specifications
MAINTENANCE: Explanation of service schedule, maintenance steps, ser-
vice tools, removal/reinstallation methods of major parts,
and firmware version up method etc.
ADJUSTMENT/SETTING: Explanation of utility mode, service mode, and mechanical
adjustment etc.
TROUBLESHOOTING: Explanation of lists of jam codes and error codes, and
their countermeasures etc.
APPENDIX: Parts layout drawings, connector layout drawings, timing
chart, overall layout drawing are attached.

SERVICE MANUAL
2008.04
Ver. 1.0
FIELD SERVICE
Main body
magicolor
5650EN/5670EN

MaintenanceAdjustment / Setting
Troubleshooting
Appendix
Field Service Ver. 1.0 Apr. 2008
i
CONTENTS
magicolor 5650EN/5670EN Main body
General
1. System configuration...............................................................................................1
2. Product specifications .............................................................................................2
Maintenance
3. Periodical check ......................................................................................................7
3.1 Maintenance items................................................................................................7
3.1.1 Parts to be replaced by users (CRU) ............................................................7
3.1.2 Parts to be replaced by a service engineer (FRU)........................................8
3.2 Maintenance parts................................................................................................8
3.2.1 Replacement parts........................................................................................8
3.3 Concept of parts life............................................................................................10
3.4 Maintenance Procedure (periodical check parts)...............................................12
3.4.1 Replacing the tray 2 feed roller ...................................................................12
3.4.2 Replacing the tray 1 feed roller ...................................................................13
3.4.3 Replacing the ozone filter............................................................................16
3.4.4 Replacing the toner cartridge (C,M,Y,K) .....................................................16
3.4.5 Replacing the imaging unit (C,M,Y,K) .........................................................19
3.4.6 Replacing the waste toner bottle.................................................................23
3.4.7 Replacing the transfer roller........................................................................24
3.4.8Replacing the transfer belt..........................................................................25
3.4.9 Replacing the fuser unit ..............................................................................27
4. Service tool ...........................................................................................................28
4.1 CE tool list...........................................................................................................28
4.2 Consumable parts ..............................................................................................28
4.2.1 Toner cartridge............................................................................................28
4.2.2 Imaging unit ................................................................................................29
4.2.3 Waste toner bottle.......................................................................................29
5. Firmware upgrade.................................................................................................30
5.1 Checking the current firmware version ...............................................................30
5.2 Firmware upgrading procedure by USB memory device....................................30
5.2.1 Preparations for firmware upgrading...........................................................30
5.3 Firmware upgrading procedure by updater.........................................................32
5.3.1 Updating method.........................................................................................32

magicolor
5650EN/5670EN
GeneralMaintenanceAdjustment / Setting
Troubleshooting
Appendix
ervice Ver. 1.0 Apr. 2008
ii
.................................. 45
6. Other..................................................................................................................... 46
6.1 Disassembly/adjustment prohibited items.......................................................... 46
6.2 Disassembly/assembly/cleaning list (other parts) .............................................. 47
6.2.1 Disassembly/assembly parts list................................................................. 47
6.2.2 Cleaning parts list....................................................................................... 48
6.3 Disassembly/assembly procedure...................................................................... 49
6.3.1 Front door ................................................................................................... 49
6.3.2 Upper front cover........................................................................................ 49
6.3.3 Right front cover.......................................................................................... 50
6.3.4 Left cover.................................................................................................... 50
6.3.5 Rear Cover.................................................................................................. 51
6.3.6 Exit tray....................................................................................................... 51
6.3.7 Right rear cover .......................................................................................... 52
6.3.8Tray 2.......................................................................................................... 53
6.3.9 Tray 1.......................................................................................................... 54
6.3.10 Operation board (OB)................................................................................. 54
6.3.11 Hard disk kit (option)................................................................................... 55
6.3.12 MFP board (MFPB)..................................................................................... 56
6.3.13 Print control board (PRCB)......................................................................... 59
6.3.14 DC power supply (DCPU)........................................................................... 61
6.3.15 High voltage unit/1 (HV1)............................................................................ 63
6.3.16 High voltage unit/2 (HV2)............................................................................ 64
6.3.17 Toner level sensor board (TLSB) ................................................................ 65
6.3.18PH Unit ....................................................................................................... 68
6.3.19 Driving unit.................................................................................................. 75
6.3.20 MFP board fan motor (FM5) ....................................................................... 76
6.3.21 Backup battery............................................................................................ 77
6.3.22 PWB box/1.................................................................................................. 78
6.3.23 PWB box/2.................................................................................................. 79
6.3.24 Color PC drum motor (M2) ......................................................................... 79
6.3.25 Developing motor/K (M5)............................................................................ 80
6.3.26 Toner supply motor/Y,M (M6)...................................................................... 80
6.3.27 Toner supply motor/C,K (M7)...................................................................... 81
6.3.28Fusing motor (M4) ...................................................................................... 81
6.3.29 Intermediate transport motor (M3).............................................................. 82
6.3.30 Registration roller clutch (CL2)................................................................... 82
6.3.31 Pressure/retraction clutch/2 (CL5) 83

magicolor
5650EN/5670EN
GeneralMaintenanceAdjustment / Setting
Troubleshooting
Appendix
Field Service Ver. 1.0 Apr. 2008
iii
6.3.32 Pressure/retraction clutch/1 (CL4) .............................................................. 85
6.3.33 Media feed clutch/1 (CL1)...........................................................................86
6.3.34 Media feed clutch/2 (CL3)...........................................................................90
6.3.35 Temperature/ humidity sensor (TEM/HUMS)..............................................93
6.3.36 IDC sensor board/Re, IDC sensor board/Fr (IDCSB/R, IDCSB/L)..............94
6.4 Cleaning procedure ............................................................................................95
6.4.1 Tray 1 feed roller..........................................................................................95
6.4.2 Tray 2 feed roller..........................................................................................95
6.4.3 Laser irradiation section..............................................................................96
Adjustment/Setting
7. How to use the adjustment section .......................................................................97
8. Description of the control panel.............................................................................98
8.1 Control panel display..........................................................................................98
8.1.1 Parts of the control panel display................................................................98
8.1.2 Message structure ......................................................................................99
8.1.3 Normal messages.....................................................................................100
8.1.4 Operator call messages............................................................................105
8.1.5 Service call messages..............................................................................106
8.1.6 Help screen...............................................................................................107
8.2 List of control panel messages.........................................................................108
8.2.1 Normal messages.....................................................................................108
8.2.2 Operator call messages............................................................................111
8.2.3 Service call messages..............................................................................114
8.3 Cancelling a print job........................................................................................116
9. Menu ...................................................................................................................117
9.1 List of menu functions.......................................................................................117
9.2 PROOF/PRINT MENU......................................................................................122
9.3 PRINT MENU ...................................................................................................122
9.3.1 CONFIGURATION PG..............................................................................122
9.3.2 DEMO PAGE.............................................................................................123
9.3.3 STATISTICS PAGE....................................................................................123
9.3.4 FONT LIST................................................................................................129
9.3.5 MENU MAP...............................................................................................129
9.3.6 DIRECTORY LIST.....................................................................................129
9.4 PAPER MENU ..................................................................................................130
9.4.1 PAPER SOURCE......................................................................................130
9.4.2 DUPLEX....................................................................................................135

agicolor
EN/5670EN
Adjustment
Troubleshooting
Appendix
Field Service Ver. 1.0 Apr. 2008
iv
9.4.3 COPIES.................................................................................................... 135
9.4.4 COLLATE.................................................................................................. 136
9.4.5 FINISHING................................................................................................ 136
9.4.6 JOB SEPARATION ................................................................................... 136
9.4.7 IMAGE ROTATION.................................................................................... 137
9.5 QUALITY MENU............................................................................................... 137
9.5.1 COLOR MODE......................................................................................... 137
9.5.2 BRIGHTNESS .......................................................................................... 137
9.5.3 HALFTONE............................................................................................... 137
9.5.4 EDGE ENHANCEMENT........................................................................... 138
9.5.5 EDGE STRENGTH................................................................................... 139
9.5.6 ECONOMY PRINT ................................................................................... 139
9.5.7 GLOSSY MODE....................................................................................... 139
9.5.8PCL SETTING.......................................................................................... 140
9.5.9 PS SETTING ............................................................................................ 142
9.5.10 CALIBRATION.......................................................................................... 146
9.5.11 COLOR SEPARATION.............................................................................. 147
9.6 MEMORY DIRECT........................................................................................... 147
9.6.1 LIST OF FILES......................................................................................... 147
9.6.2 TYPE OF FILES ....................................................................................... 148
9.7 CAMERA DIRECT............................................................................................ 148
9.7.1 PAPER SOURCE...................................................................................... 148
9.7.2 LAYOUT.................................................................................................... 148
9.7.3 PAPER MARGIN....................................................................................... 148
9.7.4 IMAGE QUALITY...................................................................................... 149
9.8INTERFACE MENU.......................................................................................... 151
9.8.1 JOB TIMEOUT.......................................................................................... 151
9.8.2 ETHERNET .............................................................................................. 151
9.8.3 MEMORY DIRECT ................................................................................... 158
9.8.4 CAMERA DIRECT.................................................................................... 158
9.9 SYS DEFAULT MENU...................................................................................... 158
9.9.1 LANGUAGE.............................................................................................. 158
9.9.2 EMULATION............................................................................................. 158
9.9.3 PAPER...................................................................................................... 161
9.9.4 GRAY SCALE PAGE................................................................................. 163
9.9.5 STARTUP OPTIONS ................................................................................ 163
9.9.6 AUTO CONTINUE .................................................................................... 163
9 9 7 HOLD JOB TIMEOUT ................ 163

magicolor
5650EN/5670EN
Adjustm
Troubleshooting
Appendix
Field Service Ver. 1.0 Apr. 2008
v
9.9.8ENERGY SAVER......................................................................................164
9.9.9 ENERGY SAVER TIME ............................................................................164
9.9.10 MENU TIMEOUT ......................................................................................164
9.9.11 LCD CONTRAST......................................................................................164
9.9.12 SECURITY................................................................................................165
9.9.13 CLOCK......................................................................................................166
9.9.14 HDD FORMAT ..........................................................................................167
9.9.15 CARD FORMAT........................................................................................167
9.9.16 RESTORE DEFAULTS..............................................................................168
9.9.17 ENABLE WARNING..................................................................................176
9.10 MAINTENANCE MENU....................................................................................178
9.10.1 How to enter the MAINTENANCE MENU.................................................178
9.10.2 PRINT MENU............................................................................................178
9.10.3 ALIGNMENT.............................................................................................179
9.10.4 SUPPLIES ................................................................................................182
9.10.5 QUICK SETTING......................................................................................182
10. Adjustment item list.............................................................................................184
11. SERVICE MENU.................................................................................................185
11.1 How to enter the service menu.........................................................................185
11.2 Service menu function tree...............................................................................186
11.3 SERVICE MENU ..............................................................................................187
11.3.1 SERIAL NUMBER.....................................................................................187
11.3.2 FIRMWARE VERSION .............................................................................187
11.3.3 ALIGNMENT.............................................................................................187
11.3.4 DIAGNOSIS MENU...................................................................................191
11.3.5 SUPPLIES ................................................................................................194
11.3.6 RESTORE PASSWARD............................................................................195
11.3.7 BK CLEAR................................................................................................195
11.3.8QUICK SETTING......................................................................................196
11.3.9 FIRMWARE UPDATE................................................................................197
11.3.10 SOFT SWITCH .........................................................................................197
12. Other functions....................................................................................................198
12.1 Rewriting security information into the hard disk kit and the compact flash .....198
12.1.1 Outline.......................................................................................................198
12.1.2 Procedure .................................................................................................198

magicolor
5650EN/5670EN
Troubleshooting
Appendix
Field Service Ver. 1.0 Apr. 2008
vi
Troubleshooting
13. Jam display......................................................................................................... 199
13.1 Misfeed display................................................................................................. 199
13.2 Misfeed display resetting procedure................................................................. 200
13.3 Sensor layout.................................................................................................... 200
13.4 Solution ............................................................................................................ 201
13.4.1 Initial check items ..................................................................................... 201
13.4.2 Misfeed at tray 2 media feed section ........................................................ 202
13.4.3 Misfeed at tray1 media feed section ......................................................... 202
13.4.4 Misfeed at transfer section........................................................................ 203
13.4.5 Misfeed at fusing/exit section.................................................................... 204
13.4.6 Media misfeed in control logic................................................................... 205
14. Malfunction code................................................................................................. 206
14.1 Trouble codes (service call).............................................................................. 206
14.1.1 Trouble code list........................................................................................ 206
14.2 Resetting a malfunction.................................................................................... 209
14.3 Solution ............................................................................................................ 210
14.3.1 0010: Color PC drum motor malfunction .................................................. 210
14.3.2 0017: Intermediate transport motor malfunction....................................... 210
14.3.3 0018: Developing motor/K malfunction..................................................... 211
14.3.4 001B: Developing motor/Y,M,C malfunction.............................................. 211
14.3.5 0046: Fusing fan motor malfunction.......................................................... 212
14.3.6 004C: Ozone ventilation fan motor malfunction........................................ 212
14.3.7 004E: DC power supply fan motor malfunction......................................... 213
14.3.80060: Fusing motor malfunction ............................................................... 213
14.3.9 0094: 2nd image transfer pressure/retraction failure ................................ 214
14.3.10 0096: 1st image transfer pressure/retraction failure ................................. 215
14.3.11 0300: Polygon motor malfunction ............................................................. 215
14.3.12 0310: Laser malfunction ........................................................................... 216
14.3.13 0500: Heating roller warm-up failure......................................................... 216
14.3.14 0501: Fusing pressure roller warm-up failure........................................... 216
14.3.15 0510: Abnormally low heating roller temperature..................................... 216
14.3.16 0511: Abnormally low fusing pressure roller temperature ........................ 216
14.3.17 0520: Abnormally high heating roller temperature.................................... 216
14.3.180521: Abnormally high fusing pressure roller temperature....................... 216
14.3.19 0F52: Toner level sensor/Y malfunction.................................................... 217
14.3.20 0F53: Toner level sensor/M malfunction ................................................... 217
14.3.21 0F54: Toner level sensor/C malfunction.................................................... 217

magicolor
5650EN/5670EN
GeneralceAppendix
Field Service Ver. 1.0 Apr. 2008
vii
14.3.22 0F55: Toner level sensor/K malfunction....................................................217
14.3.23 133B: Finisher communication malfunction ..............................................217
14.3.24 13C0: Print control board malfunction.......................................................217
14.3.25 13E2: Flash ROM write error ....................................................................218
14.3.26 13E3: Flash ROM device fault...................................................................218
14.3.27 3FFB: Finisher flash ROM error................................................................218
14.3.28C002: RAM error at startup (standard memory) .......................................218
14.3.29 C003: RAM error at startup (expanded memory)......................................218
14.3.30 C013: MAC address error at startup.........................................................219
14.3.31 C015: BOOT ROM error at startup ...........................................................219
14.3.32 C025: Controller ROM error (Configuration information error)..................219
14.3.33 C026: Controller ROM error (Access error) ..............................................219
14.3.34 C027: Controller ROM error (Data error) ..................................................219
14.3.35 C050: HDD access error...........................................................................219
14.3.36 C051: HDD full error .................................................................................220
14.3.37 C052: Compact flash access error............................................................220
14.3.38C053: Compact flash full error ..................................................................221
14.3.39 C060: Firmware update error....................................................................221
14.3.40 C071: Hardware configuration error..........................................................222
14.3.41 FFFF: Interface communication error........................................................222
15. Power supply troubles.........................................................................................223
15.1 Machine is not energized at all (DCPU operation check).................................223
15.2 Control panel indicators do not light .................................................................223
15.3 Fusing heaters do not operate..........................................................................224
16. Image quality problems.......................................................................................225
16.1 Solution.............................................................................................................225
16.1.1 White lines/bands, colored lines/bands in sub scan direction...................225
16.1.2 White lines/bands, colored lines/bands in main scan direction.................226
16.1.3 Uneven density in sub scan direction.......................................................227
16.1.4 Uneven density in main scan direction......................................................228
16.1.5 Low image density ....................................................................................229
16.1.6 Gradation reproduction failure...................................................................230
16.1.7 Foggy background.....................................................................................231
16.1.8Poor color reproduction.............................................................................232
16.1.9 Void areas, white spots.............................................................................233
16.1.10 Colored spots............................................................................................234
16.1.11 Blurred image............................................................................................235
16.1.12 Blank copy, black copy..............................................................................236

magicolor
5650EN/5670EN
GeneralMaintenanceAdjustment / Setting
Troubleshooting
Appendix
Field Service Ver. 1.0 Apr. 2008
16.1.13 Incorrect color image registration ............................................................. 237
16.1.14 Poor fusing performance, offset................................................................ 238
16.1.15 Brush effect............................................................................................... 239
16.1.16 Back marking............................................................................................ 240
16.1.17 Uneven pitch............................................................................................. 241
16.1.18No print cycles can be run as commanded via the network ..................... 242
Appendix
17. Parts layout drawing............................................................................................ 243
17.1 Main body......................................................................................................... 243
17.2 Lower feeder unit (option)................................................................................. 246
17.3 Duplex option (option) ...................................................................................... 247
17.4 Staple finisher (option) ..................................................................................... 248
18. Connector layout drawing ................................................................................... 251
19. Timing chart........................................................................................................ 252

Field Service Ver. 1.0 Apr. 20081. System configuration
1
magicolor
5650EN/5670EN
General
1. System configuration
System front view
[1] magicolor 5650EN
magicolor 5670EN
magicolor 5670EN (MPC type)
[4] Lower feeder unit
[2] Duplex option [5] Lower feeder unit
[3] Hard disk kit [6] Staple finisher
A011F1C501DA
[4]
[5]
[6]
[2]
[1]
[3]

SERVICE MANUAL
2008.042008.04
Ver. 1.0Ver. 1.0
magicolor
5650EN/5670EN
THEORY OF OPERATION

ii
Blank Page

SAFETY AND IMPORTANT WARNING ITEMS
S-2
[1] MODIFICATIONS NOT AUTHORIZED BY KONICA MINOLTA
BUSINESS TECHNOLOGIES, INC.
KONICA MINOLTA brand products are renowned for their high reliability. This reliability is
achieved through high-quality design and a solid service network.
Product design is a highly complicated and delicate process where numerous mechanical,
physical, and electrical aspects have to be taken into consideration, with the aim of arriving
at proper tolerances and safety factors. For this reason, unauthorized modifications involve
a high risk of degradation in performance and safety. Such modifications are therefore
strictly prohibited. the points listed below are not exhaustive, but they illustrate the reason-
ng behind this policy.
SAFETY WARNINGS
Prohibited Actions
DANGER
• Using any cables or power cord not specified by KMBT.
• Using any fuse or thermostat not specified by KMBT.
Safety will not be assured, leading to a risk of fire and
injury.
• Disabling fuse functions or bridging fuse terminals with
wire, metal clips, solder or similar object.
• Disabling relay functions (such as wedging paper between
relay contacts)
• Disabling safety functions (interlocks, safety circuits, etc.)
Safety will not be assured, leading to a risk of fire and
injury.
• Making any modification to the product unless instructed
by KMBT
• Using parts not specified by KMBT

SAFETY AND IMPORTANT WARNING ITEMS
S-19
A011P0C506DA
High voltage
• This area generates high
voltage.
Be careful not to touch here
when the power is turned
ON to avoid getting an elec-
tric shock.
High voltage
• This area generates high
voltage.
Be careful not to touch here
when the power is turned
ON to avoid getting an elec-
tric shock.

MEASURES TO TAKE INCASE OF ANACCIDENT
S-21
1. If an accident has occurred, the distributor who has been notified first must immediately
take emergency measures to provide relief to affected persons and to prevent further
damage.
2. If a report of a serious accident has been received from a customer, an on-site evalua-
tion must be carried out quickly and KMBT must be notified.
3. To determine the cause of the accident, conditions and materials must be recorded
through direct on-site checks, in accordance with instructions issued by KMBT.
4. For reports and measures concerning serious accidents, follow the regulations speci-
fied by every distributor.
MEASURES TO TAKE IN CASE OF AN
ACCIDENT

C-1
Composition of the service manual
This service manual consists of Theory of Operation section and Field Service section to
explain the main machine and its corresponding options.
Theory of Operation section gives, as information for the CE to get a full understanding of
the product, a rough outline of the object and role of each function, the relationship
between the electrical system and the mechanical system, and the timing of operation of
each part.
Field Service section gives, as information required by the CE at the site (or at the cus-
tomer’s premise), a rough outline of the service schedule and its details, maintenance
steps, the object and role of each adjustment, error codes and supplementary information.
The basic configuration of each section is as follows. However some options may not be
applied to the following configuration.
<Theory of Operation section>
<Field Service section>
OUTLINE: Explanation of system configuration,
product specifications, unit configuration, and paper path
COMPOSITION/OPERATION: Explanation of configuration of each unit,
operating system, and control system
GENERAL: Explanation of system configuration, and product
specifications
MAINTENANCE: Explanation of service schedule, maintenance steps, ser-
vice tools, removal/reinstallation methods of major parts,
and firmware version up method etc.
ADJUSTMENT/SETTING: Explanation of utility mode, service mode, and mechanical
adjustment etc.
TROUBLESHOOTING: Explanation of lists of jam codes and error codes, and
their countermeasures etc.
APPENDIX: Parts layout drawings, connector layout drawings, timing
chart, overall layout drawing are attached.

magicolor
5650EN/5670EN
OutlineComposition/Operation
Theory of operation Ver. 1.0 Apr. 2008
vi
Blank Page