Konica Minolta magicolor 8650 User manual

SERVICE MANUAL
2007.112007.11
Ver. 2.0Ver. 2.0
FIELD SERVICE

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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-20
Composition of the service manual ................................................................................. C-1
Notation of the service manual ....................................................................................... C-2
magicolor 8650 Main body
General...........................................................................................................................1
Maintenance ..................................................................................................................9
Adjustment/Setting......................................................................................................131
Troubleshooting...........................................................................................................273
Appendix.....................................................................................................................375
Standard controller
General...........................................................................................................................1
Maintenances..................................................................................................................3
Troubleshooting.............................................................................................................19
PC-106/205
General...........................................................................................................................1
Maintenance ...................................................................................................................3
Adjustment/Setting........................................................................................................17
Troubleshooting.............................................................................................................21
PC-406
General...........................................................................................................................1
Maintenance ...................................................................................................................3
Adjustment/Setting........................................................................................................21
Troubleshooting.............................................................................................................27
FS-519/PK-515/OT-602
General...........................................................................................................................1
Maintenance ...................................................................................................................7
Adjustment/Setting........................................................................................................59
Troubleshooting.............................................................................................................67

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MT-502
General........................................................................................................................... 1
Maintenance................................................................................................................... 3
Troubleshooting .............................................................................................................. 7
SD-505
General........................................................................................................................... 1
Maintenance................................................................................................................... 3
Adjustment/Setting ....................................................................................................... 25
Troubleshooting ............................................................................................................ 33
FS-609/PK-501
General........................................................................................................................... 1
Maintenance................................................................................................................... 5
Adjustment/Setting ....................................................................................................... 33
Troubleshooting ............................................................................................................ 59

SERVICE MANUAL
2007.11
Ver. 2.0
FIELD SERVICE

MaintenanceAdjustment / Setting
Troubleshooting
Appendix
Field Service Ver. 2.0 Nov. 2007
i
CONTENTS
magicolor 8650 Main body
General
1. System configuration...............................................................................................1
2. Product specifications .............................................................................................3
Maintenance
3. Periodical check ......................................................................................................9
3.1 Maintenance items................................................................................................9
3.1.1 Main body .....................................................................................................9
3.1.2 PC-106/205/406..........................................................................................11
3.1.3 FS-519 ........................................................................................................11
3.1.4 FS-609 ........................................................................................................11
3.2 Maintenance parts..............................................................................................12
3.2.1 Replacement parts......................................................................................12
3.2.2 Cleaning parts.............................................................................................13
3.3 Concept of parts life............................................................................................14
3.3.1 Life value of consumables and parts...........................................................14
3.3.2 Conditions for life specifications values.......................................................15
3.3.3 Control causing inhibited printing for one part when an inhibited-printing
event occurs in another part........................................................................15
3.4 Maintenance procedure (periodical check parts)................................................16
3.4.1 Cleaning of the electrostatic charger wire...................................................16
3.4.2 Cleaning of the timing roller........................................................................16
3.4.3 Cleaning of the area around the waste toner collecting port.......................17
3.4.4 Cleaning of the duplex transport rollers ......................................................17
3.4.5 Replacing the paper feed tray 2 feed roller/paper feed tray 2 pick-up roller 18
3.4.6 Replacing the paper feed tray 2 separation roller assy...............................21
3.4.7 Replacing the paper feed tray 3 feed roller/paper feed tray 3 pick-up roller 22
3.4.8 Replacing the paper feed tray 3 separation roller assy...............................25
3.4.9 Replacing the paper feed tray 1 feed roller.................................................26
3.4.10 Replacing the paper feed tray 1 separation roller assy...............................28
3.4.11 Replacing the waste toner box....................................................................29
3.4.12 Replacing the transfer roller unit.................................................................30
3.4.13 Replacing the imaging unit..........................................................................31
3.4.14 Replacing the ozone filter............................................................................35

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Troubleshooting
Appendix
Field Service Ver. 2.0 Nov. 2007
3.4.15 Replacing the toner cartridge ..................................................................... 35
3.4.16 Replacing the transfer belt unit................................................................... 37
3.4.17 Cleaning of the image transfer entrance guide........................................... 39
3.4.18 Cleaning of the IDC/registration sensor/MK,YC ......................................... 39
3.4.19 Replacing the fusing unit ............................................................................ 40
4. Service tool........................................................................................................... 42
4.1 Service material list............................................................................................ 42
4.2 CE tool list.......................................................................................................... 43
4.3 Print materials .................................................................................................... 44
4.3.1 Imaging unit single parts (IU)...................................................................... 44
4.3.2 Toner cartridge single parts (T/C)............................................................... 44
4.3.3 Waste toner box.......................................................................................... 44
4.3.4 Maintenance kit........................................................................................... 44
5. Firmware upgrade................................................................................................. 45
5.1 Outline................................................................................................................ 45
5.2 Preparations for firmware rewriting by Windows Command Prompt.................. 45
5.2.1 Service environment................................................................................... 45
5.2.2 Writing into the compact flash..................................................................... 45
5.3 Firmware rewriting by compact flash.................................................................. 48
5.3.1 Updating method ........................................................................................ 48
5.3.2 Action when data transfer fails.................................................................... 50
5.4 Updating the firmware with the Internet ISW...................................................... 51
5.4.1 Outline ........................................................................................................ 51
5.4.2 Service environment................................................................................... 51
5.4.3 Preparations for firmware rewriting............................................................. 51
5.4.4 Firmware update procedure........................................................................ 54
5.4.5 Error code list for the Internet ISW ............................................................. 56
5.5 Firmware update by customer............................................................................ 59
5.5.1 Outline ........................................................................................................ 59
6. Other..................................................................................................................... 61
6.1 Disassembly/adjustment prohibited items.......................................................... 61
6.2 Disassembly/assembly/cleaning list (other parts) .............................................. 62
6.2.1 Disassembly/assembly parts list................................................................. 62
6.2.2 Cleaning parts list....................................................................................... 64
6.3 Disassembly/assembly procedure...................................................................... 65
6.3.1 Front door ................................................................................................... 65
6.3.2 Upper front cover........................................................................................ 66
6.3.3 Right front cover/1....................................................................................... 67

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Appendix
Field Service Ver. 2.0 Nov. 2007
6.3.4 Right front cover/2.......................................................................................67
6.3.5 Left cover ....................................................................................................69
6.3.6 Rear left cover.............................................................................................70
6.3.7 Exit cover ....................................................................................................70
6.3.8 Rear right cover/1........................................................................................71
6.3.9 Rear right cover/2........................................................................................71
6.3.10 Paper feed tray 1 front cover, Paper feed tray 1 rear cover.........................72
6.3.11 Upper rear cover.........................................................................................72
6.3.12 Rear cover/1, Rear cover/2.........................................................................73
6.3.13 Lower rear cover/1, lower rear cover/2........................................................73
6.3.14 Vertical transport door.................................................................................73
6.3.15 Control panel assy ......................................................................................74
6.3.16 Output tray ..................................................................................................74
6.3.17 Paper feed tray 2.........................................................................................75
6.3.18 Paper feed tray 3.........................................................................................75
6.3.19 Front cover..................................................................................................76
6.3.20 PH unit........................................................................................................78
6.3.21 Paper feed tray 1 unit..................................................................................83
6.3.22 Main drive unit.............................................................................................84
6.3.23 Transport drive unit .....................................................................................86
6.3.24 Fusing drive unit..........................................................................................89
6.3.25 Hopper drive unit (C/K, Y/M).......................................................................91
6.3.26 Right door assy...........................................................................................92
6.3.27 PH relay board (PHREYB)..........................................................................95
6.3.28 DC power supply (DCPU)...........................................................................97
6.3.29 Printer control board (PRCB)......................................................................99
6.3.30 MFP board (MFPB)...................................................................................101
6.3.31 PWB box...................................................................................................103
6.3.32 High voltage unit (HV)...............................................................................105
6.3.33 Service EEPROM board (SVERB)...........................................................106
6.3.34 SODIMM/1, SODIMM/2 ............................................................................108
6.3.35 JMP board (JMPB)....................................................................................108
6.3.36 NVRAM board (NRB)................................................................................109
6.3.37 Paper feed tray 2 paper FD size detect board (PSDTB/1)........................109
6.3.38 Paper feed tray 3 paper FD size detect board (PSDTB/2)........................110
6.3.39 Transport motor (M1) ................................................................................111
6.3.40 Color PC motor (M2).................................................................................111

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eneral
Troublesho
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6.3.41 Fusing motor (M5) .................................................................................... 112
6.3.42 Switchback motor (M6)............................................................................. 113
6.3.43 Duplex transport motor (M7)..................................................................... 114
6.3.44 Fusing retraction motor (M12) .................................................................. 115
6.3.45 Paper feed tray 2 lift-up motor (M8) .......................................................... 116
6.3.46 Paper feed tray 3 lift-up motor (M9) .......................................................... 117
6.3.47 Toner supply motor/CK (M3)..................................................................... 119
6.3.48 Toner supply motor/YM (M4) .................................................................... 119
6.3.49 Paper feed tray 1 paper feed clutch (CL1)................................................ 120
6.3.50 Paper feed tray 3 vertical transport clutch (CL3) ...................................... 121
6.3.51 Paper feed tray 3 paper feed clutch (CL2)................................................ 122
6.3.52 Paper feed tray 1 feed clutch (CL4) .......................................................... 122
6.3.53 Transfer belt retraction clutch (CL7).......................................................... 123
6.3.54 Developing clutch/K (CL5)........................................................................ 123
6.3.55 Tim. roller clutch (CL6) ............................................................................. 124
6.3.56 IDC registration sensor/MK (IDCS/MK),
IDC registration sensor/YC (IDCS/YC)..................................................... 125
6.4 Cleaning procedure.......................................................................................... 127
6.4.1 Transfer belt unit ....................................................................................... 127
6.4.2 PH window Y,M,C,K.................................................................................. 127
6.4.3 Paper feed tray 2 feed roller, paper feed tray 2 pick-up roller, paper feed tray
1 separation roller..................................................................................... 128
6.4.4 Paper feed tray 3 feed roller, paper feed tray 3 pick-up roller, paper feed tray
3 separation roller..................................................................................... 129
6.4.5 Paper feed tray 3 transport roller .............................................................. 130
6.4.6 Paper feed tray 1 feed roller...................................................................... 130
6.4.7 Paper feed tray 1 separation roller............................................................ 130
Adjustment/Setting
7. How to use the adjustment section..................................................................... 131
8. Utility Mode......................................................................................................... 132
8.1 Control Panel.................................................................................................... 132
8.2 Utility Mode function tree.................................................................................. 133
8.3 Utility Mode function setting procedure ............................................................ 140
8.3.1 Procedure................................................................................................. 140
8.3.2 Cancelling the settings.............................................................................. 140
8.3.3 Changing the settings on the setting menu .............................................. 140
8.4 Meter Count...................................................................................................... 141
8.5 Settings in job operation................................................................................... 141

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Field Service Ver. 2.0 Nov. 2007
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8.6 Settings in Paper Tray.......................................................................................143
8.7 User setting function setting procedure............................................................145
8.7.1 Print Reports.............................................................................................145
8.7.2 Consumables............................................................................................148
8.7.3 System Settings........................................................................................148
8.7.4 Printer Settings .........................................................................................151
8.8 System settings function setting procedure......................................................157
8.8.1 System Settings........................................................................................157
8.8.2 Network Settings.......................................................................................158
8.8.3 Printer Settings .........................................................................................177
8.8.4 System Connection...................................................................................177
8.9 Admin. Settings.................................................................................................179
8.9.1 Security Settings.......................................................................................179
8.9.2 User Box Settings .....................................................................................187
8.9.3 Auth Device Setting...................................................................................188
8.9.4 Expert Adjustment.....................................................................................189
8.9.5 Option Settings .........................................................................................197
8.9.6 Firmware Update ......................................................................................198
8.10 Banner Printing.................................................................................................198
9. Adjustment item list.............................................................................................200
10. Service Mode......................................................................................................202
10.1 Service Mode function setting procedure.........................................................202
10.1.1 Procedure .................................................................................................202
10.1.2 Exiting .......................................................................................................203
10.1.3 Changing the setting value in Service Mode functions .............................203
10.2 Service Mode function tree...............................................................................204
10.3 System Settings................................................................................................209
10.3.1 Destination................................................................................................209
10.3.2 Enter Serial No..........................................................................................209
10.3.3 Initialize.....................................................................................................210
10.3.4 Foolscap Size............................................................................................210
10.3.5 Don’t go to Sleep ......................................................................................210
10.3.6 Image Controller .......................................................................................211
10.3.7 Unit Replacement .....................................................................................211
10.3.8 LCT Size Setting.......................................................................................212
10.3.9 Data Capture.............................................................................................212
10.3.10 Software SW Setting.................................................................................214
10.3.11 Enter Setup Date ......................................................................................215

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10.3.12 Comm. System......................................................................................... 215
10.3.13 Option Setting........................................................................................... 215
10.3.14 Maintenance Ctr ....................................................................................... 216
10.3.15 IU Yield Setting......................................................................................... 216
10.3.16 Change Warmup Time.............................................................................. 217
10.3.17 Status LED Setting ................................................................................... 217
10.3.18 Toner Near Empty..................................................................................... 218
10.3.19 Auth. Device Setting ................................................................................. 218
10.3.20 Inferior Cut................................................................................................ 218
10.4 Clear Counter................................................................................................... 219
10.4.1 Yield Counter............................................................................................ 219
10.4.2 JAM........................................................................................................... 219
10.4.3 Counter Service Called............................................................................. 219
10.4.4 Warning .................................................................................................... 219
10.4.5 Counter for Mode...................................................................................... 219
10.4.6 Time Series Ser Call................................................................................. 220
10.4.7 Time series JAM....................................................................................... 220
10.5 List Output........................................................................................................ 221
10.5.1 Management List...................................................................................... 221
10.5.2 Adjustment List......................................................................................... 221
10.6 Machine Status................................................................................................. 222
10.7 Test Mode......................................................................................................... 223
10.7.1 Procedure for test pattern output.............................................................. 223
10.7.2 Running Mode .......................................................................................... 223
10.7.3 Gradation Pattern ..................................................................................... 223
10.7.4 Halftone Pattern........................................................................................ 224
10.8 Machine Adjustment......................................................................................... 225
10.8.1 Fusing Temperature.................................................................................. 225
10.8.2 Fusing Speed............................................................................................ 226
10.8.3 Printer Area............................................................................................... 227
10.8.4 Printer Resist Loop................................................................................... 232
10.8.5 Color Registration Adjustment.................................................................. 233
10.8.6 LD adjustment........................................................................................... 234
10.8.7 1st Tray Adjust .......................................................................................... 235
10.8.8 Exhaust Fan Delay.................................................................................... 235
10.9 Process Adjustment ......................................................................................... 236
10.9.1 Dmax Density ........................................................................................... 236
10.9.2 TCR Level Setting..................................................................................... 236