Konica Minolta magicolor 5430 DL Service Manual
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Konica Minolta magicolor 5430 DL Service Manual

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SERVICE MANUAL
magicolor 5430 DL
magicolor 5430 DL
magicolor 5440 DL
magicolor 5440 DL
magicolor 5450
magicolor 5450
FIELD SERVICE
®
®
®
2005.04
2005.04
Ver. 3.0
Ver. 3.0

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Summary of Contents for Konica Minolta magicolor 5430 DL

  • Page 1 SERVICE MANUAL FIELD SERVICE ® magicolor 5430 DL magicolor 5430 DL magicolor 5440 DL magicolor 5440 DL ® magicolor 5450 magicolor 5450 ® 2005.04 2005.04 Ver. 3.0 Ver. 3.0...
  • Page 2 IMPORTANT NOTICE Because of possible hazards to an inexperienced person servicing this product as well as the risk of damage to the product, KONICA MINOLTA BUSINESS TECHNOLOGIES, INC. (hereafter called the KMBT) strongly recommends that all servicing be performed only by KMBT-trained service technicians.
  • Page 3 [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.
  • Page 4 SAFETY AND IMPORTANT WARNING ITEMS [2] CHECKPOINTS WHEN PERFORMING ON-SITE SERVICE Konica Minolta brand products are extensively tested before shipping, to ensure that all applicable safety standards are met, in order to protect the customer and customer engi- neer (hereafter called the CE) from the risk of injury. However, in daily use, any electrical equipment may be subject to parts wear and eventual failure.
  • Page 5 SAFETY AND IMPORTANT WARNING ITEMS WARNING: Power Plug and Cord • Check whether the power cord is not stepped on or pinched by a table and so on. Overheating may occur there, leading to a risk of fire. • Do not bundle or tie the power cord. Overheating may occur there, leading to a risk of fire.
  • Page 6 SAFETY AND IMPORTANT WARNING ITEMS WARNING: Wiring • Connect power plug directly into wall outlet having the same configuration as th plug. The use of an adapter leads to the product connecting to inadequate power supply (voltage, current capacity, grounding), and may result in fire or electrical shock. If proper wall outlet in not available, the customer shall ask qualified electrician for the installation.
  • Page 7 SAFETY AND IMPORTANT WARNING ITEMS CAUTION: Ventilation • The product generates ozone gas during operation, but it will not be harmful to the human body. If a bad smell of ozone is present in the following cases, ventilate the room. a.
  • Page 8 SAFETY AND IMPORTANT WARNING ITEMS WARNING: Work Performed with the Product Powered On • Take every care when making adjustments or performing an operation check with the product powered. If you make adjustments or perform an operation check with the external cover detached, you may touch live or high-voltage parts or you may be caught in moving gears or the timing belt, leading to a risk of injury.
  • Page 9 SAFETY AND IMPORTANT WARNING ITEMS WARNING: Safety Checkpoints • Before disassembling or adjusting the write unit (P/H unit) incorporating a laser, make sure that the power cord has been disconnected. The laser light can enter your eye, leading to a risk of loss of eyesight.
  • Page 10 SAFETY AND IMPORTANT WARNING ITEMS WARNING: HANDLING OF CONSUMABLES • Toner and developer are not harmful substances, but care must be taken not to breathe excessive amounts or let the substances come into contact with eyes, etc. It may be stimulative.
  • Page 11 SAFETY AND IMPORTANT WARNING ITEMS [3] MEASURES TO TAKE IN CASE OF AN ACCIDENT If an accident has occurred, the distributor who has been notified first must immedi- ately take emergency measures to provide relief to affected persons and to prevent further damage.
  • Page 12 SAFETY AND IMPORTANT WARNING ITEMS [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.
  • Page 13 SAFETY AND IMPORTANT WARNING ITEMS the U.S.A., Canada (CDRH Regulation) • This machine is certified as a Class I Laser product under Radiation Performance Stan- dard according to the Food, Drug and Cosmetic Act of 1990. Compliance is mandatory for Laser products marketed in the United States and is reported to the Center for Devices and Radiological Health (CDRH) of the U.S.
  • Page 14 SAFETY AND IMPORTANT WARNING ITEMS Finland, Sweden LUOKAN 1 LASERLAITE KLASS 1 LASER APPARAT VAROITUS! • Laitteen käyttäminen muulla kuin tässä käyttöohjeessa mainitulla tavalla saat- taa altistaa käyttäjän turvallisuusluokan 1 ylittävälle näkymättömälle laser- säteilylle. puolijohdelaser Laserdiodin suurin teho 15 mW aallonpituus 770-800 nm VARNING!
  • Page 15 SAFETY AND IMPORTANT WARNING ITEMS Laser Safety Label • A laser safety label is attached to the the machine as shown below. 4138safe004c0 S-14...
  • Page 16 SAFETY AND IMPORTANT WARNING ITEMS Laser Caution Label • A laser caution label is attached to the inside of the machine as shown below. 4138safe001c0 PRECAUTIONS FOR HANDLING THE LASER EQUIPMENT • When laser protective goggles are to be used, select ones with a lens conforming to the above specifications.
  • Page 17 SAFETY AND IMPORTANT WARNING ITEMS WARNING INDICATIONS ON THE MACHINE Caution labels shown are attached in some areas on/in the machine. When accessing these areas for maintenance, repair, or adjustment, special care should be taken to avoid burns and electric shock. High voltage High temperature 4138fsS001c0...
  • Page 18 SAFETY AND IMPORTANT WARNING ITEMS High voltage High voltage 4138fsS002c0 S-17...
  • Page 19 SAFETY AND IMPORTANT WARNING ITEMS S-18...
  • Page 20 SERVICE MANUAL FIELD SERVICE ® magicolor 5430 DL ® magicolor 5440 DL ® magicolor 5450 Main Unit 2005.04 Ver. 3.0...

  • Page 22: Table Of Contents

    Main Unit Field Service CONTENTS Outline System configuration.................... 1-1 Product Specifications..................1-2 Type ........................1-2 Functions ......................1-3 Maintenance ...................... 1-5 Machine Specifications ..................1-5 Operating Environment..................1-6 Maintenance Periodic Check ..................... 2-1 Service schedule ....................2-1 Maintenance Items .................... 2-2 1.2.1 Parts to be replaced by users (CRU)............
  • Page 23 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)............
  • Page 24 Malfunction messages.................. 3-9 3.2.7 Message Priority for Consumables/Periodic Replacement Parts (Units)..3-10 Canceling a Print Job ..................3-11 Menu (magicolor 5430 DL /5440 DL) ..............3-12 List of Menu Functions..................3-12 SPECIAL PAGES..................... 3-13 4.2.1 PRINT CONFIG PAGE ................3-13 4.2.2...
  • Page 25 BRIGHTNESS .................... 3-20 4.7.6 SHARPNESS ..................... 3-20 4.7.7 AUTO ROTATE ................... 3-20 Service Mode (magicolor 5430 DL/5440 DL)............. 3-21 Service Mode Entry Procedure ............... 3-21 Service Mode Function Tree................3-21 Settings/Adjustments in Service/Service Person Mode Functions....3-22 5.3.1 RESTORE FACTORY DEFAULT ..............3-22 5.3.2...
  • Page 26 Main Unit Field Service 6.1.6 Service Call messages ................3-34 6.1.7 Help screen ....................3-35 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 Canceling a Print Job ..................3-41 Menu (magicolor 5450) ..................
  • Page 27 TRANSFER POWER /IMAGE ADJ PARAM..........3-83 8.3.5 RESTORE PASSWARD ................3-84 IV Troubleshooting Jam Display......................4-1 Misfeed Display (magicolor 5430 DL / 5440 DL) ..........4-1 Misfeed Display (magicolor 5450) ..............4-2 Misfeed Display Resetting Procedure ............... 4-2 Sensor Layout ....................4-3 Solutions......................4-4 1.5.1...
  • Page 28 Misfeed at transfer section................4-7 1.5.5 Misfeed at fusing/exit section................ 4-8 1.5.6 Undefined misfeed..................4-8 Malfunction code ....................4-9 Trouble Codes (magicolor 5430 DL/5440 DL) ........... 4-9 2.1.1 Trouble code list.................... 4-9 Trouble Codes (magicolor 5450)..............4-12 2.2.1 Trouble code list..................4-12 Resetting a Malfunction ...................
  • Page 29 Machine is Not Energized at All (LV Operation Check) ........4-27 Control panel indicators do not Light............... 4-27 Fusing Heaters do not Operate ............... 4-28 Miscellaneous Malfunctions (Only for magicolor 5430 DL/5440 DL) .............. 4-29 List of Miscellaneous Malfunctions ..............4-29 ILLEGAL ERROR DUPLEX................4-29 ERROR AIDC SENSOR.................. 4-30 ERROR COMMUNICATION................
  • Page 30 Main Unit Field Service 5.1.15 Brush effect, blurred image................. 4-47 5.1.16 Back marking....................4-48 5.1.17 Uneven Pitch ....................4-49 5.1.18 No print cycles can be run as commanded via the network ....... 4-50 Appendix Parts Layout Drawing ................... 5-1 Main unit ......................5-1 Lower Feeder Unit (Option) ................
  • Page 31 Main Unit Field Service...

  • Page 32: System Configuration

    Main Unit Field Service System configuration I Outline System configuration System Front View 4138fs1501c4 Duplex Option Optional Lower Feeder Unit Optional DIMM Optional Lower Feeder Unit Optional Camera Direct Photo Print Card Main Unit (magicolor 5440 DL only) Optional Hard Disk Drive (HDD)t (magicolor 5450 only)

  • Page 33: Product Specifications

    OPC (organic photo conductor) Photoconductor Blade cleaning system Cleaning magicolor 5430 DL/5440 DL 2400 x 600 dpi x 1 bit, 1200 x 600 dpi x 1 bit, 600 x 600 dpi x 1 bit Print Density magicolor 5450 600 x 600 dpi x 4 bit...

  • Page 34: Functions

    1-sided: 14.2 seconds; 2-sided: 22.3 seconds (A4) (Plain Paper) 1-sided: 14.1 seconds; 2-sided: 22.3 seconds (Letter) magicolor 5430 DL 1-sided: 20 pages/min; 2-sided: 11.5 pages/min (A4) 1-sided: 21 pages/min; 2-sided: 11.8 pages/min (Letter) * When feeding the paper from Tray1...
  • Page 35 / 16 to 24 lb) • Recycled paper (60 to 90 g/m / 16 to 24 lb) magicolor 5430 DL Plain paper and recycled paper: 250 sheets (Tray 1) Letterhead: 150 sheets (Tray 1) Transparencies, thick stock 1, thick stock 2, postcards, double postcards, and...

  • Page 36: Maintenance

    Main Unit Field Service Product Specifications magicolor 5430 DL/5440 DL • USB 2.0 (High-Speed) compliant • 10 Base-T/100 Base-TX (IEEE 802.3) Ethernet • The magicolor 5440 DL also has a Host USB port, which supports Camera Direct Photo Printing from PictBridge-enabled cameras when an optional Interfaces Camera Direct Photo Print Card is installed.

  • Page 37: Operating Environment

    Product Specifications Main Unit Field Service Operating Environment Temperature 10° to 35° C / 50° to 95° F (with a fluctuation of 10° C / 18° F or less per hour) Humidity 15% to 85% (with a fluctuation of 20%/h) NOTE •...

  • Page 38: Ii Maintenance

    TRAY 2 TRAY 2 TRAY 3 TRAY 3 TRAY 4 • The following procedures use the magicolor 5430 DL/5440 DL tray names. Service schedule Guaranteed period (5 years or 400,000 prints) × 10,000 prints Number Per cycle × number of prints...

  • Page 39: Maintenance Items

    120,000 ****** Transfer Roller Image **** Transfer 32,000 (K Waste Toner Bottle section (magicolor 5430 DL) ***** 8,000 (Y,M,C,K **** 40,000 (K Waste Toner Bottle (magicolor 5440 DL/5450) ***** 10,000 (Y,M,C,K : The life of the Toner Cartridge furnished with the machine at the time of shipment is...

  • Page 40: Parts To Be Replaced By A Service Engineer (Fru)

    Main Unit Field Service Periodic Check 1.2.2 Parts to be Replaced by a Service Engineer (FRU) Number of Class Part to be replaced Clean Replace Description prints 150,000 (MP *) Fusing Fusing Unit section 130,000 (2P/J Tray 1/ Media feed Feed Roller 300,000 section...

  • Page 41: Concept Of Parts Life

    Periodic Check Main Unit Field Service B. Option crip Ref.Page in Class Maintenance parts Clean Replace tion this manual ☞ See the Service Lower When neces- Manual for the Feeder Feed Roller sary to prevent 300,000 Lower Feeder Unit media jams Unit.
  • Page 42 Main Unit Field Service Periodic Check A. Conditions for Life Specifications Values • The life specification values represent the number of pages printed or figures equivalent to it when the given conditions (see the table given below) are met. They may be more or less, depending on the machine operating conditions of each individual user.

  • Page 43: Maintenance Procedure (Periodic Parts Check)

    5450 MANUAL FEED TRAY TRAY 1 TRAY 1 TRAY 2 • The following procedures use the magicolor 5430 DL/5440 DL tray names. 1.5.1 Feed Roller (Tray 1) A. Cleaning Procedure 1. Slide out Tray 1. 2. Using a soft cloth dampened with alcohol, wipe the Feed Roller [1] clean of dirt.

  • Page 44: Feed Roller (Manual Feed Tray) (Magicolor 5440 Dl/5450 Only)

    Main Unit Field Service Periodic Check NOTE • When reinstalling the Feed Roller, make sure that it is mounted in the direction shown in the illustration on the left. 4138fs2528c0 1.5.2 Feed Roller (Manual Feed Tray) (magicolor 5440 DL/5450 only) A.
  • Page 45 Periodic Check Main Unit Field Service 6. Press two pins [3] in, and lift the Feed Roller Cover [4] upward to remove it. 4138fs5508c0 NOTE Make sure that the bearing goes all the way into both of [5] shown on the left when installing the Feed Roller Cover.
  • Page 46 Main Unit Field Service Periodic Check 5. Snap off C-clip [8] and remove the bearing [9] at the front. 4138fs5511c0 6. Snap off the C-clip [10] and then remove the Clutch [11] and the Feed Roller [12]. [12] [11] [10] 4138fs5512c0 NOTE •...

  • Page 47: Ozone Filter

    Periodic Check Main Unit Field Service 1.5.3 Ozone Filter A. Replacement Procedure 1. Hold onto the handle of the Ozone Filter [1] and slide it out of the machine. 2. Install a new Ozone Filter in the machine. 3. Replace the Transfer Roller. ☞...
  • Page 48 Main Unit Field Service Periodic Check B. Reinstallation Procedure 1. Take the Toner Cartridge out of its plastic bag. 2. Tilt the Toner Cartridge [1] as shown in the illustration on the left and shake it slowly two times. 4138fs2503c0 3.
  • Page 49 Periodic Check Main Unit Field Service 6. Fold down the handle [6] and slide the Toner Cartridge [7] all the way into the machine. 4138fs2507c0 7. Pull off the protective film [8]. 8. Close the Front Door. 4138fs2508c0 NOTE • When removing or reinstalling the Toner Cartridge while it is being used or after it has been used up, do not hold it or place it upside down, as spilled toner could result.

  • Page 50: Waste Toner Bottle

    Main Unit Field Service Periodic Check 1.5.5 Waste Toner Bottle A. Replacement Procedure 1. Open the Front Door. 2. Turn the lever [1] to unlock the Waste Toner Bottle. 4138fs2509c0 3. Remove the Waste Toner Bottle [2]. 4138fs2510c0 4. Remove the cap [3] from the side face of the Waste Toner Bottle and fit it at the location shown in the illustra- tion on the left.

  • Page 51: Cleaning The Laser Irradiation Section

    Periodic Check Main Unit Field Service 1.5.6 Cleaning the Laser Irradiation Section A. Cleaning Procedure 1. Open the Front Door. 2. Align the edge of the Laser lens cleaning tool [2] with the marker [1] (at four places) of the Toner Car- tridge.

  • Page 52: Replacing Units

    Setting.” 8. From the Menu, select ENGINE → ENGINE SERVICE → COLOR CAR- IBRATION and execute this function. (magicolor 5430 DL/5440 DL) ☞ For details, see “III. Adjustment/ Setting.” 9. From the Menu, select QUALITY MENU → CARIBRATION → AIDC PROCESS and execute this func- tion.

  • Page 53: Replacing The Transfer Belt Unit

    Periodic Check Main Unit Field Service 1.6.2 Replacing the Transfer Belt Unit A. Replacement Procedure 1. Turn OFF the Power Switch. 2. Open the Front Door. 3. Slide out the Toner Cartridge [1] and Waste Toner Bottle [2] about 10 cm. 4138fs2515c0 4.
  • Page 54 Main Unit Field Service Periodic Check NOTE • Lower the handle [5] of the Transfer Belt Unit in the direction shown in the illustration on the left. 4138fs2529c0 8. Prepare a new Transfer Belt Unit. NOTE • Use care not to touch the belt of the Transfer Belt Unit.
  • Page 55 ENGINE SERVICE → RESET COUNTER TRANSFER BELT. Exe- cute this function to reset the Trans- 4138fs2519c0 fer Belt Unit counter value. (magicolor 5430 DL/5440 DL) ☞ For details, see “III. Adjustment/ Setting.” 18. From the Menu, select QUALITY MENU → SUPPLIES → REPLACE →...

  • Page 56: Replacing The Fusing Unit

    20 min. 2. Open the Front Door. 3. Remove the Upper Front Cover. ☞ 2-30 4. Disconnect the four connectors [1]. (magicolor 5430 DL/5440 DL) 5. Disconnect the five connectors [1]. (magicolor 5450) 4138fs2003c1 6. Open the Right Door.

  • Page 57: Service Tool

    Service tool Main Unit Field Service Service tool CE Tool list Tool name Shape Personnel Remarks Laser Lens Cleaning Tool 4138fs2537c0 Consumable Parts 2.2.1 Toner Cartridge (TC) (as an individual part) Part name Life expectancy Standard-Capacity Toner Cartridge - Black (K) 6,000 prints Standard-Capacity Toner Cartridge - Yellow (Y) 6,000 prints...

  • Page 58: Firmware Upgrade

    Firmware Upgrade Print Control Board (PWB-P) Firmware Upgrading 3.1.1 Upgrade procedure (magicolor 5430 DL/5440 DL) 1. Connect the machine to the PC using an Ethernet cable. 2. From the Menu, select SPECIAL PAGES → PRINT CONFIG PAGE and execute the function.
  • Page 59 Firmware Upgrade Main Unit Field Service 6. Check the Command Prompt display on the progress of upgrade procedure. 4138fs2540e0 NOTE • NEVER turn the printer Power Switch OFF and ON until the message “flash update done” appears on the Command Prompt display. 7.

  • Page 60: Upgrade Procedure (Magicolor 5450)

    Main Unit Field Service Firmware Upgrade 3.1.2 Upgrade procedure (magicolor 5450) A. How to upgrade using the Network Interface 1. Connect the machine to the PC using an Ethernet cable. NOTE • For connections via a HUB, use a straight cable. •...
  • Page 61 Firmware Upgrade Main Unit Field Service 6. Wait until all of the data is sent. While the data is being sent, “FIRMWARE UPDATE” and “PROCESSING” are alter- nately displayed on the screen. NOTE • NEVER turn the printer Power Switch OFF and ON while data is being sent. 7.
  • Page 62 Main Unit Field Service Firmware Upgrade 5. Wait until all of the data is sent. (This takes approximately 2 minutes.) While the data is being sent, “FIRMWARE UPDATE” and “PROCESSING” are alter- nately displayed on the screen. NOTE • NEVER turn the printer Power Switch OFF and ON while data is being sent. 6.
  • Page 63 Firmware Upgrade Main Unit Field Service 4. Check that the “FIRMWARE UPDATE/WAIT” message is displayed. FIRMWARE UPDATE WAIT 4138F2E008DA 5. Copy the firmware data and upgrading program to any directory on the PC. 6. Start the Command Prompt and go to the directory in which the firmware data is stored.
  • Page 64 Main Unit Field Service Firmware Upgrade 9. After the data has finished being sent, the following message appears on the screen of the Command Prompt. 4138F2E007DA 10. Then the firmware upgrade starts. Wait until all the upgrade procedure is complete. FIRMWARE UPDATE WRITING DATA XX% 4138F2E010DA...

  • Page 65: Other

    • Be sure to note that the feed trays are named differently depending upon the printer model. magicolor 5430 DL / 5440 DL magicolor 5450 MANUAL FEED TRAY TRAY 1 TRAY 1 TRAY 2 • The following procedures use the magicolor 5430 DL/5440 DL tray names. 2-28...

  • Page 66: Disassembly/Assembly List (Other Parts)

    ☞ Manual Feed Tray (magicolor 5440 DL/5450 only) 2-33 ☞ HDD Unit (magicolor 5450 only) 2-34 ☞ Print Control Board (magicolor 5430 DL/5440 DL 2-35 only) ☞ Print Control Board (magicolor 5450 only) 2-36 ☞ Backup Battery (magicolor 5450 only) 2-37 ☞...

  • Page 67: Disassembly/Assembly Procedure

    Other Main Unit Field Service Disassembly/Assembly Procedure 4.4.1 Front Door, Upper Front Cover, and Right Front Cover 1. Open the Front Door. 2. Remove the C-clip [1]. 3. Slide the Front Door [2] to the left off the machine. 4138fs2006c1 4.

  • Page 68: Left Cover

    Main Unit Field Service Other 4.4.2 Left Cover 1. Open the Front Door. 2. Remove the three screws [1]. 4138fs2523c0 3. Remove the Left Cover [2]. NOTE • Remove the Left Cover as shown in the illustration on the left, taking care not to damage the three tabs [3] on the upper edge of the Left Cover.

  • Page 69: Exit Tray

    Other Main Unit Field Service 4.4.4 Exit Tray 1. Open the Front Door. 2. Remove the Upper Front Cover. ☞ 2-30 3. Remove the Left Cover. ☞ 2-31 4. Remove two screws [1] and the Exit Tray [2]. 4138fs2009c0 4.4.5 Rear Right Cover 1.

  • Page 70: Tray 1

    Main Unit Field Service Other 4.4.6 Tray 1 1. Slide out Tray 1 [1]. 2. Pressing the tabs [2] on both sides, remove Tray 1 [1]. 4138fs2010c0 4.4.7 Manual Feed Tray (magicolor 5440 DL/5450 only) 1. Open the Manual Feed Tray. 2.

  • Page 71: Control Panel (Pwb-Op)

    Other Main Unit Field Service 4.4.8 Control Panel (PWB-OP) 1. Remove the Upper Front Cover. ☞ 2-30 2. Remove the Left Cover. ☞ 2-31 3. Remove the Rear Cover. ☞ 2-31 4. Remove the Exit Tray. ☞ 2-32 5. Remove two screws [1] and the Con- trol Panel [2].

  • Page 72: Print Control Board (Pwb-P) (Magicolor 5430 Dl/5440 Dl)

    Main Unit Field Service Other 4.4.10 Print Control Board (PWB-P) (magicolor 5430 DL/5440 DL) 1. Remove the Rear Cover. ☞ 2-31 2. Remove seven screws [1] and the Print Control Board protective shield [2]. 4138fs2534c0 3. Remove the Left Cover.

  • Page 73: Print Control Board (Pwb-P) (Magicolor 5450)

    Other Main Unit Field Service 7. Remove five screws [7] and the Print Control Board [8]. NOTE • When the Print Control Board is replaced, upgrade the Firmware to the latest version. ☞ 2-21 8. Remove three screws and the inter- face protective cover [4].

  • Page 74: Backup Battery (Magicolor 5450 Only)

    Main Unit Field Service Other 5. Disconnect the two connectors [5] on the Print Control Board. 6. Disconnect the two flat cables [6] from the Print Control Board. 4138F2E013DA 7. Remove five screws [7] and the Print Control Board [8]. NOTE •...

  • Page 75: Mechanical Control Board (Pwb-A)

    Other Main Unit Field Service 3. Remove the hook, and then remove the backup battery. 4138F2E001DA 4. Insert a new backup battery. NOTE When inserting the new backup bat- tery, be sure that the + side faces toward the left. 4138F2E002DA 4.4.13 Mechanical Control Board (PWB-A)
  • Page 76 Main Unit Field Service Other 4. Remove six screws [3] and the Mechanical Control Board protective shield [4]. 4138fs2071c0 5. Disconnect all connectors and flat cables from the Mechanical Control Board [5]. 4138fs2072c1 6. Remove eight screws [6] and the Mechanical Control Board [7].
  • Page 77 Other Main Unit Field Service 7. Remove Parameter Chip (IC15) [10] from the Mechanical Control Board. NOTE • When the Mechanical Control Board (PWB-A) has been replaced, be sure to remount Parameter Chip (IC15). Unmount Parameter Chip (IC15) from the old Mechanical Control Board and mount it on the new Mechanical Control Board.

  • Page 78: Low Voltage Unit (Lv)

    Main Unit Field Service Other 4.4.14 Low Voltage Unit (LV) 1. Remove the Exit Tray. ☞ 2-32 2. Remove the Left Cover. ☞ 2-31 3. Remove the Control Panel. ☞ 2-34 4. Remove the cable [1] of the Control Panel. 4138fs2013c0 5.

  • Page 79: High Voltage Unit /1 (Hv1)

    Other Main Unit Field Service 7. Remove eight screws [4] and the Low Voltage Unit [5]. 4138fs2016c0 4.4.15 High Voltage Unit /1 (HV1) 1. Remove PWB Box/1. ☞ 2-47 2. Remove three screws [1] and the Harness Plate [2]. 4138fs2017c0 3.

  • Page 80: High Voltage Unit /2 (Hv2)

    Main Unit Field Service Other 4. Remove two screws [6], the flat cable [7], and High Voltage Unit/1 [8]. 4138fs2019c0 4.4.16 High Voltage Unit /2 (HV2) 1. Remove High Voltage Unit/1. ☞ 2-42 2. Disconnect all connectors and flat cables from High Voltage Unit/2 [1]. 4138fs2020c0 3.

  • Page 81: Toner Level Sensor Board (Pwb-D)

    Other Main Unit Field Service Precautions for Reinstallation White Blue • When reinstalling High Voltage Yellow Unit/2, make sure that each color connector is in the correct position, as shown in the illustration on the left. White Yellow Blue White 4138fs2531e0 4.4.17 Toner Level Sensor Board (PWB-D)
  • Page 82 Main Unit Field Service Other 8. Remove seven screws [2] and the Toner Level Sensor Board Assy [3]. 4138fs2075c0 9. Remove three screws [4]. 4138fs2076c0 10. Disconnect two connectors [5] and remove the Toner Level Sensor Board [6]. 4138fs2077c0 2-45...

  • Page 83: Ph Unit

    The laser beam that may be emitted can blind you. NOTE • The magicolor 5430 DL/5440 DL uses a different PH unit than does the magicolor 5450 (although the replacement procedures are identical). When replacing the PH unit, be sure to use the PH unit for the appropriate model. Using the incorrect PH unit will adversely affect image quality.

  • Page 84: Pwb Box/1

    Main Unit Field Service Other 8. Unhook two tabs [3] and remove the Waste Toner Bottle Guide [4]. 4138fs2022c1 9. Remove three shoulder screws [5] and the PH Unit [6]. 4138fs2063c1 4.4.19 PWB Box/1 1. Remove the Print Control Board. ☞...

  • Page 85: Pwb Box/2

    Other Main Unit Field Service 4.4.20 PWB Box/2 1. Remove the Print Control Board. ☞ 2-35 2. Remove the Mechanical Control Board. ☞ 2-38 3. Remove PWB Box/1. ☞ 2-47 4. Remove nine screws [1] and PWB Box/2 [2]. 4138fs2024c0 4.4.21 Developing Motor /Y, M, C (M1) 1.

  • Page 86: Developing Motor /K (M5)

    Main Unit Field Service Other 4.4.23 Developing Motor /K (M5) 1. Remove PWB Box/1. ☞ 2-47 2. Disconnect the connector [1], and remove four screws [2] and the Developing Motor/K [3]. NOTE • When installing the Developing Motor /K, try to insert it straight, and take care not to damage the gears.

  • Page 87: Fusing Motor (M4)

    Other Main Unit Field Service 4.4.26 Fusing Motor (M4) 1. Remove PWB Box/1. ☞ 2-47 2. Remove PWB Box/2. ☞ 2-48 3. Disconnect the connector [1], and remove four screws [2] and the Fus- ing Motor [3]. NOTE • When installing the Fusing Motor, try to insert it straight, and take care not to damage the gears.

  • Page 88: Pressure/Retraction Clutch /2Nd Image Transfer (Cl5)

    Main Unit Field Service Other 3. Disconnect the connector [2] and remove the Synchronizing Roller Clutch [3]. Precautions for Reinstallation • When reinstalling the Synchroniz- ing Roller Clutch, make sure that the protrusion [4] on the Synchro- nizing Roller Clutch fits into the locking slot [5].
  • Page 89 Other Main Unit Field Service 6. Remove the Front Door Sensor (PC22) [3]. 4138fs2037c0 7. Remove Gear/1 [4] and Gear/2 [5]. 4138fs2038c0 8. Remove three screws [6] and the 2nd Image Transfer Pressure/ Retraction Drive Assy [7]. 4138fs2039c0 2-52...

  • Page 90: Pressure/Retraction Clutch /1St Image Transfer (Cl4)

    Main Unit Field Service Other 9. Snap off the C-clip [8], and remove the bearing [9] and the Pressure/ Retraction Clutch/2nd Image Trans- fer [10]. Precautions for Reinstallation [12] • When reinstalling the bearing and Pressure/Retraction Clutch/2nd Image Transfer, make sure that the protrusion [11] on the Pressure/ Retraction Clutch/2nd Image Trans- fer fits into the locking slot [12].

  • Page 91: Tray 1 Paper Feed Clutch (Cl1)

    Other Main Unit Field Service Precautions for Reinstallation • When reinstalling the bearing and Pressure/Retraction Clutch/1st Image Transfer, make sure that the protrusion [7] on the Pressure/ Retraction Clutch/1st Image Trans- fer fits into the locking slot [8]. 4138fs2042c0 4.4.31 Tray 1 Paper Feed Clutch (CL1) 1.
  • Page 92 Main Unit Field Service Other 5. Disconnect the white connector [5] and the blue connector [6]. Precautions for Removing the Connector • The blue connector [6] is only on the magicolor 5440 DL/5450. 4138fs2046c1 6. Remove four screws [7]. 4138fs2045c1 7.
  • Page 93 Other Main Unit Field Service 9. Snap off the E-ring [11] and remove the bearing [12] and spring [13]. Precautions for Removing the E-ring • The E-ring [11], the bearing [12], [14] and spring [13] are on the magi- color 5440 DL/5450 only. Precautions for Reinstallation •...
  • Page 94 Main Unit Field Service Other 12. Remove the Shaft [19]. [19] 4138fs2050c1 13. Remove four screws [20] and the [20] Paper Feed and Conveyance Assy holding metal plate [21]. [21] 4138fs2051c1 14. Remove two gears [22]. [22] 4138fs2052c1 2-57...

  • Page 95: Manual Feed Tray Paper Feed Clutch (Cl3) (Magicolor 5440 Dl/5450 Only)

    Other Main Unit Field Service 15. Remove the Tray 1 Paper Feed [23] Clutch [23]. 4138fs2053c1 Precautions for Reinstallation [24] • When reinstalling the Tray1 Paper Feed Clutch, make sure that the protrusion [24] on the Tray 1 Paper [25] Feed Clutch fits into the locking slot [25].
  • Page 96 Main Unit Field Service Other 4. Remove eight screws [3] and the High Voltage Unit/1 mounting plate [4]. 4138fs2043c1 5. Disconnect the white connector [5] and the blue connector [6]. 4138fs2046c1 6. Remove four screws [7]. 4138fs2045c1 2-59...
  • Page 97 Other Main Unit Field Service 7. Remove the Gear [9] and the Gear [10]. Precautions for Reinstallation • When the Tray 1 Paper Feed Clutch is reinstalled, replace the gears that have been removed, as these gears could have been damaged. 8.
  • Page 98 Main Unit Field Service Other 11. Snap off two E-rings [17] and remove two bearings [18]. [17] [17] [18] [18] 4138fs2049c2 12. Remove the Shaft [19]. [19] 4138fs2050c1 13. Remove four screws [20] and the [20] Paper Feed and Conveyance Assy holding metal plate [21].
  • Page 99 Other Main Unit Field Service 14. Remove three gears [22]. [22] 4138fs2052c2 15. Remove the Shaft and the Manual Feed Tray Paper Feed Clutch [23]. [23] 4138fs5513c0 Precautions for Reinstallation [24] • When reinstalling the Shaft and the Manual Feed Tray Paper Feed Clutch, make sure that the protru- sion [24] on the Manual Feed Tray [25]...

  • Page 100: Temperature/ Humidity Sensor (Hs1)

    Main Unit Field Service Other 4.4.33 Temperature/ Humidity Sensor (HS1) 1. Open the Right Door. 2. Remove the screw [2] from the sen- sor holder [1]. 3. Remove the sensor holder [1] by sliding it to the front. 4138fs2061c0 4. Remove the screw [3], disconnect the connector [4], and remove the Temperature/Humidity Sensor.

  • Page 101: Aidc Sensor/Rt, Aidc Sensor/Lt (Aidc R, Aidc L)

    Other Main Unit Field Service 4.4.34 AIDC Sensor/Rt, AIDC Sensor/Lt (AIDC R, AIDC L) 1. Open the Right Door. 2. Remove the Transfer Belt Unit. ☞ 2-16 3. Remove two screws [1]. 4138fs2080c0 4. Unhook the spring and remove the cover [2].

  • Page 102: Camera Direct Photo Print Card (Magicolor 5440 Dl Only)

    Main Unit Field Service Other 4.4.35 Camera Direct Photo Print Card (magicolor 5440 DL only) 1. Push the Lever [1]. 2. Remove the Camera Direct Photo Print Card [2]. 4138fs5516c0 2-65...
  • Page 103 Other Main Unit Field Service 2-66...

  • Page 104: Iii Adjustment/Setting

    Main Unit Field Service How to Use the Adjustment Section III Adjustment/Setting How to Use the Adjustment Section • This section contains detailed information on the adjustment items and procedures for this machine. • Throughout this section the default settings are indicated by boldface. A.

  • Page 105: Adjustment Item List

    Adjustment Item List Main Unit Field Service Adjustment Item List magicolor 5430 DL/5440 DL Replacement Part/Service Job Adjustment/Setting Items COLOR CALIBRATION (2) (2) CONTROLLER VER. ENGINE VER. SERVICE RESET Transfer Roller COUNT MENU Transfer Belt Unit RESTORE USER DEFAULT SERVICE...

  • Page 106: Magicolor 5450

    Main Unit Field Service Adjustment Item List magicolor 5450 Replacement Part/Service Job Adjustment/Setting Items CALIBRATION AIDC PROCESS (2) (2) (2) REPLACE/TRANS. BELT 2 QUALITY REPLACE/ MENU SUPPLIES TRANS. ROLLER REPLACE/FUSER UNIT MENU DEFAULT RESTORE DEFAULTS MENU CONTROLLER EW SERVICE FIRMWARE ENGINE F/W MENU VERSION...

  • Page 107: Description Of The Control Panel (Magicolor 5430 Dl /5440 Dl)

    Description of the Control Panel (magicolor 5430 DL /5440 DL) Main Unit Field Service Description of the Control Panel (magicolor 5430 DL /5440 DL) Control Panel Display 3.1.1 Basic screen • The Basic Screen is the Initialization Screen that displays when warmup is complete or when the menu is cancelled.

  • Page 108: Caution Display

    Main Unit Field Service Description of the Control Panel (magicolor 5430 DL /5440 DL) 3.1.4 Caution display • A caution display appears when an event that requires user intervention, but doesn’t interrupt printing, occurs. 4138fs3509e0...

  • Page 109: List Of Control Panel Messages

    Description of the Control Panel (magicolor 5430 DL /5440 DL) Main Unit Field Service List of Control Panel Messages NOTE • When two or more messages are to be displayed, the message with the higher pri- ority will be displayed.

  • Page 110: Minor Error Messages

    Main Unit Field Service Description of the Control Panel (magicolor 5430 DL /5440 DL) 3.2.3 Minor error messages Message Description • X toner has run out. Appears only when ENGINE/TONER EMPTY: CONTINUE is set. TONER EMPTY Monochrome printing can continue even with no color toner.

  • Page 111: Serious Error Messages

    Description of the Control Panel (magicolor 5430 DL /5440 DL) Main Unit Field Service 3.2.5 Serious error messages Message Description SIZE/TYPE ERROR • The correct media size or type is not loaded in, or fed through, the machine. SIZE/TYPE ERROR •...

  • Page 112: Malfunction Messages

    Main Unit Field Service Description of the Control Panel (magicolor 5430 DL /5440 DL) 3.2.6 Malfunction messages ☞ For details of malfunction messages and troubleshooting procedures, see “IV Trouble- shooting.” Message Description • A Duplex Option is not installed. ILLEGAL ERROR •...

  • Page 113: Message Priority For Consumables/Periodic Replacement Parts (Units)

    Description of the Control Panel (magicolor 5430 DL /5440 DL) Main Unit Field Service 3.2.7 Message Priority for Consumables/Periodic Replacement Parts (Units) NOTE • When two or more messages are to be displayed, the message with the higher pri- ority will be displayed.

  • Page 114: Canceling A Print Job

    Main Unit Field Service Description of the Control Panel (magicolor 5430 DL /5440 DL) Canceling a Print Job • A print job being processed or printed can be canceled by pressing the CANCEL key. 1. If the CANCEL key is pressed while a print job is being printed, a message appears on the Control Panel.

  • Page 115: Menu (Magicolor 5430 Dl /5440 Dl)

    Menu (magicolor 5430 DL /5440 DL) Main Unit Field Service Menu (magicolor 5430 DL /5440 DL) List of Menu Functions MENU PRINT CONFIG PAGE SPECIAL PAGES PRINT TEST PAGES PRINT MENU MAP LANGUAGE TOTAL FACE COUNT COLOR FACE COUNT BW FACE COUNT ENGINE TONER EMPTY CONTROLLER VER.

  • Page 116: Special

    Main Unit Field Service Menu (magicolor 5430 DL /5440 DL) SPECIAL PAGES 4.2.1 PRINT CONFIG PAGE Function • Prints a configuration page. • To check configuration of the machine. The following items can be checked: Consumables information Number of printed pages...

  • Page 117: Engine

    Menu (magicolor 5430 DL /5440 DL) Main Unit Field Service ENGINE 4.4.1 ENGINE TONER EMPTY Function • Specifies whether to stop or continue printing when a toner empty condition is detected. • To specify whether to permit printing upon a toner empty condition.

  • Page 118: Engine Service

    Main Unit Field Service Menu (magicolor 5430 DL /5440 DL) 4.4.5 ENGINE SERVICE A. TOTAL FACE COUNT Function • Displays the total number of printed pages. • To identify the use condition of the printer by finding the total number of printed pages.
  • Page 119 Menu (magicolor 5430 DL /5440 DL) Main Unit Field Service H. RESET COUNTER TRANSFER UNIT Function • Resets the counter value of the Transfer Belt Unit. • To reset the counter when the Transfer Belt Unit is replaced. Setting/ 1. Select RESET COUNTER TRANSFER UNIT and press the MENU/SELECT key.

  • Page 120: Network

    Main Unit Field Service Menu (magicolor 5430 DL /5440 DL) M. TRANSFER VOLTAGE Function • Adjusts the Printer if there is an image problem such as void areas or white spots. • To adjust the printer when void areas or white spots occur due to the characteristics of the media being used.

  • Page 121: Gateway

    Menu (magicolor 5430 DL /5440 DL) Main Unit Field Service 4.5.4 GATEWAY Function • Sets the gateway address of the printer on the network. • To enter the printer’s gateway address. Setting/ • Enter the gateway address using the up, down, right, and left arrow keys.

  • Page 122: Consumable Usage

    Main Unit Field Service Menu (magicolor 5430 DL /5440 DL) CONSUMABLE USAGE NOTE • When the toner remaining in the cartridge is between 88% and 100%, the display shows “100%,” regardless of the actual amount. The amount of toner supplied to the toner cartridge may vary slightly.

  • Page 123: Paper Size

    Menu (magicolor 5430 DL /5440 DL) Main Unit Field Service 4.7.2 PAPER SIZE Function • Sets the paper size for Camera Direct Photo Printing. • To change the paper size for Camera Direct Photo Printing. Setting • For the ones for North America, the default setting is “LETTER.” For others, the /procedure default setting is “A4.”...

  • Page 124: Service Mode (Magicolor 5430 Dl/5440 Dl)

    Main Unit Field Service Service Mode (magicolor 5430 DL/5440 DL) Service Mode (magicolor 5430 DL/5440 DL) Service Mode Entry Procedure NOTE • Ensure appropriate security for the Service Mode entry procedure. It should NEVER be given to any unauthorized person.

  • Page 125: Settings/Adjustments In Service/Service Person Mode Functions

    Service Mode (magicolor 5430 DL/5440 DL) Main Unit Field Service Settings/Adjustments in Service/Service Person Mode Functions 5.3.1 RESTORE FACTORY DEFAULT Function • Reinitializes the settings to their factory defaults. • To return the current settings to the factory default settings.
  • Page 126 Main Unit Field Service Service Mode (magicolor 5430 DL/5440 DL) B. Items that can be reset after reinitialization Item Factory Default Value Ref. Page ☞ LANGUAGE English 3-13 ☞ ENERGY SAVER ON / 30 MINUTES 3-14 ☞ ENGINE TONER EMPTY...

  • Page 127: Service Person Sru Usage

    Service Mode (magicolor 5430 DL/5440 DL) Main Unit Field Service Item Factory Default Value Ref. Page Primary WINS grayout/disabled Secondary WINS grayout/disabled Rendezvous Service Checked Discovery Rendezvous Config KONICA MINOLTA PageScope Printer Name magicolor 54** DL Web Connection Rendezvous Config...

  • Page 128: Reset Counter Fuser Unit

    Main Unit Field Service Service Mode (magicolor 5430 DL/5440 DL) 5.3.4 RESET COUNTER FUSER UNIT Function • Resets the counter value of the Fusing Unit. • To reset the Fusing Unit counter after the Fusing Unit is replaced. Setting 1. Enter the Service mode.

  • Page 129: Description Of The Control Panel (Magicolor 5450)

    Description of the Control Panel (magicolor 5450) Main Unit Field Service Description of the Control Panel (magicolor 5450) Control Panel Display 6.1.1 Parts of the Control Panel Display • The following shows the names of each part of the control panel. These names are used throughout this manual.

  • Page 130: Message Structure

    Main Unit Field Service Description of the Control Panel (magicolor 5450) 6.1.2 Message structure There are five types of messages. Message Description Normal messages These messages are displayed after warmup has been completed: • Toner remaining gauge • Data-receiving message •...

  • Page 131: Normal Messages

    Description of the Control Panel (magicolor 5450) Main Unit Field Service 6.1.3 Normal messages The Basic Screen is displayed after warmup has been completed. The “READY LED ” lights up while the message is displayed. Display Description LCD 1 Printer mode is displayed. (Normally, “READY” is displayed.) LCD 2 The message is displayed.
  • Page 132 Main Unit Field Service Description of the Control Panel (magicolor 5450) B. Data receiving message/Print The Control Panel displays the following description at data receiving message/Print. Display Description Printer mode is displayed (for example, PRINTING). • PROCESSING is displayed during data receiving or printer startup. •...
  • Page 133 Description of the Control Panel (magicolor 5450) Main Unit Field Service C. Firmware update The Control Panel displays the following description at firmware update. Display Description LCD 1 FIRMWARE UPDATE is displayed. LCD 2 displays the type of firmware (for example, SYSTEM). •...
  • Page 134 Main Unit Field Service Description of the Control Panel (magicolor 5450) E. Job cancellation By pressing the CANCEL key after the job is sent, the Control Panel displays the Job Can- cel Menu. When no job is has been sent, pressing the CANCEL key has no effect. The Control Panel displays the following description at the Job Cancel Menu.

  • Page 135: Menu

    Description of the Control Panel (magicolor 5450) Main Unit Field Service 6.1.4 Menu The Menu is displayed when the MENU key is pressed. The Control Panel displays the following description at the Menu screen. Display Description LCD 1 A Warning icon is displayed. Menu items are displayed (3 items/ 7 items).

  • Page 136: Operator Call Messages

    Main Unit Field Service Description of the Control Panel (magicolor 5450) 6.1.5 Operator Call messages These messages are displayed when minor error(s) that can be handled by user occur. The “Error LED ” lights while the message is displayed on the Control Panel. The “Ready LED ”...

  • Page 137: Service Call Messages

    Description of the Control Panel (magicolor 5450) Main Unit Field Service 6.1.6 Service Call messages These messages are displayed when error(s) that cannot be handled by the user occur. The “Error LED ” turns ON while the message is displayed on the Control Panel. The “Ready LED ”...

  • Page 138: Help Screen

    Main Unit Field Service Description of the Control Panel (magicolor 5450) 6.1.7 Help screen This screen is displayed when the Down key is pressed when a Normal message/Warn- ing or Operator Call message is displayed. The Control Panel displays the following description at the help screen. Display Description LCD 1...

  • Page 139: List Of Control Panel Messages

    Description of the Control Panel (magicolor 5450) Main Unit Field Service List of Control Panel Messages NOTE • When two or more messages are to be displayed, the message with the higher pri- ority will be displayed. • When a message concerning Consumables/Periodic Replacement Parts (Units) is displayed, print a “Statistics Page”...
  • Page 140 Main Unit Field Service Description of the Control Panel (magicolor 5450) B. Warning messages Message Priority Description (LCD2/LCD3) UNABLE TO Print in sets disabled (Full hard disk) High 1 COLLATE JOB (This warning message is also displayed during printing.) The hard disk space is running out. NEAR FULL The specified color toner cartridge has run out.

  • Page 141: Operator Call Messages

    Description of the Control Panel (magicolor 5450) Main Unit Field Service 6.2.2 Operator Call messages Message Priority Description LCD1 LCD2/LCD3 FRONT High 1 The Front Door of the machine is open. COVER SIDE COVER The Right Door of the machine is open. COVER OPEN DUPLEX The Duplex Option door is open.
  • Page 142 Main Unit Field Service Description of the Control Panel (magicolor 5450) Message Priority Description LCD1 LCD2/LCD3 • No specified media in Trays 1 to 4. SSSS * • Tray 3/4 is loaded with the specified media but is not PAPER EMPTY TTTT * set appropriately.

  • Page 143: Service Call Messages

    Description of the Control Panel (magicolor 5450) Main Unit Field Service 6.2.3 Service Call messages ☞ For troubleshooting procedures, see “IV Troubleshooting”. Message Description LCD1 LCD2/LCD3 (Service Call ID) (Error description) 0010 P MOTOR COLOR Color PC Drum Motor malfunction 0017 P MOTOR BLACK Intermediate Transport Motor malfunction...

  • Page 144: Canceling A Print Job

    Main Unit Field Service Description of the Control Panel (magicolor 5450) Canceling a Print Job • A print job being processed or printed can be canceled by pressing the CANCEL key. • When no job has been sent, pressing the CANCEL key has no effect. 1.

  • Page 145: Menu (Magicolor 5450)

    Menu (magicolor 5450) Main Unit Field Service Menu (magicolor 5450) List of Menu Functions 7.1.1 Outline MENU POSTSCRIPT PROOF/PRINT MENU DEFAULT TRAY ☞ 3-45 CONFIGURATION PG TRAY1 DEMO PAGE TRAY2 PRINT MENU STATISTICS PAGE TRAY3** FONT LIST ☞ 3-45 TRAY4** MENU MAP TRAY CHAINING DIRECTORY LIST*...

  • Page 146: Detail

    Main Unit Field Service Menu (magicolor 5450) 7.1.2 Detail ☞ 3-47 PAPER SIZE PAPER MENU CUSTOM SIZE DEFAULT TRAY PAPER TYPE TRAY1 PAPER SOURCE TRAY2 PAPER SIZE TRAY3** PAPER TYPE DUPLEX*** TRAY4** TRAY CHAINING PAPER SIZE COPIES PAPER TYPE COLLATE**** PAPER SIZE PAPER TYPE UNIT OF MEASURE...
  • Page 147 Menu (magicolor 5450) Main Unit Field Service ☞ 3-63 SYS DEFAULT MENU WAIT TIMEOUT PS ERROR PAGE DEF.EMULATION PS PROTCOL POSTSCRIPT LANGUAGE CR/LF MAPPING FONT NUMBER EMULATION LINES PER PAGE PITCH SIZE PAPER SIZE FONT SOURCE SYMBOL SET CUSTOM SIZE DEFAULT PAPER PAPER TYPE WIDTH...

  • Page 148: Proof/Print Menu

    Main Unit Field Service Menu (magicolor 5450) PROOF/PRINT MENU Function • Selects and prints the job held temporarily in the printer. • Selects and deletes the job held temporarily in the printer. • To proof one copy of a print job before printing the rest of the copies. Setting How to print the held job /procedure...

  • Page 149: Statistics Page

    Menu (magicolor 5450) Main Unit Field Service 7.3.3 STATISTICS PAGE Function • Prints a Statistics Page. • To check consumable status and the usage of the machine. The following items can be checked: Supplies Page information Setting Select “Statistics Page” and press the MENU/SELECT key. /procedure 7.3.4 FONT LIST...

  • Page 150: Paper Menu

    Main Unit Field Service Menu (magicolor 5450) PAPER MENU 7.4.1 PAPER SOURCE A. DEFAULT TRAY Function • Sets the priority feed tray. • To set the priority media feed tray. Setting 1. Select “PAPER SOURCE” and press the MENU/SELECT key. /procedure 2.
  • Page 151 Menu (magicolor 5450) Main Unit Field Service C. TRAY 1/CUSTOM SIZE Function • Sets the CUSTOM SIZE of media in Tray 1. • To specify the custom size media loaded in Tray 1. Setting 1. Select “PAPER SOURCE” and press the MENU/SELECT key. /procedure 2.
  • Page 152 Main Unit Field Service Menu (magicolor 5450) E. TRAY 2-4/PAPER SIZE Function • Sets the paper size for Trays 2 to 4. • To specify the size of media loaded in Trays 2 to 4. Setting 1. Select “PAPER SOURCE” and press the MENU/SELECT key. /procedure 2.

  • Page 153: Duplex

    Menu (magicolor 5450) Main Unit Field Service 7.4.2 DUPLEX Function • Sets duplex printing mode. • To specify duplex printing. Setting OFF: Duplex print is OFF /procedure LONG EDGE: Duplex print is ON, long edge SHORT EDGE: Duplex print is ON, short edge 1.

  • Page 154: Unit Of Measure

    Main Unit Field Service Menu (magicolor 5450) 7.4.5 UNIT OF MEASURE Function • Sets the measurement units for TRAY 1/CUSTOM SIZE mode. • Sets the measurement units for SYS DEFAULT MENU/DEFAULT PAPER/CUSTOM SIZE mode. • To change media measurement units. Setting 1.

  • Page 155: Quality Menu

    Menu (magicolor 5450) Main Unit Field Service QUALITY MENU 7.5.1 COLOR MODE Function • Sets the color mode for printing. • To specify whether jobs should be printed in color or grayscale. Setting 1. Select “COLOR MODE” and press the MENU/SELECT key. /procedure 2.
  • Page 156 Main Unit Field Service Menu (magicolor 5450) B. SIMULATION INTENT Function • Sets the color characteristics. • To set the color characteristics at the implementation of the simulation. Setting Relative color: Reproduce the color that minimizes the color difference between origi- /procedure nal and print by adjusting the basic color (white.) Absolute color: Reproduce the color that maintains the absolute color within the device...

  • Page 157: Image Printing

    Menu (magicolor 5450) Main Unit Field Service 7.5.5 IMAGE PRINTING A. RGB COLOR Function • Sets the RGB color space of the image to be printed. • To set the input RGB color space that is used for printing the image (picture). Setting sRGB...BlueAdjustRGB: Profile that has been preset to the printer.

  • Page 158: Text Printing

    Main Unit Field Service Menu (magicolor 5450) D. HALFTONE Function Sets the halftone characteristic of image to be printed. To set the halftone characteristic that is used for the printed image (picture.) Setting Line art: HALFTONE characteristic that emphasizes the resolution of the print image. /procedure Detail: HALFTONE characteristic that emphasizes the balance between the resolution and the tone reproducibility of the print image.

  • Page 159: Graphics Printing

    Menu (magicolor 5450) Main Unit Field Service C. RGB GRAY Function • Sets the RGB gray reproduction of the text to be printed. • To set the gray print method that is used for printing text (letter). Setting Composite black: Print gray with the toner of 4 colors CMYK. /procedure Black and gray: Print black (R=G=B=0) only with K toner and print gray with toner of 4 colors CMYK.

  • Page 160: Calibration

    Main Unit Field Service Menu (magicolor 5450) 7.5.8 CALIBRATION A. TONE CALIBRATION Function • Sets the gradation adjustment (Image stabilization with the controller). • To use for a CCD malfunction or a particular calibration made by users. Setting ON: Gradation adjustment is ON. /procedure OFF: Gradation adjustment is OFF.

  • Page 161: Supplies

    Menu (magicolor 5450) Main Unit Field Service 7.5.10 SUPPLIES A. REPLACE/TRANS.BELT Function • Resets the life counter of the Transfer Belt unit. • To be used when the Transfer Belt unit is replaced. Setting 1. Select “SUPPLIES” and press the MENU/SELECT key. /procedure 2.

  • Page 162: Interface Menu

    Main Unit Field Service Menu (magicolor 5450) INTERFACE MENU 7.6.1 JOB TIMEOUT Function • Sets the time to activate JOB TIMEOUT. • To specify the amount of time before a print job times out. Setting 1. Select “JOB TIMEOUT” and press the MENU/SELECT key. /procedure 2.
  • Page 163 Menu (magicolor 5450) Main Unit Field Service B. TCP/IP /IP ADDRESS Function • Sets the IP address of the printer used for the network. • To set the printer’s IP address. Setting 1. Select “ETHERNET” and press the MENU/SELECT key. /procedure 2.
  • Page 164 Main Unit Field Service Menu (magicolor 5450) E. TCP/IP / DHCP/BOOTP Function • DHCP: Automatically acquires an IP address from the DHCP server, if there is one in the network, and specifies whether to load other network information. • BOOTP: Automatically acquires an IP address from BOOTP and specifies whether to load other network information.
  • Page 165 Menu (magicolor 5450) Main Unit Field Service H. SPEED/DUPLEX Function • Sets the communication speed and method of Network. • To set the network communication speed and method. Setting • Setting items /procedure Network speed (SPEED): AUTO, 10Mbps, 100Mbps, 1,000Mbps Duplex mode (DUP): AUTO, Full-duplex mode, Half-duplex mode 1.

  • Page 166: Sys Default Menu

    Main Unit Field Service Menu (magicolor 5450) SYS DEFAULT MENU 7.7.1 LANGUAGE Function • Sets the language of the Control Panel display. • To set the language used in the Menu. Setting 1. Select “LANGUAGE” and press the MENU/SELECT key. /procedure 2.
  • Page 167 Menu (magicolor 5450) Main Unit Field Service C. POSTSCRIPT /PS ERROR PAGE Function • Specifies whether error pages are printed at the time of a PostScript error. • To specify whether error pages are printed after a PostScript error occurs. Setting ON: Error pages are printed at the time of PostScript error.
  • Page 168 Main Unit Field Service Menu (magicolor 5450) F. PCL /LINES PER PAGE Function • Sets the lines per page for PCL printing. • To set the number of lines to be printed per page for PCL jobs. Setting 1. Select “EMULATION” and press the MENU/SELECT key. /procedure 2.
  • Page 169 Menu (magicolor 5450) Main Unit Field Service PCL /FONT SOURCE /POINT SIZE Function • Sets the point size of the PCL font for PCL printing. • To set the point size of the font to be used for printing PCL jobs. Setting 1.

  • Page 170: Default Paper

    Main Unit Field Service Menu (magicolor 5450) 7.7.3 DEFAULT PAPER A. PAPER SIZE Function • Sets the default media size. • To set the default media size. Setting 1. Select “DEFAULT PAPER” and press the MENU/SELECT key. /procedure 2. Select “PAPER SIZE” and press the MENU/SELECT key. 3.

  • Page 171: Startup Options /Do Startup Page

    Menu (magicolor 5450) Main Unit Field Service C. CUSTOM SIZE /LENGTH Function • Sets the custom media length. • To set the length of the custom media size. Setting 1. Select “DEFAULT PAPER” and press the MENU/SELECT key. /procedure 2. Select “CUSTOM SIZE” and press the MENU/SELECT key. 3.

  • Page 172: Auto Continue

    Main Unit Field Service Menu (magicolor 5450) 7.7.5 AUTO CONTINUE Function • At the time of the following Operator Call, continues auto printing by ignoring the media type or size. • “PAPER EMPTY” (except “MANUAL FEED”), “xxxx SIZE ERROR”, “xxxx TYPE ERROR”.

  • Page 173: Energy Saver Time

    Menu (magicolor 5450) Main Unit Field Service 7.7.8 ENERGY SAVER TIME Function • Sets the amount of time before the machine enters Energy Saver mode after the last print is received or the last key operated. • To change the amount of time before the machine enters Energy Saver mode. Setting 1.

  • Page 174: Security

    Main Unit Field Service Menu (magicolor 5450) 7.7.11 SECURITY A. CHANGE PASSWORD Function • Sets the password used for the LOCK PANEL function. • To change the password used for the LOCK PANEL function. Setting 0000: Panel lock function is OFF. /procedure 0001 to FFFF: Valid password for panel lock function.

  • Page 175: Clock

    Menu (magicolor 5450) Main Unit Field Service 7.7.12 CLOCK A. DATE Function • Sets the date of the printer’s built-in clock. • To change the date of the printer’s built-in clock. Setting DATE (DD.MM.YY): For Europe /procedure DATE (MM.DD.YY): For North America DATE(YY.MM.DD): For Japan The following shows how to set DATE (DD.MM.YY).

  • Page 176: Restore Defaults

    Main Unit Field Service Menu (magicolor 5450) 7.7.14 RESTORE DEFAULTS Function • Restores the factory default of each setting. • To restore the defaults of all settings. Setting RESTORE NETWORK: Restore the default for “INTERFACE MENU/ETHERNET” set- /procedure ting. RESTORE PRINTER: Restore the defaults for the settings other than “INTERFACE MENU/ETHERNET”...
  • Page 177 Menu (magicolor 5450) Main Unit Field Service List of reset items 2 Reset Item Item Initial Value Ref. Page RESTORE RESTORE RESTORE NETWORK PRINTER ☞ COLOR MODE Reset Reset COLOR 3-52 ☞ BRIGHTNESS Reset Reset 3-52 ☞ PCL CONTRAST Reset Reset 3-52 ☞...
  • Page 178 Main Unit Field Service Menu (magicolor 5450) List of reset items 3 Reset Item Item Initial Value Ref. Page RESTORE RESTORE RESTORE NETWORK PRINTER ☞ DEF. EMULATION Reset Reset AUTO 3-63 ☞ WAIT 3-63 Reset Reset TIMEOUT ☞ POST PS ERROR 3-64 Reset Reset...
  • Page 179 Menu (magicolor 5450) Main Unit Field Service List of reset items 4 Reset Item Item Initial Value Ref. Page RESTORE RESTORE RESTORE NETWORK PRINTER ☞ RESTORE DEFAULTS Reset Reset RESTORE 3-73 NETWORK ☞ ENABLE PAPER TRAY1 Reset Reset 3-77 WARNING EMPTY ☞...

  • Page 180: Enable Warning

    Main Unit Field Service Menu (magicolor 5450) 7.7.15 ENABLE WARNING A. PAPER EMPTY /TRAY1 Function • Specifies whether a “TRAY 1 Paper Empty” (Manual Feed Tray) is displayed as a Normal message when it is empty. • To specify whether to display a “TRAY 1 Paper Empty” message as a Normal message.

  • Page 181: Toner Empty

    Menu (magicolor 5450) Main Unit Field Service D. PAPER EMPTY /TRAY4 Function • Specifies whether a “TRAY 4 Paper Empty” is displayed as a Normal message when it is empty. • To specify whether to display a “TRAY 4 Paper Empty” message as a Normal message.

  • Page 182: Service Menu (Magicolor 5450)

    Main Unit Field Service Service Menu (magicolor 5450) Service Menu (magicolor 5450) How to Enter the Service Menu NOTE • Make sure not to reveal the password of the Service Menu to any unauthorized person. A. Procedure 1. Display “SERVICE MENU” on the menu screen and press the MENU/SELECT key. 2.

  • Page 183: Service Menu Setting/Adjustment

    Service Menu (magicolor 5450) Main Unit Field Service Service Menu Setting/Adjustment 8.3.1 SERIAL NUMBER Function • Displays the serial number of the printer. • To determine the printer’s serial number. Setting 1. Select “SERVICE MENU” and press the MENU/SELECT key. /procedure 2.
  • Page 184 Main Unit Field Service Service Menu (magicolor 5450) B. LEFT ADJUSTMENT Function • Adjusts the left margin of media for single-sided printing. • To correct a misaligned print image. Setting LEFT ADJ TRAY 1: Adjust the left margin of paper fed from Tray 1 (Manual tray.) /procedure LEFT ADJ TRAY 2: Adjust the left margin of paper fed from Tray 2.
  • Page 185 Service Menu (magicolor 5450) Main Unit Field Service D. TRANSFER POWER /SIMPLEX PASS Function • Adjusts the transfer power when single-sided pages have image quality problems (void areas or white spots). • To correct single-sided pages with image quality problems (void areas or white spots) due to the characteristics of the media being used.

  • Page 186: Transfer Power /Image Adj Param

    Main Unit Field Service Service Menu (magicolor 5450) F. TRANSFER POWER /MANUAL DUPLEX Function • Adjusts the transfer power when manually duplexed pages have image quality prob- lems (void areas or white spots). • To correct manually duplexed pages with image quality problems (void areas or white spots) due to the characteristics of the media being used.

  • Page 187: Restore Passward

    Service Menu (magicolor 5450) Main Unit Field Service 8.3.5 RESTORE PASSWARD Function • Reinitializes the password used for the “SYSTEM DEFAULT MENU/SECURITY/ PANEL LOCK FUNCTION” set by user. ☞ LOCK PANEL 3-71 • To reinitialize the Panel Lock function when the menu cannot be opened even when entering the correct password.

  • Page 188: Iv Troubleshooting

    TRAY 1 TRAY 2 TRAY 2 TRAY 3 TRAY 3 TRAY 4 Misfeed Display (magicolor 5430 DL / 5440 DL) • When a media misfeed occurs a message is displayed on the Control Panel. 4138fs4505e0 Misfeed processing loca- Display Misfeed Location...

  • Page 189: Misfeed Display (Magicolor 5450)

    Jam Display Main Unit Field Service Misfeed Display (magicolor 5450) • When a media misfeed occurs a message is displayed on the Control Panel. PAPER JAM TRAY1 for help 4138F4E001DA Display Misfeed processing Misfeed Location Action location LCD 1 LCD 2 ☞...

  • Page 190: Sensor Layout

    Main Unit Field Service Jam Display Sensor Layout • System equipped with two Lower Feeder Units and one Duplex Option 4138fs4502c1 Exit Sensor Synchronizing Roller Sensor Lower Feeder Paper Feed Paper Loop Sensor PC3 PF Sensor Sensor on Duplex Board PWB-E DU...

  • Page 191: Solutions

    Jam Display Main Unit Field Service Solutions 1.5.1 Initial Check Items • When a media misfeed occurs, first make checks of the following initial check items. Check Item Action Does media meet product specifications? • Change media. • Change media. Is media curled, wavy, or damp.

  • Page 192: Misfeed At Tray 1 Media Feed Section (Misfeed At Tray 2 Media Feed Section)

    5430 DL / 5440 DL magicolor 5450 TRAY 1 TRAY 2 • The following procedures use the name for magicolor 5430 DL/5440 DL. A. Detection Timing Type Description Detection of The media does not unblock the Synchronizing Roller Sensor (PC4) even after...

  • Page 193: Misfeed At Manual Feed Tray Media Feed Section (Misfeed At Tray 1 Media Feed Section)

    5430 DL / 5440 DL magicolor 5450 MANUAL FEED TRAY TRAY 1 • The following procedures use the name for magicolor 5430 DL/5440 DL. A. Detection Timing Type Description Detection of The media does not unblock the Synchronizing Roller Sensor (PC4) even after...

  • Page 194: Misfeed At Transfer Section

    Main Unit Field Service Jam Display 1.5.4 Misfeed at transfer section A. Detection Timing Type Description The Synchronizing Roller Sensor (PC4) is not blocked even after the lapse of a given period of time after the media has unblocked PC4. Detection of The media does not block the Exit Sensor (PC8) even after the lapse of a given misfeed at transfer...

  • Page 195: Misfeed At Fusing/Exit Section

    Jam Display Main Unit Field Service 1.5.5 Misfeed at fusing/exit section A. Detection Timing Type Description The Exit Sensor (PC8) is not unblocked even after the lapse of a given period of time after the media has blocked PC8. Detection of misfeed at fusing/ The media does not block the sensor on the Duplex Board (PWB-E DU) even exit section...

  • Page 196: Malfunction Code

    Main Unit Field Service Malfunction code Malfunction code Trouble Codes (magicolor 5430 DL/5440 DL) • The printer’s CPU performs a self-diagnostics function that, on detecting a malfunction, gives the corresponding malfunction code and maintenance call mark on the Touch Panel.
  • Page 197 Malfunction code Main Unit Field Service Code Item Detection Timing • The Motor Lock signal remains HIGH for a given period 004EH LV Cooling Fan Motor malfunction of consecutive time while the LV Cooling Fan Motor is being rotated. • The Fusing Motor does not rotate evenly even after the lapse of a given period of time while it is being started.
  • Page 198 Main Unit Field Service Malfunction code Code Item Detection Timing • The temperature detected by the Fusing Pressure Abnormally high Fusing Pressure 0521H Roller Thermistor remains higher than the specified Roller temperature value for a given period of time or longer. •...

  • Page 199: Trouble Codes (Magicolor 5450)

    Malfunction code Main Unit Field Service Trouble Codes (magicolor 5450) • The printer’s CPU performs a self-diagnostics function that, on detecting a malfunction, gives the corresponding malfunction code and maintenance call mark on the Touch Panel. SERVICE CALL C002 RAM ERROR 4138F3E005DA 2.2.1 Trouble code list...
  • Page 200 Main Unit Field Service Malfunction code LCD1 LCD2/LCD3 (Service (Error Item Detection Timing call ID) description) • The Motor Lock signal remains HIGH for a given POWER LV Cooling Fan Motor 004E period of consecutive time while the LV Cooling malfunction Fan Motor is being rotated.
  • Page 201 Malfunction code Main Unit Field Service LCD1 LCD2/LCD3 (Service (Error Item Detection Timing call ID) description) • The temperature detected by the Fusing Pres- Abnormally low Fusing FUSER sure Roller Thermistor remains lower than the 0511 Pressure Roller tem- ERROR specified value for a given period of time or perature longer.

  • Page 202: Resetting A Malfunction

    Main Unit Field Service Malfunction code LCD1 LCD2/LCD3 (Service (Error Item Detection Timing call ID) description) HOLD JOB • The Duplex Option is not installed, but it is Hold job error/No C061 ERROR required for printing the job held in the HDD. Duplex unit DUPLEX HOLD JOB...

  • Page 203: 001Bh: Developing Motor/Y,M,C Malfunction

    Malfunction code Main Unit Field Service 2.4.2 001BH: Developing Motor/Y,M,C malfunction Relevant Electrical Parts Developing Motor/Y,M,C (M1) Mechanical Control Board (PWB-A) Low Voltage Unit (LV) WIRING DIAGRAM Location Step Action Control Signal (Electrical Component) Check the M1 connector for proper connection and correct as necessary.

  • Page 204: 0018H: Developing Motor/K Malfunction

    Main Unit Field Service Malfunction code 2.4.4 0018H: Developing Motor/K malfunction Relevant Electrical Parts Developing Motor/K (M5) Mechanical Control Board (PWB-A) Low Voltage Unit (LV) WIRING DIAGRAM Location Step Action Control Signal (Electrical Component) Check the M5 connector for proper connection and correct as necessary.

  • Page 205: 004Ch: Ozone Ventilation Fan Motor Malfunction

    Malfunction code Main Unit Field Service 2.4.6 004CH: Ozone Ventilation Fan Motor malfunction Relevant Electrical Parts Ozone Ventilation Fan Motor (M12) Mechanical Control Board (PWB-A) WIRING DIAGRAM Location Step Action Control Signal (Electrical Component) Check the M12 connector for proper connection and correct as necessary.

  • Page 206: 0060H: Fusing Motor Malfunction

    Main Unit Field Service Malfunction code 2.4.8 0060H: Fusing Motor malfunction Relevant Electrical Parts Fusing Motor (M4) Mechanical Control Board (PWB-A) WIRING DIAGRAM Location Step Action Control Signal (Electrical Component) Check the M4 connector for proper connection and correct as necessary. Check the Fusing Unit driving mechanism for possible overload and correct as necessary.

  • Page 207: 0096H: 1St Image Transfer Pressure/Retraction Failure

    Malfunction code Main Unit Field Service 2.4.10 0096H: 1st image transfer pressure/retraction failure Relevant Electrical Parts Retraction Position Sensor/1st Image Transfer Mechanical Control Board (PWB-A) (PC9) Pressure/Retraction Clutch /1st Image Transfer (CL4) Intermediate Transport Motor (M3) WIRING DIAGRAM Location Step Action Control Signal (Electrical...

  • Page 208: 0310H: Laser Malfunction

    Main Unit Field Service Malfunction code 2.4.12 0310H: Laser malfunction Relevant Electrical Parts PH Unit Mechanical Control Board (PWB-A) WIRING DIAGRAM Location Step Action Control Signal (Electrical Component) Check the cable and connector for proper con- nection and correct as necessary. Change PH Unit.

  • Page 209: 13D0H: Parameter Chip Failure

    Malfunction code Main Unit Field Service 2.4.19 13D0H: Parameter Chip failure Relevant Electrical Parts Parameter Chip (IC15) Mechanical Control Board (PWB-A) WIRING DIAGRAM Location Step Action Control Signal (Electrical Component) Unplug the power cord and plug it in, then turn OFF and ON the Power Switch.

  • Page 210: C013: Mac Address Error (Only For Magicolor 5450) C015: Boot Rom Error (Only For Magicolor 5450) C022: Nvram Error (Only For Magicolor 5450)

    Main Unit Field Service Malfunction code 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) Relevant Electrical Parts Print Control Board (PWB-P) WIRING DIAGRAM Location Step Action Control Signal...

  • Page 211: C050: Hard Disk Access Error (Only For Magicolor 5450)

    Malfunction code Main Unit Field Service 2.4.24 C050: Hard disk access error (Only for magicolor 5450) Relevant Electrical Parts Print Control Board (PWB-P) Hard disk unit (HDD) WIRING DIAGRAM Location Step Action Control Signal (Electrical Component) Turn OFF the Power Switch of the printer and turn it ON again (Restart of the printer.) Check the HDD connector for proper connection and correct as necessary.

  • Page 212: C060: Firmware Update Error (Only For Magicolor 5450)

    Main Unit Field Service Malfunction code 2.4.26 C060: Firmware Update error (Only for magicolor 5450) Relevant Electrical Parts Print Control Board (PWB-P) WIRING DIAGRAM Location Step Action Control Signal (Electrical Component) Turn OFF the Power Switch of the printer and turn it ON again (Restart of the printer.) Check the cable that has been used for update of the firmware for proper connection and correct as...

  • Page 213: Ffff: Interface Communication Error (Only For Magicolor 5450)

    Malfunction code Main Unit Field Service 2.4.28 FFFF: Interface Communication error (Only for magicolor 5450) Relevant Electrical Parts Print Control Board (PWB-P) Mechanical Control Board (PWB-A) WIRING DIAGRAM Location Step Action Control Signal (Electrical Component) Turn OFF the Power Switch of the printer and turn it ON again (Restart of the printer.) Check the PWB-P connector for proper connec- tion and correct as necessary...

  • Page 214: Power Supply Troubles

    Main Unit Field Service Power Supply Troubles Power Supply Troubles Machine is Not Energized at All (LV Operation Check) Relevant Electrical Parts Power Switch Low Voltage Unit (LV) Mechanical Control Board (PWB-A) Location Step Check Item (Electrical Result Action Component) Check wiring from Is the power source voltage being applied to 12-L...

  • Page 215: Fusing Heaters Do Not Operate

    Power Supply Troubles Main Unit Field Service Fusing Heaters do not Operate Relevant Electrical Parts Safety Switch/Fr (S2) Low Voltage Unit (LV) Safety Switch/Rt (S3) Fusing Unit Location Step Check Item (Electrical Result Action Component) Is the power source voltage being applied to Check wiring from CN1LV on LV? power outlet to PG1 to...

  • Page 216: Miscellaneous Malfunctions (Only For Magicolor 5430 Dl/5440 Dl)

    Main Unit Field Service Miscellaneous Malfunctions (Only for magicolor 5430 DL/5440 DL) Miscellaneous Malfunctions (Only for magicolor 5430 DL/5440 DL) List of Miscellaneous Malfunctions Message Description • The Duplex Option is not installed. ILLEGAL ERROR • A 2-sided print cycle is run using the type and size of media that are not good DUPLEX for 2-sided printing.

  • Page 217: Error Aidc Sensor

    Miscellaneous Malfunctions (Only for magicolor 5430 DL/5440 DL) Main Unit Field Service ERROR AIDC SENSOR Relevant Electrical Parts AIDC Sensor/Rt (AIDC R) Mechanical Control Board (PWB-A) AIDC Sensor/Lt (AIDC L) WIRING DIAGRAM Location Step Action Control Signal (Electrical Component) Check the AIDC R connector for proper connec- tion and correct as necessary.

  • Page 218: Error Engine Interface

    Main Unit Field Service Miscellaneous Malfunctions (Only for magicolor 5430 DL/5440 DL) ERROR ENGINE INTERFACE Relevant Electrical Parts Mechanical Control Board (PWB-A) Print Control Board (PWB-P) WIRING DIAGRAM Location Step Action Control Signal (Electrical Component) Turn OFF and ON the Power Switch.

  • Page 219: Error Rom

    Miscellaneous Malfunctions (Only for magicolor 5430 DL/5440 DL) Main Unit Field Service ERROR ROM Relevant Electrical Parts Print Control Board (PWB-P) WIRING DIAGRAM Location Step Action Control Signal (Electrical Component) Check the PWB-P connector for proper connec- tion and correct as necessary.

  • Page 220: Image Quality Problems

    Main Unit Field Service Image Quality Problems Image Quality Problems Solutions 5.1.1 White lines in FD, white bands in FD, colored lines in FD, and colored bands in FD A. Typical Faulty Images White lines in FD White bands in FD Colored lines in FD Colored bands in FD 4036fs4022c0...

  • Page 221: White Lines In Cd, White Bands In Cd, Colored Lines In Cd, And Colored Bands In Cd

    Image Quality Problems Main Unit Field Service 5.1.2 White lines in CD, white bands in CD, colored lines in CD, and colored bands in CD A. Typical Faulty Images White lines in CD White bands in CD Colored lines in CD Colored bands in CD 4036fs4028c0 4036fs4026c0...

  • Page 222: Uneven Density In Fd

    4036fs4044c0 4036fs4045c0 B. Troubleshooting Procedure Step Section Check Item Result Action Adjust the image with “ALTITUDE SETUP” (magicolor 5430 DL/ 5440 DL) → ENGINE/ENGINE SERVICE/ RESTORE USER DEFAULT/ Adjustment The Printer is being operated at ALTITUDE SETUP /Setting high altitude.

  • Page 223: Uneven Density In Cd

    4036fs4046c0 4036fs4047c0 B. Troubleshooting Procedure Step Section Check Item Result Action Adjust the image with “ALTITUDE SETUP” (magicolor 5430 DL/ 5440 DL) → ENGINE/ENGINE SERVICE/ Adjustment The Printer is being operated at RESTORE USER DEFAULT/ /Setting high altitude. ALTITUDE SETUP Adjust the image with “IMAGE...

  • Page 224: Low Image Density

    Action Adjust the image with “DUPLEX The Duplex Option is being used, DENSITY” and also the Printer is being oper- (magicolor 5430 DL/5440 DL) ated in the climate such as dry or → ENGINE/ENGINE SERVICE/ highly humid. RESTORE USER DEFAULT/...

  • Page 225: Gradation Reproduction Failure

    Image Quality Problems Main Unit Field Service 5.1.6 Gradation reproduction failure A. Typical Faulty Images 4036fs4048c0 4036fs4049c0 B. Troubleshooting Procedure Step Section Check Item Result Action Toner Cartridge Is the outside dirty? Clean. PH Unit Is the window surface dirty? Clean.

  • Page 226: Foggy Background

    Action Adjust the image with “DUPLEX The Duplex Option is being used, DENSITY.” and also the Printer is being oper- (magicolor 5430 DL/5440 DL) ated in the climate such as dry or → ENGINE/ENGINE SERVICE/ highly humid. RESTORE USER DEFAULT/...

  • Page 227: Poor Color Reproduction

    Image Quality Problems Main Unit Field Service 5.1.8 Poor color reproduction A. Typical Faulty Images 4138fs4503c0 B. Troubleshooting Procedure Step Section Check Item Result Action Replace the paper with paper that Paper Is the paper damp? has just been unwrapped. Transfer Belt Unit Is the terminal dirty? Clean.

  • Page 228: Void Areas, White Spots

    B. Troubleshooting Procedure Step Section Check Item Result Action Adjust the image with “TRANS- FER VOLTAGE.” (magicolor 5430 DL/5440 DL) → ENGINE/ENGINE SERVICE/ RESTORE USER DEFAULT/ Adjustment Thick or Special media is being TRANSFER VOLTAGE /Setting used. Adjust the image with “TRANS- FER POWER.”...

  • Page 229: Colored Spots

    Image Quality Problems Main Unit Field Service 5.1.10 Colored spots A. Typical Faulty Images Colored spots 4036fs4052c0 B. Troubleshooting Procedure Step Section Check Item Result Action Are the spots in a single color? Change the Toner Cartridge. Toner Cartridge Are there scratches or lines evi- Change the Toner Cartridge.

  • Page 230: Blurred Image

    Main Unit Field Service Image Quality Problems 5.1.11 Blurred image A. Typical Faulty Images Blurred image 4036fs4031c0 B. Troubleshooting Procedure Step Section Check Item Result Action PH Unit Is the window surface dirty? Clean. Toner Cartridge Is the outside dirty? Clean.

  • Page 231: Blank Copy, Black Copy

    Image Quality Problems Main Unit Field Service 5.1.12 Blank copy, black copy A. Typical Faulty Images Blank print Black print 4036fs4038c0 4036fs4039c0 B. Troubleshooting Procedure Step Section Check Item Result Action Check the PH Unit connector for Image check Does a blank print occur? proper connection.

  • Page 232: Incorrect Color Image Registration

    Main Unit Field Service Image Quality Problems 5.1.13 Incorrect color image registration A. Typical Faulty Images 4036fs4032c0 B. Troubleshooting Procedure Step Section Check Item Result Action Is the Transfer Belt dirty with fin- gerprints, oil, or other foreign mat- Clean. ter? Wipe the surface clean of dirt with Is the Transfer Belt dirty or...

  • Page 233: Poor Fusing Performance, Offset

    Image Quality Problems Main Unit Field Service 5.1.14 Poor fusing performance, offset A. Typical Faulty Images Poor fusing performance Offset 4036fs4059c0 4036fs4060c0 B. Troubleshooting Procedure Step Section Check Item Result Action Does the paper being used con- Paper Change the media. form to specifications? Change the Fusing Unit.

  • Page 234: Brush Effect, Blurred Image

    Main Unit Field Service Image Quality Problems 5.1.15 Brush effect, blurred image A. Typical Faulty Images Brush effect Blurred image 4036fs4061c0 4036fs4031c0 B. Troubleshooting Procedure Step Section Check Item Result Action Replace the paper with paper Is the paper damp? that has just been unwrapped.

  • Page 235: Back Marking

    Image Quality Problems Main Unit Field Service 5.1.16 Back marking A. Typical Faulty Images 4036fs4062c0 4036fs4063c0 B. Troubleshooting Procedure Step Section Check Item Result Action Is there a foreign matter on the Media path Remove the foreign matter. paper path? Is the Fusing Entrance Guide Clean or change.

  • Page 236: Uneven Pitch

    Main Unit Field Service Image Quality Problems 5.1.17 Uneven Pitch A. Typical Faulty Images 4138fs4507c0 B. Troubleshooting Procedure Step Section Check Item Result Action Is the Toner Cartridge for each Toner Cartridge color of toner installed in posi- Reinstall. tion? Is the PH Unit secured in position PH Unit Secure it in position.

  • Page 237: No Print Cycles Can Be Run As Commanded Via The Network

    Is the Network/Forced Modes set- ting made correctly according to the network environment being Operation Panel/ used? MENU (magicolor 5430 DL/5440 DL) Reset. Is the INTERFACE MENU/ETH- ERNET/TCP/IP/SPEED/DUPLEX setting made correctly according to the network environment being used? (magicolor 5450) Reinstall.

  • Page 238: Appendix

    Main Unit Field Service Parts Layout Drawing V Appendix Parts Layout Drawing Main unit 4138fs5501c0 Mechanical Control Board (PWB-A) High Voltage Unit /2 (HV2) Low Voltage Unit (LV) High Voltage Unit /1 (HV1) Control Panel (PWB-OP) Print Control Board (PWB-P) Toner Level Sensor Board (PWB-D)
  • Page 239 Parts Layout Drawing Main Unit Field Service [16] [15] [14] [13] [12] [11] [10] 4138fs5502c1 Tray 1 Paper Feed Clutch (CL1) Intermediate Transport Motor (M3) Manual Feed Tray Paper Feed Clutch (CL3) [10] Developing Motor /K (M5) Fusing Cooling Fan Motor (M11) [11] Ozone Ventilation Fan Motor (M12) Fusing Motor (M4) [12] Developing Motor /Y,M,C (M1)
  • Page 240 Main Unit Field Service Parts Layout Drawing [19] [18] [17] [10] [16] [11] [13] [12] [14] [15] 4138fs5503c2 Paper Loop Sensor (PC6) [11] Front Door Sensor (PC22) Paper Size Sensor (PC23) [12] Synchronizing Roller Sensor (PC4) Paper Full sensor (PC20) [13] OHP Sensor (PC7) Manual Feed Tray Paper Empty Sensor (PC3) [14] Tray 1 Paper Empty Sensor (PC1) AIDC Sensor /Rt (AIDC R)

  • Page 241: Lower Feeder Unit (Option)

    Parts Layout Drawing Main Unit Field Service Lower Feeder Unit (Option) 4537fs5501c0 Lower Feeder Right Door Switch (PC5 PF) Lower Feeder Paper Size Switch (S1 PF) Lower Feeder Motor (M1 PF) Lower Feeder Board (PWB-F PF) Lower Feeder Paper Feed Sensor Lower Feeder Paper Feed Clutch (PC3 PF) (CL1 PF)

  • Page 242: Duplex Option (Option)

    Main Unit Field Service Parts Layout Drawing Duplex Option (Option) 4538fs5501c0 Duplex Door Sensor (PC2 DU) Duplex Board (PWB-E DU) Duplex Transport Motor (M1 DU) Duplex Reverse Motor (M2 DU)

  • Page 243: Connector Layout Drawing

    Connector Layout Drawing Main Unit Field Service Connector Layout Drawing Description ➀ Number of Pin Possible to confirm by removing external cover. Not possible to confirm by removing external cover. [14] [13] [12] [11] [10] 4138fs5504c2 CN No. Location CN No. Location CN16 3-G∼H...

  • Page 244: Timing Chart

    Main Unit Field Service Timing chart Timing chart Color A4 2-print Polygon Motor Inetrmediate Transport Motor (M3) Color PC Drum Motor (M2) Developing Motor/Y,M,C (M1) Developing Motor/K (M5) Drum Charge Corona Bias/K Drum Charge Corona Bias/Y,M,C Developing Bias/Y Developing Bias/M Developing Bias/C Developing Bias/K /TOD...
  • Page 245 SERVICE MANUAL FIELD SERVICE Lower Feeder Unit 2005.04 Ver. 2.0...
  • Page 247 How to use the adjustment section ..............3-1 Mechanical Adjustment ..................3-2 Registration adjustment ..................3-2 IV Troubleshooting Jam Display......................4-1 Misfeed display (magicolor 5430 DL/5440 DL) ..........4-1 Misfeed display (magicolor 5450) ..............4-1 Misfeed display resetting procedure ..............4-1 Sensor layout ..................... 4-2 1.4.1 For a system equipped with two Lower Feeder Units ........
  • Page 248 Lower Feeder Unit Field Service Ver. 2.0 April 2005...

  • Page 249: Product Specifications

    Lower Feeder Unit Field Service Ver. 2.0 April 2005 Product specifications I General Product specifications Type Name Add-on 500-sheet paper feed cassette Type Front-loading type Installation Desk type Paper Feeding System Paper separation by a small-diameter roller with torque limiter Document Alignment Center Paper type...
  • Page 250 Product specifications Lower Feeder Unit Field Service Ver. 2.0 April 2005...

  • Page 251: Ii Maintenance

    Lower Feeder Unit Field Service Ver. 2.0 April 2005 Periodic check II Maintenance Periodic check Maintenance procedure (Periodic parts check) NOTE • The alcohol used in this cleaning procedure is isopropyl alcohol. 1.1.1 Feed Roller A. Cleaning procedure 1. Open the Lower Feeder Unit Right Cover.

  • Page 252: Other

    Other Lower Feeder Unit Field Service Ver. 2.0 April 2005 Other Disassembly/adjustment-prohibited items A. Paint-locked screws NOTE • Paint-locked screws show that the assembly or unit secured can only be adjusted or set at the factory and should not be adjusted, set, or removed in the field. B.

  • Page 253: Disassembly/Assembly Procedure

    Lower Feeder Unit Field Service Ver. 2.0 April 2005 Other Disassembly/assembly procedure 2.3.1 Tray 1. Slide out the Tray [1]. 2. Remove two Screws [2], and remove the Stopper [3]. 3. Pressing the tab [4], remove the Tray [1]. 4537fs2001c1 2.3.2 Lower Feeder Board (PWB-F PF) 1.
  • Page 254 Other Lower Feeder Unit Field Service Ver. 2.0 April 2005 6. Slightly raise the PWB Protective Cover [6] and, at the same time, dis- connect the connector [8] from the Lower Feeder Board [7]. 7. Remove the PWB Protective Cover [6].

  • Page 255: Lower Feeder Paper Feed Clutch (Cl1 Pf)

    Lower Feeder Unit Field Service Ver. 2.0 April 2005 Other 2.3.3 Lower Feeder Paper Feed Clutch (CL1 PF) 1. Remove the Lower Feeder Unit from the machine. 2. Slide out the Tray. 3. Open the Lower Feeder Unit Right Door [1]. 4.
  • Page 256 Other Lower Feeder Unit Field Service Ver. 2.0 April 2005 8. Remove four screws [9], disconnect three connectors [10], and remove the Paper Feed Drive Assy [11]. [11] [10] 4537fs2007c0 9. Remove two screws [12], snap off the C-clip [13] and bearing [14], and [14] [15] remove the Lower Feeder Paper...

  • Page 257: Lower Feeder Motor (M1 Pf)

    Lower Feeder Unit Field Service Ver. 2.0 April 2005 Other 2.3.4 Lower Feeder Motor (M1 PF) 1. Remove the Paper Feed Drive Assy and Lower Feeder Paper Feed Clutch. ☞ 2-5 2. Remove two screws [1] and the Lower Feeder Motor Assy [2]. 4537fs2010c0 3.
  • Page 258 Other Lower Feeder Unit Field Service Ver. 2.0 April 2005...

  • Page 259: Iii Adjustment/Setting

    Lower Feeder Unit Field Service Ver. 2.0 April 2005 How to use the adjustment section III Adjustment/Setting How to use the adjustment section • This section contains detailed information on the adjustment items and procedures for this machine. • Throughout this section the default settings are indicated by boldface. A.

  • Page 260: Mechanical Adjustment

    Mechanical Adjustment Lower Feeder Unit Field Service Ver. 2.0 April 2005 Mechanical Adjustment Registration adjustment This adjustment must be made if: • The printed image deviates in the CD direction. 1. Remove the tray. 2. Loosen two screws [1]. 4537fs3501c0 3.

  • Page 261: Iv Troubleshooting

    Lower Feeder Unit Field Service Ver. 2.0 April 2005 Jam Display IV Troubleshooting Jam Display NOTE Make sure that the feed tray is called differently between magicolor 5430 DL/5440 DL and magicolor 5450. magicolor 5430 DL / 5440 DL magicolor 5450 TRAY 2...

  • Page 262: Sensor Layout

    Jam Display Lower Feeder Unit Field Service Ver. 2.0 April 2005 Sensor layout 1.4.1 For a system equipped with two Lower Feeder Units 4537fs4504c0 Lower Feeder Paper Feed Paper Loop Sensor PC3 PF Sensor Synchronizing Roller Sensor...

  • Page 263: Solution

    Lower Feeder Unit Field Service Ver. 2.0 April 2005 Jam Display Solution 1.5.1 Initial check items • When a paper misfeed occurs, first check the following initial check items. Check Item Action Does the paper meet product specifications? Change the paper. Change the paper.

  • Page 264: Misfeed At The Tray 2 Paper Feed Section,, Tray 3 Paper Feed Section,

    Jam Display Lower Feeder Unit Field Service Ver. 2.0 April 2005 1.5.2 Misfeed at the Tray 2 paper feed section, Tray 3 paper feed section, and vertical conveyance section A. Detection Timing Type Description Detection of mis- feed at Tray 2 paper The paper does not block the Lower Feeder Paper Feed Sensor (PC3 PF) even feed section or Tray after the lapse of a given period of time after the paper feed sequence has been...
  • Page 265 Lower Feeder Unit Field Service Ver. 2.0 April 2005 Jam Display B. Action Relevant Electrical Parts Lower Feeder Paper Feed Sensor (PC3 PF) Lower Feeder Board (PWB-F PF) Synchronizing Roller Sensor (PC4) Mechanical Control Board (PWB-A) Paper Loop Sensor (PC6) Lower Feeder Right Door Switch (PC5 PF) Lower Feeder Paper Feed Clutch (CL1 PF) Synchronizing Roller Clutch (CL2)
  • Page 266 SERVICE MANUAL FIELD SERVICE Duplex Option 2005.04 Ver. 2.0...
  • Page 268 Duplex Transport Motor (M1) ................ 2-6 2.3.5 Duplex Reverse Motor (M2)................2-6 Troubleshooting Jam Display......................3-1 Misfeed Display (magicolor 5430 DL/5440 DL) ..........3-1 Misfeed Display (magicolor 5450)..............3-1 Misfeed Display Resetting Procedure..............3-1 Sensor layout ..................... 3-2 Solution......................3-3 1.5.1...
  • Page 269 Duplex Option Field Service Ver. 2.0 April 2005...

  • Page 270: Product Specifications

    Duplex Option Field Service Ver. 2.0 April 2005 Product specifications I General Product specifications Type Name Duplex Unit Type Switchback and Circulating Duplex Unit Installation Mounted on the right side door of main unit Reversing System Exit Roller switchback Conveyance system Rubber roller + driven rolls Document Alignment Center...
  • Page 271 Product specifications Duplex Option Field Service Ver. 2.0 April 2005...

  • Page 272: Ii Maintenance

    Duplex Option Field Service Ver. 2.0 April 2005 Periodic check II Maintenance Periodic check Maintenance procedure (Periodic parts check) NOTE • The alcohol used in this cleaning procedure is isopropyl alcohol. 1.1.1 Transport Roller A. Cleaning procedure 1. Open the Duplex Door. 2.

  • Page 273: Other

    Other Duplex Option Field Service Ver. 2.0 April 2005 Other Disassembly/adjustment-prohibited items A. Paint-locked screws NOTE • Paint-locked screws show that the assembly or unit secured can only be adjusted or set at the factory and should not be adjusted, set, or removed in the field. B.

  • Page 274: Disassembly/Assembly List (Other Parts)

    Duplex Option Field Service Ver. 2.0 April 2005 Other Disassembly/assembly list (other parts) Section Part name Ref. page ☞ Duplex Option ☞ Exterior parts Right Cover ☞ Board and etc. Duplex Board ☞ Duplex Transport Motor Others ☞ Duplex Reverse Motor...

  • Page 275: Disassembly/Assembly Procedure

    Other Duplex Option Field Service Ver. 2.0 April 2005 Disassembly/assembly procedure 2.3.1 Duplex Option 1. Open the Right Door. 2. Remove the Support Wire [1] from the machine. 3. Close the Right Door. 4538fs2501c0 4. Open the Duplex Option Door. 5.

  • Page 276: Right Cover

    Duplex Option Field Service Ver. 2.0 April 2005 Other 2.3.2 Right cover 1. Remove the Duplex Option. ☞ 2-4 2. Remove two screws and the Right Cover [2]. 4538fs2001c0 2.3.3 Duplex Board (PWB-E DU) 1. Remove the Right Cover. ☞ 2-5 2.

  • Page 277: Duplex Transport Motor (M1)

    Other Duplex Option Field Service Ver. 2.0 April 2005 2.3.4 Duplex Transport Motor (M1) 1. Remove the Duplex Board. ☞ 2-5 2. Remove two screws [1], disconnect the connector [2], and remove the Duplex Transport Motor [3]. 4538fs2005c1 2.3.5 Duplex Reverse Motor (M2) 1.

  • Page 278: Iii Troubleshooting

    Duplex Option Field Service Ver. 2.0 April 2005 Jam Display III Troubleshooting Jam Display Misfeed Display (magicolor 5430 DL/5440 DL) • When a paper misfeed occurs, a message is displayed on the Control Panel. 4538fs4503e0 Display Misfeed location Misfeed clearing location Ref.

  • Page 279: Sensor Layout

    Jam Display Duplex Option Field Service Ver. 2.0 April 2005 Sensor layout 4538fs4502c0 Sensor on Duplex Board PWB-E DU Synchronizing Roller Sensor PWB-E DU...

  • Page 280: Solution

    Duplex Option Field Service Ver. 2.0 April 2005 Jam Display Solution 1.5.1 Initial Check Items • When a paper misfeed occurs, first make checks of the following initial check items. Check Item Action Does paper meet product specifications? Change paper. Change paper.

  • Page 281: Misfeed At Duplex Option Paper Feed Section

    Jam Display Duplex Option Field Service Ver. 2.0 April 2005 1.5.2 Misfeed at Duplex Option paper feed section A. Detection Timing Type Description Detection of mis- The paper does not block the Synchronizing Roller Sensor (PC4) even after the feed at Duplex lapse of a given period of time after the paper feed sequence has been started at Option paper feed the Duplex Option.

  • Page 282: Misfeed At Duplex Option Paper Conveyance Section

    Duplex Option Field Service Ver. 2.0 April 2005 Jam Display 1.5.3 Misfeed at Duplex Option paper conveyance section A. Detection Timing Type Description The paper does not block the Synchronizing Roller Sensor (PC4) even after the Detection of mis- lapse of a given period of time after the sensor on the Duplex Board (PWB-E DU) feed at Duplex has been blocked.

  • Page 283: Undefined Misfeed

    Miscellaneous Malfunctions Duplex Option Field Service Ver. 2.0 April 2005 1.5.4 Undefined misfeed A. Detection Timing Type Description Detection of unde- Conflicting settings are made in the printer driver. fined misfeed B. Action Relevant Electrical Parts Print Control Board (PWB-P) Mechanical Control Board (PWB-A) WIRING DIAGRAM Location...
  • Page 284 © 2005 KONICA MINOLTA BUSINESS TECHNOLOGIES, INC. © 2005 KONICA MINOLTA BUSINESS TECHNOLOGIES, INC. Printed in Japan Printed in Japan Use of this manual should be strictly supervised to Use of this manual should be strictly supervised to 4138-7991-31 4138-7991-31 avoid disclosure of confidential information.

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Magicolor 5440 dlMagicolor 5450

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