5430 Service Manual

SERVICE MANUAL

2005.042005.04Ver. 3.0Ver. 3.0

2005.04

V

er.3

.02005

.04 V

er.3

.0

2005 KONICA MINOLTA BUSINESS TECHNOLOGIES, INC. 2005 KONICA MINOLTA BUSINESS TECHNOLOGIES, INC.

FIELD SERVICE

FIELD SERVIC

E

Printed in JapanPrinted in Japan4138-7991-314138-7991-31Use of this manual should be strictly supervised to

avoid disclosure of confidential information.Use of this manual should be strictly supervised toavoid disclosure of confidential information.

magicolor 5430 DLmagicolor 5440 DLmagicolor 5450


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SAFETY AND IMPORTANT WARNING ITEMS

Read carefully the Safety and Important Warning Items described below to understand them before doing service work.

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.Changes may have beManual was printed. Athe information containThe user of this Servicthe product while serviTherefore, this Servicecourse of technical traithe product properly.Keep this Service Man

In this Service Manual" CAUTION" is definmeaning. When servicing the prorepair, maintenance, e

Symbols used for safe


IMPORTANT NOTICE

DESCRIPTIOWARNING AN

DANGER: Actio

WARNING: Act

CAUTION: Actitrou

:Precaution whenproduct.

:Prohibition whenproduct.

:Direction when sproduct.

5450_E.book_PDF.book 1 S-1

en made to this product to improve its performance after this Service ccordingly, KMBT does not warrant, either explicitly or implicitly, that ed in this Service Manual is complete and accurate.e Manual must assume all risks of personal injury and/or damage to cing the product for which this Service Manual is intended. Manual must be carefully read before doing service work both in the ning and even after that, for performing maintenance and control of

ual also for future service.

, each of three expressions " DANGER", " WARNING", and ed as follows together with a symbol mark to be used in a limited

duct, the relevant works (disassembling, reassembling, adjustment, tc.) need to be conducted with utmost care.

ty and important warning items are defined as follows:

N ITEMS FOR DANGER, D CAUTION

n having a high possibility of suffering death or serious injury

ion having a possibility of suffering death or serious injury

on having a possibility of suffering a slight wound, medium ble, and property damage

servicing theGeneral

precautionElectric hazard High temperature

servicing the General

prohibitionDo not touch with wet hand

Do not disassemble

ervicing the General

instructionUnplug Ground/Earth


[1] MODIFICATIONS NOT AUTHORIZED BY KONICA MINOLTA BUSINESS TECHNOLOGIES, INC.

KONICA MINOLTA brand products are renowned for their high reliability. This reliability is achieved through high-quality design and a solid service network.Product design is a highly complicated and delicate process where numerous mechanical, physical, and electrical aspects have to be taken into consideration, with the aim of arriving at proper tolerances and safety factors. For this reason, unauthorized modifications involve a high risk of degradatstrictly prohibited. the ping behind this policy.

SAFETY WARNINGS

D Using any cables or

Using any fuse or thSafety will not be asinjury.

Disabling fuse functwire, metal clips, so

Disabling relay funcrelay contacts)

Disabling safety funSafety will not be asinjury.

Making any modificby KMBT

Using parts not spe


ion in performance and safety. Such modifications are therefore oints listed below are not exhaustive, but they illustrate the reason-

ANGER : PROHIBITED ACTIONS power cord not specified by KMBT.

ermostat not specified by KMBT. sured, leading to a risk of fire and

ions or bridging fuse terminals with lder or similar object.

tions (such as wedging paper between

ctions (interlocks, safety circuits, etc.) sured, leading to a risk of fire and

ation to the product unless instructed

cified by KMBT


[2] CHECKPOINTS WHEN PERFORMING ON-SITE SERVICEKonica 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. In order to maintain safety and reliability, the CE must perform regular safety checks.

1. Power Supply

WARNING: Wall Outlet

Check that mains vocord into the dedicathan the maximum If excessive currenresult.

If two or more poweoutlet, the total loadoutlet.If excessive currenresult.

Make sure the powesecurely.Contact problems overheating, and t

Check whether the whether the sheathIf the power plug, cwith a new power end) specified by Kmay result in fire o

When using the powproduct, be sure to a. Make sure the co

on the left side pab. If the power cord

new power cord (KMBT. If the power cordproduct securely,increased resista


ltage is as specified. Plug the power ted wall outlet with a capacity greater power consumption.t flows in the wall outlet, fire may

r cords can be plugged into the wall must not exceed the rating of the wall

t flows in the wall outlet, fire may

WARNING: Power Plug and Cord

r cord is plugged in the wall outlet

may lead to increased resistance, he risk of fire.

power cord is damaged. Check is damaged.ord, or sheath is damaged, replace

cord (with plug and connector on each MBT. Using the damaged power cord

r electric shock.

er cord (inlet type) that came with this observe the following precautions: nnector is securely inserted in the inlet nel of the product.

or sheath is damaged, replace with a with plugs on both ends) specified by

(inlet type) is not connected to the a contact problem may lead to nce, overheating, and risk of fire.


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.

Check whether dusand wall outlet.Using the power pdust may result in

Do not insert the pohand.The risk of electric

When unplugging thcable.The cable may be electric shock.

WARNING: Power Plug and Cord

Never use multi-plugin the same outlet.If used, the risk of

When an extensionCurrent that can flousing a too long extDo not use an exteup. Fire may resul


t is collected around the power plug

lug and wall outlet without removing fire.

wer plug into the wall outlet with a wet

shock exists.

e power cord, grasp the plug, not the

broken, leading to a risk of fire and

WARNING: Wiring

adapters to plug multiple power cords

fire exists.

cord is required, use a specified one.w in the extension cord is limited, so ension cord may result in fire.nsion cable reel with the cable taken

t.


2. Installation Requi

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.

For the product whiAttach power plugage and input currplug shall meet thethe region, and sh

WARNING: Wiring

Check whether the If current leakage may suffer electricConnect power plu

W

Do not place the protile materials that mA risk of fire exists

Do not place the proas rain.A risk of fire and e

WARNI

When the product istime (holidays, etc.)cord.Dust collected arocause fire.


rements

ch power plug is not attached. adequate for the products rated volt-ent before the installation. The power requirements of safety regulation for

all have grounding terminal.

WARNING: Ground Connection

product is grounded properly.occurs in an ungrounded product, you shock while operating the product. g to grounded wall outlet.

ARNING: Prohibited Installation Places

duct near flammable materials or vola-ay catch fire..

duct in a place exposed to water such

lectric shock exists.

NG: When not Using the Product for a long time

not used over an extended period of , switch it off and unplug the power

und the power plug and outlet may


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. When the product is used in a poorly ventilated roomb. When taking a lot of copiesc. When using multiple products at the same time

Be sure to lock the In the case of an eslide, leading to a

Before conducting amentation (service proceed with the inscedure, using only tadjustment not desIf the prescribed puct may break and

Before conducting athe power plugs froWhen the power punits are still poweturned OFF. A risk

The area around thYou may get burnt


CAUTION: Stability

caster stoppers.arthquake and so on, the product may injury.

CAUTION: Inspection before Servicing

n inspection, read all relevant docu-manual, technical notices, etc.) and pection following the prescribed pro-he prescribed tools. Do not make any cribed in the documentation.rocedure or tool is not used, the prod- a risk of injury or fire exists.n inspection, be sure to disconnect

m the product and options.lug is inserted in the wall outlet, some red even if the POWER switch is of electric shock exists.

e fixing unit is hot..


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.

Take every care when servicing with the external cover detached.High-voltage existstric shock exists.

Check the exterior adamages.The user or CE ma

Do not allow any mescrews to fall into thThey can short intor fire.

Check wiring for squCurrent can leak, lfire.

Carefully remove alcal parts and electrunit.Current can leak, lfire.

Check high-voltageCurrent can leak, lfire.

Check electrode undeterioration and siCurrent can leak, l


around the drum unit. A risk of elec-

WARNING: Safety Checkpoints

nd frame for edges, burrs, and other

y be injured.tal parts such as clips, staples, and

e product.ernal circuits and cause electric shock

eezing and any other damage. eading to a risk of electric shock or

l toner remnants and dust from electri-ode units such as a charging corona

eading to a risk of product trouble or

cables and sheaths for any damage.eading to a risk of electric shock or

its such as a charging corona unit for gn of leakage.eading to a risk of trouble or fire.


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.

Do not remove the cover of the write unit. Do not supply power with the write unit shifted from the specified mount-ing position.The laser light canloss of eyesight.

When replacing a liium battery specifieof the used lithium blocal authority.Improper replacem

After replacing a paoptical lamp and fixtion state.A risk of fire exists

Check the interlockcheck whether the iIf the interlock doeelectric shock or bthe product (e.g., f

Make sure the wirinedges, burrs, or othCurrent can leak, lfire.

Make sure that all stors, etc. that were nance have been respecial attention to forgotten screws, etA risk of product tr

WARNING: Safety Checkpoints


enter your eye, leading to a risk of

thium battery, replace it with a new lith-d in the Parts Guide Manual. Dispose attery using the method specified by

ent can cause explosion.

rt to which AC voltage is applied (e.g., ing lamp), be sure to check the installa-

.

switch and actuator for loosening and nterlock functions properly.s not function, you may receive an e injured when you insert your hand in or clearing paper jam).g cannot come into contact with sharp er pointed parts.eading to a risk of electric shock or

crews, components, wiring, connec-removed for safety check and mainte-installed in the original location. (Pay forgotten connectors, pinched cables, c.)ouble, electric shock, and fire exists.


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.If the substances get in the eye, rinse with plenty of water immediately. When symptoms are noticeable, consult a physician.

Never throw the useYou may be burne

CAUT

Unplug the power cDrum cleaner (isoptone-based) are hiwith care. A risk of

Do not replace the cany solvent remnanevaporated.A risk of fire exists

Use only a small amcare not to spill anywipe it off.A risk of fire exists

When using any soBreathing large qudiscomfort.


d cartridge and toner into fire.d due to dust explosion.

ION: HANDLING OF SERVICE MATERIALS

ord from the wall outlet.ropyl alcohol) and roller cleaner (ace-

ghly flammable and must be handled fire exists.

over or turn the product ON before ts on the cleaned parts have fully

.

ount of cleaner at a time and take liquid. If this happens, immediately

.

lvent, ventilate the room well.antities of organic solvents can lead to


[3] MEASURES TO TAKE IN CASE OF AN ACCIDENT1. 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 preventfurther damage.

2. If a report of a serious accident has been received from a customer, an on-site evalua-tion must be carried out quickly and KMBT must be notified.

3. To determine the cause of the accident, conditions and materials must be recordedthrough direct on-site checks, in accordance with instructions issued by KMBT.

[4] CONCLUSION1. Safety of users an

administration. Thwork conducted b

2. When performingtomer engineer mthe equipment.


d customer engineers depends highly on accurate maintenance anderefore, safety can be maintained by the appropriate daily servicey the customer engineer. service, each product on the site must be tested for safety. The cus-ust verify the safety of parts and ensure appropriate management of


[5] Laser Safety This is a digital machine certified as a class 1 laser product. There is no possibility of

danger from a laser, provided the machine is serviced according to the instruction in this manual.

5.1 Internal Laser Radiation

*:at laser aperture of th

This product employdiode and the scann

The print head unit ishould not be opene

semiconductor laserMaximum power of the laser diode 15 mW

Maximum average radiation power (*) 7.2 WWavelen

This figure shows theinside the Front Door


e Print Head Unit

s a Class 3b laser diode that emits an invisible laser beam. The laser ing polygon mirror are incorporated in the print head unit.s NOT A FIELD SERVICEABLE ITEM. Therefore, the print head unit d under any circumstances.

gth 770-800 nm

4138safe002c0

view .

Laser Aperture ofthe Print Head Unit


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. Food and Drug Administration of the U.S. Department of Health and Human Services (DHHS). This means that the device does not produce hazardous laser radiation.

The label shown to page 16 indicates compliance with the CDRH regulations and must be attached to laser products marketed in the United States.

.

All Areas

Denmark

CAUTION Use of controls, a

specified in this m

Maximum poweWav

CAUTION Use of controls, a

specified in this m

Maximum poweWav

ADVARSEL Usynlig laserstr

Undg udsttelssikkerheds krave

Laserdiodenblge


djustments or performance of procedures other than those anual may result in hazardous radiation exposure.

semiconductor laserr of the laser diode 15 mWelength 770-800 nm

djustments or performance of procedures other than those anual may result in hazardous radiation exposure.

semiconductor laserr of the laser diode 15 mWelength 770-800 nm

ling ved bning, nr sikkerhedsafbrydere er ude af funktion. e for strling. Klasse 1 laser produkt der opfylder IEC60825-1 ne.

halvlederlasers hjeste styrke 15 mWlngden 770-800 nm


Finland, Sweden

Norway

LUOKAN 1 LASERLAITEKLASS 1 LASER APPARAT

VAROITUS! Laitteen kyttminen muulla kuin tss kyttohjeessa mainitulla tavalla saat-

taa altistaa kyttjn turvallisuusluokan 1 ylittvlle nkymttmlle laser-steilylle.

puolijohdelaserLaserdiodi

aallo

VARNING! Om apparaten an

kan anvndaren ufr laserklass 1.

Den maximala effevgl

VARO! Avattaessa ja suo

steilylle. l kat

VARNING! Osynlig laserstr

Betrakta ej strie

ADVERSEL Dersom apparate

ing, kan brukerenfor laser klass 1.

Maksimal effeblge


n suurin teho 15 mWnpituus 770-800 nm

vnds p annat stt n i denna bruksanvisning specificerats, tsttas fr osynlig laserstrlning, som verskrider grnsen

halvledarlaser kten fr laserdioden 15 mW

ngden 770-800 nm

jalukitus ohitettaessa olet alttiina nkymttomlle laser-so steeseen.

ining nr denna del r ppnad och sprren r urkopplad. n.

t brukes p annen mte enn spesifisert i denne bruksanvisn- utsettes fr unsynlig laserstrlning, som overskrider grensen

halvleder laserkt till laserdiode 15 mWlengde 770-800 nm


5.2 Laser Safety Label A laser safety label is attached to the the machine as shown below.


4138safe004c0


5.3 Laser Caution Label A laser caution label is attached to the inside of the machine as shown below.

5.4 PRECAUTI When laser protectiv

above specifications When a disassembly

working around the If the job requires th

protective goggles. A highly reflective to

utmost care when h The Print Head are

Assembly including perform Control Boa


ONS FOR HANDLING THE LASER EQUIPMENTe goggles are to be used, select ones with a lens conforming to the .

job needs to be performed in the laser beam path, such as when printerhead and PC Drum, be sure first to turn the printer OFF.at the printer be left ON, take off your watch and ring and wear laser

ol can be dangerous if it is brought into the laser beam path. Use andling tools on the users premises.not to be disassembled or adjusted in the field. Replace the Unit or the Control Board. Therefore, remove the Laser Diode, and do not rd trimmer adjustment.

4138safe001c0


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.

WARNING INDICATIONS ON THE MACHINE

High tempe


4138fsS001c0

rature

High voltage


High voltag

High volta


4138fsS002c0

e

ge

SERVICE MANUAL

2005.04Ver. 3.0

FIELD SERVICE


Main Unit

5450_E.book_PDF.book 1

5450_E.book_PDF.book 2

Main Unit Field Service

I Out

line

CONTENTS

I Outline1. System configuration............................................................................................1-12. Product Specifications..........................................................................................1-2

2.1 Type ...................................................................................................................1-22.2 Functions ...........................................................................................................1-32.3 Maintenance ......................................................................................................1-52.4 Machine Specifications ......................................................................................1-52.5 Operating En

II Maintenan1. Periodic Check

1.1 Service sche1.2 Maintenance

1.2.1 Parts to b1.2.2 Parts to b

1.3 Maintenance1.4 Concept of p1.5 Maintenance

1.5.1 Feed Roll1.5.2 Feed Roll1.5.3 Ozone Fil1.5.4 Toner Car1.5.5 Waste Ton1.5.6 Cleaning

1.6 Replacing Un1.6.1 Replacing1.6.2 Replacing1.6.3 Replacing

2. Service tool ...2.1 CE Tool list..2.2 Consumable

2.2.1 Toner Car2.2.2 Waste Ton2.2.3 Maintenan

3. Firmware Upg3.1 Print Control

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vironment......................................................................................1-6

ce.....................................................................................................2-1

dule ...............................................................................................2-1 Items ............................................................................................2-2e replaced by users (CRU)............................................................2-2e Replaced by a Service Engineer (FRU) .....................................2-3 parts .............................................................................................2-3arts life...........................................................................................2-4 Procedure (Periodic Parts Check)................................................2-6er (Tray 1) ......................................................................................2-6er (Manual Feed Tray) (magicolor 5440 DL/5450 only) .................2-7ter ................................................................................................2-10tridge (C/M/Y/Bk) ........................................................................2-10er Bottle .....................................................................................2-13

the Laser Irradiation Section .......................................................2-14its................................................................................................2-15 the Transfer Roller .....................................................................2-15 the Transfer Belt Unit .................................................................2-16 the Fusing Unit ..........................................................................2-19..................................................................................................... 2-20..................................................................................................... 2-20 Parts ...........................................................................................2-20tridge (TC) (as an individual part) ...............................................2-20er Bottle .....................................................................................2-20ce Kit..........................................................................................2-20

rade .............................................................................................2-21 Board (PWB-P) Firmware Upgrading ......................................... 2-21

Main Unit Field ServiceI O

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3.1.1 Upgrade procedure (magicolor 5430 DL/5440 DL) .................................... 2-213.1.2 Upgrade procedure (magicolor 5450) ........................................................ 2-23

4. Other .................................................................................................................. 2-284.1 Disassembly/Adjustment-Prohibited Items...................................................... 2-284.2 Names of Feed Trays....................................................................................... 2-284.3 Disassembly/Assembly list (Other parts)......................................................... 2-294.4 Disassembly/Assembly Procedure .................................................................. 2-30

4.4.1 Front Door, Upper Front Cover, and Right Front Cover .............................. 2-304.4.2 Left Cover................................................................................................... 2-314.4.3 Rear Cov4.4.4 Exit Tray.4.4.5 Rear Righ4.4.6 Tray 1.....4.4.7 Manual F4.4.8 Control P4.4.9 Hard Disk4.4.10 Print Con4.4.11 Print Con4.4.12 Backup B4.4.13 Mechanic4.4.14 Low Volta4.4.15 High Volta4.4.16 High Volta4.4.17 Toner Lev4.4.18 PH Unit ..4.4.19 PWB Box4.4.20 PWB Box4.4.21 Developin4.4.22 Color PC 4.4.23 Developin4.4.24 Toner Sup4.4.25 Toner Sup4.4.26 Fusing M4.4.27 Intermedi4.4.28 Synchron4.4.29 Pressure/4.4.30 Pressure/4.4.31 Tray 1 Pa

5450_E.book_PDF.book ii ii

er ................................................................................................. 2-31..................................................................................................... 2-32t Cover........................................................................................ 2-32

..................................................................................................... 2-33eed Tray (magicolor 5440 DL/5450 only)..................................... 2-33anel (PWB-OP)............................................................................ 2-34 Unit (HDD) (magicolor 5450 only) ............................................. 2-34trol Board (PWB-P) (magicolor 5430 DL/5440 DL) ..................... 2-35trol Board (PWB-P) (magicolor 5450).......................................... 2-36attery (magicolor 5450 only) ....................................................... 2-37al Control Board (PWB-A)........................................................... 2-38ge Unit (LV) ................................................................................. 2-41ge Unit /1 (HV1) ......................................................................... 2-42ge Unit /2 (HV2) ......................................................................... 2-43el Sensor Board (PWB-D)........................................................... 2-44..................................................................................................... 2-46/1 ................................................................................................. 2-47/2 ................................................................................................. 2-48g Motor /Y, M, C (M1) ................................................................. 2-48Drum Motor (M2) ........................................................................ 2-48g Motor /K (M5)........................................................................... 2-49ply Motor /Y, M (M6) ................................................................... 2-49ply Motor /C, K (M7) ................................................................... 2-49

otor (M4) ...................................................................................... 2-50ate Transport Motor (M3)............................................................. 2-50izing Roller Clutch (CL2) ............................................................. 2-50Retraction Clutch /2nd Image Transfer (CL5).............................. 2-51Retraction Clutch /1st Image Transfer (CL4)............................... 2-53per Feed Clutch (CL1) ................................................................. 2-54


I Out

line

4.4.32 Manual Feed Tray Paper Feed Clutch (CL3) (magicolor 5440 DL/5450 only) ..................................................................2-58

4.4.33 Temperature/ Humidity Sensor (HS1).........................................................2-634.4.34 AIDC Sensor/Rt, AIDC Sensor/Lt (AIDC R, AIDC L)..................................2-644.4.35 Camera Direct Photo Print Card (magicolor 5440 DL only)........................2-65

III Adjustment/Setting1. How to Use the Adjustment Section.....................................................................3-12. Adjustment Item List.............................................................................................3-2

2.1 magicolor 542.2 magicolor 54

3. Description of (magicolor 543

3.1 Control Pane3.1.1 Basic scre3.1.2 Warning s3.1.3 Error disp3.1.4 Caution d

3.2 List of Contro3.2.1 Normal st3.2.2 Caution m3.2.3 Minor erro3.2.4 Error mes3.2.5 Serious e3.2.6 Malfunctio3.2.7 Message

3.3 Canceling a 4. Menu (magico

4.1 List of Menu 4.2 SPECIAL PA

4.2.1 PRINT CO4.2.2 PRINT TE4.2.3 PRINT ME

4.3 LANGUAGE4.4 ENGINE......

4.4.1 ENGINE T4.4.2 ENERGY4.4.3 AUTO CO4.4.4 TRAY CH

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30 DL/5440 DL..............................................................................3-250 ..................................................................................................3-3the Control Panel 0 DL /5440 DL) .............................................................................3-4l Display ........................................................................................3-4en .................................................................................................3-4creen ............................................................................................3-4lay..................................................................................................3-4isplay .............................................................................................3-5l Panel Messages .........................................................................3-6ate messages................................................................................3-6essages........................................................................................3-6r messages...................................................................................3-7sages ............................................................................................3-7rror messages ...............................................................................3-8n messages..................................................................................3-9Priority for Consumables/Periodic Replacement Parts (Units)....3-10Print Job ......................................................................................3-11lor 5430 DL /5440 DL) .................................................................3-12Functions.....................................................................................3-12GES.............................................................................................3-13NFIG PAGE ............................................................................... 3-13ST PAGES.................................................................................. 3-13NU MAP ....................................................................................3-13

..................................................................................................... 3-13

.....................................................................................................3-14ONER EMPTY...........................................................................3-14

SAVER .......................................................................................3-14NTINUE ......................................................................................3-14AINING........................................................................................3-14


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4.4.5 ENGINE SERVICE..................................................................................... 3-154.5 NETWORK ...................................................................................................... 3-17

4.5.1 DHCP:XX / BOOTP:XX .............................................................................. 3-174.5.2 IP ADDRESS.............................................................................................. 3-174.5.3 SUBNET MASK.......................................................................................... 3-174.5.4 GATEWAY .................................................................................................. 3-184.5.5 MAC ADDRESS ......................................................................................... 3-184.5.6 HTTP.......................................................................................................... 3-184.5.7 SNMP......................................................................................................... 3-184.5.8 FORCED

4.6 CONSUMAB4.6.1 BLACK T4.6.2 CYAN TO4.6.3 MAGENT4.6.4 YELLOW

4.7 DIRECT PRI4.7.1 IMAGE Q4.7.2 PAPER S4.7.3 MEDIA TY4.7.4 LAYOUT.4.7.5 BRIGHTN4.7.6 SHARPN4.7.7 AUTO RO

5. Service Mode 5.1 Service Mod5.2 Service Mod5.3 Settings/Adju

5.3.1 RESTOR5.3.2 SERVICE5.3.3 RESET C5.3.4 RESET C

6. Description of 6.1 Control Pane

6.1.1 Parts of th6.1.2 Message 6.1.3 Normal m6.1.4 Menu .....6.1.5 Operator

5450_E.book_PDF.book iv iv

MODES...................................................................................... 3-18LE USAGE.................................................................................. 3-19ONER .......................................................................................... 3-19NER ............................................................................................ 3-19A TONER..................................................................................... 3-19 TONER ....................................................................................... 3-19NT ............................................................................................... 3-19UALITY........................................................................................ 3-19IZE............................................................................................... 3-20PE.............................................................................................. 3-20

..................................................................................................... 3-20ESS............................................................................................ 3-20

ESS ............................................................................................. 3-20TATE ........................................................................................... 3-20(magicolor 5430 DL/5440 DL)..................................................... 3-21e Entry Procedure ....................................................................... 3-21e Function Tree............................................................................ 3-21stments in Service/Service Person Mode Functions.................. 3-22

E FACTORY DEFAULT ................................................................ 3-22 PERSON SRU USAGE.............................................................. 3-24ONTROLLER.............................................................................. 3-24OUNTER FUSER UNIT .............................................................. 3-25the Control Panel (magicolor 5450) ............................................ 3-26l Display ...................................................................................... 3-26e Control Panel Display.............................................................. 3-26structure...................................................................................... 3-27essages ...................................................................................... 3-28..................................................................................................... 3-32Call messages............................................................................. 3-33


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6.1.6 Service Call messages............................................................................... 3-346.1.7 Help screen ................................................................................................3-35

6.2 List of Control Panel Messages .......................................................................3-366.2.1 Normal messages.......................................................................................3-366.2.2 Operator Call messages.............................................................................3-386.2.3 Service Call messages............................................................................... 3-40

6.3 Canceling a Print Job ......................................................................................3-417. Menu (magicolor 5450) ......................................................................................3-42

7.1 List of Menu Functions.....................................................................................3-427.1.1 Outline ...7.1.2 Detail .....

7.2 PROOF/PRIN7.3 PRINT MENU

7.3.1 CONFIGU7.3.2 DEMO PA7.3.3 STATISTI7.3.4 FONT LIS7.3.5 MENU MA7.3.6 DIRECTO

7.4 PAPER MEN7.4.1 PAPER S7.4.2 DUPLEX7.4.3 COPIES .7.4.4 COLLATE7.4.5 UNIT OF

7.5 QUALITY ME7.5.1 COLOR M7.5.2 BRIGHTN7.5.3 PCL CON7.5.4 PS PROF7.5.5 IMAGE P7.5.6 TEXT PR7.5.7 GRAPHIC7.5.8 CALIBRA7.5.9 COLOR S7.5.10 SUPPLIE

7.6 INTERFACE7.6.1 JOB TIME

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..................................................................................................... 3-42

.....................................................................................................3-43T MENU.....................................................................................3-45..................................................................................................3-45

RATION PG................................................................................ 3-45GE ..............................................................................................3-45

CS PAGE .....................................................................................3-46T .................................................................................................3-46P ................................................................................................3-46RY LIST ......................................................................................3-46U .................................................................................................3-47OURCE .......................................................................................3-47..................................................................................................... 3-50..................................................................................................... 3-50.................................................................................................... 3-50MEASURE .................................................................................. 3-51NU..............................................................................................3-52ODE ...........................................................................................3-52ESS ............................................................................................3-52TRAST........................................................................................3-52ILE ..............................................................................................3-52RINTING......................................................................................3-54INTING ........................................................................................3-55S PRINTING............................................................................... 3-56

TION ............................................................................................3-57EPARATION ............................................................................... 3-57S ..................................................................................................3-58 MENU .........................................................................................3-59OUT ...........................................................................................3-59


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7.6.2 ETHERNET................................................................................................ 3-597.7 SYS DEFAULT MENU ..................................................................................... 3-63

7.7.1 LANGUAGE................................................................................................ 3-637.7.2 EMULATION............................................................................................... 3-637.7.3 DEFAULT PAPER ....................................................................................... 3-677.7.4 STARTUP OPTIONS /DO STARTUP PAGE............................................... 3-687.7.5 AUTO CONTINUE...................................................................................... 3-697.7.6 HOLD JOB TIMEOUT ................................................................................ 3-697.7.7 ENERGY SAVER ....................................................................................... 3-697.7.8 ENERGY7.7.9 MENU TI7.7.10 LCD BRIG7.7.11 SECURIT7.7.12 CLOCK..7.7.13 HDD FOR7.7.14 RESTOR7.7.15 ENABLE 7.7.16 TONER E

8. Service Menu 8.1 How to Enter8.2 Service mod8.3 Service Men

8.3.1 SERIAL N8.3.2 FIRMWAR8.3.3 ALIGNME8.3.4 TRANSFE8.3.5 RESTOR

IV Troublesho1. Jam Display...

1.1 Misfeed Disp1.2 Misfeed Disp1.3 Misfeed Disp1.4 Sensor Layo1.5 Solutions.....

1.5.1 Initial Che1.5.2 Misfeed a

(Misfeed a

5450_E.book_PDF.book vi vi

SAVER TIME.............................................................................. 3-70MEOUT........................................................................................ 3-70

HTNESS.................................................................................... 3-70Y ................................................................................................. 3-71..................................................................................................... 3-72MAT............................................................................................ 3-72

E DEFAULTS ............................................................................... 3-73WARNING................................................................................... 3-77MPTY ......................................................................................... 3-78(magicolor 5450) ......................................................................... 3-79 the Service Menu....................................................................... 3-79e function tree.............................................................................. 3-79u Setting/Adjustment ................................................................... 3-80UMBER...................................................................................... 3-80E VERSION............................................................................... 3-80NT .............................................................................................. 3-80R POWER /IMAGE ADJ PARAM............................................... 3-83

E PASSWARD ............................................................................. 3-84

oting....................................................................................................... 4-1lay (magicolor 5430 DL / 5440 DL) ............................................... 4-1lay (magicolor 5450) ..................................................................... 4-2lay Resetting Procedure ............................................................... 4-2ut ................................................................................................... 4-3....................................................................................................... 4-4ck Items ........................................................................................ 4-4t Tray 1 media feed section t Tray 2 media feed section)......................................................... 4-5


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1.5.3 Misfeed at Manual Feed Tray media feed section (Misfeed at Tray 1 media feed section) .........................................................4-6

1.5.4 Misfeed at transfer section............................................................................4-71.5.5 Misfeed at fusing/exit section........................................................................4-81.5.6 Undefined misfeed........................................................................................4-8

2. Malfunction code ..................................................................................................4-92.1 Trouble Codes (magicolor 5430 DL/5440 DL) ...................................................4-9

2.1.1 Trouble code list............................................................................................4-92.2 Trouble Codes (magicolor 5450)......................................................................4-12

2.2.1 Trouble co2.3 Resetting a M2.4 Solutions .....

2.4.1 0010H: C2.4.2 001BH: D2.4.3 0017H: In2.4.4 0018H: D2.4.5 0046H: Fu2.4.6 004CH: O2.4.7 004EH: LV2.4.8 0060H: Fu2.4.9 0094H: 2n2.4.10 0096H: 1s2.4.11 0300H: Po2.4.12 0310H: La2.4.13 0500H: H2.4.14 0501H: Fu2.4.15 0510H: A2.4.16 0511H: A2.4.17 0520H: A2.4.18 0521H: A2.4.19 13D0H: P2.4.20 13E2H: F

13E3H: F2.4.21 C002, C02.4.22 C013: MA

C015: BOC022: NV

2.4.23 C025, C02.4.24 C050: Ha

5450_E.book_PDF.book vii vii

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de list..........................................................................................4-12alfunction ................................................................................... 4-15

.....................................................................................................4-15olor PC Drum Motor malfunction .................................................4-15eveloping Motor/Y,M,C malfunction.............................................4-16termediate Transport Motor malfunction ..................................... 4-16eveloping Motor/K malfunction ....................................................4-17sing Cooling Fan Motor malfunction ..........................................4-17zone Ventilation Fan Motor malfunction...................................... 4-18 Cooling Fan Motor malfunction.................................................4-18sing Motor malfunction...............................................................4-19d image transfer pressure/retraction failure................................4-19t image transfer pressure/retraction failure.................................4-20lygon Motor malfunction............................................................. 4-20ser malfunction...........................................................................4-21

eating Roller warm-up failure ......................................................4-21sing Pressure Roller warm-up failure......................................... 4-21

bnormally low Heating Roller temperature ..................................4-21bnormally low Fusing Pressure Roller temperature.....................4-21bnormally high Heating Roller temperature .................................4-21bnormally high Fusing Pressure Roller temperature ................... 4-21arameter Chip failure...................................................................4-22lash ROM write errorlash ROM device fault..................................................................4-2203: RAM error (Only for magicolor 5450) ....................................4-22C address error (Only for magicolor 5450)OT ROM error (Only for magicolor 5450)RAM error (Only for magicolor 5450) ..........................................4-2326, C027: Controller ROM error (Only for magicolor 5450).........4-23rd disk access error (Only for magicolor 5450)............................4-24


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2.4.25 C051: Hard disk full error (Only for magicolor 5450).................................. 4-242.4.26 C060: Firmware Update error (Only for magicolor 5450) ........................... 4-252.4.27 C061: Hold job error/No Duplex unit (Only for magicolor 5450)

C062: Hold job error/No Tray 3 (Only for magicolor 5450)C063: Hold job error/No Tray 4 (Only for magicolor 5450)C064: Hold job error/No Memory (Only for magicolor 5450)...................... 4-25

2.4.28 FFFF: Interface Communication error (Only for magicolor 5450)............... 4-263. Power Supply Troubles....................................................................................... 4-27

3.1 Machine is Not Energized at All (LV Operation Check) ................................... 4-273.2 Control pane3.3 Fusing Heate

4. Miscellaneous(Only for magi

4.1 List of Misce4.2 ILLEGAL ER4.3 ERROR AID4.4 ERROR COM4.5 ERROR ENG4.6 ERROR RAM4.7 ERROR DIM4.8 ERROR ROM4.9 ERROR CON

5. Image Quality 5.1 Solutions.....

5.1.1 White lineand color

5.1.2 White lineand color

5.1.3 Uneven d5.1.4 Uneven d5.1.5 Low imag5.1.6 Gradation5.1.7 Foggy ba5.1.8 Poor colo5.1.9 Void area5.1.10 Colored s5.1.11 Blurred im5.1.12 Blank cop5.1.13 Incorrect 5.1.14 Poor fusin

5450_E.book_PDF.book viii viii

l indicators do not Light............................................................... 4-27rs do not Operate ....................................................................... 4-28

Malfunctions color 5430 DL/5440 DL) .............................................................. 4-29llaneous Malfunctions.................................................................. 4-29ROR DUPLEX............................................................................. 4-29C SENSOR.................................................................................. 4-30

MUNICATION............................................................................ 4-30INE INTERFACE........................................................................ 4-31................................................................................................... 4-31

M................................................................................................. 4-31.................................................................................................. 4-32

TROLLER .................................................................................. 4-32Problems..................................................................................... 4-33..................................................................................................... 4-33s in FD, white bands in FD, colored lines in FD,

ed bands in FD ............................................................................ 4-33s in CD, white bands in CD, colored lines in CD,

ed bands in CD............................................................................ 4-34ensity in FD ................................................................................. 4-35ensity in CD................................................................................. 4-36e density...................................................................................... 4-37 reproduction failure .................................................................... 4-38ckground...................................................................................... 4-39r reproduction .............................................................................. 4-40s, white spots .............................................................................. 4-41pots ............................................................................................. 4-42age ............................................................................................. 4-43y, black copy ............................................................................... 4-44color image registration ............................................................... 4-45g performance, offset ................................................................. 4-46


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5.1.15 Brush effect, blurred image.........................................................................4-475.1.16 Back marking..............................................................................................4-485.1.17 Uneven Pitch ..............................................................................................4-495.1.18 No print cycles can be run as commanded via the network .......................4-50

V Appendix1. Parts Layout Drawing ...........................................................................................5-1

1.1 Main unit ............................................................................................................5-11.2 Lower Feeder Unit (Option) ...............................................................................5-41.3 Duplex Optio

2. Connector Lay3. Timing chart ..

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n (Option) ......................................................................................5-5out Drawing ...................................................................................5-6.......................................................................................................5-7


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5450_E.book_PDF.book x x

Main Unit Field Service System configuration

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I Outline1. System configurationSystem Front View

[1] Duplex Option[2] Optional DIMM

[3] Optional Camera (magicolor 5440 D

[4] Optional Hard Dis(magicolor 5450 o

[5]

[6]

[7] [1]

5450_E.book_PDF.book 1 1-1

[5] Optional Lower Feeder Unit[6] Optional Lower Feeder Unit

Direct Photo Print Card L only) [7] Main Unit

k Drive (HDD)tnly)

4138fs1501c4

[2]

[3]

[4]

Product Specifications Main Unit Field ServiceI O

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2. Product Specifications2.1 Type

Type Desktop tandem full-color laser beam printerPrinting System Semiconductor laser and electrostatic image transfer to plain paperExposure System 4 laser diode and polygon mirrorPC Drum Type OPC (organic photo conductor)Photoconductor Cleaning Blade cleaning system

Print Density

m2m6

Paper Feeding System

mO*

mT*

mT*

Developing System SCharging System DImage Transfer System I

Paper Separating System C

Fusing System BPaper Exit System F


agicolor 5430 DL/5440 DL400 x 600 dpi x 1 bit, 1200 x 600 dpi x 1 bit, 600 x 600 dpi x 1 bitagicolor 545000 x 600 dpi x 4 bitagicolor 5430 DLne-way system (Tray 1: 250 sheets)

Expandable up to a three-way system by adding optional Lower Feeder Units (up to two)

agicolor 5440 DLwo-way system (Tray 1: 500 sheets, Manual Feed Tray: 100 sheets) Expandable up to a four-way system by adding optional Lower Feeder Units

(up to two)agicolor 5450

wo-way system (Tray 1: 100 sheets, Tray 2: 500 sheets) Expandable up to a four-way system by adding optional Lower Feeder Units

(up to two)ingle-element developing systemC comb electrode Scorotron system

ntermediate transfer belt system

urvature separation + charge-neutralizing system

elt fusingace down (Output Tray capacity: 250 sheets)

Main Unit Field Service Product Specifications

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2.2 Functions

Warm-up Time Average: 30 sec. or less (at ambient temperature of 23 C/73.4 F and rated source voltage)System Speed 152 mm/sec (Plain Paper)First-Page-Out-Time(Plain Paper)

1-sided: 14.2 seconds; 2-sided: 22.3 seconds (A4)1-sided: 14.1 seconds; 2-sided: 22.3 seconds (Letter)

Print Speed(Plain Paper)

magicolor 5430 DL1-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 Tray1magicolor 5440 DL11*

m11*

Custom Paper Sizes

mPPmPPmPP

Media Types

mT


-sided: 25.6 pages/min; 2-sided: 12.3 pages/min (A4)-sided: 27 pages/min; 2-sided: 12.5 pages/min (Letter) When feeding the paper from Tray1agicolor 5450-sided: 25.6 pages/min; 2-sided: 12.3 pages/min (A4)-sided: 27 pages/min; 2-sided: 12.5 pages/min (Letter) When feeding the paper from Tray 2agicolor 5430 DLaper width: 92 to 216 mm (3.6 to 8.5 inch) (Tray 1)aper length: 148 to 297 mm (5.8 to 11.7 inch) (Tray 1)agicolor 5440 DLaper width: 92 to 216 mm (3.6 to 8.5 inch) (Manual Feed Tray)aper length: 148 to 356 mm (5.8 to 14.0 inch) (Manual Feed Tray)agicolor 5450aper width: 92 to 216 mm (3.6 to 8.5 inch) (Tray 1)aper length: 148 to 355.6 mm (5.8 to 14.0 inch) (Tray 1)agicolor 5430 DL

ray 1Plain paper (60 to 90 g/m2 / 16 to 24 lb)Recycled paper (60 to 90 g/m2 / 16 to 24 lb)OHP transparenciesThick stock 1 (91 to 150 g/m2/ 24 to 40 lb)Thick stock 2 (151 to 210 g/m2/ 41 to 56 lb)PostcardsDouble postcards (Print before folding)EnvelopesLetterheadLabels


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Media Types

magicolor 5440 DL Tray 1 Plain paper (60 to 90 g/m2 / 16 to 24 lb) Recycled paper (60 to 90 g/m2 / 16 to 24 lb)Manual Feed Tray Plain paper (60 to 90 g/m2 / 16 to 24 lb) Recycled paper (60 to 90 g/m2 / 16 to 24 lb) OHP transparencies Thick stock 1 (91 to 150 g/m2/ 24 to 40 lb) Thick stock 2 (151 to 210 g/m2/ 41 to 56 lb) Postcards

mT

T

Tray Capacities

mPLTlaEmPPTleEmPTleEP


Double postcards (Print before folding)EnvelopesLetterheadLabelsagicolor 5450

ray 1Plain paper (60 to 90 g/m2 / 16 to 24 lb)Recycled paper (60 to 90 g/m2 / 16 to 24 lb)OHP transparenciesThick stock 1 (91 to 150 g/m2/ 24 to 40 lb)Thick stock 2 (151 to 210 g/m2/ 41 to 56 lb)PostcardsDouble postcards (Print before folding)EnvelopesLetterheadLabels

ray 2 (Manual Feed Tray)Plain paper (60 to 90 g/m2 / 16 to 24 lb)Recycled paper (60 to 90 g/m2 / 16 to 24 lb)agicolor 5430 DLlain paper and recycled paper: 250 sheets (Tray 1)etterhead: 150 sheets (Tray 1)ransparencies, thick stock 1, thick stock 2, postcards, double postcards, and bels: 20 sheets (Tray 1)nvelopes: 10 sheets (Tray 1)agicolor 5440 DLlain paper and recycled paper: 500 sheets (Tray 1)lain paper and recycled paper: 100 sheets (Manual Feed Tray)ransparencies, thick stock 1, thick stock 2, postcards, double postcards, tterhead, and labels: 20 sheets (Manual Feed Tray)nvelopes: 10 sheets (Manual Feed Tray)agicolor 5450lain paper and recycled paper: 100 sheets (Tray 1)ransparencies, thick stock 1, thick stock 2, postcards, double postcards, tterhead, and labels: 20 sheets (Tray 1)nvelopes: 10 sheets (Tray 1)lain paper and recycled paper: 500 sheets (Tray 2)

Main Unit Field Service Product Specifications

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Lower Feeder Unit: Onlb)

Duplex Option: Onlb)

For details, see the

2.3 Maintenanc

2.4 Machine Sp

Interfaces

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 Camera Direct Photo Print Card is installed.

magicolor 5450 Parallel (IEEE 1284) Support only an ECP mode USB 2.0 (High-Speed) compliant 10 Base-T/100 Base-TX/1000 Base-T (IEEE 802.3) Ethernet

CPU magicolor 5430 DL/5440 DLARM9 956EJ-S 200 MHz

Standard memory

mMm6

Hard disk m2

Machine Durability 4

Power RequirementsVoltage:

AA

Frequency: 5Max Power Consumption 1

Dimensions 41

Weight

mAmA

Operating Noise DD


ly plain paper and recycled paper weighing 60 to 90 g/m2 (16 to 24 can be loaded.ly plain paper and recycled paper weighing 60 to 90 g/m2 (16 to 24 can be fed through the unit. Service Manual for each option.

e

ecifications

agicolor 5450otorola PowerPC 7447A 667 MHzagicolor 5430 DL/5440 DL4 MB (Expandable up to a 576 MB)agicolor 545056 MB (Expandable up to a 1024 MB)

00,000 prints or 5 years, whichever comes first

C 110 to 127 VC 220 to 240 V0/60 Hz 3 Hz

250 W

20 mm (W) x 520 mm (D) x 440 mm (H) 6.5 inch (W) x 20.5 inch (D) x 17.3 inch (H)agicolor 5430 DLpprox. 30 kg (66.25 lb) without TCagicolor 5440 DL/5450pprox. 31 kg (66.25 lb) without TCuring standby : 39 dB (A) or lessuring printing : 54 dB (A) or less


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2.5 Operating Environment

NOTE These specifications are subject to change without notice.

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)


Main Unit Field Service Periodic Check

II Maintenance1. Periodic CheckNOTE Be sure to note that the feed trays are named differently depending upon the

printer model.

The following proc

1.1 Service schGuaranteed period (5

magicolor 5430 DL / 5440 DL magicolor 5450MANUAL FEED TRAY TRAY 1

TRAY 1 TRAY 2

Per cycle num

Main Unit

Upo(20300

Lower Feeder Unit 300


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edures use the magicolor 5430 DL/5440 DL tray names.

eduleyears or 400,000 prints)

TRAY 2 TRAY 3TRAY 3 TRAY 4

ber of prints 10,000 prints Number

of times20 30 40n each call

0,000) 2

,000 1

,000 1

Periodic Check Main Unit Field ServiceII

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1.2 Maintenance Items1.2.1 Parts to be replaced by users (CRU)

* : The life of the T3,000 printed p

** : Continuous prin*** : 2 pages/job**** : When printed in***** : When printed in****** : The Transfer Ro

the same time

No Class Part to be replaced Number of prints Clean Replace Description

1

Processing section

Standard Toner Cartridge *(TC Y/TC M/TC C/ TC K) 6,000 (MP **)

2High-Capacity Toner Cartridge *

(TC Y/TC M/TC C/ TC K)12,000 (MP **)

2 Ozone Filter****** 120,000

3Tray 1/

Media feed section

Feed R

4

Manual feed section(magicolor 5440 DL/

5450 only)

Feed R

5

Image Transfer section

Transfe

6 Transfe

7

Waste (magic

Waste (magic


oner Cartridge furnished with the machine at the time of shipment is agesting

black only color onlyller and Ozone Filter are available as a kit and must be replaced at

oller When malfunction occurs

oller When malfunction occurs

r Belt Unit120,000 (MP **)100,000 (2P/J***)

r Roller****** 12,000

Toner Bottleolor 5430 DL)

32,000 (K****)8,000 (Y,M,C,K*****)

Toner Bottleolor 5440 DL/5450)

40,000 (K****)10,000 (Y,M,C,K*****)


1.2.2 Parts to be Replaced by a Service Engineer (FRU)

* : Continuous printing** : 2 pages/job

1.3 Maintenanc To ensure that the m

ommended that the instructed.

Replace with referen Maintenance conditi

A. Main Unit

* : Continuous printing** : 2 pages/job

No Class Part to be replaced Number of prints Clean Replace Description

1 Fusing section Fusing Unit

150,000 (MP *)130,000(2P/J**)

2Tray 1/

Media feed section

Feed Roller 300,000

3

Manual Feed section

(magicolor 5440 DL/5450

only)

Feed

4 Lower Feeder Unit Feed

No Class Main

1 Tray 1 Feed R

2

Manual Feed Tray(magicolor 5440 DL/5450 only)

Feed R

3 Fusing section Fusing


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e partsachine produces good prints and to extend its service life, it is rec-maintenance jobs described in this schedule be carried out as

ce to the numeric values displayed on the Life counter.ons are based on A4 or Letter, Standard mode and Preheat OFF.

Roller 300,000

Roller 300,000

tenance parts Clean Replace DescriptionRef.Page

in this manual

ollerWhen neces-

sary to prevent media jams

300,000 2-6

ollerWhen neces-


300,000

2-7

Unit -

150,000 (MP *)

2-19

130,000(2P/J**)


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B. Option

1.4 Concept of parts life

* : Continuous p** : 2 pages print*** : Continuous p**** : 2 Pages print

No Class Maintenance parts Clean Replace

Description

s

Ref.Page in this manual

1Lower Feeder Unit

Feed RollerWhen neces-


300,000 See the Service

Manual for the Lower Feeder Unit.

Waste Toner Bottle

(magicolor 5430 DL)

Detesens

A wadetechroducepagetonedete

Waste Toner Bottle

(magicolor 5440 DL/5450)

Fusing UnitThe peFusingcounte

Ozone Filter

Transfer Roller A correpages

Transfer Belt Unit

The peTransfecounte

Toner Cartridge shipped with the

machine C,M,Y,K

The the Tener

A fusettiablecond

Standard Toner Cartridge C,M,Y,K

High-Capacity Toner Cartridge

C,M,Y,K (For exchange:

magicolor 5440 DL/5450 only)


rinting under the environment shown as A (See next page)ing/job (2P/J) under the environment shown as A (See next page)rinting under the environment shown as B/C (See next page)ing/job (2P/J) under the environment shown as B/C (See next page)

Description Near Life Value Life Valuected by the waste toner full or.ste toner full condition is cted when about 4,000* mono-me printed pages are pro-d or about 1,000* color printed s are produced after a waste

r near full condition has been cted.

Monochrome: 28,000 prints


Color: 7,000 prints Color: 8,000 prints



Color: 9,000 prints Color: 10,000 prints

riod of time through which the Motor has been energized is d.

120,000 prints(Continuous printing)

150,000 prints(Continuous printing)

104,000 prints (2P/J) 130,000 prints (2P/J)- - 120,000 prints

sponding number of printed is counted. 96,000 prints 120,000 prints

riod of time through which the r Belt Unit has been turned is d.

80,000 prints 100,000 prints

period of time through which oner Supply Motor has been gized is counted.nction is available that allows ng to be made to enable or dis- printing during a toner empty ition.

2,250 prints * 3,000 prints *2,060 prints ** 2,750 prints **1,800 prints *** 2,400 prints ***

1,650 prints **** 2,200 prints****5,100 prints * 6,000 prints *4,675 prints ** 5,500 prints **3,840 prints *** 4,800 prints ***3,520 prints **** 4,400 prints ****10,200 prints * 12,000 prints*9,350 prints ** 11,000 prints **8,160 prints *** 9,600 prints ***

7,480 prints **** 8,800 prints ****


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.

Item DescriptionJob Type 2 consecutive pages (2 pages/job)Media Size A4 or LetterOriginal Density C/W ratio = 5% each color

Operating Environment

Humidity


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Temperature


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1.5 Maintenance Procedure (Periodic Parts Check)NOTE The alcohol referred to in the following procedures is isopropyl alcohol. Be sure to note that the feed trays are named differently depending upon the

printer model.

The following procedures use the magicolor 5430 DL/5440 DL tray names.

1.5.1 Feed Roller

magicolor 5430 DL / 5440 DL magicolor 5450MANUAL FEED TRAY TRAY 1

TRAY 1 TRAY 2

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(Tray 1)A. Cleaning Procedure1. Slide out Tray 1.2. Using a soft cloth dampened with

alcohol, wipe the Feed Roller [1] clean of dirt.

B. Replacement Procedure1. Slide out Tray 1.2. Lock the Paper Lift Plate [1].3. Snap off two C-clips [2] and remove

the bearing [3] at the front.

4. Snap off the C-clip [4] and remove the Feed Roller [5].

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NOTE When reinstalling the Feed Roller,

make sure that it is mounted in the direction shown in the illustration on the left.

1.5.2 Feed Roller

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(Manual Feed Tray) (magicolor 5440 DL/5450 only)A. Cleaning Procedure1. Open the Manual Feed Tray.2. Remove the Connector Cover.3. Disconnect the connector [1].

4. Move two Lock Levers [2] down.5. Remove the Manual Feed Tray.

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6. Press two pins [3] in, and lift the Feed Roller Cover [4] upward to remove it.[3]

[4]

[5]

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NOTEMake sure that the bearing goes all the way into both of [5] shown on the left when installing the Feed Roller Cover.

7. Using a soft cloth dampened with alcohol, wipe the Feed Roller [6] clean of dirt.

B. Replacement Procedure1. Remove the Manual Feed Tray. (See

Cleaning procedure 1 to 5)2. Remove the Feed Roller Cover (See

Cleaning procedure 6)3. Remove the two screws [7].4. Remove the Cover [8].

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5. Snap off C-clip [8] and remove the bearing [9] at the front.

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6. Snap off the C-clip [10] and then remove the Clutch [11] and the Feed Roller [12].

NOTE When reinstalling the Feed Roller

and the Clutch, make sure that it is mounted in the direction shown in the illustration on the left.

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1.5.3 Ozone Filter

A. Replacement Procedure1. 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. 2-15

1.5.4 Toner Cartr

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idge (C/M/Y/Bk)A. Removal Procedure1. Open the Front Door.2. Press the Push mark [1] on the

Toner Cartridge and slide out the Toner Cartridge.

3. Holding the Toner Cartridge [2] as shown in the illustration on the left, slide it out of the machine.

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B. Reinstallation Procedure1. 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.

3. Open the Photo Conductor Cover [2].

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4. Slide the Photo Conductor Cover [3] off the cartridge.

5. Holding the Toner Cartridge [4] at the location shown in the illustration on the left, insert it along the rail [5] until it hits against a stopper.

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6. Fold down the handle [6] and slide the Toner Cartridge [7] all the way into the machine.

NOTE When removing or

has been used up,result.

[7]

[6]

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7. Pull off the protective film [8].8. Close the Front Door.

reinstalling the Toner Cartridge while it is being used or after it do not hold it or place it upside down, as spilled toner could

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1.5.5 Waste Toner Bottle

A. Replacement Procedure1. Open the Front Door.2. Turn the lever [1] to unlock the Waste

Toner Bottle.

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[2]

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ce3. Remove the Waste Toner Bottle [2].

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.

5. To reinstall, reverse the order of removal.

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1.5.6 Cleaning the Laser Irradiation Section

A. Cleaning Procedure1. 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. Insert the tool [2] and make two to three reciprocating motions to clean the laser irradiation section.

NOTE For cleaning, do not use any tool

[1]

[2]


other than the specified Laser Lens Cleaning Tool.

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1.6 Replacing Units1.6.1 Replacing the Transfer Roller

A. Replacement Procedure1. Open the Right Door.2. Press the locks [2] located at the

front and rear ends of the Transfer Roller [1] inward to unlock the Trans-fer Roller [1].

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3. Holding the levers, remove the Transfer Roller [3].

4. To reinstall, reverse the order of removal.

5. Replacing the Ozone Filter. 2-106. From the Menu, select ENGINE

ENGINE SERVICE RESET COUNTER TRANSFER ROLLER. Execute this function to reset the Transfer Unit counter value. (magi-color 5430 DL/5440 DL)

For details, see III. Adjustment/Setting.

7. From the Menu, select From the Menu, select QUALITY MENU SUPPLIES REPLACE TRANS. ROLLER. Execute this function to reset the Transfer Unit counter value. (magicolor 5450)


8. From the Menu, select ENGINE ENGINE SERVICE COLOR CAR-IBRATION and execute this function. (magicolor 5430 DL/5440 DL)


9. From the Menu, select QUALITY MENU CARIBRATION AIDC PROCESS and execute this func-tion. (magicolor 5450)

For details, see III. Adjustment/Set-ting.

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1.6.2 Replacing the Transfer Belt Unit

A. Replacement Procedure1. 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.[2]

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4. Open the Right Door.5. Loosen two screws [3] and unlock

the Transfer Belt Unit.

6. Remove the Left Cover. 2-317. Slide out the Transfer Belt Unit [4].

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NOTE Lower the handle [5] of the Transfer

Belt Unit in the direction shown in the illustration on the left.

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8. Prepare a new Transfer Belt Unit.NOTE Use care not to touch the belt of the

Transfer Belt Unit.9. Insert the Transfer Belt Unit [7] along

the rail [6].NOTE When inserting the unit, use care

not to allow the docking gear to hit against the rail or other mechanism to prevent damage.

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10. Tighten the two screws [8] to secure the Transfer Belt Unit in position.

11. Reinstall the Left Cover.12. Close the Right Door.13. Reinstall the Waste Toner Bottle.14. Reinstall the Toner Cartridge.15. Close the Front Door.16. Turn ON the Power Switch.17. From the Menu, select ENGINE

ENGINE SERVICE RESET COUNTER TRANSFER BELT. Exe-

[8]

[8]


cute this function to reset the Trans-fer Belt Unit counter value. (magicolor 5430 DL/5440 DL)


18. From the Menu, select QUALITY MENU SUPPLIES REPLACE TRANS. BELT. Execute this func-tion to reset the Transfer Belt Unit counter value. (magicolor 5450)


19. From the Menu, select ENGINE ENGINE SERVICE COLOR CALI-BRATION and execute this function. (magicolor 5430 DL/5440 DL)


20. From the Menu, select QUALITY MENU CALIBRATION AIDC PROCESS and execute this function.


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1.6.3 Replacing the Fusing UnitNOTE Before replacing the Fusing Unit, make sure that it has sufficiently cooled down.

1. Turn OFF the Power Switch, unplug the power cord from the power outlet, and let the machine to stand idle for about 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)


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5. Disconnect the five connectors [1]. (magicolor 5450)

6. Open the Right Door.7. Remove two screws [2] and the Fus-

ing Unit.8. Install the new Fusing Unit.9. From the SERVICE mode, select

RESET COUNTER FUSER UNIT. Then, execute this function to reset the Fusing Unit counter value. (magicolor 5430 DL/5440 DL)


10. From the Menu, select QUALITY MENU SUPPLIES REPLACE FUSER UNIT. Then, execute this function to reset the Fusing Unit counter value. (magicolor 5450)


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Service tool Main Unit Field ServiceII

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2. Service tool2.1 CE Tool list

2.2 Consumab2.2.1 Toner Cartr

For the predeterm

NOTE The life of the Tone

is 3000 pages.

2.2.2 Waste Tone

For the predeterm

2.2.3 MaintenancA Maintenance Kit is n

Tool name Shape Personnel Remarks

Laser Lens Cleaning Tool 1

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ParStandard-Capacity TonerStandard-Capacity TonerStandard-Capacity TonerStandard-Capacity Toner

Part nam

Waste Tone


le Partsidge (TC) (as an individual part)

ined conditions, see 2-5.

r Cartridges furnished with the machine at the time of shipment

r Bottle

ined conditions, see 2-5.

e Kit ot available.

t name Life expectancy Cartridge - Black (K) 6,000 prints Cartridge - Yellow (Y) 6,000 prints Cartridge - Magenta (M) 6,000 prints Cartridge - Cyan (C) 6,000 prints

e Life expectancy

r BottleMonochrome: 32,000 printsColor: 8,000 prints

Main Unit Field Service Firmware Upgrade

3. Firmware Upgrade3.1 Print Control Board (PWB-P) Firmware Upgrading3.1.1 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. Then, check the IP address [1] of the machine. For how to execute PRINT CONFIG PAGE, see III Adjustment/Setting.

3. Copy the firmware4. Start the Comman

stored.5. Execute the flashu

(The screen shown

Data to be upgradedApplication flBOOT flXXX.XXX.XXX.XXX : IP ****** : Fir


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data and upgrading program to any directory on the PC.d Prompt and go to the directory in which the firmware data is

pdate command to start the transfer of firmware data. below indicates that the firmware data resides on the C drive.)

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Commandashupdate -r XXX.XXX.XXX.XXX vxworks.zashupdate -b XXX.XXX.XXX.XXX ******.fltaddress of the machinemware data file name

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Firmware Upgrade Main Unit Field ServiceII

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6. Check the Command Prompt display on the progress of upgrade procedure.

NOTE NEVER turn the pri

done appears on

7. After the firmware then ON again.

8. Check that the con For how to check t


nter Power Switch OFF and ON until the message flash update the Command Prompt display.

upgrade procedure has been completed, turn the printer OFF and

troller firmware version number has been upgraded.he firmware version number, see III. Adjustment/Setting.

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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. For direct connections between the printer and PC, use the crossover cable. For PCs that support 1000BASE-T (Gigabit Ethernet), use a 1000BASE-T-enabled

Ethernet cable (over category 5e.) If a cable that is not compatible with 1000BASE-T is used, communication may not be made correctly.

Check that printing is available over the network.

2. From the Menu, setion. Then, check t

For how to execute

3. Copy the firmware4. Start the Comman

stored.5. Execute the follow

(The screen shown

Data to be upgradedFW upgraded dataXXX.XXX.XXX.XXX : IP ****** : Fil


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lect PRINT MENU CONFIGURATION PG and execute the func-he IP address [1] of the machine. CONFIGURATION PG, see III Adjustment/Setting.

data and upgrading program to any directory on the PC.d Prompt and go to the directory in which the firmware data is

ing command to start the transfer of the firmware data to the printer. below indicates that the firmware data resides on the C drive.)

[1]

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Command> lpr -S XXX.XXX.XXX.XXX -P lp -o l 4138**********.pr

5430 Service Manual

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