Lexmark 5021-0XX - Manual

viii Service Manual 5021-0XX Laser unit assembly (printhead) removal . . . . . . . . . . . . . . . .4-24Laser unit fan assembly removal . . . . . . . . . . . . . . . . . . . . . .4-26Erase lamp removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-27 Right side removals . . . . . ...

ix 5021-0XX Locations and connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3 Elec...

Laser notices xi 5021-0XX Laser notices The following laser notice labels may be affixed to this printer as shown: Laser advisory label

xii Service Manual 5021-0XX Class 1 Laser statement label

Laser notices xiii 5021-0XX Laser notice The printer is certified in the U.S. to conform to the requirements of DHHS 21 CFR Subchapter J for Class I (1) laser products, and elsewhere is certified as a Class I laser product conforming to the requirements of IEC 60825-1. Class I laser products are not...

xiv Service Manual 5021-0XX Avis relatif à l’utilisation de laser Pour les Etats-Unis : cette imprimante est certifiée conforme aux provisions DHHS 21 CFR alinéa J concernant les produits laser de Classe I (1). Pour les autres pays : cette imprimante répond aux normes IEC 60825-1 relatives aux produ...

Laser notices xv 5021-0XX Avisos sobre el láser Se certifica que, en los EE.UU., esta impresora cumple los requisitos para los productos láser de Clase I (1) establecidos en el subcapítulo J de la norma CFR 21 del DHHS (Departamento de Sanidad y Servicios) y, en los demás países, reúne todas las con...

xvi Service Manual 5021-0XX Laserinformatie De printer voldoet aan de eisen die gesteld worden aan een laserprodukt van klasse I. Voor de Verenigde Staten zijn deze eisen vastgelegd in DHHS 21 CFR Subchapter J, voor andere landen in IEC 60825-1. Laserprodukten van klasse I worden niet als ongevaarli...

Laser notices xvii 5021-0XX Huomautus laserlaitteesta Tämä kirjoitin on Yhdysvalloissa luokan I (1) laserlaitteiden DHHS 21 CFR Subchapter J -määrityksen mukainen ja muualla luokan I laserlaitteiden IEC 60825-1 -määrityksen mukainen. Luokan I laserlaitteiden ei katsota olevan vaarallisia käyttäjälle...

xviii Service Manual 5021-0XX Laser-melding Skriveren er godkjent i USA etter kravene i DHHS 21 CFR, underkapittel J, for klasse I (1) laserprodukter, og er i andre land godkjent som et Klasse I-laserprodukt i samsvar med kravene i IEC 60825-1. Klasse I-laserprodukter er ikke å betrakte som farlige....

Laser notices xix 5021-0XX Japanese laser notice Chinese laser notice

Safety information xxi 5021-0XX Safety information • The safety of this product is based on testing and approvals of the original design and specific components. The manufacturer is not responsible for safety in the event of use of unauthorized replacement parts. • The maintenance information for th...

xxii Service Manual 5021-0XX Norme di sicurezza • La sicurezza del prodotto si basa sui test e sull'approvazione del progetto originale e dei componenti specifici. Il produttore non è responsabile per la sicurezza in caso di sostituzione non autorizzata delle parti. • Le informazioni riguardanti la ...

Safety information xxiii 5021-0XX Pautas de Seguridad • La seguridad de este producto se basa en pruebas y aprobaciones del diseño original y componentes específicos. El fabricante no es responsable de la seguridad en caso de uso de piezas de repuesto no autorizadas. • La información sobre el manten...

xxiv Service Manual 5021-0XX Informació de Seguretat • La seguretat d'aquest producte es basa en l'avaluació i aprovació del disseny original i els components específics. El fabricant no es fa responsable de les qüestions de seguretat si s'utilitzen peces de recanvi no autoritzades. • La informació ...

xxvi Service Manual 5021-0XX Preface This manual contains maintenance procedures for service personnel. It is divided into the following chapters: 1. General information contains a general description of the printer and the maintenance approach used to repair it. Special tools and test equipment are...

General information 1-1 5021-0XX 1. General information This Lexmark™ C510 color laser printer is the ideal printer for presentations, business graphics, line art, and text. It uses laser diode electrophotographic technology to deliver remarkable quality print images and text. The printer can be use...

1-2 Service Manual 5021-0XX Serial number Look for the label on the rear cover of your printer for serial number information. The serial number is also listed in the menu settings page and can be printed from the utilities menu.

General information 1-3 5021-0XX Acronyms ASIC Application-Specific Integrated Circuit CS Customer Ordered CSU Customer Setup DRAM Dynamic Random Access Memory EEPROM Electrically Erasable Programmable Read-Only Memory EP Electrophotographic Process ESD Electrostatic Discharge FRU Field Replaceable ...

1-4 Service Manual 5021-0XX Specifications Resolution 600 x 600 dpi2400 image quality Model differences Technical specifications Toner darkness There are five settings to balance print darkness and toner savings. The higher the setting, the darker the print. The toner darkness default setting is 4. ...

General information 1-5 5021-0XX Manual: Allows users to customize color correction output from the operator panel. Setting selectable from the driver. Physical specifications and weight The following table contains the dimensions and weights for each printer model and option. This does not include ...

1-6 Service Manual 5021-0XX Operating clearances Packaging and shipping dimensions Printer sides C510 & C510n C510 & C510n with 530-sheet tray C510 & C510n with duplex unit C510dtn with 530-sheet tray Left side 8 in (203 mm) 8 in (203 mm) 8 in (203 mm) 8 in (203 mm) Right side 20 in (508...

General information 1-7 5021-0XX Print speed and performance Time to first print Processor 500 MHz Simplex printing Duplex printing pages/minute) (sides/minute) Media size Standard tray Standard tray Letter 30 8 15 4 A4 30 8 15 4 Legal 16 8 5 4 Transparencies 3 2 N/S N/S Thick card stock 3 2 N/S N/S...

1-8 Service Manual 5021-0XX Duty cycle Maximum duty cycle-35,000 pages (one month's usage)Machine life-120,000 pages/300,000 images Printer memory Memory configuration Available memory options Optional 64MB and 128MB SDRAM DIMMs are available. Flash memory options Optional 16MB and 32MB DIMMs are av...

General information 1-9 5021-0XX Input and output configurations The following table shows the standard number of input sources and output destinations, as well as the estimated capacity of each. Capacity may vary and is subject to media specifications and printer operating environment. The capaciti...

1-10 Service Manual 5021-0XX Media input types and weights Source Type Standard tray Legal tray 530-Sheet tray Duplex Printer menu Item Paper type Paper weight Paper 1,2 (grain long) Xerographic or bond paper 60-74g/m 2 (16-19 lb) 60-74 g/m 2 (16-19 lb) 60-74g/m 2 (16-19 lb) Plain paper Light Xerogr...

General information 1-11 5021-0XX Media sizes Media sizes Dimensions Input Output Sta nda rd 2 50-she e t tr a y 1 Op ti onal l egal tr a y Op ti onal 5 30-she e t tr a y 2 Op ti onal d uple x uni t Sta nda rd 2 50-she e t bi n mm in. A4 210 x 297 8.27 x 11.7 X X X X X A5 148 x 210 5.83 x 8.27 X X X...

1-12 Service Manual 5021-0XX Output capacity by media and source Media guidelines With the Lexmark C510 print technology, paper designed for use with xerographic copiers should provide satisfactory print quality and feed reliability. Other media types may be suitable. We recommend that users test an...

1-14 Service Manual 5021-0XX • Glossy paper is only supported from tray 1 (standard or legal trays). Connectivity Cables Personal computers • A parallel printer cable is required for attachment of the printer and must be ordered separately. • For serial attachment, optional RS-232C serial interface ...

General information 1-15 5021-0XX Power and electrical specifications Printing states C510 C510n C510dtn Off 0 W O W O W Average power while printing Continuous mono printing 550 W 550 W 550 W Continuous color printing 370 W 370 W 370 W Power consumption, standby Power saver on 12 W 13 W 13 W Power ...

1-16 Service Manual 5021-0XX Environment Environment Specifications Operating Air temperature - product operating 10 to 32.5°C (50 to 90.5°F) Air temperature - product power off 5 to 35°C (41 to 95°F) Air relative humidity 15 to 80% Altitude 0 - 2,500 m (0 - 8,200 ft.) Ship / Storage Temperature-pri...

General information 1-17 5021-0XX Printer identification

1-18 Service Manual 5021-0XX Options identification

General information 1-19 5021-0XX Printer theory of operation The following diagram shows the major parts of the printer and paper path.

1-20 Service Manual 5021-0XX Printer paper path The following illustration shows the paper path and the associated paper jam messages for jams at specific points in the paper path. The printer depicted in the illustration has a duplex unit and secondary paper feed assembly installed:

General information 1-21 5021-0XX Printer systems description See the illustration “Printer component systems” on page 1-23, for more information. Basic principles of color printing Color printing is made through the subtractive process of combining the three primary colors: yellow, magenta, and cya...

1-22 Service Manual 5021-0XX Control system The control system consists of four control parts and runs the printer by processing the interface signals transmitted from the computer and the other printer systems such as the print, transfer, optical, and transport system: sequence control, laser contr...

General information 1-23 5021-0XX Printer component systems

1-24 Service Manual 5021-0XX Basic process of color printing 1. This printer has a toner cartridge for each color — yellow, magenta, cyan, and black. 2. The toner image is developed with primary colors and then transferred to the transfer belt for color combination. 3. The toner image formed on the ...

General information 1-25 5021-0XX Print system and transfer system This illustration shows the basic structure of the print system having the OPC belt as a main function, and the transfer system including the transfer belt. A color print is accomplished by actuating each process in the print system ...

1-26 Service Manual 5021-0XX Structure of OPC belt (photo developer cartridge) The OPC belt consists of a surface layer having an optical photoconductor (OPC) of organic material, the inner layer consists of an insulator material (PET), and the aluminum deposit layer in between. The OPC belt is a ma...

General information 1-27 5021-0XX Basic structure of the print system The print system process consists of the following: 1. The OPC belt is biased to the -CBV(V) by power supply CBV. 2. The OPC belt is then evenly charged to the negative high voltage by the OPC charging system. The charging system ...

General information 1-29 5021-0XX Details of the print system Charging process In the charging process, the OPC belt is evenly charged by the charger. See “Printer theory of operation” on page 1-19 for charger unit location. The charger unit consists of a charging brush and a discharge roller. 1. Th...

General information 1-31 5021-0XX Exposing process In the exposing process, the OPC belt surface is exposed to the laser light which forms an electrostatic latent image. The luminous source of the laser is a semiconductor laser. See “Printer theory of operation” on page 1-19 for optical unit locatio...

1-32 Service Manual 5021-0XX Developing process In the developing process, an electrostatic latent image attracts printer toner and becomes visible on the OPC belt. There are four toner cartridges. See “Printer theory of operation” on page 1-19 for toner cartridges location. The toner cartridges are...

General information 1-33 5021-0XX The first illustration shows the relationship between the toner, the -Vo(V) at the non-exposed area of the OPC belt and the -VR(V) at the exposed area of the OPC belt. 3. Developing is processed by toner adhering to the OPC belt due to the attraction between the ton...

1-34 Service Manual 5021-0XX First transfer (drum) process The first transfer process consists of toner images on the OPC belt being transferred to the transfer belt. The transfer belt is composed of a special rubber. See “Printer theory of operation” on page 1-19 for transfer belt location. 1. Afte...

1-36 Service Manual 5021-0XX Belt cleaning process In the belt cleaning process, residual toner adhering to the OPC belt surface is mechanically removed by a blade edge. OPC belt OPC belt cleaning (blade) First transfer OPC belt discharging (erase lamp)

1-38 Service Manual 5021-0XX Details of the transfer system Second transfer (paper) process In the second transfer process, the toner image on the transfer belt is transferred to paper. See “Printer theory of operation” on page 1-19 for second transfer roller location. The transfer roller, normally ...

General information 1-39 5021-0XX Transfer belt cleaning process The residual toner on the surface of the transfer belt is removed after the paper transfer process. See “Printer theory of operation” on page 1-19 for transfer belt cleaner unit location. The belt cleaner brush is a semiconductor-type ...

1-40 Service Manual 5021-0XX Details of the optical system In the optical system process, the printer utilizes a semiconductor laser diode as a light source. This laser diode is controlled by fast switching which matches the transmitted image data (video signal). The generated laser light scans the ...

1-42 Service Manual 5021-0XX Details of the paper transportation system In the paper transportation process, paper is automatically fed by the pick-up roller and transported to the registration roller. The registration roller synchronizes with the transfer belt. The registration roller transports th...

General information 1-43 5021-0XX 4 Transfer roller Works in conjunction with the transfer belt to transfer the image to paper and to transport the paper to the fuser. 5 Fuser unit Utilizes a heat roller to fuse the toner image to the paper. 6 Paper exit roller Exits the fused paper from the printer...

1-44 Service Manual 5021-0XX Fusing unit The fusing unit utilizes a thermal fusing system that contains a heated fusing roller and a belt-like backup roller. The heated roller contains an inner heating element. The backup roller contains three pressure members located behind the belt. Paper carrying...

General information 1-45 5021-0XX 4 Thermistor Sensor that detects the temperature of the fuser roller’s surface. 5 Thermal fuse Protective device that prevents the fuser roller from being excessively heated. No. Part Function

1-46 Service Manual 5021-0XX Fusing process 1. When the paper reaches the fuser, the toner image is transferred on the paper, but not yet fused to the paper. 2. The transported paper passes between the heated roller and the back-up roller. The heated roller’s temperature is approximately 338°F (170°...

General information 1-47 5021-0XX Control system structure Electrical system and function The engine board controls most of the main electrical parts in this printer. No. Control process Function 1 Print process control Controls print process from paper feed through paper exit. 2 Laser output contro...

1-48 Service Manual 5021-0XX Control of print process Control block diagram Note: A micro CPU mounted on the engine board controls the print processes. No. Control process Function 1 Sequence control Controls print sequence of printer. 2 Temperature control Controls temperature of fuser unit. 3 Cons...

General information 1-49 5021-0XX Print sequence diagram

1-50 Service Manual 5021-0XX Laser drive control circuit The laser drive control circuit (LDC) consists of a video signal input circuit, laser drive circuit, laser diode, output sensing circuit, and output control circuit. See the illustration. 1. When the video signal is received, the laser drive c...

General information 1-51 5021-0XX Interface control Interface type Through the video interface, the RIP controls the printer and operator panel using command/status communication and transmits the synchronized video data to the printer laser diode. The operator panel is physically resident on the en...

Diagnostic information 2-1 5021-0XX 2. Diagnostic information Start CAUTION: Remove power from the printer before you connect or disconnect any cable, electronic board or assembly, for personal safety and to prevent damage to the printer. Always use the hand grips on the side of the printer and be s...

2-2 Service Manual 5021-0XX Service error codes Error code Action 900 RIP Software Contact customer service center, or Lexmark support center 901 Yellow developer clutch error (DCLY) Go to “901—Yellow developer clutch service check” on page 2-29 . 902 Magenta developer clutch error (DCLM) Go to “902...

Diagnostic information 2-9 5021-0XX Operator messages Message Description Action Change Tray <x><type> <size> Printer is requesting different media than what is loaded in specified tray or defined by paper size or paper type settings for tray. Ensure tray contains proper type and s...

2-12 Service Manual 5021-0XX Power Saver Printer is ready to receive and process data. If printer remains inactive for period of time specified in Power Saver menu item (20 minutes is factory default), Power Saver message replaces Ready message on display. Send a job to print. Press Go to quickly wa...

2-20 Service Manual 5021-0XX 87 Fuser Exhausted Fuser is completely used. Replace fuser. If problem persists, check cable for continuity that connects engine controller board connector FUCN and fuser. If cable is bad, replace cable. Otherwise, replace engine controller board. Go to “Engine controlle...

2-22 Service Manual 5021-0XX Paper jam messages The following illustration lists paper jam messages indicating where paper jam occurred. CAUTION: When clearing paper jams, inside of the printer may be hot. Allow printer to cool before touching any internal components.

Diagnostic information 2-25 5021-0XX Symptom tables Printer symptom table Symptom Action Operator panel buttons do not work See “Operator panel service check” on page 2-84 . Operator panel display is blank, printer beeps 5 times See “Operator panel service check” on page 2-84 . Operator panel contin...

Diagnostic information 2-27 5021-0XX Print quality symptom table Symptom Action Background See “Background service check” on page 2-101 . Missing image at edge See “Missing image at edge service check” on page 2-110 . Jitter See “Jitter service check” on page 2-109 . Ribbing See “Ribbing service che...

Diagnostic information 2-29 5021-0XX Printer service checks 901—Yellow developer clutch service check Step Questions / actions Yes No 1 Turn printer off and remove right cover. See “Right cover removal” on page 4-22 . Is developer clutch cable properly connected? Go to step 2. Properly connect cable...

2-30 Service Manual 5021-0XX 5 If waste toner bottle is removed, reinsert it. Ensure rear cover assembly cover is shut. Override top and front cover interlock switches. For location, see “Interlock switch locations” on page 5-8 . Reconnect operator panel. Turn printer on. Does 901 error reappear? Go...

Diagnostic information 2-31 5021-0XX 902—Magenta developer clutch service check Step Questions / actions Yes No 1 Turn printer off and remove right cover. See “Right cover removal” on page 4-22 . Is developer clutch cable properly connected? Go to step 2. Properly connect cable. Go to step 5. 2 Is d...

Diagnostic information 2-33 5021-0XX 903—Cyan developer clutch service check Step Questions / actions Yes No 1 Turn printer off and remove right cover. See “Right cover removal” on page 4-22 . Is developer clutch cable properly connected? Go to step 2. Properly connect cable. Go to step 5. 2 Is deve...

Diagnostic information 2-35 5021-0XX 904—Black developer clutch service check Step Questions / actions Yes No 1 Turn printer off and remove right cover. See “Right cover removal” on page 4-22 . Is developer clutch cable properly connected? Go to step 2. Properly connect cable. Go to step 5. 2 Is dev...

Diagnostic information 2-37 5021-0XX 905—Yellow toner retract solenoid service check Step Questions / actions Yes No 1 Turn printer off and remove I/O board shield. See “I/O board removal” on page 4-70 for steps to remove I/O board shield. Disconnect DCN4 connector from I/O board. Measure resistance...

Diagnostic information 2-39 5021-0XX 906—Magenta toner retract solenoid service check Step Questions / actions Yes No 1 Turn printer off and remove I/O board shield. See “I/O board removal” on page 4-70 for steps to remove I/O board shield. Disconnect DCN4 connector from I/O board. Measure resistanc...

Diagnostic information 2-41 5021-0XX 907—Cyan toner retract solenoid service check Step Questions / actions Yes No 1 Turn printer off and remove I/O board shield. See “I/O board removal” on page 4-70 for steps to remove I/O board shield. Disconnect DCN4 connector from I/O board. Measure resistance b...

Diagnostic information 2-43 5021-0XX 908—Black toner retract solenoid service check Step Questions / actions Yes No 1 Turn printer off and remove I/O board shield. See “I/O board removal” on page 4-70 for steps to remove I/O board shield. Disconnect DCN4 connector from I/O board. Measure resistance ...

Diagnostic information 2-45 5021-0XX 910—Developer motor service check Step Questions / actions Yes No 1 Are there any unusual noises heard around developer motor or developer drive assembly before error posts? Replace toner cartridge (customer ordered supply). Go to step 2. Go to step 4. 2 Does noi...

Diagnostic information 2-47 5021-0XX 7 Disconnect cable from DCN13 on I/O board. Check the following on disconnected cable connector: Pin 1 to pin 2—24VDCPin 9 to pin 12—5VDC Are voltages present? Replace I/O board. See “I/O board removal” on page 4-70 . Go step 8. Replace cable that connects ACN1 o...

2-48 Service Manual 5021-0XX 911—Main motor service check Step Questions / actions Yes No 1 Turn printer off and remove right cover. See “Right cover removal” on page 4-22 . Open top cover and override top cover interlock switch. Restart printer and observe main motor and photodeveloper cartridge OP...

Diagnostic information 2-51 5021-0XX 912—Power supply fan service check Step Questions / actions Yes No 1 Turn printer off and remove I/O board shield. See “I/O board removal” on page 4-70 for steps to remove I/O board shield. Is cable properly connected to I/O board connector DCN20? Go to step 2. P...

2-52 Service Manual 5021-0XX 913—Fuser fan service check Step Questions / actions Yes No 1 Turn printer off and remove I/O board shield. See “I/O board removal” on page 4-70 for steps to remove I/O board shield. Is cable properly connected to I/O board connector DCN7? Go to step 2. Properly connect ...

Diagnostic information 2-53 5021-0XX 914—Laser fan service check Step Questions / actions Yes No 1 Turn printer off and remove I/O board shield. See “I/O board removal” on page 4-70 for steps to remove I/O board shield. Is cable properly connected to I/O board connector DCN8? Go to step 2. Properly ...

2-54 Service Manual 5021-0XX 915—Erase lamp service check Step Questions / actions Yes No 1 Turn printer off and remove toner cartridges and photodeveloper cartridge. Check erase lamp cable for proper connection. Is erase lamp cable properly connected? Go to step 2. Properly connect erase lamp. Rete...

2-56 Service Manual 5021-0XX 916—Toner empty sensor (sender-TPD) service check Step Questions / actions Yes No 1 Turn printer off and remove I/O board shield. See “I/O board removal” on page 4-70 for steps to remove I/O board shield. Is cable properly connected to I/O board connector DCN15? Go to st...

2-58 Service Manual 5021-0XX 918—HVPS connection service check Step Questions / actions Yes No 1 Turn printer off and remove engine controller board shield. See “Engine controller board removal” on page 4-55 for steps to remove shield. Is cable properly connected to engine controller board HVCN conn...

2-60 Service Manual 5021-0XX 920—Fuser thermistor service check Step Questions / actions Yes No 1 Remove and reinstall fuser assembly. See “Fuser assembly removal” on page 4-9 . Does error clear? Problem solved. Go to step 2. 2 Check fuser connector for damage. Replace if necessary. Does error clear...

Diagnostic information 2-63 5021-0XX 985—Duplex connection error 1 service check Step Questions / actions Yes No 1 Check duplex unit cable. is cable properly connected? Replace duplex unit. See “Duplex unit assembly removal” on page 4-13 . If problem persists, go to step 2. Properly connect cable. I...

2-64 Service Manual 5021-0XX 986—Duplex connection error 2 service check Step Questions / actions Yes No 1 Check duplex unit cable. is cable properly connected? Replace duplex unit. See “Duplex unit assembly removal” on page 4-13 . If problem persists, go to step 2. Properly connect cable. If proble...

Diagnostic information 2-65 5021-0XX 990—Transfer belt unit service check Step Questions / actions Yes No 1 Open rear cover assembly and check transfer belt unit markers for stains. Are markers stained? Clean belt marker area with cotton cloth. If problem persists go to step 2. Go to step 2. 2 Remov...

Diagnostic information 2-67 5021-0XX 991—Transfer roller clutch service check Step Questions / actions Yes No 1 Turn printer off and remove printer right cover. See “Right cover removal” on page 4-22 . Disconnect transfer roller clutch from cable. Measure resistance between two outer pins on transfe...

2-68 Service Manual 5021-0XX 992—Transfer belt cleaning roller clutch service check Step Questions / actions Yes No 1 Turn printer off and remove printer right cover. See “Right cover removal” on page 4-22 . Disconnect transfer belt cleaning roller clutch from cable. Measure resistance between two o...

Diagnostic information 2-69 5021-0XX 993—Fuser clutch service check Step Questions / actions Yes No 1 Turn printer off and remove printer right cover. See “Right cover removal” on page 4-22 . Disconnect fuser clutch from cable. Measure resistance between two outer pins on fuser clutch. Does resistan...

2-70 Service Manual 5021-0XX 994—OPC belt marker sensor service check Step Questions / actions Yes No 1 Remove photodeveloper cartridge and observe markers on side. Are belt markers covered with foreign particles? Clean marker area with cotton cloth. If problem persists go to step 2. Go to step 2. 2...

2-72 Service Manual 5021-0XX 995—High voltage power supply (HVPS) service check Step Questions / actions Yes No 1 Remove photodeveloper cartridge and ensure charging unit on bottom of photodeveloper cartridge is not damaged. Is charging unit damaged? Replace photodeveloper cartridge. See “Photodevel...

2-74 Service Manual 5021-0XX 996—Low voltage power supply (LVPS) service check Step Questions / actions Yes No 1 Check cable for continuity between engine controller board connector LVCN and HVPS ACN5 connector. Check cable for continuity between I/O board DCN21 and HVPS ACN5 connector. Also check f...

Diagnostic information 2-75 5021-0XX Cover open service check Step Questions / actions Yes No 1 Turn printer off and remove right cover. See “Right cover removal” on page 4-22 . Check all interlock switch (top, rear and front) actuators for proper operation. Are actuators good? Go to step 2. Replace...

2-78 Service Manual 5021-0XX Incorrect media service check Step Questions / actions Yes No 1 Turn printer off and remove I/O board shield. See “I/O board removal” on page 4-70 for steps to remove I/O board shield. Is cable properly connected to I/O board connector DCN16? Go to step 2. Properly conne...

2-80 Service Manual 5021-0XX Missing photodeveloper cartridge service check Step Questions / actions Yes No 1 Check photodeveloper cartridge for proper installation. Is cartridge installed properly? Go to step 2. Install properly. 2 Check printer contacts (A) and photodeveloper cartridge contacts (B...

Diagnostic information 2-81 5021-0XX Missing toner cartridge service check Step Questions / actions Yes No 1 Remove toner cartridge in question. Holding toner cartridge with developer roller away from you, check toner present sensor actuators located on left rear of toner cartridge. Are actuators da...

2-84 Service Manual 5021-0XX Operator panel service check Printer emits 5 beeps when it detects a problem with operator panel assembly, operator panel cable, controller RIP board or when a POR does not complete. If operator panel operates properly, except for a PEL or a few PELs missing or broken, r...

Diagnostic information 2-85 5021-0XX Output tray full service check Step Questions / actions Yes No 1 Ensure output tray full sensor flag swings with ease and is not broken or damaged. Is flag working properly? Go to step 2. Replace paper exit assembly. See “Paper exit assembly removal” on page 4-49...

Diagnostic information 2-87 5021-0XX Paper size sensing service check Step Questions / actions Yes No 1 Turn printer off and remove I/O board shield. See “I/O board removal” on page 4-70 for steps to remove I/O board shield. Is cable properly connected to I/O board connector DCN19? Go to step 2. Pro...

Diagnostic information 2-89 5021-0XX Printer no power service check Note: If secondary paper feed assembly or duplex unit is installed, disconnect or remove before checking base printer operation. Step Questions / actions Yes No 1 Reset printer and listen for any activation of motors and for power s...

Diagnostic information 2-91 5021-0XX Toner feed service check Step Questions / actions Yes No 1 Check toner cartridge for damage. Check to see if toner cartridge moves easily into and out of printer. Is toner cartridge damaged or is there resistance moving in and out of printer? Replace toner cartri...

2-92 Service Manual 5021-0XX Toner low/empty service check Step Questions / actions Yes No 1 Turn printer off and remove I/O board shield. See “I/O board removal” on page 4-70 for steps to remove I/O board shield. Is cable properly connected to I/O board connector DCN15? Go to step 2. Properly conne...

Diagnostic information 2-93 5021-0XX Transfer roller missing service check Step Questions / actions Yes No 1 Turn printer off and check transfer roller contacts. Are contacts present and not damaged? Go to step 2. If contact A has slipped off frame, put it back on. If you cannot see it, remove HVPS ...

Diagnostic information 2-95 5021-0XX Tray empty service check Step Questions / actions Yes No 1 Remove paper tray from printer. Press bottom of spring platform latches located in rear corners of paper tray. This releases spring platform of paper tray. Ensure tray is raising paper after insertion. Is...

Diagnostic information 2-97 5021-0XX Waste toner bottle service check Step Questions / actions Yes No 1 Remove waste toner bottle from printer. Inside waste toner bottle holder, check sensor flag. Does flag work properly and is it not damaged? Go to step 2. Replace waste toner bottle holder. See “Wa...

2-98 Service Manual 5021-0XX Waste toner feed service check Step Questions / actions Yes No 1 Is transfer belt unit cleaning roller properly installed. Go to step 2. Properly install cleaning roller. 2 Check cleaning roller clutch gear (located inside printer) for damage. Is cleaning roller clutch d...

Diagnostic information 2-99 5021-0XX Paper feed service checks Printer paper feed service check Problem area Action 1 Check for recommended paper Ensure paper being used is recommended. Ensure paper is stored in an area free from high humidity. Note: Disconnect secondary paper assembly and duplex un...

Diagnostic information 2-101 5021-0XX Print quality service checks Background service check Background is smeared due to toner spread. Problem area Action 1 Toner cartridge Too small charging amount in the development process. 2 Check developer high voltage contact points. Insufficient contact of de...

2-102 Service Manual 5021-0XX Back stain service check Backside of paper is stained. Problem area Action 1 Fuser assembly • Fuser roller and back-up roller are stained. • Fusing offset error occurred. Replace fuser assembly. See “Fuser assembly removal” on page 4-9 . Note: Fuser assembly is a custom...

Diagnostic information 2-103 5021-0XX Banding service check A banding line appears in horizontal direction. Problem area Action 1 Photodeveloper (OPC) cartridge Transfer failure due to uneven rotational speed caused by a shock which occurs when the seam of the OPC belt passes over the cleaning blade...

2-104 Service Manual 5021-0XX Black line service check A fine black line appears in printer image. Problem area Action 1 Toner cartridge Toner cartridge blade is deformed. Replace toner cartridge. 2 Photodeveloper (OPC) cartridge OPC belt’s surface is damaged. Replace photodeveloper cartridge. See “...

Diagnostic information 2-105 5021-0XX Color misregistration service check Color misregistration between two colors. Problem area Action 1 Transfer roller and transfer belt cleaning roller Transfer belt fails to maintain regular and proper rotation due to impact caused when transfer roller or transfe...

Diagnostic information 2-107 5021-0XX Insufficient fusing service check Printed image is partially missing. Problem area Action 1 Fuser tension release lever Fuser tension release lever is open. Check fuser and remove shipping pieces if still installed. Close release lever. 2 Driver media settings D...

2-108 Service Manual 5021-0XX Insufficient gloss service check Gloss on paper is not sufficient. Problem area Action 1 Driver media settings Driver media setting is wrong. Ensure proper media setting is selected for specific media in use. 2 Fuser Fuser roller is deteriorated. Fuser temperature is no...

Diagnostic information 2-109 5021-0XX Jitter service check Uneven optical density appears periodically in horizontal direction. Problem area Action 1 Photodeveloper cartridge Replace faulty photodeveloper cartridge. See “Photodeveloper cartridge removal” on page 4-11 . Note: Photodeveloper cartridge...

2-110 Service Manual 5021-0XX Missing image at edge service check Image has missing or peeling toner at edge. Problem area Action 1 Toner cartridge Too small a toner mass amount and charging amount in the development process. Replace toner cartridge. 2 Photodeveloper cartridge OPC belt is deformed a...

Diagnostic information 2-111 5021-0XX Mixed color image service check Mixed color image appears. Problem area Action 1 Toner cartridge Ensure toner cartridge moves in and out of printer without a lot of resistance. Compare toner cartridge in question with one of the other known working cartridges. R...

2-112 Service Manual 5021-0XX Mottle service check Variation of optical density is found in image. Problem area Action 1 Rear cover assembly Rear cover assembly is not fixed in place. Open rear cover assembly and close properly. 2 Transfer roller Transfer roller is not properly installed. Remove and...

Diagnostic information 2-113 5021-0XX Residual image service check Image of preceding page appears on every other page. Problem area Action 1 Transfer unit cleaning roller Cleaning roller is not installed properly. Remove and reinstall. Ensure left side of cleaning roller is making good contact with...

2-114 Service Manual 5021-0XX Ribbing service check Light print occurs in right or left side of image. Problem area Action 1 Printer is not level Table printer is sitting on is slightly tilted. Tilt should be less than 1/2 inch. Confirm the printer table is large enough and the printer is level. 2 T...

Diagnostic information 2-115 5021-0XX 6 Toner retract system Toner retract solenoid assembly is failing for specific toner cartridge. Replace toner retact solenoid assembly. See “Toner retract solenoid and cam removal” on page 4-64 . Problem area Action

2-116 Service Manual 5021-0XX Toner drop service check A toner spot stain on paper is caused by ambient toner within printer engine. Problem area Action 1 Waste toner feed system • Waste toner auger• Waste toner feeder Toner drops on the transfer drum due to a breakdown of the waste toner feed syste...

2-118 Service Manual 5021-0XX Vertical line service check A vertical line appears in printed image. Problem area Action 1 Photodeveloper cartridge (OPC belt) and transfer belt Foreign particles (dust and so on) adhere to parts located around photodeveloper cartridge and transfer belt unit which cons...

Diagnostic information 2-119 5021-0XX Vertical staggering image service check Printed image staggers in vertical direction. Problem area Action 1 Printer vibration Check for printer vibrations or shock to printer. 2 Laser unit assembly (printhead) Optical unit failure caused by vibration from scanne...

2-120 Service Manual 5021-0XX Vertical white band service check White band appears in vertical direction of printed image. Problem area Action 1 Toner cartridge Replace faulty toner cartridge. 2 Photodeveloper cartridge Replace faulty photodeveloper cartridge. See “Photodeveloper cartridge removal” ...

Diagnostic information 2-121 5021-0XX White band service check Horizontal white banding creates missing portion of image. Problem area Action 1 Transfer roller • Transfer roller bias pole is not making proper contact with high voltage spring contact. Remove and reinstall transfer roller. Ensure spri...

2-122 Service Manual 5021-0XX White line I service check Ver tical white line appears in a specific color area when print quality test print is run. Problem area Action 1 Test print Run print quality test prints. See “Print quality test pages” on page 3-5 . White line appears on specific color. 2 To...

Diagnostic information 2-123 5021-0XX White line II service check Vertical white line appears from leading edge to trailing edge of printed image. Problem area Action 1 Laser unit assembly (printhead) Dust proof glass of laser unit is smeared with toner or foreign particles. Clean glass: • Remove to...

2-124 Service Manual 5021-0XX White spot / black spot service check A white spot and black spot appear on paper. Problem area Action 1 Photodeveloper cartridge There are foreign particles adhering to photodeveloper OPC belt. Remove photodeveloper cartridge (see “Photodeveloper cartridge removal” on ...

Diagnostic information 2-125 5021-0XX White print service check Blank page (no print at all) is printed or a specific color is missing. Problem area Action Solid white print 1 Optical Unit (Printhead) Laser light path is blocked by paper or other material stuck at the opening of the optical unit. En...

2-126 Service Manual 5021-0XX Wrinkle / image migration service check Banding shadows of different optical density appear due to wrinkle, image migration, and color misregistration occurring on paper. Problem area Action 1 Non-recommended paper Paper being used is not recommended for printer. Replac...

2-128 Service Manual 5021-0XX 6 Transfer belt unit Replace faulty transfer belt unit. See “Transfer belt unit removal” on page 4-7 . 7 Toner retract system Replace faulty specific toner retract system. See “Toner retract solenoid and cam removal” on page 4-64 . Problem area Action

Diagnostic information 2-129 5021-0XX Spacing table Roller specifications Name of roller Diameter(mm) Number of rotation(rpm) Repeating defect on print(mm) Registration assembly rubber roller ø 14 283 43 Registration assembly steel roller ø 12 321 38 Transfer roller ø 20 194 63 Developer roller ø 18...

Diagnostic aids 3-1 5021-0XX 3. Diagnostic aids This chapter explains the tests and procedures to identify printer failures and to verify repairs have corrected the problem. The following diagnostic aids can be initiated at POR by pressing certain button sequences. These tests are also available in ...

3-2 Service Manual 5021-0XX Paper jam sequence Go to “Paper jam messages” on page 2-22 for more information. Paper Jam 201 - Indicates media is jammed in inner area (between paper registration sensor and paper exit sensor) of printer. Open rear cover assembly to access area of paper jam. Paper Jam 2...

Diagnostic aids 3-3 5021-0XX Paper Jam 23X • 230 Duplex - Indicates that media is jammed between duplex redrive and duplex door. Open duplex door to access jam. • 231 Duplex - Indicates media is jammed behind duplex redrive. Open duplex door and pull duplex redrive down to access the jam. Paper Jam ...

3-4 Service Manual 5021-0XX Diagnostic mode To enter the diagnostic mode: 1. Turn the printer Off. 2. Press and hold the Go and Return buttons. 3. Turn the printer On. 4. Release the buttons when "Performing Self Test" displays on the operator panel. The tests display on the operator panel i...

Diagnostic aids 3-5 5021-0XX • Device tests (displayed only if the flash or disk options are installed – Quick disk test (only when disk is installed) – Disk test/clean (only when disk is installed) – Flash test (only displayed when a non-defective flash memory option is installed) • Printer setup –...

3-6 Service Manual 5021-0XX To run the print quality test pages: 1. Turn the printer Off. 2. Press and hold Select and Return, while turning On the printer. 3. Release the buttons once “Performing the Self Test” displays. After POR completes, the CONFIG Menu displays. 4. Select Prt Quality Pgs from ...

Diagnostic aids 3-7 5021-0XX Two alignment pages automatically print for the change made. A correct adjustment is determined when the pages are held to the light and the lines on both pages line up with each other. Note: If you select the Continuous Option under Duplex Quick Test, you will need to p...

3-8 Service Manual 5021-0XX The contents of the print test page vary depending on the media installed in the selected input source. If a source is selected that contains paper, legal, letter and so on, a page similar to the quick test page is printed. However, the page does not contain the print reg...

3-10 Service Manual 5021-0XX Once the maximum pass or fail count is reached, the test stops and the final test results are displayed. 3. Press Return or Stop to exit the test. ROM memory test The ROM memory test is used to check the validity of the RIP board code and fonts. To run the ROM memory tes...

3-12 Service Manual 5021-0XX 3 = operational serial port #3. • P represents the number of times the test has passed (finished successfully). Initially 000000 is displayed for ######. The maximum pass count is 999,999. • F represents the number of times the test has failed or finished with errors. In...

Diagnostic aids 3-13 5021-0XX Duplex tests Duplex left margin The left margin adjust lets the user set the left margin for the duplex option so it matches the base machine left margin, for alignment purposes. It can also be used to print a page for duplex testing. To set the duplex left margin: 1. E...

3-14 Service Manual 5021-0XX Device tests Quick disk test This test performs a non-destructive read/write on one block per track on the disk. The test reads one block on each track, saves the data, and proceeds to write and read four test patterns to the bytes in the block. If the block is good, the...

Diagnostic aids 3-15 5021-0XX If the test passes, then the following message is displayed: • Disk Test/CleanTest Passed If the test fails, then the following message is displayed: • Disk Test/CleanTest Failed 2. Press Go, Return, or Stop to return to the device tests menu after the test is complete....

3-16 Service Manual 5021-0XX Printer setup Note: Defaults within this printer can be set to either U.S. or Non-U.S. Setting the page count This lets the servicer change the page count from the diagnostic menu. This is used whenever the operator panel cable is replaced because this contains the print...

3-18 Service Manual 5021-0XX • If the ID is valid then the ID is saved in NVRAM and the printer automatically PORs to activate the new setting. Note: When the printer PORs it does so in the normal mode. Parallel strobe adjustment This setting lets the user adjust the factory setting for the amount o...

Diagnostic aids 3-19 5021-0XX Error log Viewing the error log The error log provides a history of printer errors. The error log contains the 12 most recent errors that have occurred on the printer. The most recent error displays in position 1 and the oldest error displays in position 12 (if 12 error...

Diagnostic aids 3-21 5021-0XX Exiting diagnostic mode Select Exit Diagnostics to exit the diagnostics mode and return to normal mode.

Repair information 4-1 5021-0XX 4. Repair information Removal and cleaning precautions Observe the following precautions whenever you service the printer: • Be sure to unplug the printer from the outlet before attempting to service the printer. • To reassemble the printer, reverse the order of remov...

Repair information 4-3 5021-0XX Photodeveloper cartridge The following precautions must be observed when handling the photodeveloper cartridge or commonly called OPC (optical photo conductor). The photodeveloper car tridge is a supply item you will have to remove during some of the repair procedures...

4-4 Service Manual 5021-0XX Printer removal procedures Precautions to take before maintenance work Do not implement any operation, removal, or modification and so on, which are not presented in this manual. 1. Turn the printer power off and unplug the power cable from the outlet prior to starting re...

Repair information 4-5 5021-0XX CRU/FRU and supplies removals There are FRU/CRUs and supply items that will need to be removed prior to some of the removal procedures. The removal procedure will specify when the par t must be removed.

4-6 Service Manual 5021-0XX Cleaning roller cover removal 1. Open top cover. 2. Depress tabs and remove cleaning roller cover. Transfer belt cleaning roller removal 1. Remove cleaning roller cover. See “Cleaning roller cover removal” on page 4-6 . 2. Lift and remove transfer belt cleaning roller.

Repair information 4-7 5021-0XX Transfer belt unit removal Note: If the duplex unit is installed, remove it to allow greater rear cover assembly clearance. The captive screw on the right can be removed by pulling out the plastic sleeve and rotating or by using a screwdriver. 1. Open rear cover assem...

4-8 Service Manual 5021-0XX 3. Pull transfer belt unit toward rear of printer, lift and remove. Transfer roller removal 1. Open rear cover assembly. 2. Rotate transfer roller to release; lift and remove.

Repair information 4-9 5021-0XX Fuser assembly removal 1. Push rear cover assembly latch and lower rear cover assembly. 2. Turn two green fuser release levers (A). 3. Lift fuser straight up and away from printer.

4-10 Service Manual 5021-0XX Waste toner bottle removal 1. Open front cover. 2. Remove waste toner bottle. Warning: Ensure that waste toner bottle is secured and not allowed to tip over during repair process. Failure to adhere to this warning may result in toner spillage.

Repair information 4-11 5021-0XX Photodeveloper cartridge removal Warning: Follow precautionary procedures (see “Photodeveloper cartridge” on page 4-3 ) when removing photodeveloper cartridge. 1. Open top cover assembly. 2. Depress release levers (A). 3. Lift and remove photodeveloper cartridge. 4. ...

Repair information 4-13 5021-0XX Duplex unit assembly removal 1. Unplug duplex connector. 2. Turn bracket mounting screw counterclockwise to loosen it. Unhook the bracket (A) from the slot.

4-16 Service Manual 5021-0XX Secondary paper feed assembly removal 1. Remove left secondary paper feed assembly cover. Repeat for the right side. 2. Loosen thumbscrew (A) on left bracket and remove bracket. Repeat for right side. 3. With aid from another person, lift printer by recessed handholds an...

4-18 Service Manual 5021-0XX Top cover assembly removal 1. Remove cleaning roller cover. See “Cleaning roller cover removal” on page 4-6 . 2. Remove photodeveloper cartridge. See “Photodeveloper cartridge removal” on page 4-11 . 3. Open rear cover assembly. 4. Open front cover. 5. Remove screw (A) f...

Repair information 4-19 5021-0XX 10. Release tabs on front of top cover assembly. 11. Lift top cover assembly and remove. Front cover assembly removal 1. Open front cover assembly. 2. Remove 8 screws (A) from inner front cover.

4-22 Service Manual 5021-0XX Right cover removal 1. Remove waste toner bottle. See “Waste toner bottle removal” on page 4-10 . 2. Remove top cover assembly. See “Top cover assembly removal” on page 4-18 . 3. Remove 2 screws (A) from bottom of right cover. 4. Remove right cover from printer. Maneuver...

4-24 Service Manual 5021-0XX Left cover removal 1. Remove rip board. See “RIP board removal” on page 4-45 . 2. Remove top cover assembly. See “Top cover assembly removal” on page 4-18 . 3. Remove two screws (A) from bottom of left cover. 4. Remove left cover from printer. Laser unit assembly (printh...

4-26 Service Manual 5021-0XX 7. Remove four screws (B) from laser unit assembly. 8. Remove laser unit assembly from printer. 9. Disconnect connector from laser unit assembly. Laser unit fan assembly removal 1. Open front cover. 2. Remove toner car tridges. 3. Remove photodeveloper cartridge. See “Ph...

Repair information 4-27 5021-0XX 5. Disconnect laser unit fan assembly connector (A). 6. Remove screw (B). 7. Remove fan assembly. Erase lamp removal 1. Remove all toner cartridges. 2. Remove photodeveloper cartridge. See “Photodeveloper cartridge removal” on page 4-11 . 3. Remove transfer belt unit...

Repair information 4-29 5021-0XX Right side removals Front door interlock switch removal 1. Remove top cover assembly. See “Top cover assembly removal” on page 4-18 . Note: The interlock cable may be difficult to remove. Use a flat tip tool to disengage the mechanical lock between the cable connecto...

Repair information 4-31 5021-0XX Front door interlock switch with bracket 1. Remove developer drive assembly. See “Developer drive assembly removal” on page 4-32 . 2. Remove screw (A). 3. Remove switch with bracket. Developer motor removal 1. Remove right cover. See “Right cover removal” on page 4-2...

4-32 Service Manual 5021-0XX Waste toner bottle holder removal 1. Remove right cover. See “Right cover removal” on page 4-22 . 2. Disconnect waste toner bottle holder connector (A). 3. Remove two screws (B) from waste toner bottle holder. 4. Remove waste toner bottle holder from printer. Developer d...

Repair information 4-33 5021-0XX 3. Remove four clips and developer drive gears (A) from inside of printer. Note: The cables that connect to the developer clutches are color coded. One wire of the cable is white while the other wire represents the color of the toner for the associated developer clut...

Repair information 4-35 5021-0XX Toner sensor (sender) removal 1. Remove developer drive assembly. See “Developer drive assembly removal” on page 4-32 . 2. Remove two screws (A) from toner sensor. Note: Bottom screw is longer than top screw. 3. Pull toner sensor away from printer, disconnect cable, ...

4-36 Service Manual 5021-0XX Cleaning roller clutch removal 1. Remove transfer belt cleaning roller. See “Transfer belt cleaning roller removal” on page 4-6 . 2. Remove right cover. See “Right cover removal” on page 4-22 . 3. Using a flat tip tool, pry and remove cleaning roller clutch gear from ins...

4-38 Service Manual 5021-0XX Main motor assembly removal 1. Remove right cover. See “Right cover removal” on page 4-22 . 2. Remove clutch wires from wire guide and swing wire guide away from printer. 3. Disconnect main motor assembly cable (A) from main motor.

4-40 Service Manual 5021-0XX Clutch removal Note: This procedure applies to the fuser clutch, transfer roller clutch, registration clutch, and the paper feed clutch. 1. Remove right cover. See “Right cover removal” on page 4-22 . 2. Disconnect clutch cable (A). 3. Remove clip from clutch (B). 4. Sli...

Repair information 4-41 5021-0XX Main drive gear assembly removal 1. Remove cleaning roller clutch. See “Toner sensor (sender) removal” on page 4-35 . 2. Remove main motor assembly. See “Main motor assembly removal” on page 4-38 . Note: If you are removing the main drive gear assembly to get to the ...

4-42 Service Manual 5021-0XX 8. Remove main drive gear assembly from printer. Note: When reinserting the main drive gear assembly, ensure that you start with the bottom right corner. This allows proper installation of the assembly. The photo depicts proper removal and the first par t of reinstalling...

Repair information 4-45 5021-0XX RIP board removal 1. Disconnect any attached cables. 2. Remove four screws (A). 3. Slide RIP board out of printer. Bracket assembly removal 1. Remove erase lamp. See “Erase lamp removal” on page 4-27 . 2. Remove two screws (A). 3. Disconnect connector (B) from transf...

4-46 Service Manual 5021-0XX 4. Disconnect connector (C) from toner density sensor. 5. Lift and remove bracket assembly. Paper guide assembly removal 1. Remove duplex unit if attached. See “Duplex unit assembly removal” on page 4-13 . 2. Remove lower duplex cover from rear cover assembly.

Repair information 4-47 5021-0XX 3. Remove two screws (A) that attach paper guide assembly to printer. Screws are located in holes. 4. Open rear cover assembly. 5. Lift and remove paper guide assembly (B) from printer. Paper guide (C) assembly removal 1. Remove paper guide assembly. See “Paper guide...

4-48 Service Manual 5021-0XX 3. Remove support pin, disconnecting suppor t cable (A) from printer. 4. Remove two screws (B) that attach paper guide (C) assembly to printer. 5. Disconnect three sensor cables from sensors located on paper guide (C) assembly and remove paper guide (C) assembly. Paper f...

Repair information 4-49 5021-0XX Paper exit assembly removal 1. Open rear cover assembly. 2. Remove plastic bracket (A). 3. Disconnect cable (B).

4-52 Service Manual 5021-0XX Registration assembly removal 1. Remove transfer roller. See “Transfer roller removal” on page 4-8 . 2. Remove three metal screws (A) and three plastic screws (B). 3. Lift and remove registration assembly.

Repair information 4-53 5021-0XX Left side removals

4-54 Service Manual 5021-0XX Operator panel cable removal 1. Remove left cover. See “Left cover removal” on page 4-24 . 2. Remove three screws (A) from engine controller board shield; remove shield. 3. Disconnect operator panel cable (B) from engine controller board and remove. A

Repair information 4-55 5021-0XX Engine controller board removal 1. Remove left cover. See “Left cover removal” on page 4-24 . 2. Remove RIP board. See “RIP board removal” on page 4-45 . 3. Remove three screws (A) from engine controller board shield; remove shield. 4. Disconnect all connectors from ...

Repair information 4-57 5021-0XX RIP board cage removal 1. Remove engine controller board. See “Operator panel cable removal” on page 4-54 . 2. Remove screw (A) from power supply fan. 3. Lay power supply fan to side. A

Repair information 4-59 5021-0XX 5. Remove three screws (B) from RIP board cage. 6. Remove RIP board cage. High voltage power supply (HVPS) removal 1. Remove RIP board cage. See “RIP board cage removal” on page 4-57 . 2. Disconnect all connectors from HVPS. Note: When reinstalling flat cable, ensure...

4-60 Service Manual 5021-0XX 3. Remove 11 screws (A) (4 corner screws are gold in color (metal), inner screws are silver (plastic)); remove HVPS. Low voltage power supply (LVPS) with cage removal 1. Remove transfer belt unit. See “Transfer belt unit removal” on page 4-7 . 2. Remove RIP board cage. S...

4-62 Service Manual 5021-0XX HVPS cage removal 1. Remove HVPS. See “High voltage power supply (HVPS) removal” on page 4-59 . 2. Remove LVPS with cage. See “Low voltage power supply (LVPS) with cage removal” on page 4-60 . 3. Remove five screws (A) from shield cover. 4. Disconnect toner present senso...

Repair information 4-63 5021-0XX 5. Remove four screws (C); remove HVPS cage. Toner present sensor removal 1. Remove HVPS cage. See “HVPS cage removal” on page 4-62 . 2. Remove two screws (A); remove toner present sensor.

4-64 Service Manual 5021-0XX Toner sensor (receiver) removal Note: The toner sensor is comprised of two separate parts: the sender and receiver. The sender portion of the toner sensor is located on the right side of the printer. See “Toner sensor (sender) removal” on page 4-35 for removal. 1. Remove...

Repair information 4-65 5021-0XX 4. Remove two screws (B); remove toner retract solenoid and toner retract cam. Left tray guide assembly removal 1. Remove HVPS cage. See “HVPS cage removal” on page 4-62 . 2. Remove five screws (A) from shield cover (top); remove shield cover. A B A

Repair information 4-69 5021-0XX Marker sensor assembly removal 1. Remove all toner cartridges. 2. Remove photodeveloper cartridge. See “Photodeveloper cartridge removal” on page 4-11 . 3. Remove transfer belt unit. See “Transfer belt unit removal” on page 4-7 . 4. Remove screw (A) from bracket. 5. ...

4-70 Service Manual 5021-0XX I/O board removal 1. Remove top cover assembly. See “Top cover assembly removal” on page 4-18 . 2. Remove five (A) screws from shield cover. 3. Disconnect all cables attached to I/O board. Warning: There are several cables connected to the I/O board that can be interchan...

4-72 Service Manual 5021-0XX Waste toner auger removal 1. Remove photodeveloper cartridge. See “Photodeveloper cartridge removal” on page 4-11 . 2. Remove transfer belt unit. See “Transfer belt unit removal” on page 4-7 . 3. Remove top cover assembly. See “Top cover assembly removal” on page 4-18 . ...

Repair information 4-73 5021-0XX Waste toner agitator removal 1. Remove waste toner auger. See “Waste toner auger removal” on page 4-72 . 2. Remove gear (A) from cleaning roller clutch. 3. Pull agitator off shaft; lift and remove.

4-74 Service Manual 5021-0XX Power supply fan removal 1. Remove top cover assembly. See “Top cover assembly removal” on page 4-18 . 2. Remove 5 (A) screws from I/O shield cover. 3. Disconnect cable from DCN20 on I/O board. 4. Remove screw (A) from power supply fan. 5. Disconnect cables from interloc...

Locations and connectors 5-1 5021-0XX 5. Locations and connectors Printer

5-4 Service Manual 5021-0XX Electronic components Sensor locations Name Code Function Paper size sensor PSU Detects paper size. Registration sensor PT1 Detects whether paper is fed from paper drawer. Fuser exit sensor PT2 Detects when paper exits from rear cover assembly. Tray empty sensor PEU Detec...

5-6 Service Manual 5021-0XX Printer circuit board locations Name Function Engine controller board Controls the following printer processes Fuser temperature controlLaser output controlOperator panel indicationToner empty sensing controlError processing controlInterface control Operator panel Display...

5-8 Service Manual 5021-0XX Interlock switch locations Name Code Function Front cover interlock switch DSW1 Safety interlock switches that break power when covers are opened. Rear cover assembly interlock switch DSW2 Top cover interlock switch DSW3

Locations and connectors 5-9 5021-0XX Solenoid/clutch locations Name Code Function Paper feed clutch PCLU Feeds paper by coupling feed roller to the main gear unit at the time of a paper feed. Registration clutch RECL Transports paper by coupling registration roller to main gear unit as synchronized...

Locations and connectors 5-11 5021-0XX Symbol and part name table Symbol Part name BR Back-up roller CTFAN Control fan motor (cooling fan PS) DCLKDCLYDCLMDCLC Developer clutch (K.Y.M.C.) DM Developer motor DPJ Drum jam sensor DSW1 Interlock switch (front) DSW2 Interlock switch (top) DSW3 Interlock s...

5-14 Service Manual 5021-0XX Wiring diagram / cable harness reference Notes: – See cable diagram foldout in the back of this manual. – Cables are marked, in large circles, with the # sign.

5-16 Service Manual 5021-0XX Engine controller board

Locations and connectors 5-19 5021-0XX Printer cables Cable 1 connector assignments Cable 1 connector pin assignments Engine controller board I1CN—I/O board DCN1 I1CNPin No. Signal name DCN1Pin No. 39 SGND 1 38 +5V-S 2 37 I1RDWR 3 36 I1DATA 4 35 I1CK 5 34 I1LOAD 6 33 I1SCDO 7 32 NC 8 31 NC 9 30 DSL(...

5-22 Service Manual 5021-0XX Cable 2 connector assignments Cable 2 connector pin assignments Engine controller board I2CN—I/O board DCN3 I2CNPin No. Signal name DCN3Pin No. 31 SGND 1 30 COLSEL1 2 29 COLSEL2 3 28 DCL(C)ON-P 4 27 DCL(M)ON-P 5 26 DCL(Y)ON-P 6 25 DCL(K)ON-P 7 24 PSL(KY)ON-P 8 23 PSL(MC)...

5-24 Service Manual 5021-0XX Cable 3 connector assignments Cable 3 connector pin assignments Engine controller board HVCN—HVPS CN1 HVCN Pin No. Signal name CN1Pin No. 21 PGND 1 20 PGND 2 19 PGND 3 18 +24V-1D 4 17 +24V-1D 5 16 +24V-1D 6 15 BRVON-N 7 14 CLVP-N 8 13 PWMON-N 9 12 BRVPWM-N 10 11 BRVERR 1...

Locations and connectors 5-25 5021-0XX 9 THVRON-N 13 8 DBV(MC)PWM-N 14 7 THVPWM-N 15 6 DBV(KY)PWM-N 16 5 THV-I 17 4 FCBVPWM-N 18 3 ID (PGND) 19 2 PGND 20 1 HVUCNCHK-N 21 HVCN Pin No. Signal name CN1Pin No.

5-26 Service Manual 5021-0XX Cable 4 connector assignments Cable 4 connector pin assignments Engine controller board P2CN—Operator panel P2CNPin No. Signal name Operator panelPin No. 1 N/A 1 2 N/A 2 3 N/A 3 4 N/A 4 5 N/A 5

Locations and connectors 5-27 5021-0XX Cable 5 connector assignments Cable 5 connector pin assignments I/O board DCN13—LVPS ACN1 DCN13Pin No. Signal name ACN1Pin No. 1 +24-1D 2 2 PGND 1 3 +24-1D 4 4 PGND 3 5 +24-1D 6 6 PGND 5 7 +24-1D 8 8 PGND 7 9 +5V-1 10 10 SGND 9

5-28 Service Manual 5021-0XX LVPS ACN2—Interlock switches I/O board DCN18—Interlock switches Interlock switches—Interlock switches 11 +5V-1 12 12 SGND 11 ACN2Pin No. Signal name Interlock switchPin No. 1 DSW-O:F Front-1 2 DSW-I:R Rear-2 DCN18Pin No. Signal name Interlock switchPin No. 1 REARDOPEN-P ...

Locations and connectors 5-29 5021-0XX LVPS ACN5—Engine controller board DCN21 LVPS ACN5—Engine controller board LVCN ACN5Pin No. Signal name DCN21Pin No. 1 TESTO1 1 2 TESTO2 2 3 TESTI1 3 4 TESTI2 4 ACN5Pin No. Signal name LVCNPin No. 5 +5VDO-N 1 6 +5V-1R 2 7 BRON-N 3 8 DCOFF1-P 4 9 ACOFF-P 5 10 HRO...

Locations and connectors 5-31 5021-0XX Engine controller board POCN—LVPS ACN3 POCNPin No. Signal name ACN3Pin No. 1 +5V-2(CNT) 2 2 SGND(CNT) 1 3 +5V-2(CNT) 4 4 SGND(CNT) 3 5 +5V-2(CNT) 6 6 SGND(CNT) 5 7 +3.3V-2 8 8 SGND(CNT) 7 9 +3.3V-2 10 10 SGND(CNT) 9 11 +3.3V-2 12 12 SGND(CNT) 11 13 +5V-1(MCTL) ...

5-32 Service Manual 5021-0XX Cable 6 connector assignments Cable 6 connector pin assignments I/O board DCN4—Toner retract solenoids DCN4Pin No. Signal name Developer solenoidPin No. Black toner retract solenoid 1 DSL(K)ON-N no number 2 +24V-F2 no number Yellow toner retract solenoid 3 DSL(Y)ON-N no ...

Locations and connectors 5-33 5021-0XX I/O board DCN5—Photodeveloper (OPC) marker sensor I/O board DCN8—Laser fan I/O board DCN15—Toner present sensor, erase lamp DCN5Pin No. Signal name Marker sensorPin No. 1 PBSEN-N 1 2 +5V-S 2 3 SGND 2 DCN8Pin No. Signal name Laser fanPin No. 1 LDFANON-P no numbe...

Locations and connectors 5-35 5021-0XX I/O board DCN16—Sensors DCN16Pin No. Signal name SensorPin No. Transfer belt unit marker sensor 1 +5V-S no number 2 TBEN-N no number 3 SGND no number Registration sensor 4 +5V-S no number 5 PT1-N no number 6 SGND no number Paper empty sensor 7 +5V-S no number 8...

5-36 Service Manual 5021-0XX Cable 7 connector assignments Cable 7 connector pin assignments I/O board DCN7—Rear cover assembly DCN7Pin No. Signal name Pin No. Fuser exit sensor 1 +5V-S no number 2 PT2-N no number 3 SGND no number 4 NC 5 NC 6 NC Output tray full sensor 7 +5V-1 no number 8 PEFULL-N n...

5-40 Service Manual 5021-0XX I/O board DCN11—Developer motor I/O board DCN12—Main motor DCN11Pin No. Signal name Developer motorPin No. 1 DMRDY-N 1 2 DMON-N 2 3 DMCLK 3 4 +24V-1D 4 5 PGND 5 6 +24V-1D 6 7 PGND 7 8 PGND 8 9 SGND 9 10 +5V-1 10 11 DMGAIN 11 12 DMOVLD 12 DCN12Pin No. Signal name Main mot...

5-42 Service Manual 5021-0XX Cable 9 connector assignments Cable 9 connector pin assignments Engine board LCN—Printhead LDU LCNPin No. Signal name LDUPin No. 1 +5V-1R 1 2 LCONT1 2 3 LREADY 3 4 LCONT2 4 5 SGND 5 6 LDREF4 6 7 VIDEO-N 7 8 LDREF3 8 9 VIDEO-P 9 10 LDREF2 10 11 SGND 11 12 LDREF1 12 13 BDT...

5-44 Service Manual 5021-0XX Cable 10 connector assignments Cable 10 connector pin assignments I/O board DCN14—Lower feeder unit DCN14Pin No. Signal name Lower feeder unit Pin No.(pin 1 is pin closest to front of printer) 1 connects to DCN14 pin 16 LFCN-RET N/A 2 +24V-F2 1 3 PKCLL1ON-N 2 4 NC/FDCLL1...

5-46 Service Manual 5021-0XX Cable 11 connector assignments Cable 11 connector pin assignments I/O board DCN19—Paper size sensor and temperature thermistor DCN19Pin No. Signal name Pin No. Paper size sensor (PSU) 1 +5V-1 1 2 PSU1 2 3 PSU2 3 4 PSU3 4 5 PSU4 5 6 NOT USED N/A 7 SGND 6 8 NOT USED Temper...

Locations and connectors 5-47 5021-0XX Cable 12 connector assignments Cable 12 connector pin assignments Fuser connector—LVPS ( 120V Printer) Fuser connector—LVPS ( 240V Printer) Fuser connector Pin No. Signal name LVPS Pin No. 1 FG Ground screw 2 P P 3 NC N/A 4 P2 P2 Fuser connector Pin No. Signal ...

5-48 Service Manual 5021-0XX Cable 13 connector assignments Cable 13 connector pin assignments Engine controller board FUCN—fuser FUCNPin No. Signal name Fuser connector 1 TH1 1 2 TH1 2 3 TH2 3 4 TH2 4 5 FUTEMP 5 6 SGND 6 7 NC 7 8 NC 8

Locations and connectors 5-49 5021-0XX Engine controller board DPCN—Duplex unit DUPL LVPS ACN4—Duplex unit (DUPL) and duplex power DPCNPin No. Signal name DUPLPin No. 1 D-COMMAND 1 2 connects to DPCN pin 11 DPCN-RET N/A 3 DUMBUSY2-N 2 4 SGND 3 5 D-STATUS 4 6 SGND 5 7 DUPMON-P 6 8 SGND 7 9 DUREON-P 8...

Preventive maintenance 6-1 5021-0XX 6. Preventive maintenance There is no preventive maintenance for the Lexmark C510.

Parts catalog 7-1 5021-0XX 7. Parts catalog How to use this parts catalog • SIMILAR ASSEMBLIES: If two assemblies contain a majority of identical parts, they are shown on the same list. Common parts are shown by one index number. Parts peculiar to one or the other of the assemblies are listed separa...

7-2 Service Manual 5021-0XX Assembly 1: Base printer

Parts catalog 7-3 5021-0XX Assembly 1: Base printer Index P/N Units Description 1-1 56P1611 1 Cover, cleaning roller 2 56P1607 1 Roller, cleaning 3 56P1651 1 Transfer unit 4 56P1660 1 Transfer roller assembly 5 56P1669 1 Paper tray, standard 6 12G7008 1 Power cord, USA 6 1339517 1 Power cord, LV, US...

Parts catalog 7-17 5021-0XX Assembly 8: RIP board Index P/N Units Description 8-1 56P2714 1 Board, Base RIP 2 56P2715 1 Board, Network RIP 3 12G7229 1 Card assembly, riser 4 56P1667 1 Shield, INA NS 99A1611 1 Shield, Ethernet NS 99A2432 1 Shield, parallel

I-5 5021-0XX Part number index P/N Description page 11A6199 Cable, 50-foot serial . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1912G7008 Power cord, USA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-312G7229 Card assembly, riser . . . . . . . . ...