Lexmark C510 Service Manual
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Lexmark C510 Service Manual

Service manual
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Download this manual See also: User Manual, Setup Manual
Revised March, 2005
Lexmark C510
5021-0XX
• Table of Contents
• Start Diagnostics
• Safety and Notices
• Trademarks
• Index
Lexmark and Lexmark with diamond
design are trademarks of Lexmark
International, Inc., registered in the
United States and/or other countries.

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Summary of Contents for Lexmark C510

  • Page 1 Revised March, 2005 Lexmark C510 5021-0XX • Table of Contents • Start Diagnostics • Safety and Notices • Trademarks • Index Lexmark and Lexmark with diamond design are trademarks of Lexmark International, Inc., registered in the United States and/or other countries.
  • Page 2 You can purchase additional copies of publications related to this product by calling 1-800-553-9727. In other countries, contact your point of purchase. Lexmark and Lexmark with diamond design are trademarks of Lexmark International, Inc., registered in the United States and/or other countries.

  • Page 3: Table Of Contents

    5021-0XX Table of contents Laser notices ......... . . xi Safety information.
  • Page 4 5021-0XX Basic structure of the print system .....1-27 Details of the print system ......1-29 Charging process .
  • Page 5 5021-0XX 914—Laser fan service check......2-53 915—Erase lamp service check ..... . 2-54 916—Toner empty sensor (sender-TPD) service check .
  • Page 6 5021-0XX Insufficient gloss service check ..... .2-108 Jitter service check .......2-109 Missing image at edge service check .
  • Page 7 5021-0XX Flash test........3-15 Printer setup .
  • Page 8 5021-0XX Laser unit assembly (printhead) removal ....4-24 Laser unit fan assembly removal ..... .4-26 Erase lamp removal .
  • Page 9 5021-0XX Locations and connectors ....... 5-1 Printer ......... . . 5-1 Options .
  • Page 10 5021-0XX Preventive maintenance ....... . .6-1 Parts catalog ......... .7-1 How to use this parts catalog .

  • Page 11: Laser Notices

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

  • Page 12: Class 1 Laser Statement Label

    5021-0XX Class 1 Laser statement label Service Manual...
  • Page 13 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.
  • Page 14 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 produits laser de Classe I.
  • Page 15 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 condiciones expuestas en la norma IEC 60825-1 para productos láser de Clase I (1).
  • Page 16 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 ongevaarlijk aangemerkt.
  • Page 17 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. Kirjoittimessa on sisäinen luokan IIIb (3b) 5 milliwatin galliumarsenidilaser, joka toimii aaltoalueella 770 - 795 nanometriä.
  • Page 18 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. Skriveren inneholder internt en klasse IIIb (3b)-laser, som består av en gallium-arsenlaserenhet som avgir stråling i bølgelengdeområdet 770-795 nanometer.
  • Page 19 5021-0XX Japanese laser notice Chinese laser notice Laser notices...
  • Page 20 5021-0XX Korean laser notice Service Manual...

  • Page 21: Safety Information

    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 this product has been prepared for use by a professional service person and is not intended to be used by others.
  • Page 22 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 manutenzione di questo prodotto sono indirizzate soltanto al personale di assistenza autorizzato.
  • Page 23 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. •...
  • Page 24 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. •...
  • Page 25 5021-0XX Safety information...

  • Page 26: Preface

    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 listed, as well as general environmental and safety instructions.

  • Page 27: General Information

    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 used as a shared network or desktop printer.

  • Page 28: Serial Number

    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. Service Manual...

  • Page 29: Acronyms

    5021-0XX Acronyms ASIC Application-Specific Integrated Circuit Customer Ordered Customer Setup DRAM Dynamic Random Access Memory EEPROM Electrically Erasable Programmable Read-Only Memory Electrophotographic Process Electrostatic Discharge Field Replaceable Unit High Voltage HVPS High Voltage Power Supply Local Area Network LASER Light Amplification by Stimulated Emission of Radiation Liquid Crystal Display Light-Emitting Diode...

  • Page 30: Specifications

    5021-0XX Specifications Resolution 600 x 600 dpi 2400 image quality Model differences C510 C510n C510dtn USB 2.0 Parallel Ethernet Memory (MB) Options available 530-sheet drawer (tray 2) Duplex Hard disk Technical specifications Toner darkness There are five settings to balance print darkness and toner savings.

  • Page 31: Physical Specifications And Weight

    This does not include packaging but does include the print cartridge that ships with the printer. Width Depth Height Weight inch inch inch Printers Lexmark C510 19.5 16.5 15.2 67.0 30.3 Lexmark C510n 19.5 16.5 15.2 67.0...

  • Page 32: Operating Clearances

    5021-0XX Operating clearances Printer sides C510 & C510n C510 & C510n C510 & C510n C510dtn with with 530-sheet with duplex 530-sheet tray tray unit Left side 8 in (203 mm) 8 in (203 mm) 8 in (203 mm) 8 in (203 mm)

  • Page 33: Print Speed And Performance

    5021-0XX Print speed and performance Simplex printing Duplex printing pages/minute) (sides/minute) Media size Standard tray Standard tray Letter Legal Transparencies Thick card stock Labels (letter & Medium thick card stock (letter & A4) Envelopes N/S - Media size not supported in this tray Note: For media size A4 duplex mode with custom paper sizes, size sensing is turned off.

  • Page 34: Duty Cycle

    Paper and media specifications Print area The C510 printable area is up to 4.0 mm (0.158 in.) from the top and bottom of the media, and up to 3.0 mm (0.118 in.) from the left and right edges. Any information placed outside this specified printable area will not print.
  • Page 35 Capacity may vary and is subject to media specifications and printer operating environment. The capacities listed are based on plain paper at 75 g/m Sources and capacities C510/C510n C510dtn Input sources Number of standard sources Number of optional input drawers...
  • Page 36 5021-0XX Media input types and weights Source Type Standard 530- Duplex Printer menu Item tray Legal Sheet tray tray Paper Paper type weight Paper Xerographic 60-74 60-74 60-74 Plain paper Light (grain long) or bond paper (16-19 lb) (16-19 lb) (16-19 lb) Xerographic 75-120...

  • Page 37: Media Sizes

    5021-0XX Media sizes Media sizes Dimensions Input Output 210 x 297 8.27 x 11.7 148 x 210 5.83 x 8.27 JIS B5 182 x 257 7.17 x 10.1 Letter 216 x 279.4 8.5 x 11 Legal 216 x 356 8.5 x 14 Executive 184.2 x 266.7 7.25 x 10.5 Folio...

  • Page 38: Output Capacity By Media And Source

    Face down 50 Transparencies 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 any particular brand for suitability to their applications.
  • Page 39 Labels • Labels should be selected using guidelines found in the User's Reference, Complete Printer Reference, or the Card stock & Label Guide (located at www.lexmark.com), and tested for acceptability. • Vinyl labels are not supported. • Labels are only supported in tray 1 (standard or legal trays).

  • Page 40: Connectivity

    Controller, refer to the IBM AS/400 ASCII Workstation Reference and Example manual (SA41-9922) for specific cable information. The printer requires the optional RS-232C serial interface card (P/N 11K4602). Connections C510 C510n C510dtn Standard local connections Parallel & USB 2.0 Ethernet & USB Ethernet &...

  • Page 41: Power And Electrical Specifications

    5021-0XX Power and electrical specifications Printing states C510 C510n C510dtn 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...

  • Page 42: Environment

    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-printer and supplies 0 to 35°C (32 to 95°F)

  • Page 43: Printer Identification

    5021-0XX Printer identification 1-17 General information...

  • Page 44: Options Identification

    5021-0XX Options identification 1-18 Service Manual...

  • Page 45: Printer Theory Of Operation

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

  • Page 46: Printer Paper Path

    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: 1-20 Service Manual...

  • Page 47: Printer Systems Description

    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 cyan. Mechanical and electrical structures This color laser printer consists of five engineering systems: print, transfer, optical, paper transport, and control system.
  • Page 48 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 control, fusing temperature control, and interface control.

  • Page 49: Printer Component Systems

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

  • Page 50: Basic Process Of Color Printing

    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.

  • Page 51: Print System And Transfer System

    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 and the transfer system.

  • Page 52: Structure Of Opc Belt (Photo Developer Cartridge)

    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 main part of the print system. 1-26 Service Manual...

  • Page 53: Basic Structure Of The Print System

    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.
  • Page 54 5021-0XX 5. Variation of the OPC belt potential: a. The OPC belt is biased to -CBV(V). b. The OPC belt surface is evenly charged to -Vo(V) during the charging process. c. During the exposing process, the optical unit emits a laser beam that strikes the OPC belt surface forming an electrostatic image.

  • Page 55: Details Of The Print System

    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.
  • Page 56 5021-0XX 3. Before charging, the OPC belt surface is -CBV(V). The charger unit evenly charges the OPC belt surface to -Vo(V) by generating a negative charge. 1-30 Service Manual...

  • Page 57: Exposing Process

    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 location.

  • Page 58: Developing Process

    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 located in the printer from top to bottom in the order of black, yellow, magenta, and cyan.
  • Page 59 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. Dev. roller (-CBV)+(-DBV) Toner (-CBV) OPC belt 3. Developing is processed by toner adhering to the OPC belt due to the attraction between the toner and the -VR(V) charge at the exposed area of OPC belt.

  • Page 60: First Transfer (Drum) Process

    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.

  • Page 61: Belt Discharge (Erase Lamp) Process

    5021-0XX 4. The toner image is then transferred to paper. Belt discharge (erase lamp) process Electrical belt cleaning is accomplished by an erase lamp radiating on the OPC belt. Radiation discharges the residual charge -VR(V) remaining on the belt after the first transfer process. Electrical cleaning occurs after each toner color transfer.

  • Page 62: Belt Cleaning Process

    5021-0XX OPC belt OPC belt cleaning (blade) OPC belt discharging First transfer (erase lamp) Belt cleaning process In the belt cleaning process, residual toner adhering to the OPC belt surface is mechanically removed by a blade edge. 1-36 Service Manual...
  • Page 63 5021-0XX The residual toner is collected in a waste toner container located by the waste toner feeder. OPC belt OPC belt cleaning (blade) OPC belt discharging First transfer (erase lamp) 1-37 General information...

  • Page 64: Details Of The Transfer System

    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 separated from the transfer belt, is positively biased by the power supply THV.

  • Page 65: Transfer Belt Cleaning Process

    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 fur brush. The cleaning roller is charged by voltage FCBV.

  • Page 66: Details Of The Optical System

    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 OPC belt through a polygon mirror and lens.
  • Page 67 5021-0XX Description F-lens: laser beam focus lens Mirror: laser beam path reflecting mirror 1-41 General information...

  • Page 68: Details Of The Paper Transportation System

    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 the paper to the transfer roller. During the transfer process, the transfer roller forwards the paper to the fuser rollers.
  • Page 69 5021-0XX Part Function Transfer roller Works in conjunction with the transfer belt to transfer the image to paper and to transport the paper to the fuser. Fuser unit Utilizes a heat roller to fuse the toner image to the paper. Paper exit Exits the fused paper from the printer.

  • Page 70: Fusing Unit

    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 a toner image passes between the rollers where heat and pressure are applied to the paper to fuse the toner to the paper.
  • Page 71 5021-0XX Part Function Thermistor Sensor that detects the temperature of the fuser roller’s surface. Thermal fuse Protective device that prevents the fuser roller from being excessively heated. 1-45 General information...

  • Page 72: Fusing Process

    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°C).

  • Page 73: Control System Structure

    5021-0XX Control system structure Electrical system and function The engine board controls most of the main electrical parts in this printer. Control process Function Print process Controls print process from paper feed control through paper exit. Laser output Automatically controls laser output to the control default.

  • Page 74: Control Of Print Process

    5021-0XX Control of print process Control block diagram Control process Function Sequence control Controls print sequence of printer. Temperature Controls temperature of fuser unit. control Consumables’ life Controls toner empty status for each toner control cartridge and life of periodic replacement parts.

  • Page 75: Print Sequence Diagram

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

  • Page 76: Laser Drive Control Circuit

    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 control circuit switches the laser diode switch on and radiates according to the video signal.

  • Page 77: Interface Control

    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 engine. Interface connection The interface connector of the laser printer is connected to the host system as shown in the following illustration.
  • Page 78 5021-0XX 1-52 Service Manual...

  • Page 79: Diagnostic Information

    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 sure your fingers are not under the printer when you set the printer down.

  • Page 80: Service Error Codes

    5021-0XX Service error codes Error code Action Contact customer service center, or Lexmark support center RIP Software Go to “901—Yellow developer clutch service check” on page 2-29. Yellow developer clutch error (DCLY) Go to “902—Magenta developer clutch service check” on page 2-31.
  • Page 81 5021-0XX Error code Action Go to “910—Developer motor service check” on page 2-45. Developing motor (DM) error Go to “911—Main motor service check” on page 2-48. Main motor (MM) error Go to “912—Power supply fan service check” on page 2-51. Power supply fan (PSFAN) error Go to...
  • Page 82 5021-0XX Error code Action Go to “920—Fuser thermistor service check” on page 2-60. Fuser thermistor error 921/922/923/924/925 Go to “921,922,923,924,925—Fuser assembly service check” on page 2-61. Fuser temperature error Fuser is in a maintenance state and needs to be replaced before any other action can be taken. Fuser exhausted Replace fuser assembly (see “Fuser assembly...
  • Page 83 5021-0XX Error code Action Turn power off and then back on. Engine controller If error still exists, replace engine controller board. hardware error Go to “Engine controller board removal” on page 4-55. Indicates synchronization signal from main motor (MM) is not inputted. Process timing clock error Go to...
  • Page 84 5021-0XX Error code Action Indicates RAM in slot 1 is bad. Replace memory in slot 1. If error persists, replace RIP board. Go to “RIP Memory error board removal” on page 4-45. Indicates RAM in slot 2 is bad. Replace memory in slot 2.
  • Page 85 5021-0XX Error code Action Indicates a problem with the network port. Flash parts failed • Network printer while programming Replace RIP board. Go to “RIP board removal” on network port page 4-45. • Standard printer with INA Replace INA. If terror persists, replace RIP board. Go “RIP board removal”...
  • Page 86 5021-0XX Error code Action Indicates unstable transfer belt rotation; color matching cannot be secured. Transfer belt (transfer unit) error Go to “990—Transfer belt unit service check” on page 2-65. Indicates a problem with transfer roller cable connection. Transfer roller clutch error Go to “991—Transfer roller clutch service check”...

  • Page 87: Operator Messages

    5021-0XX Operator messages Message Description Action Change Tray <x> Printer is requesting Ensure tray contains proper <type> <size> different media than type and size of media for job. what is loaded in Remove tray from machine. specified tray or defined by paper Remove paper from tray.
  • Page 88 5021-0XX Message Description Action Did you replace Fuser page counter Replace fuser. Fuser? has exceeded fuser page limit. Note: This is a customer ordered part. Pressing Select clears maintenance counter. Press Stop to continue printing. This does not clear maintenance counter. Fuser remains in warning state, and message appears again each time rear cover is opened.
  • Page 89 5021-0XX Message Description Action Menus Disabled Printer menus have If operator has disabled menu been disabled. This and you want to run operator occurs when print tests, turn machine Off <Menu> is pressed and then press Return and while printer is Select as you turn machine Ready and menu lockout is active.
  • Page 90 5021-0XX Message Description Action Power Saver Printer is ready to Send a job to print. receive and process data. If printer Press Go to quickly warm remains inactive for printer to normal operating period of time temperature and display specified in Power Ready message.
  • Page 91 5021-0XX Message Description Action Tray <x> Empty Input tray is empty. Load media of size and type requested in second line of display in specified tray. Printer automatically clears message and continues printing job. If problem persists, go to “Tray empty service check”...
  • Page 92 5021-0XX Message Description Action 35 Res Save Off Printer lacks Press Go to disable Resource Deficient Memory memory needed to Save and continue printing. enable Resource To enable Resource Save after Save. This you get this message: message usually indicates too much •...
  • Page 93 5021-0XX Message Description Action 37 Insufficient Printer memory is Press Go to clear message Memory full and cannot and continue current print job. continue processing Printer frees memory by current print jobs. deleting oldest held job and continues deleting held jobs until there is enough printer memory to process job.
  • Page 94 5021-0XX Message Description Action 39 Complex Page Page may not print Press Go to clear message correctly because and continue printing job. Job print information on may not print correctly. page is too Press Menu to open Job Menu complex. and cancel current job.
  • Page 95 5021-0XX Message Description Action 54 Serial Option Printer has detected Make sure serial link is set up <x> Error a serial interface correctly and you are using error on a serial appropriate cable. 54 Standard Serial port. Error Press Go to clear message and continue printing.
  • Page 96 5021-0XX Message Description Action 56 Parallel Port <x> Data has been sent Press Go to clear message. Disabled to printer through a Printer discards any data parallel port, but received through parallel port. 56 Std Parallel Port parallel port is Disabled Make sure Parallel Buffer disabled.
  • Page 97 5021-0XX Message Description Action 64 Unsupported Printer detects an Press Go to clear message. Disk Format unsupported disk Format disk. format. Note: Disk operations are not allowed until disk is formatted. 80 Transfer Roller Transfer roller is Ensure transfer roller is Missing missing or not properly installed.
  • Page 98 5021-0XX Message Description Action 87 Fuser Exhausted Fuser is completely Replace fuser. used. 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 controller board removal”...
  • Page 99 5021-0XX Message Description Action 88 <color> Toner Printer has ceased Replace specified toner Empty operating because cartridge. If problem persists, specified toner go to “Toner low/empty cartridge is empty. service check” on page 2-92. 88 <color> Toner Printer has detected Replace specified toner that toner supply in cartridge.

  • Page 100: Paper Jam Messages

    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. 2-22 Service Manual...
  • Page 101 5021-0XX To locate the Message Action jam… 201 Paper Jam Open rear Indicates media is jammed in inner Open Rear Door cover area (between paper registration assembly sensor and paper exit sensor) of printer. • Open rear cover assembly to access area of paper jam.
  • Page 102 5021-0XX To locate the Message Action jam… 230 Paper Jam Open duplex Indicates media is jammed between Open Duplex door duplex redrive and duplex door. Door • Open duplex door to access jam. • Clear all paper from paper path. •...

  • Page 103: Symptom Tables

    5021-0XX Symptom tables Printer symptom table Symptom Action Operator panel buttons do not “Operator panel service work check” on page 2-84. Operator panel display is blank, “Operator panel service printer beeps 5 times check” on page 2-84. Operator panel continuously “Operator panel service displays all diamonds and beeps check”...
  • Page 104 5021-0XX Symptom Action The transfer roll is not transferring “White band service check” images or does not turn on page 2-121. No power “Printer no power service check” on page 2-89. Waste toner feed problems “Waste toner feed service check” on page 2-98.

  • Page 105: Print Quality Symptom Table

    5021-0XX Print quality symptom table Symptom Action Background “Background service check” on page 2-101. Missing image at edge “Missing image at edge service check” on page 2-110. Jitter “Jitter service check” on page 2-109. Ribbing “Ribbing service check” on page 2-114.
  • Page 106 5021-0XX Symptom Action Color misregistration “Color misregistration service check” on page 2-105. Mottle “Mottle service check” on page 2-112. Residual image “Residual image service check” on page 2-113. Insufficient gloss “Insufficient gloss service check” on page 2-108. Back stain “Back stain service check” on page 2-102.

  • Page 107: Printer Service Checks

    5021-0XX Printer service checks 901—Yellow developer clutch service check Step Questions / actions Turn printer off and remove Go to step 2. Properly connect right cover. See “Right cable. Go to step cover removal” on page 4-22. Is developer clutch cable properly connected? Is developer clutch cable Replace...
  • Page 108 5021-0XX Step Questions / actions If waste toner bottle is Go to step 6. Problem solved. 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.

  • Page 109: 902-Magenta Developer Clutch Service Check

    5021-0XX 902—Magenta developer clutch service check Step Questions / actions Turn printer off and remove Go to step 2. Properly connect right cover. See “Right cable. Go to step cover removal” on page 4-22. Is developer clutch cable properly connected? Is developer clutch cable Replace Go to step 3.
  • Page 110 5021-0XX Step Questions / actions If waste toner bottle is Go to step 6. Problem solved. 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.

  • Page 111: 903-Cyan Developer Clutch Service Check

    5021-0XX 903—Cyan developer clutch service check Step Questions / actions Turn printer off and remove Go to step 2. Properly connect right cover. See “Right cable. Go to step cover removal” on page 4-22. Is developer clutch cable properly connected? Is developer clutch cable Replace Go to step 3.
  • Page 112 5021-0XX Step Questions / actions If waste toner bottle is Go to step 6. Problem solved. 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.

  • Page 113: 904-Black Developer Clutch Service Check

    5021-0XX 904—Black developer clutch service check Step Questions / actions Turn printer off and remove Go to step 2. Properly connect right cover. See “Right cable. Go to step cover removal” on page 4-22. Is developer clutch cable properly connected? Is developer clutch cable Replace Go to step 3.
  • Page 114 5021-0XX Step Questions / actions If waste toner bottle is Go to step 6. Problem solved. 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.

  • Page 115: 905-Yellow Toner Retract Solenoid Service Check

    5021-0XX 905—Yellow toner retract solenoid service check Step Questions / actions Turn printer off and remove Replace I/O Go to step 2. I/O board shield. See “I/O board. See “I/O board removal” on board removal” page 4-70 for steps to on page 4-70.
  • Page 116 5021-0XX Step Questions / actions Reassemble and retest Turn printer off Problem solved. printer. Does 905 error and replace reappear? engine controller board. See “Engine controller board removal” on page 4-55. 2-38 Service Manual...

  • Page 117: 906-Magenta Toner Retract Solenoid Service Check

    5021-0XX 906—Magenta toner retract solenoid service check Step Questions / actions Turn printer off and remove Replace I/O Go to step 2. I/O board shield. See “I/O board. See “I/O board removal” on board removal” page 4-70 for steps to on page 4-70.
  • Page 118 5021-0XX Step Questions / actions Reassemble and retest Turn printer off Problem solved. printer. Does 906 error and replace reappear? engine controller board. See “Engine controller board removal” on page 4-55. 2-40 Service Manual...

  • Page 119: 907-Cyan Toner Retract Solenoid Service Check

    5021-0XX 907—Cyan toner retract solenoid service check Step Questions / actions Turn printer off and remove Replace I/O Go to step 2. I/O board shield. See “I/O board. See “I/O board removal” on board removal” page 4-70 for steps to on page 4-70.
  • Page 120 5021-0XX Step Questions / actions Reassemble and retest Turn printer off Problem solved. printer. Does 907 error and replace reappear? engine controller board. See “Engine controller board removal” on page 4-55. 2-42 Service Manual...

  • Page 121: 908-Black Toner Retract Solenoid Service Check

    5021-0XX 908—Black toner retract solenoid service check Step Questions / actions Turn printer off and remove Replace I/O Go to step 2. I/O board shield. See “I/O board. See “I/O board removal” on board removal” page 4-70 for steps to on page 4-70.
  • Page 122 5021-0XX Step Questions / actions Reassemble and retest Turn printer off Problem solved. printer. Does 908 error and replace reappear? engine controller board. See “Engine controller board removal” on page 4-55. 2-44 Service Manual...

  • Page 123: 910-Developer Motor Service Check

    5021-0XX 910—Developer motor service check Step Questions / actions Are there any unusual Replace toner Go to step 4. noises heard around cartridge developer motor or (customer developer drive assembly ordered supply). before error posts? Go to step 2. Does noise go away? Problem solved.
  • Page 124 5021-0XX Step Questions / actions If waste toner bottle is Replace Go to step 6. removed, reinsert it. developer motor. Ensure rear cover “Developer assembly is shut. Override motor removal” top and front cover on page 4-31. interlock switches. For Go to step 8 location, see “Interlock...
  • Page 125 5021-0XX Step Questions / actions Disconnect cable from Replace I/O Replace cable DCN13 on I/O board. board. See “I/O that connects Check the following on board removal” ACN1 on LVPS disconnected cable on page 4-70. to DCN13 on I/O connector: Go step 8.

  • Page 126: 911-Main Motor Service Check

    5021-0XX 911—Main motor service check Step Questions / actions Turn printer off and remove Replace Go to step 2. right cover. See “Right photodeveloper cover removal” on cartridge. page 4-22. Open top cover and override top cover Note: Photo- interlock switch. Restart developer printer and observe main cartridge is a...
  • Page 127 5021-0XX Step Questions / actions If waste toner bottle is Replace main Go to step 7. removed, reinsert it. motor. See Ensure rear cover “Main motor assembly cover is shut. assembly Override top and front removal” on cover interlock switches. page 4-38.
  • Page 128 5021-0XX Step Questions / actions Disconnect cable from Replace I/O Replace cable DCN13 on I/O board. board. See “I/O that connects Check the following on board removal” ACN1 on LVPS disconnected cable on page 4-70. to DCN13 on I/O connector: Go step 10.

  • Page 129: 912-Power Supply Fan Service Check

    5021-0XX 912—Power supply fan service check Step Questions / actions Turn printer off and remove Go to step 2. Properly connect I/O board shield. See “I/O cable. board removal” on page 4-70 for steps to remove I/O board shield. Is cable properly connected to I/O board connector DCN20?

  • Page 130: 913-Fuser Fan Service Check

    5021-0XX 913—Fuser fan service check Step Questions / actions Turn printer off and remove Go to step 2. Properly connect I/O board shield. See “I/O cable. board removal” on page 4-70 for steps to remove I/O board shield. Is cable properly connected to I/O board connector DCN7? Ensure rear cover...

  • Page 131: 914-Laser Fan Service Check

    5021-0XX 914—Laser fan service check Step Questions / actions Turn printer off and remove Go to step 2. Properly connect I/O board shield. See “I/O cable. board removal” on page 4-70 for steps to remove I/O board shield. Is cable properly connected to I/O board connector DCN8? Ensure rear cover...

  • Page 132: 915-Erase Lamp Service Check

    5021-0XX 915—Erase lamp service check Step Questions / actions Turn printer off and remove Go to step 2. Properly connect toner cartridges and erase lamp. photodeveloper cartridge. Retest printer. If Check erase lamp cable for error clears, proper connection. Is erase problem solved, lamp cable properly otherwise go to...
  • Page 133 5021-0XX Step Questions / actions Disconnect cable from Replace I/O Replace cable. erase lamp and DCN15. board. See “I/O Retest printer. If Check DCN15 pin 11 to board removal” error clears, erase lamp cable on page 4-70. problem solved, connector pin 1 and Go to step 6.

  • Page 134: 916-Toner Empty Sensor (Sender-Tpd) Service Check

    “Engine controller board removal” on page 4-55. Retest printer. Does error clear? Turn printer off and replace Problem solved. Call Lexmark toner empty sensor support. (sender-TPD). See “Toner sensor (sender) removal” on page 4-35 for steps. Retest printer. Does error...

  • Page 135: 917-Toner Empty Sensor (Receiver-Ttr) Service Check

    5021-0XX 917—Toner empty sensor (receiver-TTR) service check Step Questions / actions Turn printer off and remove Go to step 2. Properly connect I/O board shield. See “I/O cable. Retest board removal” on printer. If error page 4-70 for steps to clears, problem remove I/O board shield.

  • Page 136: 918-Hvps Connection Service Check

    5021-0XX 918—HVPS connection service check Step Questions / actions Turn printer off and remove Go to step 2. Properly connect engine controller board cable. Retest shield. See “Engine printer. If error controller board removal” clears, problem on page 4-55 for steps to solved, remove shield.

  • Page 137: 919-Lower Feed Unit (Secondary Paper Assembly) Service Check

    5021-0XX 919—Lower feed unit (secondary paper assembly) service check Step Questions / actions Turn printer off and remove Go to step 2. Properly connect I/O board shield. See “I/O cable. Retest board removal” on printer. If error page 4-70 for steps to clears, problem remove I/O board shield.

  • Page 138: 920-Fuser Thermistor Service Check

    5021-0XX 920—Fuser thermistor service check Step Questions / actions Remove and reinstall fuser Problem solved. Go to step 2. assembly. See “Fuser assembly removal” on page 4-9. Does error clear? Check fuser connector for Problem solved. Go to step 3. damage.

  • Page 139: 921,922,923,924,925-Fuser Assembly Service Check

    5021-0XX 921,922,923,924,925—Fuser assembly service check Step Questions / actions Check for proper input line Go to step 2. Provide proper voltage. Is line voltage line voltage. correct? Remove and reinstall fuser Problem solved. Go to step 3. assembly. See “Fuser assembly removal”...

  • Page 140: 930,931,932-Laser Unit Assembly Service Check

    5021-0XX 930,931,932—Laser unit assembly service check Step Questions / actions Check LCN connection on Go to step 2. Properly connect laser assembly LDU board. LCN cable. If Is connector properly error clears, connected? problem solved, otherwise go to step 2. Check LCN connection on Go to step 3.

  • Page 141: 985-Duplex Connection Error 1 Service Check

    5021-0XX 985—Duplex connection error 1 service check Step Questions / actions Check duplex unit cable. is Replace duplex Properly connect cable properly connected? unit. See cable. If problem “Duplex unit persists, go to assembly step 2. removal” on page 4-13. If problem persists, go to step 2.

  • Page 142: 986-Duplex Connection Error 2 Service Check

    5021-0XX 986—Duplex connection error 2 service check Step Questions / actions Check duplex unit cable. is Replace duplex Properly connect cable properly connected? unit. See cable. If problem “Duplex unit persists, go to assembly step 2. removal” on page 4-13. If problem persists, go to step 2.

  • Page 143: 990-Transfer Belt Unit Service Check

    5021-0XX 990—Transfer belt unit service check Step Questions / actions Open rear cover assembly Clean belt Go to step 2. and check transfer belt unit marker area with markers for stains. Are cotton cloth. If markers stained? problem persists go to step 2. Remove transfer belt unit Replace transfer Reinstall transfer...
  • Page 144 5021-0XX Step Questions / actions Reconnect DCN16 and LVPS is Replace LVPS. providing 5 VDC “Low disconnect cable from to I/O board. voltage power DCN13. On cable, check Replace faulty supply (LVPS) for 5 VDC from pin 9 to I/O board. See with cage ground (you can touch “I/O board...

  • Page 145: 991-Transfer Roller Clutch Service Check

    5021-0XX 991—Transfer roller clutch service check Step Questions / actions Turn printer off and remove Go to step 2. Replace faulty printer right cover. See transfer roller “Right cover removal” on clutch. See page 4-22. Disconnect “Clutch transfer roller clutch from removal”...

  • Page 146: 992-Transfer Belt Cleaning Roller Clutch Service Check

    5021-0XX 992—Transfer belt cleaning roller clutch service check Step Questions / actions Turn printer off and remove Go to step 2. Replace faulty printer right cover. See cleaning roller “Right cover removal” on clutch. See page 4-22. Disconnect “Cleaning roller transfer belt cleaning roller clutch removal”...

  • Page 147: 993-Fuser Clutch Service Check

    5021-0XX 993—Fuser clutch service check Step Questions / actions Turn printer off and remove Go to step 2. Replace faulty printer right cover. See fuser clutch. See “Right cover removal” on “Clutch page 4-22. Disconnect removal” on fuser clutch from cable. page 4-40.

  • Page 148: 994-Opc Belt Marker Sensor Service Check

    5021-0XX 994—OPC belt marker sensor service check Step Questions / actions Remove photodeveloper Clean marker Go to step 2. cartridge and observe area with cotton markers on side. Are belt cloth. If problem markers covered with persists go to foreign particles? step 2.
  • Page 149 5021-0XX Step Questions / actions Reconnect DCN5 and LVPS is Replace LVPS. providing 5 VDC “Low disconnect cable from to I/O board. voltage power DCN13. On cable, check Replace faulty supply (LVPS) for 5 VDC from pin 11 to I/O board. See with cage ground (you can touch “I/O board...

  • Page 150: 995-High Voltage Power Supply (Hvps) Service Check

    5021-0XX 995—High voltage power supply (HVPS) service check Questions / Step actions Remove Replace Go to step 2. photodeveloper photodeveloper cartridge and cartridge. See ensure charging unit “Photodevelop on bottom of er cartridge photodeveloper removal” on cartridge is not page 4-11.
  • Page 151 5021-0XX Questions / Step actions Replace HVPS. See Problem solved. Go to step 6. “High voltage power supply (HVPS) removal” on page 4-59. Has error cleared? Replace engine Problem solved. Replace I/O board. See “I/O controller board. board removal” “Engine on page 4-70.

  • Page 152: 996-Low Voltage Power Supply (Lvps) Service Check

    5021-0XX 996—Low voltage power supply (LVPS) service check Step Questions / actions Check cable for continuity Go to step 2. Replace cable. between engine controller board connector LVCN and HVPS ACN5 connector. Check cable for continuity between I/O board DCN21 and HVPS ACN5 connector.

  • Page 153: Cover Open Service Check

    5021-0XX Cover open service check Step Questions / actions Turn printer off and remove Go to step 2. Replace right cover. See “Right appropriate cover removal” on actuator: page 4-22. Check all Front cover for interlock switch (top, rear front cover and front) actuators for interlock switch.
  • Page 154 5021-0XX Step Questions / actions Turn printer on. Check for 5 Go to step 5. Go to step 4. VDC between front cover interlock switch pin 1 (top pin) and ground. Is 5 VDC present? Turn printer off and check Replace LVPS.
  • Page 155 5021-0XX Step Questions / actions Check following cables for Replace cable. Replace engine continuity: controller board. “Engine • I/O DCN18 pin 1 to rear controller cover interlock switch pin board removal” on page 4-55. • I/O DCN18 pin 3 to top cover interlock switch pin •...

  • Page 156: Incorrect Media Service Check

    5021-0XX Incorrect media service check Step Questions / actions Turn printer off and remove Go to step 2. Properly connect I/O board shield. See “I/O cable. board removal” on page 4-70 for steps to remove I/O board shield. Is cable properly connected to I/O board connector DCN16? Reconnect operator panel.
  • Page 157 5021-0XX Step Questions / actions Turn printer off. Check Replace OHP Replace cable. cable for continuity that sensor. See connects DCN16 pins 10, “Paper guide 11, 12, and 13 to OHP (C) assembly sensor sensor. Also check removal” on for shorted pins. Is cable page 4-47.

  • Page 158: Missing Photodeveloper Cartridge Service Check

    5021-0XX Missing photodeveloper cartridge service check Step Questions / actions Check photodeveloper Go to step 2. Install properly. cartridge for proper installation. Is cartridge installed properly? Check printer contacts (A) Replace Replace photodeveloper photodeveloper and photodeveloper cartridge. See cartridge. See cartridge contacts (B) for “Photodevelop “Photodevelop...

  • Page 159: Missing Toner Cartridge Service Check

    5021-0XX Missing toner cartridge service check Step Questions / actions Remove toner cartridge in Replace toner Go to step 2. question. Holding toner cartridge. cartridge with developer roller away from you, check toner present sensor actuators located on left rear of toner cartridge. Are actuators damaged? Insert toner cartridge and Go to step 3.
  • Page 160 5021-0XX Step Questions / actions Push toner cartridge fully Replace I/O Replace toner in. Check voltage level on board. See “I/O present sensor. DCN2 pin 1. Is 0 VDC board removal” “Toner present? on page 4-70. If present sensor problem removal”...

  • Page 161: Opc Belt (Photodeveloper) Cartridge Drive Service Check

    5021-0XX OPC belt (photodeveloper) cartridge drive service check Step Questions / actions Check photodeveloper Go to step 2. Install properly. cartridge for proper installation. Is cartridge installed properly? Check photodeveloper Replace Go to step 3. photodeveloper cartridge for damage. Is cartridge.

  • Page 162: Operator Panel Service Check

    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, run “LCD test” in diagnostic mode.

  • Page 163: Output Tray Full Service Check

    5021-0XX Output tray full service check Step Questions / actions Ensure output tray full Go to step 2. Replace paper sensor flag swings with exit assembly. ease and is not broken or “Paper exit damaged. Is flag working assembly properly? removal”...
  • Page 164 5021-0XX Step Questions / actions Turn printer off. Check Replace paper Replace cable. cable for continuity that exit assembly. connects DCN7 pins 7, 8, “Paper exit and 9 to output tray full assembly sensor. Also check for removal” on shorted pins. Is cable page 4-49.

  • Page 165: Paper Size Sensing Service Check

    5021-0XX Paper size sensing service check Step Questions / actions Turn printer off and remove Go to step 2. Properly connect I/O board shield. See “I/O cable. board removal” on page 4-70 for steps to remove I/O board shield. Is cable properly connected to I/O board connector DCN19?
  • Page 166 5021-0XX Step Questions / actions If paper tray is removed, Replace I/O Go to step 6. set paper tray for desired board. See “I/O paper size and insert paper board removal” tray into printer. Using table on page 4-70. If below, check for proper problem paper size sensor action by...

  • Page 167: Printer No Power Service Check

    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 Reset printer and listen for Go to step 2. Go to step 3. any activation of motors and for power supply fan.
  • Page 168 5021-0XX Step Questions / actions Remove items (see “RIP Go to step 7. Replace power board cage removal” on supply bracket. page 4-57) from left side of “Low printer to expose power voltage power supply bracket. Using an supply (LVPS) ohmmeter, ensure power with cage switch is good.

  • Page 169: Toner Feed Service Check

    5021-0XX Toner feed service check Step Questions / actions Check toner cartridge for Replace toner Go to step 2. damage. Check to see if cartridge. toner cartridge moves easily into and out of printer. Is toner cartridge damaged or is there resistance moving in and out of printer? Is developer motor...

  • Page 170: Toner Low/Empty Service Check

    5021-0XX Toner low/empty service check Step Questions / actions Turn printer off and remove Go to step 2. Properly connect I/O board shield. See “I/O cable. board removal” on page 4-70 for steps to remove I/O board shield. Is cable properly connected to I/O board connector DCN15? Reconnect operator panel.

  • Page 171: Transfer Roller Missing Service Check

    5021-0XX Transfer roller missing service check Step Questions / actions Turn printer off and check Go to step 2. If contact A has transfer roller contacts. Are slipped off contacts present and not frame, put it damaged? back on. If you cannot see it, remove HVPS cage (see...
  • Page 172 5021-0XX Step Questions / actions Replace engine controller Problem solved. Replace HVPS. board. See “Engine “High controller board removal” voltage power on page 4-55. Does error supply (HVPS) clear? removal” on page 4-59. 2-94 Service Manual...

  • Page 173: Tray Empty Service Check

    5021-0XX Tray empty service check Step Questions / actions Remove paper tray from Go to step 2. Replace paper printer. Press bottom of tray. spring platform latches located in rear corners of paper tray. This releases spring platform of paper tray.
  • Page 174 5021-0XX Step Questions / actions Remove paper tray, fill with Replace I/O Replace paper paper and reinsert. Check board. See “I/O guide (C) voltage level on DCN16 pin board removal” assembly . See 8. Is 0 VDC present? on page 4-70.

  • Page 175: Waste Toner Bottle Service Check

    5021-0XX Waste toner bottle service check Step Questions / actions Remove waste toner bottle Go to step 2. Replace waste from printer. Inside waste toner bottle toner bottle holder, check holder. See sensor flag. Does flag work “Waste toner properly and is it not bottle holder damaged? removal”...

  • Page 176: Waste Toner Feed Service Check

    5021-0XX Waste toner feed service check Step Questions / actions Is transfer belt unit cleaning Go to step 2. Properly install roller properly installed. cleaning roller. Check cleaning roller clutch Replace Go to step 3. gear (located inside printer) cleaning roller for damage.

  • Page 177: Paper Feed Service Checks

    5021-0XX Paper feed service checks Printer paper feed service check Problem area Action Check for recommended Ensure paper being used is recommended. paper Ensure paper is stored in an area free from high humidity. Note: Disconnect secondary paper assembly and duplex unit, if installed, to help isolate a paper transport problem.
  • Page 178 5021-0XX Problem area Action Fuser assembly Ensure fuser assembly is not damaged or dirty. Ensure fuser assembly guides and gears are not broken and are free of paper. Note: Fuser assembly is a customer ordered supply. • Paper exit assembly Check rear cover assembly for damage.

  • Page 179: Print Quality Service Checks

    5021-0XX Print quality service checks Background service check Background is smeared due to toner spread. Problem area Action Toner cartridge Too small charging amount in the development process. Check developer high Insufficient contact of developer voltage contact points. roller's primary or secondary high voltage contact points.

  • Page 180: Back Stain Service Check

    5021-0XX Back stain service check Backside of paper is stained. Problem area Action 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 customer order supply.

  • Page 181: Banding Service Check

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

  • Page 182: Black Line Service Check

    5021-0XX Black line service check A fine black line appears in printer image. Problem area Action Toner cartridge Toner cartridge blade is deformed. Replace toner cartridge. Photodeveloper (OPC) OPC belt’s surface is damaged. cartridge Replace photodeveloper cartridge. “Photodeveloper cartridge removal” on page 4-11.

  • Page 183: Color Misregistration Service Check

    5021-0XX Color misregistration service check Color misregistration between two colors. Problem area Action Transfer roller and transfer Transfer belt fails to maintain regular belt cleaning roller and proper rotation due to impact caused when transfer roller or transfer belt cleaning roller contacts transfer belt.
  • Page 184 5021-0XX Problem area Action Transfer belt unit Transfer belt is off track. Replace transfer belt unit. See “Transfer belt unit removal” on page 4-7. 2-106 Service Manual...

  • Page 185: Insufficient Fusing Service Check

    5021-0XX Insufficient fusing service check Printed image is partially missing. Problem area Action Fuser tension release lever Fuser tension release lever is open. Check fuser and remove shipping pieces if still installed. Close release lever. Driver media settings Driver media setting is wrong. Ensure proper media setting is selected for specific media in use.

  • Page 186: Insufficient Gloss Service Check

    5021-0XX Insufficient gloss service check Gloss on paper is not sufficient. Problem area Action Driver media settings Driver media setting is wrong. Ensure proper media setting is selected for specific media in use. Fuser Fuser roller is deteriorated. Fuser temperature is not properly controlled.

  • Page 187: Jitter Service Check

    5021-0XX Jitter service check Uneven optical density appears periodically in horizontal direction. Problem area Action Photodeveloper cartridge Replace faulty photodeveloper cartridge. See “Photodeveloper cartridge removal” on page 4-11. Note: Photodeveloper cartridge is a customer order supply. Main motor assembly • Irregular rotation of main motor assembly •...

  • Page 188: Missing Image At Edge Service Check

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

  • Page 189: Mixed Color Image Service Check

    5021-0XX Mixed color image service check Mixed color image appears. Problem area Action 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. Replace toner cartridge if defective.

  • Page 190: Mottle Service Check

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

  • Page 191: Residual Image Service Check

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

  • Page 192: Ribbing Service Check

    5021-0XX Ribbing service check Light print occurs in right or left side of image. Problem area Action 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.
  • Page 193 5021-0XX Problem area Action 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. 2-115 Diagnostic information...

  • Page 194: Toner Drop Service Check

    5021-0XX Toner drop service check A toner spot stain on paper is caused by ambient toner within printer engine. Problem area Action Waste toner feed system Toner drops on the transfer drum due to a breakdown of the waste toner •...
  • Page 195 5021-0XX Problem area Action Toner cartridge Replace faulty toner cartridge. 2-117 Diagnostic information...

  • Page 196: Vertical Line Service Check

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

  • Page 197: Vertical Staggering Image Service Check

    5021-0XX Vertical staggering image service check Printed image staggers in vertical direction. Problem area Action Printer vibration Check for printer vibrations or shock to printer. Laser unit assembly Optical unit failure caused by (printhead) vibration from scanner motor rotation. Replace laser unit assembly. See “Laser unit assembly (printhead) removal”...

  • Page 198: Vertical White Band Service Check

    5021-0XX Vertical white band service check White band appears in vertical direction of printed image. Problem area Action Toner cartridge Replace faulty toner cartridge. Photodeveloper cartridge Replace faulty photodeveloper cartridge. See “Photodeveloper cartridge removal” on page 4-11. Transfer belt unit TReplace faulty transfer belt unit.

  • Page 199: White Band Service Check

    5021-0XX White band service check Horizontal white banding creates missing portion of image. Problem area Action Transfer roller • Transfer roller bias pole is not making proper contact with high voltage spring contact. Remove and reinstall transfer roller. Ensure spring contact on left side (looking from front of printer) is not damaged.

  • Page 200: White Line I Service Check

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

  • Page 201: White Line Ii Service Check

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

  • Page 202: White Spot / Black Spot Service Check

    5021-0XX White spot / black spot service check A white spot and black spot appear on paper. Problem area Action Photodeveloper cartridge There are foreign particles adhering to photodeveloper OPC belt. Remove photodeveloper cartridge (see “Photodeveloper cartridge removal” on page 4-11).

  • Page 203: White Print Service Check

    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 Optical Unit (Printhead) Laser light path is blocked by paper or other material stuck at the opening of the optical unit.

  • Page 204: Wrinkle / Image Migration Service Check

    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 Non-recommended paper Paper being used is not recommended for printer. Replace paper with recommended paper. Rear cover assembly Open rear cover assembly and reclose, ensuring that both sides...

  • Page 205: Uneven Density (Right And Left)

    5021-0XX Uneven density (right and left) Optical density is different between right and left side of printed image. Problem area Action Rear cover assembly Open rear cover assembly and reclose, ensuring that both sides properly latch. If rear cover assembly will not properly latch, ensure that white door actuators located at top of rear cover assembly are not...
  • Page 206 5021-0XX Problem area Action Transfer belt unit Replace faulty transfer belt unit. See “Transfer belt unit removal” on page 4-7. Toner retract system Replace faulty specific toner retract system. See “Toner retract solenoid and cam removal” on page 4-64. 2-128 Service Manual...

  • Page 207: Spacing Table

    5021-0XX Spacing table Roller specifications Repeating Number of Diameter defect on Name of roller rotation (mm) print (rpm) (mm) Registration assembly ø 14 rubber roller Registration assembly ø 12 steel roller Transfer roller ø 20 Developer roller ø 18 Transfer belt drive roller ø...
  • Page 208 5021-0XX 2-130 Service Manual...

  • Page 209: Diagnostic Aids

    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 diagnostic mode.

  • Page 210: Paper Jam Sequence

    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 202 - Indicates media is jammed in outer area (fuser exit sensor) of printer.
  • Page 211 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.

  • Page 212: Diagnostic Mode

    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 in the order shown: Note: Tray 2 refers to the 530-sheet tray located in the secondary paper feed assembly.

  • Page 213: Diagnostics Menu Structure

    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) •...

  • Page 214: Print Registration

    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.

  • Page 215: Setting Top Margin

    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 press the stop button to cancel the test.

  • Page 216: Hardware Tests

    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 registration diamonds.

  • Page 217: Lcd Test

    5021-0XX LCD test To run the LCD test: 1. Select LCD Test from the diagnostic menu. The LCD test continually executes the LCD display test. 2. Press Return or Stop to cancel the test. Button test To run the button test: 1.

  • Page 218: Rom Memory Test

    5021-0XX Init Busy Error Init Rise Error Host Busy Error RAM Data FF Error RAM Data AA Error RAM Data 00 Error RAM Data 55 Error DMA Count Error DMA Address Error DMA Interrupt Error DMA Memory Error DMA Background Error Clear Init Rise Error False Init Rise Error False Init Fall Error...

  • Page 219: Dram Memory Test

    5021-0XX Once the maximum pass or fail count is reached, the test stops and the final results display on the screen. DRAM memory test The purpose of this test is to check the validity of DRAM, both standard and optional. The test writes patterns of data to DRAM to verify that each bit in memory can be set and read correctly.
  • Page 220 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.

  • Page 221: Duplex Tests

    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.

  • Page 222: Device Tests

    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.

  • Page 223: Flash Test

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

  • Page 224: Printer Setup

    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 printer NVRAM memory where the page count is stored.

  • Page 225: Serial Number

    5021-0XX Serial number The serial number is set at the factory and cannot be changed. This is for viewing the serial number only. The serial number will be XXXXXXXX (8-digit string) Where X=A to Z, or 0 to 9. If you replace the engine controller board, the serial number needs to be identified from the serial number label on the printer.

  • Page 226: Parallel Strobe Adjustment

    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 of time strobe is sampled.

  • Page 227: Error Log

    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 errors have occurred).

  • Page 228: Clearing The Error Log

    5021-0XX Clearing the error log To clear the error log: 1. Select Clear Log from the error log menu. 2. Select YES to clear the error log or NO to exit the clear log menu. If YES is selected, the empty error log displays on the screen. 3.

  • Page 229: Exiting Diagnostic Mode

    5021-0XX Exiting diagnostic mode Select Exit Diagnostics to exit the diagnostics mode and return to normal mode. 3-21 Diagnostic aids...
  • Page 230 5021-0XX 3-22 Service Manual...

  • Page 231: Repair Information

    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 removal unless otherwise specified.

  • Page 232: Handling The Printed Circuit Boards With

    5021-0XX Handling the printed circuit boards with MOS ICs The following precautions must be observed when handling circuit boards with MOS (Metal Oxide Semiconductor) ICs. During transportation/storage: • Do not remove new circuit boards from their protective conductive bags until needed. •...

  • Page 233: Photodeveloper Cartridge

    5021-0XX Photodeveloper cartridge The following precautions must be observed when handling the photodeveloper cartridge or commonly called OPC (optical photo conductor). The photodeveloper cartridge is a supply item you will have to remove during some of the repair procedures: During transportation/storage Use the specified carton whenever moving or storing the photodeveloper cartridge.

  • Page 234: Printer Removal Procedures

    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 removals or checks.

  • Page 235: Cru/Fru And Supplies Removals

    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 part must be removed. Repair information...

  • Page 236: Cleaning Roller Cover Removal

    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. Service Manual...

  • Page 237: Transfer Belt Unit Removal

    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.

  • Page 238: Transfer Roller Removal

    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. Service Manual...

  • Page 239: Fuser Assembly Removal

    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. Repair information...

  • Page 240: Waste Toner Bottle Removal

    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. 4-10 Service Manual...

  • Page 241: Photodeveloper Cartridge Removal

    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. Lay photodeveloper cartridge as shown in a clean area. 4-11 Repair information...
  • Page 242 5021-0XX 5. Cover photodeveloper cartridge with a piece of paper as shown. 4-12 Service Manual...

  • Page 243: Duplex Unit Assembly Removal

    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. 4-13 Repair information...
  • Page 244 5021-0XX 3. Open duplex rear door (A) and pull down redrive assembly (B). 4. Pull green thumbscrews (C) out and turn counterclockwise until loosened. Note: During reinstallation of duplex unit, ensure that thumbscrews are fully depressed after tightening. Failure to fully depress the thumbscrews may result in paper jams.
  • Page 245 5021-0XX 5. Lift duplex unit up and away from printer. 4-15 Repair information...

  • Page 246: Secondary Paper Feed Assembly Removal

    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 and remove from secondary paper feed assembly.

  • Page 247: Cover Removals

    5021-0XX Cover removals 4-17 Repair information...

  • Page 248: Top Cover Assembly Removal

    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) from operator panel. 6.

  • Page 249: Front Cover Assembly Removal

    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. 4-19 Repair information...
  • Page 250 5021-0XX 3. Disengage support strap from printer. 4. Release tabs on front cover. 5. Remove front cover from inner front cover. 6. Raise front inner cover. 4-20 Service Manual...
  • Page 251 5021-0XX 7. Rotate support pin away from printer and slide toward center of printer to remove. Repeat for other support pin. 8. Remove front inner cover from printer. 4-21 Repair information...

  • Page 252: Right Cover Removal

    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.
  • Page 253 5021-0XX 4. Disconnect rear cover assembly connector (A). 5. Remove support pin (B), disconnecting support cable from printer. 6. Remove two screws (C) from rear cover assembly. 7. Slide right side of rear cover assembly away from printer until hinge clears slot. 8.

  • Page 254: Left Cover Removal

    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 (printhead) removal 1.
  • Page 255 5021-0XX 5. Remove two screws (A) from laser unit assembly cover. Photograph shows looking through opening in top cover assembly. 6. Unlatch and remove laser unit assembly cover. 4-25 Repair information...

  • Page 256: Laser Unit Fan Assembly Removal

    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 cartridges. 3. Remove photodeveloper cartridge. See “Photodeveloper cartridge removal”...

  • Page 257: Erase Lamp Removal

    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. See “Transfer belt unit removal”...
  • Page 258 5021-0XX 4. Disconnect erase lamp cable (A). 5. Remove two screws (B). 6. Remove erase lamp. 4-28 Service Manual...

  • Page 259: Right Side Removals

    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 connector and switch contacts.
  • Page 260 5021-0XX 2. Disconnect interlock switch cable from interlock switch. 3. Remove interlock switch from switch bracket. 4-30 Service Manual...

  • Page 261: Front Door Interlock Switch With Bracket

    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 4-22.

  • Page 262: Waste Toner Bottle Holder Removal

    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 drive assembly removal 1.
  • Page 263 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 clutch. 4.
  • Page 264 5021-0XX 6. Disengage developer drive assembly from retaining tabs (C) and remove developer drive assembly from printer. 4-34 Service Manual...

  • Page 265: Toner Sensor (Sender) Removal

    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, and remove sensor.

  • Page 266: Cleaning Roller Clutch Removal

    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 inside of printer.
  • Page 267 5021-0XX 4. Remove wires from cable guide on front of cleaning roller clutch (A). 5. Disconnect cleaning roller clutch cable (B). 6. Remove three screws (C) from cleaning roller clutch. 7. Remove cleaning roller clutch from printer. 4-37 Repair information...

  • Page 268: Main Motor Assembly Removal

    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. 4-38 Service Manual...
  • Page 269 5021-0XX 4. Remove 4 screws (B) from the main motor assembly. 5. Remove main motor assembly from printer. 4-39 Repair information...

  • Page 270: Clutch Removal

    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.

  • Page 271: Main Drive Gear Assembly Removal

    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 waste toner feeder you do not have to remove the fuser, transfer roller, registration, or paper feed clutch.

  • Page 272: Waste Toner Feeder Removal

    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 part of reinstalling.
  • Page 273 5021-0XX 3. Remove screw (B) from waste toner feeder pipe. 4. Remove waste toner feeder pipe from waste toner bottle holder. 5. Pull and remove waste toner feeder from printer. 4-43 Repair information...

  • Page 274: Rear Removals

    5021-0XX Rear removals 4-44 Service Manual...

  • Page 275: Rip Board Removal

    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.

  • Page 276: Paper Guide Assembly Removal

    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. 4-46 Service Manual...

  • Page 277: Paper Guide (C) Assembly Removal

    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 assembly removal”...

  • Page 278: Paper Feed Roller Removal

    5021-0XX 3. Remove support pin, disconnecting support 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 feed roller removal 1.

  • Page 279: Paper Exit Assembly Removal

    5021-0XX Paper exit assembly removal 1. Open rear cover assembly. 2. Remove plastic bracket (A). 3. Disconnect cable (B). 4-49 Repair information...
  • Page 280 5021-0XX 4. Remove two screws (C). 4-50 Service Manual...
  • Page 281 5021-0XX 5. Disconnect cable (D). 6. Remove two screws (E). 7. Remove paper exit (F). 4-51 Repair information...

  • Page 282: Registration Assembly Removal

    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. 4-52 Service Manual...

  • Page 283: Left Side Removals

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

  • Page 284: Operator Panel Cable Removal

    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. 4-54 Service Manual...

  • Page 285: Engine Controller Board Removal

    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 engine controller board. 4-55 Repair information...
  • Page 286 5021-0XX 5. Remove four screws (B) from engine controller board; remove engine controller board. Note: When reinstalling flat cables, ensure blue side of cable is opposite pins on connectors HVCN, I1CN, and I2CN. Flat cable pins are exposed on only one side (opposite blue side) and must make contact with metal pins on connectors.

  • Page 287: Rip Board Cage Removal

    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. 4-57 Repair information...
  • Page 288 5021-0XX 4. Remove ducting. 4-58 Service Manual...

  • Page 289: High Voltage Power Supply (Hvps) Removal

    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 blue side of cable is opposite pins on connector CN1.

  • Page 290: Low Voltage Power Supply (Lvps) With Cage Removal

    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.
  • Page 291 5021-0XX 3. Remove grounding terminal screw (A). 4. Disconnect power supply bracket connector (B). 5. Remove three screws (C) that attach power supply bracket; remove power supply bracket. 6. Disconnect all connectors from LVPS. 7. Remove three metal screws (D) and 3 plastic screws (E) that attach LVPS with cage;...

  • Page 292: Hvps Cage Removal

    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.

  • Page 293: Toner Present Sensor Removal

    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. 4-63 Repair information...

  • Page 294: Toner Sensor (Receiver) Removal

    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.

  • Page 295: Left Tray Guide Assembly Removal

    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.
  • Page 296 5021-0XX 3. Disconnect cable from DCN19 on I/O board. 4. Remove two (B) screws that secure left tray guide assembly to printer frame. 5. Reroute cable from I/O board to allow sufficient cable length for removing left tray guide assembly from frame. 4-66 Service Manual...
  • Page 297 5021-0XX 6. Using a flat blade tool, disengage tabs on left tray guide assembly from printer frame. 7. Slide left tray guide assembly out front of printer. 4-67 Repair information...

  • Page 298: Top Removals

    5021-0XX Top removals 4-68 Service Manual...

  • Page 299: Marker Sensor Assembly Removal

    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.

  • Page 300: I/O Board Removal

    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 interchanged.
  • Page 301 5021-0XX Connector Number of pins Cable wire colors DCN13 DCN14 DCN15 DCN16 DCN17 DCN18 DCN19 DCN20 DCN21 DCN22 Do not remove the jumper. 4. Remove six screws (B) from I/O board; remove I/O board. Note: When reinstalling flat cables, ensure blue side of cable is opposite pins on connectors DCN1 and DCN3.

  • Page 302: Waste Toner Auger Removal

    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.

  • Page 303: Waste Toner Agitator Removal

    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. 4-73 Repair information...

  • Page 304: Power Supply Fan Removal

    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.

  • Page 305: Locations And Connectors

    5021-0XX 5. Locations and connectors Printer Locations and connectors...
  • Page 306 5021-0XX Part name Description Paper stopper Stopper for exited papers. Operator panel/cover Displays status of printer operation. Top cover assembly Upper enclosure and also the paper exit tray. Rear cover assembly Printer rear enclosure that opens allowing clearing of internal paper jams or maintenance work.

  • Page 307: Options

    5021-0XX Options Locations and connectors...

  • Page 308: Electronic Components

    5021-0XX Electronic components Sensor locations Name Code Function Paper size sensor Detects paper size. Registration Detects whether paper is fed from paper sensor drawer. Fuser exit sensor Detects when paper exits from rear cover assembly. Tray empty sensor Detects if paper is loaded in paper drawer.
  • Page 309 5021-0XX Name Code Function Waste toner Detects when waste toner bottle is full. sensor (LED/TR) Temperature Thermistor that detects fuser sensor for fuser temperature. unit Output tray full Detects when paper exit tray is full. PFUL sensor Toner key sensor Detects presence of toner cartridge.

  • Page 310: Printer Circuit Board Locations

    5021-0XX Printer circuit board locations Erase lamp Operator panel I/O board HVPS LVPS Engine controller board Name Function Engine controller Controls the following printer processes board Fuser temperature control Laser output control Operator panel indication Toner empty sensing control Error processing control Interface control Operator panel Displays the printer operation status and supports the...

  • Page 311: Fan/Motor Locations

    5021-0XX Fan/motor locations Name Code Function Main motor Drives OPC belt and paper transport system. Developer Drives toner cartridge and developing motor system. Scanner motor Drives laser beam scanning in optical unit S C M Power supply Exhausts heat from power PSFAN supply unit and interface controller.

  • Page 312: Interlock Switch Locations

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

  • Page 313: Solenoid/Clutch Locations

    5021-0XX Solenoid/clutch locations Cleaning roller clutch Toner retract solenoid Fuser clutch Transfer roller clutch Registration clutch Left side (shown with all Paper feed boards removed) clutch Developer clutches Name Code Function Paper feed clutch Feeds paper by coupling feed roller to the PCLU main gear unit at the time of a paper feed.
  • Page 314 5021-0XX Name Code Function Toner retract Places selected toner cartridge in solenoid development position during development (Y,M,C,K) phase. Transfer roller Cam action clutch that rotates, allowing clutch transfer roller to press against the back of paper during second transfer. The TRCL transfer roller touching the back of paper causes toner to release from transfer belt...

  • Page 315: Symbol And Part Name Table

    5021-0XX Symbol and part name table Symbol Part name Back-up roller CTFAN Control fan motor (cooling fan DCLK DCLY Developer clutch (K.Y.M.C.) DCLM DCLC Developer motor Drum jam sensor DSW1 Interlock switch (front) DSW2 Interlock switch (top) DSW3 Interlock switch (rear) Duplex unit Erase lamp Erase lamp...
  • Page 316 5021-0XX Symbol Part name Laser drive unit P.W.B. Lower paper feeding unit LVPS Power supply unit MCTL Main engine (MCTL P.W.B.) board Main motor OHP sensor Oil sensor Optical unit Optical unit OZFAN Ozone fan motor (cooling fan PANEL Operator panel P.W.B. Belt sensor PCLU Upper paper feeding clutch...
  • Page 317 5021-0XX Symbol Part name Themistor Toner key sensor Toner empty sensor TRCM Transfer cam clutch 5-13 Locations and connectors...

  • Page 318: Wiring Diagram / Cable Harness Reference

    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. 5-14 Service Manual...

  • Page 319: Rip Board

    5021-0XX RIP board 5-15 Locations and connectors...

  • Page 320: Engine Controller Board

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

  • Page 321: Input/Output (I/O) Board

    5021-0XX Input/output (I/O) board 5-17 Locations and connectors...

  • Page 322: Low Voltage Power Supply (Lvps) Board

    5021-0XX Low voltage power supply (LVPS) board High voltage power supply (HVPS) board 5-18 Service Manual...

  • Page 323: Printer Cables

    5021-0XX Printer cables Cable 1 connector assignments Cable 1 connector pin assignments Engine controller board I1CN—I/O board DCN1 I1CN DCN1 Signal name Pin No. Pin No. SGND +5V-S I1RDWR I1DATA I1CK I1LOAD I1SCDO DSL(K)ON-P DSL(C)ON-P 5-19 Locations and connectors...
  • Page 324 5021-0XX I1CN DCN1 Signal name Pin No. Pin No. DSL(M)ON-P DSL(Y)ON-P IDATA ILOAD ISCK SGND LEDON-N HTFANON-P CTFANON-P TBEN-N PBSEN-N ELON-P PKCLL1ON-P IOD1VOFF-P (+5V-SOFF-P) OILLES-P PWMSEND BANKSEL I/ODATA0 I/ODATA1 I/ODATA2 I/ODATA3 I/ODATA4 I/ODATA5 I/OAD0 5-20 Service Manual...
  • Page 325 5021-0XX I1CN DCN1 Signal name Pin No. Pin No. I/OAD1 I/OAD2 SGND 5-21 Locations and connectors...

  • Page 326: Cable 2 Connector Assignments

    5021-0XX Cable 2 connector assignments Cable 2 connector pin assignments Engine controller board I2CN—I/O board DCN3 I2CN DCN3 Signal name Pin No. Pin No. SGND COLSEL1 COLSEL2 DCL(C)ON-P DCL(M)ON-P DCL(Y)ON-P DCL(K)ON-P PSL(KY)ON-P PSL(MC)ON-P SGND MMCLK MMON-N MMREV-N 5-22 Service Manual...
  • Page 327 5021-0XX I2CN DCN3 Signal name Pin No. Pin No. MMENC MMGAIN GARESET-N RECLON-P FBCLON-P FBSLON-P TRSLON-P HTFANON-P/* OZFANON-P FUCLON-P PKCLU1ON-P SGND DMCLK DMRDY-N DMON-N DMGAIN TALWDDA SEPASLON-P SGND 5-23 Locations and connectors...

  • Page 328: Cable 3 Connector Assignments

    5021-0XX Cable 3 connector assignments Cable 3 connector pin assignments Engine controller board HVCN—HVPS CN1 HVCN Signal name Pin No. Pin No. PGND PGND PGND +24V-1D +24V-1D +24V-1D BRVON-N CLVP-N PWMON-N BRVPWM-N BRVERR CBVPWM-N 5-24 Service Manual...
  • Page 329 5021-0XX HVCN Signal name Pin No. Pin No. THVRON-N DBV(MC)PWM-N THVPWM-N DBV(KY)PWM-N THV-I FCBVPWM-N ID (PGND) PGND HVUCNCHK-N 5-25 Locations and connectors...

  • Page 330: Cable 4 Connector Assignments

    5021-0XX Cable 4 connector assignments Cable 4 connector pin assignments Engine controller board P2CN—Operator panel Operator P2CN Signal name panel Pin No. Pin No. 5-26 Service Manual...

  • Page 331: Cable 5 Connector Assignments

    5021-0XX Cable 5 connector assignments Cable 5 connector pin assignments I/O board DCN13—LVPS ACN1 DCN13 ACN1 Signal name Pin No. Pin No. +24-1D PGND +24-1D PGND +24-1D PGND +24-1D PGND +5V-1 SGND 5-27 Locations and connectors...
  • Page 332 5021-0XX DCN13 ACN1 Signal name Pin No. Pin No. +5V-1 SGND LVPS ACN2—Interlock switches Interlock ACN2 Signal name switch Pin No. Pin No. DSW-O:F Front-1 DSW-I:R Rear-2 I/O board DCN18—Interlock switches Interlock DCN18 Signal name switch Pin No. Pin No. REARDOPEN-P Rear-3 TOPDOPEN-P...
  • Page 333 5021-0XX LVPS ACN5—Engine controller board DCN21 ACN5 DCN21 Signal name Pin No. Pin No. TESTO1 TESTO2 TESTI1 TESTI2 LVPS ACN5—Engine controller board LVCN ACN5 LVCN Signal name Pin No. Pin No. +5VDO-N +5V-1R BRON-N DCOFF1-P ACOFF-P HRON-N ACSYNC-N SWRUS-P PGND PGND SGND CN-CHK...
  • Page 334 5021-0XX ACN5 LVCN Signal name Pin No. Pin No. no connection no connection 5-30 Service Manual...
  • Page 335 5021-0XX Engine controller board POCN—LVPS ACN3 POCN ACN3 Signal name Pin No. Pin No. +5V-2(CNT) SGND(CNT) +5V-2(CNT) SGND(CNT) +5V-2(CNT) SGND(CNT) +3.3V-2 SGND(CNT) +3.3V-2 SGND(CNT) +3.3V-2 SGND(CNT) +5V-1(MCTL) SGND(MCTL) +5V-1(MCTL) SGND(MCTL) +24V-1D PGND +24V-1D PGND no connection no connection 5-31 Locations and connectors...

  • Page 336: Cable 6 Connector Assignments

    5021-0XX Cable 6 connector assignments Cable 6 connector pin assignments I/O board DCN4—Toner retract solenoids Developer DCN4 Signal name solenoid Pin No. Pin No. Black toner retract solenoid DSL(K)ON-N no number +24V-F2 no number Yellow toner retract solenoid DSL(Y)ON-N no number +24V-F2 no number Magenta toner retract solenoid...
  • Page 337 5021-0XX I/O board DCN5—Photodeveloper (OPC) marker sensor Marker DCN5 Signal name sensor Pin No. Pin No. PBSEN-N +5V-S SGND I/O board DCN8—Laser fan DCN8 Laser fan Signal name Pin No. Pin No. LDFANON-P no number PGND no number LDFAN ERR no number I/O board DCN15—Toner present sensor, erase lamp DCN15...
  • Page 338 5021-0XX DCN15 Sensor Signal name Pin No. Pin No. TLESCHK SGND Erase lamp +24V-1DF3 ELON-N 5-34 Service Manual...
  • Page 339 5021-0XX I/O board DCN16—Sensors DCN16 Sensor Signal name Pin No. Pin No. Transfer belt unit marker sensor +5V-S no number TBEN-N no number SGND no number Registration sensor +5V-S no number PT1-N no number SGND no number Paper empty sensor +5V-S no number PEU-P...

  • Page 340: Cable 7 Connector Assignments

    5021-0XX Cable 7 connector assignments Cable 7 connector pin assignments I/O board DCN7—Rear cover assembly DCN7 Signal name Pin No. Pin No. Fuser exit sensor +5V-S no number PT2-N no number SGND no number Output tray full sensor +5V-1 no number PEFULL-N no number 5-36...
  • Page 341 5021-0XX DCN7 Signal name Pin No. Pin No. SGND no number Exit fan HTFANON-P no number PGND no number HTFANERR no number 5-37 Locations and connectors...
  • Page 342 5021-0XX I/O board DCN10—Developer drive assembly, clutches, and waste toner sensor Sensor/ DCN10 solenoid/ Signal name Pin No. clutch Pin No. Cleaning roller solenoid +24V-1DF3 no number FBCLON-N no number Fuser clutch +24V-1DF3 no number FUCLON-N no number Transfer roller clutch +24V-1DF3 no number TRSLON-N...
  • Page 343 5021-0XX Sensor/ DCN10 solenoid/ Signal name Pin No. clutch Pin No. SGND no number Cyan developer clutch +24V-1DF3 no number DCL(C)ON-N no number Magenta developer clutch +24V-1DF3 no number DCL(M)ON-N no number Yellow developer clutch +24V-1DF3 no number DCL(Y)ON-N no number Black developer clutch +24V-1DF3 no number...
  • Page 344 5021-0XX I/O board DCN11—Developer motor Developer DCN11 Signal name motor Pin No. Pin No. DMRDY-N DMON-N DMCLK +24V-1D PGND +24V-1D PGND PGND SGND +5V-1 DMGAIN DMOVLD I/O board DCN12—Main motor DCN12 Main motor Signal name Pin No. Pin No. MMRDY-N MMON-N MMCLK +24-1D...
  • Page 345 5021-0XX DCN12 Main motor Signal name Pin No. Pin No. PGND SGND +5V-1 MMENC MMREV-N MMGAIN MMOVLD 5-41 Locations and connectors...

  • Page 346: Cable 9 Connector Assignments

    5021-0XX Cable 9 connector assignments Cable 9 connector pin assignments Engine board LCN—Printhead LDU Signal name Pin No. Pin No. +5V-1R LCONT1 LREADY LCONT2 SGND LDREF4 VIDEO-N LDREF3 VIDEO-P LDREF2 SGND LDREF1 BDT-P LDREF0 BDT-N +5V-1 5-42 Service Manual...
  • Page 347 5021-0XX Signal name Pin No. Pin No. SGND SGND SCMRDY-N SCMCLK PGND SCMON-N +24V-1 +3.3V 5-43 Locations and connectors...

  • Page 348: Cable 10 Connector Assignments

    5021-0XX Cable 10 connector assignments Cable 10 connector pin assignments I/O board DCN14—Lower feeder unit Lower feeder unit Pin No. DCN14 Signal name (pin 1 is pin Pin No. closest to front of printer) 1 connects LFCN-RET to DCN14 pin 16 +24V-F2 PKCLL1ON-N NC/FDCLL1ON-N...
  • Page 349 5021-0XX Lower feeder unit Pin No. DCN14 Signal name (pin 1 is pin Pin No. closest to front of printer) +5V-S +5V-1 16 connects LFCN-CHK-N to DCN14 pin 1 5-45 Locations and connectors...

  • Page 350: Cable 11 Connector Assignments

    5021-0XX Cable 11 connector assignments Cable 11 connector pin assignments I/O board DCN19—Paper size sensor and temperature thermistor DCN19 Signal name Pin No. Pin No. Paper size sensor (PSU) +5V-1 PSU1 PSU2 PSU3 PSU4 NOT USED SGND NOT USED Temperature thermistor (RT) SGND 5-46 Service Manual...

  • Page 351: Cable 12 Connector Assignments

    5021-0XX Cable 12 connector assignments Cable 12 connector pin assignments Fuser connector—LVPS 120V Printer) Fuser LVPS connector Signal name Pin No. Pin No. Ground screw Fuser connector—LVPS 240V Printer) Fuser LVPS connector Signal name Pin No. Pin No. Ground screw 5-47 Locations and connectors...

  • Page 352: Cable 13 Connector Assignments

    5021-0XX Cable 13 connector assignments Cable 13 connector pin assignments Engine controller board FUCN—fuser FUCN Fuser Signal name Pin No. connector FUTEMP SGND 5-48 Service Manual...
  • Page 353 5021-0XX Engine controller board DPCN—Duplex unit DUPL DPCN DUPL Signal name Pin No. Pin No. D-COMMAND 2 connects DPCN-RET to DPCN pin 11 DUMBUSY2-N SGND D-STATUS SGND DUPMON-P SGND DUREON-P DUPCHK-N 11 connects DPCN-CHK to DPCN pin 2 SLEEP-P‘ LVPS ACN4—Duplex unit (DUPL) and duplex power ACN4 DUPL Signal name...
  • Page 354 5021-0XX ACN4 DUPL Signal name Pin No. Pin No. 9 connects CN-CHK to ACN4 pin Duplex power +24V-2 +24V-2 PGND PGND 5-50 Service Manual...

  • Page 355: Preventive Maintenance

    5021-0XX 6. Preventive maintenance There is no preventive maintenance for the Lexmark C510. Preventive maintenance...
  • Page 356 5021-0XX Service Manual...

  • Page 357: Parts Catalog

    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 separately and identified by description.
  • Page 358 5021-0XX Assembly 1: Base printer Service Manual...
  • Page 359 5021-0XX Assembly 1: Base printer Index Units Description 56P1611 Cover, cleaning roller 56P1607 Roller, cleaning 56P1651 Transfer unit 56P1660 Transfer roller assembly 56P1669 Paper tray, standard 12G7008 Power cord, USA 1339517 Power cord, LV, USA, APG, Bolivia, Canada, Columbia, Costa Rica, Ecuador, El Salvador, Guatemala, Honduras, Mexico, Nicaragua, Panama, Peru, Venezuela...
  • Page 360 5021-0XX Assembly 2: Covers Service Manual...
  • Page 361 5021-0XX Assembly 2: Covers Index Units Description 56P1676 Assembly, paper ramp and stop 56P1612 Cover assembly, top 56P1677 Assembly, paper exit (contains output tray full sensor and flag, fuser exit sensor and flag) 56P1672 Actuator, paper exit Packet, parts P/N 56P1662 56P1679 Assembly, registration 56P1685...
  • Page 362 5021-0XX Assembly 3: Front Service Manual...
  • Page 363 5021-0XX Assembly 3: Front Index Units Description 56P1688 Cover, laser unit assembly lens 56P1632 Laser unit assembly (printhead) 56P1671 Fan assembly, laser unit 56P1680 Left tray guide assembly (includes paper size sensor and temperature thermistor) 56P1633 Right tray guide 56P1657 Lamp, erase Parts catalog...
  • Page 364 5021-0XX Assembly 4: Right Service Manual...
  • Page 365 5021-0XX Assembly 4: Right Index Units Description 56P1625 Gear assembly, main drive 56P1622 Clutch, fuser Packet, parts P/N 56P1662 56P1621 Clutch, registration 56P1623 Clutch, transfer roller 56P1620 Clutch, paper feed 56P1624 Clutch, cleaning roller 56P1626 Waste toner feeder 56P1619 Motor assembly, main 56P1628 Drive assembly, developer 56P1629...
  • Page 366 5021-0XX Assembly 5: Rear 7-10 Service Manual...
  • Page 367 5021-0XX Assembly 5: Rear Index Units Description 56P1678 Assembly, bracket (includes marker sensor (transfer belt unit), toner density sensor) 56P1682 Paper guide assembly 56P1654 Paper guide (C) assembly (includes registration sensor, OHP sensor, tray empty sensor) 56P1655 Roller, paper feed 56P1656 Pad, separator 7-11...
  • Page 368 5021-0XX Assembly 6: Left 7-12 Service Manual...
  • Page 369 5021-0XX Assembly 6: Left Index Units Description 56P1640 Power supply, high voltage 56P1683 Assembly, toner retract 56P1631 Sensor, toner, receiver TTR (This is a two-piece sensor system. Ordering of this part number includes both the right and left side.) 56P1648 Sensor, toner present 56P1641 Power supply, 110 V low voltage...
  • Page 370 5021-0XX Assembly 7: Top 7-14 Service Manual...
  • Page 371 5021-0XX Assembly 7: Top Index Units Description 56P1618 Cover, I/O board 56P1637 Auger, waste toner 56P1638 Agitator, waste toner 56P1617 Board, I/O 56P1684 Assembly, marker sensor (OPC) (includes bracket) 56P1644 Fan, power supply (includes top cover and rear cover assembly interlock switches) 7-15 Parts catalog...
  • Page 372 5021-0XX Assembly 8: RIP board 7-16 Service Manual...
  • Page 373 5021-0XX Assembly 8: RIP board Index Units Description 56P2714 Board, Base RIP 56P2715 Board, Network RIP 12G7229 Card assembly, riser 56P1667 Shield, INA 99A1611 Shield, Ethernet 99A2432 Shield, parallel 7-17 Parts catalog...
  • Page 374 5021-0XX Assembly 9: Miscellaneous/Options 7-18 Service Manual...
  • Page 375 5021-0XX Assembly 9: Miscellaneous/Options Index Units Description 56P1663 Assembly, duplex unit 56P1664 Assembly, secondary paper feed 56P1665 Tray, secondary paper feed 56P1670 Paper tray, legal 56P1419 Drive assembly, 20+GB hard disk with adapter 56P1661 Parts packet, harness 56P1662 Parts packet, screw 7372640 Field relocation kit 56P0698...
  • Page 376 5021-0XX Assembly 9: Miscellaneous/Options Index Units Description 56P1436 Card, RS-232C serial 56P1741 Card, N2100t Token Ring 56P1742 Card, N2101e 10/100TX 7-20 Service Manual...

  • Page 377: Index

    5021-0XX Index setting the page count 3-16 setting top margin acronyms setting tray 2 left margin viewing error log 3-19 viewing page count 3-16 belt cleaning process 1-36 diagnostic information belt discharge (erase lamp) process operator messages 1-35 printer service checks 2-29 symptom tables 2-25...

  • Page 378: Part Number Index

    5021-0XX wiring diagram and cable harness engine controller board 4-55 reference 5-14 erase lamp 4-27 front cover assembly 4-19 front door interlock switch 4-29 fuser assembly maintenance approach high voltage power supply (HVPS) messages 4-59 operator HVPS cage 4-62 I/O board 4-70 4-74 laser unit assembly (printhead)
  • Page 379 5021-0XX waste toner feeder 4-42 repair information safety information second transfer (paper) process 1-38 Serial Number 3-17 service checks operator panel 2-84 paper feed 2-99 print quality 2-101 printer 2-29 spacing table 2-129 symptom tables print quality 2-27 printer 2-25 tests button device...
  • Page 380 5021-0XX Service Manual...

  • Page 381: Part Number Index

    5021-0XX Part number index Description page 11A6199 Cable, 50-foot serial ........7-19 12G7008 Power cord, USA .
  • Page 382 5021-0XX 56P1604 Cable, operator panel ........7-5 56P1607 Cover, cleaning roller .
  • Page 383 5021-0XX 56P1666 Cover, operator panel ........7-5 56P1667 Shield, INA .
  • Page 384 5021-0XX Service Manual...

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