Revised March 24
United States Government Rights
5021-0XX
Table of contents
Diagnostic information
5021-0XX
Diagnostic aids
Vii
5021-0XX
Locations and connectors
5021-0XX
Laser notices
Laser advisory label
Class 1 Laser statement label
Laser
Laser notice
Avvertenze sui prodotti laser
Avis relatif à l’utilisation de laser
Avisos sobre el lá ser
Lasermeddelelse
Laserinformatie
Laser-notis
Huomautus laserlaitteesta
Avís sobre el Là ser
Laser-melding
Japanese laser notice Chinese laser notice
Korean laser notice
Consignes de sé curité
Safety information
Sicherheitshinweise
Norme di sicurezza
Informaçõ es de Seguranç a
Pautas de Seguridad
Informació de Seguretat
5021-0XX
Definitions
Preface
Tools required for service
Maintenance approach
Serial number
Acronyms
Model differences
Specifications
Resolution
Technical specifications
Width Depth Height Weight4 Inch Printers
Physical specifications and weight
Operating clearances
Packaging and shipping dimensions
500 MHz General information
Print speed and performance
Time to first print
Processor
Paper and media specifications
Duty cycle
Printer memory
Sources and capacities C510/C510n C510dtn
5021-0XX Input and output configurations
5021-0XX Media input types and weights
JIS B53
Media sizes
Envelopes
Output capacity by media and source
Media guidelines
Paper
Transparencies
Labels
Glossy Paper
Connections
Connectivity
Cables Personal computers
IBM AS/400
Power and electrical specifications
Environment
Environment Specifications
Printer identification
Options identification
Printer theory of operation
Printer paper path
Printer systems description
Basic principles of color printing
Mechanical and electrical structures
5021-0XX Control system
Printer component systems
Basic process of color printing
Print system and transfer system
Structure of OPC belt photo developer cartridge
Basic structure of the print system
CBV DBV
Charging process
Details of the print system
5021-0XX
Exposing process
Developing process
DBV
First transfer drum process
Toner image is then transferred to paper
Belt discharge erase lamp process
Belt cleaning process
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Second transfer paper process
Details of the transfer system
Transfer belt cleaning process
Description
Details of the optical system
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Part Function
Details of the paper transportation system
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Fusing unit
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Fusing process
Electrical system and function
Control system structure
Control of print process
Control block diagram
Print sequence diagram
Laser drive control circuit
Interface control
Interface type
Interface connection
5021-0XX
Start
Diagnostic information
Service error codes
Go to 913-Fuser fan service check on
Go to 910-Developer motor service check on
Go to 911-Main motor service check on
Go to 912-Power supply fan service check on
RIP board. Go to RIP board removal on
Go to 920-Fuser thermistor service check on
Go to 921,922,923,924,925-Fuser assembly
Go to 930,931,932-Laser unit assembly service
Board removal on
Controller board removal on
Panel cable removal on
To RIP board removal on
Download emulations on
Go to 986-Duplex connection error 2 service
Go to 985-Duplex connection error 1 service
Go to 993-Fuser clutch service check on
Go to 990-Transfer belt unit service check on
Go to 991-Transfer roller clutch service check
Go to 992-Transfer belt cleaning roller clutch
Paper size sensing service
Cover open service check
Operator messages
5021-0XX
Performing Self Test
TMA
Go to Output tray full
To Paper size sensing
Empty service check on
Cartridge service check on
To Incorrect media service
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Insufficient Memory and Held
Memory may be defective
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Configuration Change
Waste toner bottle service
Missing service check on
Removal on
Assembly removal on
Fuser assembly removal
Engine controller board
Go to Toner low/empty
Paper jam messages
Engine controller board removal
Paper guide C assembly
Paper exit assembly removal on
Board. See I/O board removal
Feed assembly removal on
See Duplex unit assembly
Problem, see Paper feed service
Assembly. See Secondary paper
Printer symptom table
Symptom tables
See Service error codes on
See White band service check
See Printer no power service
See Waste toner feed service
Print quality symptom table
See Back stain service check on
See Mottle service check on
See Residual image service
See Insufficient gloss service
Yellow developer clutch service check
Printer service checks
Interlock switch Locations on
Magenta developer clutch service check
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Cyan developer clutch service check
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Black developer clutch service check
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Yellow toner retract solenoid service check
Engine Controller Board removal
Magenta toner retract solenoid service check
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Cyan toner retract solenoid service check
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Black toner retract solenoid service check
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4-32. Go
Developer motor service check
See Developer
Motor removal
On page 4-70for steps to
Switch locations on
Board cage
4-57. Go
See Engine
Fuser
Main motor service check
Assembly
Main motor
4-38. Go
Board removal
Fan removal on
Power supply fan service check
Power supply
Interlock switch
Locations on Removal on
Fuser fan service check
Interlock switch Cover assembly
See Rear
Laser fan service check
Interlock switch Removal on
Laser unit fan
Erase lamp service check
Erase lamp Removal on
Erase lamp
5021-0XX
Toner empty sensor sender-TPD service check
See Engine controller Board removal on
Sensor sender removal On page 4-35for steps
Receiver
Toner empty sensor receiver-TTR service check
See Engine controller
Toner sensor
Hvps connection service check
Right cover removal on
Lower feed unit secondary paper assembly service check
Fuser thermistor service check
See Fuser assembly
Removal on See Engine
921,922,923,924,925-Fuser assembly service check
Removal on 4-24. Go
930,931,932-Laser unit assembly service check
Laser unit
Printhead
Duplex connection error 1 service check
Duplex connection error 2 service check
Bracket
Transfer belt unit service check
Transfer belt
Unit removal
For 5 VDC from pin 9 to Replace faulty
Transfer roller clutch service check
Clutch
On page 4-70. If
Transfer belt cleaning roller clutch service check
Cleaning roller
Clutch removal
Right cover removal on Clutch
Fuser clutch service check
4-69. If
OPC belt marker sensor service check
Removal on page 4-70for
Marker sensor
For 5 VDC from pin 11 to Replace faulty
Photodeveloper Cartridge removal On page 4-11 . Has
High voltage power supply Hvps service check
Photodevelop
Er cartridge
High voltage Power supply Hvps removal On page 4-59. Has
Low voltage power supply Lvps service check
Voltage power supply Lvps with cage Removal on
Controller board removal Board removal On page 4-55. Does
Cover open service check
Cable that connects to
Cover interlock switch pin
Incorrect media service check
With cage Removal on
Paper guide
Missing photodeveloper cartridge service check
High voltage Power supply
Photodevelop Er cartridge
Present sensor
Missing toner cartridge service check
On page 4-70. If Present sensor
Board removal See Toner
See Main See Main drive
OPC belt photodeveloper cartridge drive service check
Motor Gear assembly Assembly Removal on
Photodevelop Er cartridge Removal on
Operator panel service check
Controller board removal On page 4-55. Does
RIP board Removal on
Board removal See Paper exit
Output tray full service check
On page 4-70. If Assembly
See Paper exit
9 to output tray full
Paper size sensing service check
Left tray guide
Operator
Printer no power service check
4-60for
Board cage removal on
Toner feed service check
Developer Retract solenoid Drive assembly Cam Removal on
See Developer Motor removal
4-35and
Toner low/empty service check
On page 4-70. Does error See Engine
Sensor sender
Registration
Transfer roller missing service check
Hvps cage
4-62and
5021-0XX
Tray empty service check
Assembly removal on Paper guide
On page 4-70. If Paper guide
See Paper guide C
Bottle holder removal on
Waste toner bottle service check
Waste toner
Bottle holder
Waste toner feed service check
Paper feed service checks
Printer paper feed service check
Registration assembly removal on
5021-0XX
Photodeveloper cartridge
Print quality service checks
Background service check
Background is smeared due to toner spread
Backside of paper is stained
Back stain service check
Banding service check
Banding line appears in horizontal direction
See Photodeveloper cartridge
Fine black line appears in printer image
Black line service check
Color misregistration between two colors
Color misregistration service check
Transfer belt unit removal on
Printed image is partially missing
Insufficient fusing service check
Gloss on paper is not sufficient
Insufficient gloss service check
Cartridge removal on
Jitter service check
Main motor assembly removal on
Assembly. See Developer drive
Image has missing or peeling toner at edge
Missing image at edge service check
Toner retract solenoid and cam
Mixed color image service check
Mixed color image appears
Clutch removal on
See Transfer roller removal on
Mottle service check
Voltage power supply Hvps
Variation of optical density is found in image
Residual image service check
See Transfer belt cleaning roller
Image of preceding page appears on every other
Light print occurs in right or left side of image
Ribbing service check
Solenoid and cam removal on
Removal on page 4-6 . Prior to
Toner drop service check
Auger removal on
Waste toner feeder removal on
Toner cartridge Replace faulty toner cartridge
Vertical line appears in printed image
Vertical line service check
Vertical staggering image service check
Laser unit assembly printhead
Printed image staggers in vertical direction
White band appears in vertical direction of printed image
Vertical white band service check
See Clutch removal on
White band service check
Horizontal white banding creates missing portion of image
Transfer roller removal on
Print quality test pages on
White line I service check
White line II service check
White spot / black spot service check
White spot and black spot appear on paper
Belt unit see Transfer belt unit
System. See Toner retract solenoid
White print service check
Reinstall. See Transfer roller
Removal on page 4-8 . Ensure
Wrinkle / image migration service check
Uneven density right and left
Transfer belt unit Replace faulty transfer belt unit. See
Spacing table
Roller specifications
5021-0XX
Disabling download emulations
Select the Disable Option
Go to Paper jam messages on page 2-22for more information
Paper jam sequence
5021-0XX Paper Jam
Diagnostic mode
Diagnostics menu structure
Print quality test pages
Print Quality Description
Setting tray 2 left margin
Print registration
Select Registration Select Left Margin Adj
Menu
Setting top margin
Print tests
Select Registration Select Top Margin
Hardware tests
Select Single or Continuous
Following hardware tests can be selected from this menu
LCD test
Button test
Parallel wrap test
ROM memory test
Serial wrap test
Dram memory test
Transmit Data Interrupt Error
Duplex tests
Duplex left margin
Select Duplex Test Select Duplex Left Margin
Disk test/clean
Device tests
Quick disk test
Flash test
Select either Color Page Counts or Mono Page Counts
Printer setup
Setting the page count
Viewing the permanent page count
Serial number
Setting configuration ID
Parallel strobe adjustment
Error log
Viewing the error log
Printing the error log
Restore EP factory defaults
Clearing the error log
Exiting diagnostic mode
5021-0XX
Repair information
Removal and cleaning precautions
During inspection
During replacement
Handling the printed circuit boards with MOS ICs
During transportation/storage
Photodeveloper cartridge
Handling
Parts not to be touched
Precautions to take before maintenance work
Printer removal procedures
CRU/FRU and supplies removals
Transfer belt cleaning roller removal
Cleaning roller cover removal
Transfer belt unit removal
Transfer roller removal
Fuser assembly removal
Open front cover Remove waste toner bottle
Waste toner bottle removal
Photodeveloper cartridge removal
5021-0XX
Duplex unit assembly removal
5021-0XX
Lift duplex unit up and away from printer Repair information
Secondary paper feed assembly removal
Cover removals
Top cover assembly removal
Front cover assembly removal
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5021-0XX
Right cover removal
Rear cover assembly removal
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Left cover removal
Laser unit assembly printhead removal
5021-0XX
Laser unit fan assembly removal
Erase lamp removal
5021-0XX
Right side removals
Front door interlock switch removal
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Developer motor removal
Front door interlock switch with bracket
Waste toner bottle holder removal
Developer drive assembly removal
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5021-0XX
Toner sensor sender removal
Cleaning roller clutch removal
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Main motor assembly removal
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Clutch removal
Remove fuser clutch. See Clutch removal on
Main drive gear assembly removal
Waste toner feeder removal
Remove main drive gear assembly from printer
5021-0XX
Rear removals
RIP board removal
Bracket assembly removal
Paper guide assembly removal
Paper guide C assembly removal
Paper feed roller removal
Paper exit assembly removal
Remove two screws C
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Remove transfer roller. See Transfer roller removal on
Registration assembly removal
Left side removals
Remove left cover. See Left cover removal on
Operator panel cable removal
Engine controller board removal
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RIP board cage removal
Remove ducting
Disconnect all connectors from Hvps Repair information
High voltage power supply Hvps removal
Low voltage power supply Lvps with cage removal
5021-0XX
Hvps cage removal
Remove HVPS. See High voltage power supply Hvps removal on
Remove four screws C remove Hvps cage
Toner present sensor removal
Toner retract solenoid and cam removal
Toner sensor receiver removal
Left tray guide assembly removal
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5021-0XX
Top removals
Marker sensor assembly removal
Board removal
Do not remove the jumper
Waste toner auger removal
Waste toner agitator removal
Power supply fan removal
Printer
Locations and connectors
Part name Description
Options
Sensor locations
Electronic components
TNK
Name Function
Printer circuit board locations
Fan/motor locations
Interlock switch locations
Fbcl
Solenoid/clutch locations
Toner retract
Symbol Part name
Symbol and part name table
LDU
TTR Trcm
Wiring diagram / cable harness reference
RIP board
Engine controller board
Input/output I/O board
5021-0XX
Engine controller board I1CN-I/O board DCN1
Printer cables
5021-0XX
OAD1 OAD2 Sgnd
DCN3
Engine controller board I2CN-I/O board DCN3
5021-0XX
Engine controller board HVCN-HVPS CN1
Hvcn
Engine controller board P2CN-Operator panel
Board DCN13-LVPS ACN1
Lvps ACN2-Interlock switches
Board DCN18-Interlock switches
Interlock switches-Interlock switches
Lvps ACN5-Engine controller board Lvcn
Lvps ACN5-Engine controller board DCN21
No connection
ACN3
Engine controller board POCN-LVPS ACN3
DCN4
Board DCN4-Toner retract solenoids
5021-0XX Board DCN5-Photodeveloper OPC marker sensor
Board DCN8-Laser fan
Board DCN15-Toner present sensor, erase lamp
Tleschk Sgnd
DCN16
Board DCN16-Sensors
DCN7
Board DCN7-Rear cover assembly
Htfanerr
DCN10
DCLCON-N
Board DCN12-Main motor
5021-0XX Board DCN11-Developer motor
Mmenc MMREV-N Mmgain Mmovld
LDU
Engine board LCN-Printhead LDU
Sgnd SCMRDY-N Scmclk Pgnd SCMON-N
DCN14
Board DCN14-Lower feeder unit
LFCN-CHK-N
DCN19
Board DCN19-Paper size sensor and temperature thermistor
Fuser connector-LVPS 240V Printer
Fuser connector-LVPS 120V Printer
Engine controller board FUCN-fuser
5021-0XX Engine controller board DPCN-Duplex unit Dupl
Lvps ACN4-Duplex unit Dupl and duplex power
Duplex
Preventive maintenance
5021-0XX
Parts catalog
How to use this parts catalog
Assembly 1 Base printer
Index Units Description
Assembly 1 Base printer
Assembly 2 Covers
Assembly 2 Covers
Assembly 3 Front
Assembly 3 Front
Assembly 4 Right
Assembly 4 Right
Assembly 5 Rear
Assembly 5 Rear
Assembly 6 Left
Assembly 6 Left
Assembly 7 Top
Assembly 7 Top
Assembly 8 RIP board
Assembly 8 RIP board
Assembly 9 Miscellaneous/Options
DIMM, 128MB Sdram
Assembly 9 Miscellaneous/Options
Assembly 9 Miscellaneous/Options
Index
Paper transportation system
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5021-0XX
Part number index
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5021-0XX