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
Resolution
Specifications
Technical specifications
Model differences
Width Depth Height Weight4 Inch Printers
Physical specifications and weight
Operating clearances
Packaging and shipping dimensions
Time to first print
Print speed and performance
Processor
500 MHz General information
Duty cycle
Paper and media specifications
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
Media guidelines
Output capacity by media and source
Paper
Envelopes
Labels
Transparencies
Glossy Paper
Cables Personal computers
Connectivity
IBM AS/400
Connections
Power and electrical specifications
Environment
Environment Specifications
Printer identification
Options identification
Printer theory of operation
Printer paper path
Basic principles of color printing
Printer systems description
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 type
Interface control
Interface connection
5021-0XX
Start
Diagnostic information
Service error codes
Go to 911-Main motor service check on
Go to 910-Developer motor service check on
Go to 912-Power supply fan service check on
Go to 913-Fuser fan service check on
Go to 921,922,923,924,925-Fuser assembly
Go to 920-Fuser thermistor service check on
Go to 930,931,932-Laser unit assembly service
RIP board. Go to RIP board removal on
Panel cable removal on
Controller board removal on
To RIP board removal on
Board removal on
Download emulations on
Go to 986-Duplex connection error 2 service
Go to 985-Duplex connection error 1 service
Go to 991-Transfer roller clutch service check
Go to 990-Transfer belt unit service check on
Go to 992-Transfer belt cleaning roller clutch
Go to 993-Fuser clutch service check on
Cover open service check
Paper size sensing service
Operator messages
5021-0XX
Performing Self Test
TMA
Go to Output tray full
Cartridge service check on
Empty service check on
To Incorrect media service
To Paper size sensing
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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
Fuser assembly removal
Assembly removal on
Engine controller board
Removal on
Go to Toner low/empty
Paper jam messages
Paper exit assembly removal on
Paper guide C assembly
Board. See I/O board removal
Engine controller board removal
Problem, see Paper feed service
See Duplex unit assembly
Assembly. See Secondary paper
Feed assembly removal on
Printer symptom table
Symptom tables
See Printer no power service
See White band service check
See Waste toner feed service
See Service error codes on
Print quality symptom table
See Residual image service
See Mottle service check on
See Insufficient gloss service
See Back stain service check on
Yellow developer clutch service check
Printer service checks
Interlock switch Locations on
Magenta developer clutch service check
5021-0XX
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
5021-0XX
See Developer
Developer motor service check
Motor removal
4-32. Go
On page 4-70for steps to
Switch locations on
4-57. Go
Board cage
See Engine
Fuser
Main motor service check
Main motor
Assembly
4-38. Go
Board removal
Power supply
Power supply fan service check
Interlock switch
Fan removal on
Interlock switch Cover assembly
Fuser fan service check
See Rear
Locations on Removal on
Interlock switch Removal on
Laser fan service check
Laser unit fan
Erase lamp Removal on
Erase lamp service check
Erase lamp
5021-0XX
See Engine controller Board removal on
Toner empty sensor sender-TPD service check
Sensor sender removal On page 4-35for steps
See Engine controller
Toner empty sensor receiver-TTR service check
Toner sensor
Receiver
Hvps connection service check
Right cover removal on
Lower feed unit secondary paper assembly service check
See Fuser assembly
Fuser thermistor service check
Removal on See Engine
921,922,923,924,925-Fuser assembly service check
Laser unit
930,931,932-Laser unit assembly service check
Printhead
Removal on 4-24. Go
Duplex connection error 1 service check
Duplex connection error 2 service check
Transfer belt
Transfer belt unit service check
Unit removal
Bracket
For 5 VDC from pin 9 to Replace faulty
Clutch
Transfer roller clutch service check
On page 4-70. If
Cleaning roller
Transfer belt cleaning roller clutch service check
Clutch removal
Right cover removal on Clutch
Fuser clutch service check
Removal on page 4-70for
OPC belt marker sensor service check
Marker sensor
4-69. If
For 5 VDC from pin 11 to Replace faulty
Photodevelop
High voltage power supply Hvps service check
Er cartridge
Photodeveloper Cartridge removal On page 4-11 . Has
High voltage Power supply Hvps removal On page 4-59. Has
Voltage power supply Lvps with cage Removal on
Low voltage power supply Lvps service check
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
High voltage Power supply
Missing photodeveloper cartridge service check
Photodevelop Er cartridge
Present sensor
Missing toner cartridge service check
On page 4-70. If Present sensor
Board removal See Toner
Motor Gear assembly Assembly Removal on
OPC belt photodeveloper cartridge drive service check
Photodevelop Er cartridge Removal on
See Main See Main drive
Controller board removal On page 4-55. Does
Operator panel service check
RIP board Removal on
On page 4-70. If Assembly
Output tray full service check
See Paper exit
Board removal 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
Developer Retract solenoid Drive assembly Cam Removal on
Toner feed service check
See Developer Motor removal
On page 4-70. Does error See Engine
Toner low/empty service check
Sensor sender
4-35and
Hvps cage
Transfer roller missing service check
4-62and
Registration
5021-0XX
Tray empty service check
On page 4-70. If Paper guide
Assembly removal on Paper guide
See Paper guide C
Waste toner
Waste toner bottle service check
Bottle holder
Bottle holder removal on
Waste toner feed service check
Printer paper feed service check
Paper feed service checks
Registration assembly removal on
5021-0XX
Background service check
Print quality service checks
Background is smeared due to toner spread
Photodeveloper cartridge
Backside of paper is stained
Back stain service check
Banding line appears in horizontal direction
Banding service check
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
Main motor assembly removal on
Jitter service check
Assembly. See Developer drive
Cartridge removal on
Image has missing or peeling toner at edge
Missing image at edge service check
Mixed color image appears
Mixed color image service check
Clutch removal on
Toner retract solenoid and cam
Voltage power supply Hvps
Mottle service check
Variation of optical density is found in image
See Transfer roller removal on
See Transfer belt cleaning roller
Residual image service check
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
Auger removal on
Toner drop service check
Waste toner feeder removal on
Removal on page 4-6 . Prior to
Toner cartridge Replace faulty toner cartridge
Vertical line appears in printed image
Vertical line service check
Laser unit assembly printhead
Vertical staggering image service check
Printed image staggers in vertical direction
White band appears in vertical direction of printed image
Vertical white band service check
Horizontal white banding creates missing portion of image
White band service check
Transfer roller removal on
See Clutch removal on
Print quality test pages on
White line I service check
White line II service check
White spot and black spot appear on paper
White spot / black spot service check
Belt unit see Transfer belt unit
Reinstall. See Transfer roller
White print service check
Removal on page 4-8 . Ensure
System. See Toner retract solenoid
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
Print quality test pages
Diagnostics menu structure
Print Quality Description
Print registration
Setting tray 2 left margin
Select Registration Select Left Margin Adj
Print tests
Setting top margin
Select Registration Select Top Margin
Menu
Select Single or Continuous
Hardware tests
Following hardware tests can be selected from this menu
Button test
LCD test
Parallel wrap test
ROM memory test
Serial wrap test
Dram memory test
Transmit Data Interrupt Error
Duplex left margin
Duplex tests
Select Duplex Test Select Duplex Left Margin
Device tests
Disk test/clean
Quick disk test
Flash test
Setting the page count
Printer setup
Viewing the permanent page count
Select either Color Page Counts or Mono Page Counts
Serial number
Setting configuration ID
Parallel strobe adjustment
Viewing the error log
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
Handling the printed circuit boards with MOS ICs
During replacement
During transportation/storage
During inspection
Handling
Photodeveloper cartridge
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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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
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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
5021-0XX
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
5021-0XX
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
Board DCN18-Interlock switches
Lvps ACN2-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
Board DCN8-Laser fan
5021-0XX Board DCN5-Photodeveloper OPC marker sensor
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