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Lexmark 5021-0XX manual

Models: 5021-0XX

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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.

4-14Service Manual

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Lexmark 5021-0XX manual

Contents

Revised March 24 5021-0XX United States Government RightsTable of contents Diagnostic information 5021-0XX Diagnostic aids Vii 5021-0XX Locations and connectors 5021-0XX Laser advisory label Laser noticesClass 1 Laser statement label Laser notice LaserAvis relatif à l’utilisation de laser Avvertenze sui prodotti laserAvisos sobre el lá ser Laserinformatie LasermeddelelseHuomautus laserlaitteesta Laser-notisLaser-melding Avís sobre el Là serJapanese laser notice Chinese laser notice Korean laser notice Safety information Consignes de sé curitéNorme di sicurezza SicherheitshinweisePautas de Seguridad Informaçõ es de Seguranç aInformació de Seguretat 5021-0XX Preface DefinitionsMaintenance approach Tools required for serviceSerial number Acronyms Specifications ResolutionTechnical specifications Model differencesPhysical specifications and weight Width Depth Height Weight4 Inch PrintersPackaging and shipping dimensions Operating clearancesPrint speed and performance Time to first printProcessor 500 MHz General informationDuty cycle Paper and media specificationsPrinter memory 5021-0XX Input and output configurations Sources and capacities C510/C510n C510dtn5021-0XX Media input types and weights Media sizes JIS B53Output capacity by media and source Media guidelinesPaper EnvelopesLabels TransparenciesGlossy Paper Connectivity Cables Personal computersIBM AS/400 ConnectionsPower and electrical specifications Environment Specifications EnvironmentPrinter identification Options identification Printer theory of operation Printer paper path Basic principles of color printing Printer systems descriptionMechanical 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 Details of the print system Charging process5021-0XX Exposing process Developing process DBV First transfer drum process Belt discharge erase lamp process Toner image is then transferred to paperBelt cleaning process 5021-0XX Details of the transfer system Second transfer paper processTransfer belt cleaning process Details of the optical system Description5021-0XX Details of the paper transportation system Part Function5021-0XX Fusing unit 5021-0XX Fusing process Control system structure Electrical system and functionControl block diagram Control of print processPrint sequence diagram Laser drive control circuit Interface type Interface controlInterface connection 5021-0XX Diagnostic information StartService error codes Go to 910-Developer motor service check on Go to 911-Main motor service check onGo to 912-Power supply fan service check on Go to 913-Fuser fan service check onGo to 920-Fuser thermistor service check on Go to 921,922,923,924,925-Fuser assemblyGo to 930,931,932-Laser unit assembly service RIP board. Go to RIP board removal onController board removal on Panel cable removal onTo RIP board removal on Board removal onDownload emulations on Go to 985-Duplex connection error 1 service Go to 986-Duplex connection error 2 serviceGo to 990-Transfer belt unit service check on Go to 991-Transfer roller clutch service checkGo to 992-Transfer belt cleaning roller clutch Go to 993-Fuser clutch service check onCover open service check Paper size sensing serviceOperator messages 5021-0XX Performing Self Test Go to Output tray full TMAEmpty service check on Cartridge service check onTo Incorrect media service To Paper size sensing5021-0XX Insufficient Memory and Held Memory may be defective 5021-0XX Configuration Change Missing service check on Waste toner bottle serviceAssembly removal on Fuser assembly removalEngine controller board Removal onGo to Toner low/empty Paper jam messages Paper guide C assembly Paper exit assembly removal onBoard. See I/O board removal Engine controller board removalSee Duplex unit assembly Problem, see Paper feed serviceAssembly. See Secondary paper Feed assembly removal onSymptom tables Printer symptom tableSee White band service check See Printer no power serviceSee Waste toner feed service See Service error codes onPrint quality symptom table See Mottle service check on See Residual image serviceSee Insufficient gloss service See Back stain service check onPrinter service checks Yellow developer clutch service checkInterlock switch Locations on Magenta developer clutch service check 5021-0XX Cyan developer clutch service check 5021-0XX Black developer clutch service check 5021-0XX Yellow toner retract solenoid service check Engine Controller Board removal Magenta toner retract solenoid service check 5021-0XX Cyan toner retract solenoid service check 5021-0XX Black toner retract solenoid service check 5021-0XX Developer motor service check See DeveloperMotor removal 4-32. GoSwitch locations on On page 4-70for steps to4-57. Go Board cageSee Engine Main motor service check FuserMain motor Assembly4-38. Go Board removal Power supply fan service check Power supplyInterlock switch Fan removal onFuser fan service check Interlock switch Cover assemblySee Rear Locations on Removal onInterlock switch Removal on Laser fan service checkLaser unit fan Erase lamp Removal on Erase lamp service checkErase lamp 5021-0XX See Engine controller Board removal on Toner empty sensor sender-TPD service checkSensor sender removal On page 4-35for steps Toner empty sensor receiver-TTR service check See Engine controllerToner sensor ReceiverHvps connection service check Lower feed unit secondary paper assembly service check Right cover removal onSee Fuser assembly Fuser thermistor service checkRemoval on See Engine 921,922,923,924,925-Fuser assembly service check 930,931,932-Laser unit assembly service check Laser unitPrinthead Removal on 4-24. GoDuplex connection error 1 service check Duplex connection error 2 service check Transfer belt unit service check Transfer beltUnit removal BracketFor 5 VDC from pin 9 to Replace faulty Clutch Transfer roller clutch service checkOn page 4-70. If Cleaning roller Transfer belt cleaning roller clutch service checkClutch removal Fuser clutch service check Right cover removal on ClutchOPC belt marker sensor service check Removal on page 4-70forMarker sensor 4-69. IfFor 5 VDC from pin 11 to Replace faulty High voltage power supply Hvps service check PhotodevelopEr cartridge Photodeveloper Cartridge removal On page 4-11 . HasHigh voltage Power supply Hvps removal On page 4-59. Has Voltage power supply Lvps with cage Removal on Low voltage power supply Lvps service checkController 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 Paper guide With cage Removal onHigh voltage Power supply Missing photodeveloper cartridge service checkPhotodevelop Er cartridge Missing toner cartridge service check Present sensorBoard removal See Toner On page 4-70. If Present sensorOPC belt photodeveloper cartridge drive service check Motor Gear assembly Assembly Removal onPhotodevelop Er cartridge Removal on See Main See Main driveController board removal On page 4-55. Does Operator panel service checkRIP board Removal on Output tray full service check On page 4-70. If AssemblySee Paper exit Board removal See Paper exit9 to output tray full Paper size sensing service check Left tray guide Printer no power service check OperatorBoard cage removal on 4-60forDeveloper Retract solenoid Drive assembly Cam Removal on Toner feed service checkSee Developer Motor removal Toner low/empty service check On page 4-70. Does error See EngineSensor sender 4-35andTransfer roller missing service check Hvps cage4-62and Registration5021-0XX Tray empty service check On page 4-70. If Paper guide Assembly removal on Paper guideSee Paper guide C Waste toner bottle service check Waste tonerBottle holder Bottle holder removal onWaste toner feed service check Printer paper feed service check Paper feed service checksRegistration assembly removal on 5021-0XX Print quality service checks Background service checkBackground is smeared due to toner spread Photodeveloper cartridgeBack stain service check Backside of paper is stainedBanding line appears in horizontal direction Banding service checkSee Photodeveloper cartridge Black line service check Fine black line appears in printer imageColor misregistration service check Color misregistration between two colorsTransfer belt unit removal on Insufficient fusing service check Printed image is partially missingInsufficient gloss service check Gloss on paper is not sufficientJitter service check Main motor assembly removal onAssembly. See Developer drive Cartridge removal onMissing image at edge service check Image has missing or peeling toner at edgeMixed color image service check Mixed color image appearsClutch removal on Toner retract solenoid and camMottle service check Voltage power supply HvpsVariation of optical density is found in image See Transfer roller removal onSee Transfer belt cleaning roller Residual image service checkImage of preceding page appears on every other Ribbing service check Light print occurs in right or left side of imageSolenoid and cam removal on Toner drop service check Auger removal onWaste toner feeder removal on Removal on page 4-6 . Prior toToner cartridge Replace faulty toner cartridge Vertical line service check Vertical line appears in printed imageLaser unit assembly printhead Vertical staggering image service checkPrinted image staggers in vertical direction Vertical white band service check White band appears in vertical direction of printed imageWhite band service check Horizontal white banding creates missing portion of imageTransfer roller removal on See Clutch removal onWhite line I service check Print quality test pages onWhite line II service check White spot and black spot appear on paper White spot / black spot service checkBelt unit see Transfer belt unit White print service check Reinstall. See Transfer rollerRemoval on page 4-8 . Ensure System. See Toner retract solenoidWrinkle / image migration service check Uneven density right and left Transfer belt unit Replace faulty transfer belt unit. See Roller specifications Spacing table5021-0XX Select the Disable Option Disabling download emulationsPaper jam sequence Go to Paper jam messages on page 2-22for more information5021-0XX Paper Jam Diagnostic mode Print quality test pages Diagnostics menu structurePrint Quality Description Print registration Setting tray 2 left marginSelect Registration Select Left Margin Adj Setting top margin Print testsSelect Registration Select Top Margin MenuSelect Single or Continuous Hardware testsFollowing hardware tests can be selected from this menu Button test LCD testParallel wrap test ROM memory test Dram memory test Serial wrap testTransmit Data Interrupt Error Duplex left margin Duplex testsSelect Duplex Test Select Duplex Left Margin Device tests Disk test/cleanQuick disk test Flash test Printer setup Setting the page countViewing the permanent page count Select either Color Page Counts or Mono Page CountsSetting configuration ID Serial numberParallel strobe adjustment Viewing the error log Error logPrinting the error log Clearing the error log Restore EP factory defaultsExiting diagnostic mode 5021-0XX Removal and cleaning precautions Repair informationDuring replacement Handling the printed circuit boards with MOS ICsDuring transportation/storage During inspectionHandling Photodeveloper cartridgeParts not to be touched Printer removal procedures Precautions to take before maintenance workCRU/FRU and supplies removals Cleaning roller cover removal Transfer belt cleaning roller removalTransfer belt unit removal Transfer roller removal Fuser assembly removal Waste toner bottle removal Open front cover Remove waste toner bottlePhotodeveloper 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 5021-0XX 5021-0XX Rear cover assembly removal Right cover removal5021-0XX Laser unit assembly printhead removal Left cover removal5021-0XX Laser unit fan assembly removal Erase lamp removal 5021-0XX Front door interlock switch removal Right side removals5021-0XX Front door interlock switch with bracket Developer motor removalDeveloper drive assembly removal Waste toner bottle holder removal5021-0XX 5021-0XX Toner sensor sender removal Cleaning roller clutch removal 5021-0XX Main motor assembly removal 5021-0XX Clutch removal Main drive gear assembly removal Remove fuser clutch. See Clutch removal onRemove main drive gear assembly from printer Waste toner feeder removal5021-0XX Rear removals Bracket assembly removal RIP board removalPaper guide assembly removal Paper guide C assembly removal Paper feed roller removal Paper exit assembly removal Remove two screws C 5021-0XX Registration assembly removal Remove transfer roller. See Transfer roller removal onLeft side removals Operator panel cable removal Remove left cover. See Left cover removal onEngine controller board removal 5021-0XX RIP board cage removal Remove ducting High voltage power supply Hvps removal Disconnect all connectors from Hvps Repair informationLow voltage power supply Lvps with cage removal 5021-0XX Remove HVPS. See High voltage power supply Hvps removal on Hvps cage removalToner present sensor removal Remove four screws C remove Hvps cageToner sensor receiver removal Toner retract solenoid and cam removalLeft tray guide assembly removal 5021-0XX 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 Locations and connectors PrinterPart name Description Options Electronic components Sensor locationsTNK Printer circuit board locations Name FunctionFan/motor locations Interlock switch locations Solenoid/clutch locations FbclToner retract Symbol and part name table Symbol Part nameLDU TTR Trcm Wiring diagram / cable harness reference RIP board Engine controller board Input/output I/O board 5021-0XX Printer cables Engine controller board I1CN-I/O board DCN15021-0XX OAD1 OAD2 Sgnd Engine controller board I2CN-I/O board DCN3 DCN35021-0XX Engine controller board HVCN-HVPS CN1 Hvcn Engine controller board P2CN-Operator panel Board DCN13-LVPS ACN1 Board DCN18-Interlock switches Lvps ACN2-Interlock switchesInterlock switches-Interlock switches Lvps ACN5-Engine controller board DCN21 Lvps ACN5-Engine controller board LvcnNo connection Engine controller board POCN-LVPS ACN3 ACN3Board DCN4-Toner retract solenoids DCN4Board DCN8-Laser fan 5021-0XX Board DCN5-Photodeveloper OPC marker sensorBoard DCN15-Toner present sensor, erase lamp Tleschk Sgnd Board DCN16-Sensors DCN16Board DCN7-Rear cover assembly DCN7Htfanerr DCN10 DCLCON-N 5021-0XX Board DCN11-Developer motor Board DCN12-Main motorMmenc MMREV-N Mmgain Mmovld Engine board LCN-Printhead LDU LDUSgnd SCMRDY-N Scmclk Pgnd SCMON-N Board DCN14-Lower feeder unit DCN14LFCN-CHK-N Board DCN19-Paper size sensor and temperature thermistor DCN19Fuser connector-LVPS 120V Printer Fuser connector-LVPS 240V PrinterEngine controller board FUCN-fuser Lvps ACN4-Duplex unit Dupl and duplex power 5021-0XX Engine controller board DPCN-Duplex unit DuplDuplex Preventive maintenance 5021-0XX How to use this parts catalog Parts catalogAssembly 1 Base printer Assembly 1 Base printer Index Units DescriptionAssembly 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 Assembly 9 Miscellaneous/Options DIMM, 128MB SdramAssembly 9 Miscellaneous/Options Index Paper transportation system 5021-0XX 5021-0XX Part number index 5021-0XX 5021-0XX 5021-0XX