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Lexmark 5021-0XX manual Printer theory of operation

Models: 5021-0XX

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5021-0XX

Printer theory of operation

The following diagram shows the major parts of the printer and paper path.

General information 1-19

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Lexmark 5021-0XX manual Printer theory of operation

Contents

Revised March 24 United States Government Rights 5021-0XXTable of contents Diagnostic information 5021-0XX Diagnostic aids Vii 5021-0XX Locations and connectors 5021-0XX Laser notices Laser advisory labelClass 1 Laser statement label Laser Laser noticeAvvertenze sui prodotti laser Avis relatif à l’utilisation de laserAvisos sobre el lá ser Lasermeddelelse LaserinformatieLaser-notis Huomautus laserlaitteestaAvís sobre el Là ser Laser-meldingJapanese laser notice Chinese laser notice Korean laser notice Consignes de sé curité Safety informationSicherheitshinweise Norme di sicurezzaInformaçõ es de Seguranç a Pautas de SeguridadInformació de Seguretat 5021-0XX Definitions PrefaceTools required for service Maintenance approachSerial number Acronyms Resolution SpecificationsTechnical specifications Model differencesWidth Depth Height Weight4 Inch Printers Physical specifications and weightOperating clearances Packaging and shipping dimensionsTime to first print Print speed and performanceProcessor 500 MHz General informationPaper and media specifications Duty cyclePrinter memory Sources and capacities C510/C510n C510dtn 5021-0XX Input and output configurations5021-0XX Media input types and weights JIS B53 Media sizesMedia guidelines Output capacity by media and sourcePaper EnvelopesTransparencies LabelsGlossy Paper Cables Personal computers ConnectivityIBM AS/400 ConnectionsPower and electrical specifications Environment Environment SpecificationsPrinter identification Options identification Printer theory of operation Printer paper path Printer systems description Basic principles of color printingMechanical 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 system5021-0XX Exposing process Developing process DBV First transfer drum process Toner image is then transferred to paper Belt discharge erase lamp processBelt cleaning process 5021-0XX Second transfer paper process Details of the transfer systemTransfer belt cleaning process Description Details of the optical system5021-0XX Part Function Details of the paper transportation system5021-0XX Fusing unit 5021-0XX Fusing process Electrical system and function Control system structureControl of print process Control block diagramPrint sequence diagram Laser drive control circuit Interface control Interface typeInterface connection 5021-0XX Start Diagnostic informationService error codes Go to 911-Main motor service check on Go to 910-Developer motor service check onGo to 912-Power supply fan service check on Go to 913-Fuser fan service check onGo to 921,922,923,924,925-Fuser assembly Go to 920-Fuser thermistor service check onGo to 930,931,932-Laser unit assembly service RIP board. Go to RIP board removal onPanel cable removal on Controller board removal onTo RIP board removal on Board removal onDownload emulations on Go to 986-Duplex connection error 2 service Go to 985-Duplex connection error 1 serviceGo to 991-Transfer roller clutch service check Go to 990-Transfer belt unit service check onGo to 992-Transfer belt cleaning roller clutch Go to 993-Fuser clutch service check onPaper size sensing service Cover open service checkOperator messages 5021-0XX Performing Self Test TMA Go to Output tray fullCartridge service check on Empty service check onTo Incorrect media service To Paper size sensing5021-0XX Insufficient Memory and Held Memory may be defective 5021-0XX Configuration Change Waste toner bottle service Missing service check onFuser assembly removal Assembly removal onEngine controller board Removal onGo to Toner low/empty Paper jam messages Paper exit assembly removal on Paper guide C assemblyBoard. See I/O board removal Engine controller board removalProblem, see Paper feed service See Duplex unit assemblyAssembly. See Secondary paper Feed assembly removal onPrinter symptom table Symptom tablesSee Printer no power service See White band service checkSee Waste toner feed service See Service error codes onPrint quality symptom table See Residual image service See Mottle service check onSee Insufficient gloss service See Back stain service check onYellow developer clutch service check Printer service checksInterlock 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 See Developer Developer motor service checkMotor removal 4-32. GoOn page 4-70for steps to Switch locations onBoard cage 4-57. GoSee Engine Fuser Main motor service checkAssembly Main motor4-38. Go Board removal Power supply Power supply fan service checkInterlock switch Fan removal onInterlock switch Cover assembly Fuser fan service checkSee Rear Locations on Removal onLaser fan service check Interlock switch Removal onLaser unit fan Erase lamp service check Erase lamp Removal onErase lamp 5021-0XX Toner empty sensor sender-TPD service check See Engine controller Board removal onSensor sender removal On page 4-35for steps See Engine controller Toner empty sensor receiver-TTR service checkToner sensor ReceiverHvps connection service check Right cover removal on Lower feed unit secondary paper assembly service checkFuser thermistor service check See Fuser assemblyRemoval on See Engine 921,922,923,924,925-Fuser assembly service check Laser unit 930,931,932-Laser unit assembly service checkPrinthead Removal on 4-24. GoDuplex connection error 1 service check Duplex connection error 2 service check Transfer belt Transfer belt unit service checkUnit removal BracketFor 5 VDC from pin 9 to Replace faulty Transfer roller clutch service check ClutchOn page 4-70. If Transfer belt cleaning roller clutch service check Cleaning rollerClutch removal Right cover removal on Clutch Fuser clutch service checkRemoval on page 4-70for OPC belt marker sensor service checkMarker sensor 4-69. IfFor 5 VDC from pin 11 to Replace faulty Photodevelop High voltage power supply Hvps service checkEr cartridge Photodeveloper Cartridge removal On page 4-11 . HasHigh voltage Power supply Hvps removal On page 4-59. Has Low voltage power supply Lvps service check Voltage power supply Lvps with cage Removal onController 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 guideMissing photodeveloper cartridge service check High voltage Power supplyPhotodevelop Er cartridge Present sensor Missing toner cartridge service checkOn page 4-70. If Present sensor Board removal See TonerMotor Gear assembly Assembly Removal on OPC belt photodeveloper cartridge drive service checkPhotodevelop Er cartridge Removal on See Main See Main driveOperator panel service check Controller board removal On page 4-55. DoesRIP board Removal on On page 4-70. If Assembly Output tray full service checkSee Paper exit Board removal See Paper exit9 to output tray full Paper size sensing service check Left tray guide Operator Printer no power service check4-60for Board cage removal onToner feed service check Developer Retract solenoid Drive assembly Cam Removal onSee Developer Motor removal On page 4-70. Does error See Engine Toner low/empty service checkSensor sender 4-35andHvps cage Transfer roller missing service check4-62and Registration5021-0XX Tray empty service check Assembly removal on Paper guide On page 4-70. If Paper guideSee Paper guide C Waste toner Waste toner bottle service checkBottle holder Bottle holder removal onWaste toner feed service check Paper feed service checks Printer paper feed service checkRegistration assembly removal on 5021-0XX Background service check Print quality service checksBackground is smeared due to toner spread Photodeveloper cartridgeBackside of paper is stained Back stain service checkBanding service check Banding line appears in horizontal directionSee Photodeveloper cartridge Fine black line appears in printer image Black line service checkColor misregistration between two colors Color misregistration service checkTransfer belt unit removal on Printed image is partially missing Insufficient fusing service checkGloss on paper is not sufficient Insufficient gloss service checkMain motor assembly removal on Jitter service checkAssembly. See Developer drive Cartridge removal onImage has missing or peeling toner at edge Missing image at edge service checkMixed color image appears Mixed color image service checkClutch removal on Toner retract solenoid and camVoltage power supply Hvps Mottle service checkVariation of optical density is found in image See Transfer roller removal onResidual image service check See Transfer belt cleaning rollerImage of preceding page appears on every other Light print occurs in right or left side of image Ribbing service checkSolenoid and cam removal on Auger removal on Toner drop service checkWaste toner feeder removal on Removal on page 4-6 . Prior toToner cartridge Replace faulty toner cartridge Vertical line appears in printed image Vertical line service checkVertical staggering image service check Laser unit assembly printheadPrinted image staggers in vertical direction White band appears in vertical direction of printed image Vertical white band service checkHorizontal white banding creates missing portion of image White band service checkTransfer roller removal on See Clutch removal onPrint quality test pages on White line I service checkWhite line II service check White spot / black spot service check White spot and black spot appear on paperBelt unit see Transfer belt unit Reinstall. See Transfer roller White print service checkRemoval 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 Spacing table Roller specifications5021-0XX Disabling download emulations Select the Disable OptionGo to Paper jam messages on page 2-22for more information Paper jam sequence5021-0XX Paper Jam Diagnostic mode Diagnostics menu structure Print quality test pagesPrint Quality Description Setting tray 2 left margin Print registrationSelect Registration Select Left Margin Adj Print tests Setting top marginSelect Registration Select Top Margin MenuHardware tests Select Single or ContinuousFollowing hardware tests can be selected from this menu LCD test Button testParallel wrap test ROM memory test Serial wrap test Dram memory testTransmit Data Interrupt Error Duplex tests Duplex left marginSelect Duplex Test Select Duplex Left Margin Disk test/clean Device testsQuick disk test Flash test Setting the page count Printer setupViewing the permanent page count Select either Color Page Counts or Mono Page CountsSerial number Setting configuration IDParallel strobe adjustment Error log Viewing the error logPrinting the error log Restore EP factory defaults Clearing the error logExiting diagnostic mode 5021-0XX Repair information Removal and cleaning precautionsHandling the printed circuit boards with MOS ICs During replacementDuring transportation/storage During inspectionPhotodeveloper cartridge HandlingParts not to be touched Precautions to take before maintenance work Printer removal proceduresCRU/FRU and supplies removals Transfer belt cleaning roller removal Cleaning roller cover removalTransfer belt unit removal Transfer roller removal Fuser assembly removal Open front cover Remove waste toner bottle Waste toner bottle removalPhotodeveloper 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 Right cover removal Rear cover assembly removal5021-0XX Left cover removal Laser unit assembly printhead removal5021-0XX Laser unit fan assembly removal Erase lamp removal 5021-0XX Right side removals Front door interlock switch removal5021-0XX Developer motor removal Front door interlock switch with bracketWaste toner bottle holder removal Developer drive assembly removal5021-0XX 5021-0XX Toner sensor sender removal Cleaning roller clutch removal 5021-0XX Main motor assembly removal 5021-0XX Clutch removal Remove fuser clutch. See Clutch removal on Main drive gear assembly removalWaste toner feeder removal Remove main drive gear assembly from printer5021-0XX Rear removals RIP board removal Bracket assembly removalPaper 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 removalLeft side removals Remove left cover. See Left cover removal on Operator panel cable removalEngine controller board removal 5021-0XX RIP board cage removal Remove ducting Disconnect all connectors from Hvps Repair information High voltage power supply Hvps removalLow voltage power supply Lvps with cage removal 5021-0XX Hvps cage removal Remove HVPS. See High voltage power supply Hvps removal onRemove four screws C remove Hvps cage Toner present sensor removalToner retract solenoid and cam removal Toner sensor receiver 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 Printer Locations and connectorsPart name Description Options Sensor locations Electronic componentsTNK Name Function Printer circuit board locationsFan/motor locations Interlock switch locations Fbcl Solenoid/clutch locationsToner retract Symbol Part name Symbol and part name tableLDU 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 cables5021-0XX OAD1 OAD2 Sgnd DCN3 Engine controller board I2CN-I/O board DCN35021-0XX Engine controller board HVCN-HVPS CN1 Hvcn Engine controller board P2CN-Operator panel Board DCN13-LVPS ACN1 Lvps ACN2-Interlock switches Board DCN18-Interlock switchesInterlock switches-Interlock switches Lvps ACN5-Engine controller board Lvcn Lvps ACN5-Engine controller board DCN21No connection ACN3 Engine controller board POCN-LVPS ACN3DCN4 Board DCN4-Toner retract solenoids5021-0XX Board DCN5-Photodeveloper OPC marker sensor Board DCN8-Laser fanBoard DCN15-Toner present sensor, erase lamp Tleschk Sgnd DCN16 Board DCN16-SensorsDCN7 Board DCN7-Rear cover assemblyHtfanerr DCN10 DCLCON-N Board DCN12-Main motor 5021-0XX Board DCN11-Developer motorMmenc MMREV-N Mmgain Mmovld LDU Engine board LCN-Printhead LDUSgnd SCMRDY-N Scmclk Pgnd SCMON-N DCN14 Board DCN14-Lower feeder unitLFCN-CHK-N DCN19 Board DCN19-Paper size sensor and temperature thermistorFuser connector-LVPS 240V Printer Fuser connector-LVPS 120V PrinterEngine controller board FUCN-fuser 5021-0XX Engine controller board DPCN-Duplex unit Dupl Lvps ACN4-Duplex unit Dupl and duplex powerDuplex Preventive maintenance 5021-0XX Parts catalog How to use this parts catalogAssembly 1 Base printer Index Units Description Assembly 1 Base printerAssembly 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/OptionsAssembly 9 Miscellaneous/Options Index Paper transportation system 5021-0XX 5021-0XX Part number index 5021-0XX 5021-0XX 5021-0XX