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Lexmark 5021-0XX manual

Models: 5021-0XX

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5021-0XX

No.	Description

8F-lens: laser beam focus lens

9Mirror: laser beam path reflecting mirror

General information 1-41

Image 67

Lexmark 5021-0XX manual

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 Model differences SpecificationsResolution Technical specificationsWidth Depth Height Weight4 Inch Printers Physical specifications and weightOperating clearances Packaging and shipping dimensions500 MHz General information Print speed and performanceTime to first print ProcessorDuty cycle Paper and media specificationsPrinter memory Sources and capacities C510/C510n C510dtn 5021-0XX Input and output configurations5021-0XX Media input types and weights JIS B53 Media sizesEnvelopes Output capacity by media and sourceMedia guidelines PaperLabels TransparenciesGlossy Paper Connections ConnectivityCables Personal computers IBM AS/400Power and electrical specifications Environment Environment SpecificationsPrinter 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 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 type Interface controlInterface connection 5021-0XX Start Diagnostic informationService error codes Go to 913-Fuser fan service check on Go to 910-Developer motor service check onGo to 911-Main motor service check on Go to 912-Power supply fan service check onRIP board. Go to RIP board removal on Go to 920-Fuser thermistor service check onGo to 921,922,923,924,925-Fuser assembly Go to 930,931,932-Laser unit assembly serviceBoard removal on Controller board removal onPanel cable removal on To RIP board removal onDownload emulations on Go to 986-Duplex connection error 2 service Go to 985-Duplex connection error 1 serviceGo to 993-Fuser clutch service check on Go to 990-Transfer belt unit service check onGo to 991-Transfer roller clutch service check Go to 992-Transfer belt cleaning roller clutchCover open service check Paper size sensing serviceOperator messages 5021-0XX Performing Self Test TMA Go to Output tray fullTo Paper size sensing Empty service check onCartridge service check on To Incorrect media service5021-0XX Insufficient Memory and Held Memory may be defective 5021-0XX Configuration Change Waste toner bottle service Missing service check onRemoval on Assembly removal onFuser assembly removal Engine controller boardGo to Toner low/empty Paper jam messages Engine controller board removal Paper guide C assemblyPaper exit assembly removal on Board. See I/O board removalFeed assembly removal on See Duplex unit assemblyProblem, see Paper feed service Assembly. See Secondary paperPrinter symptom table Symptom tablesSee Service error codes on See White band service checkSee Printer no power service See Waste toner feed servicePrint quality symptom table See Back stain service check on See Mottle service check onSee Residual image service See Insufficient gloss serviceYellow 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 4-32. Go Developer motor service checkSee Developer Motor removalOn page 4-70for steps to Switch locations on4-57. Go Board cageSee Engine Fuser Main motor service checkMain motor Assembly4-38. Go Board removal Fan removal on Power supply fan service checkPower supply Interlock switchLocations on Removal on Fuser fan service checkInterlock switch Cover assembly See RearInterlock 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 Receiver Toner empty sensor receiver-TTR service checkSee Engine controller Toner sensorHvps connection service check Right cover removal on Lower feed unit secondary paper assembly service checkSee Fuser assembly Fuser thermistor service checkRemoval on See Engine 921,922,923,924,925-Fuser assembly service check Removal on 4-24. Go 930,931,932-Laser unit assembly service checkLaser unit PrintheadDuplex connection error 1 service check Duplex connection error 2 service check Bracket Transfer belt unit service checkTransfer belt Unit removalFor 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 Right cover removal on Clutch Fuser clutch service check4-69. If OPC belt marker sensor service checkRemoval on page 4-70for Marker sensorFor 5 VDC from pin 11 to Replace faulty Photodeveloper Cartridge removal On page 4-11 . Has High voltage power supply Hvps service checkPhotodevelop Er cartridgeHigh 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 With cage Removal on Paper guideHigh voltage Power supply Missing photodeveloper cartridge service checkPhotodevelop Er cartridge Present sensor Missing toner cartridge service checkOn page 4-70. If Present sensor Board removal See TonerSee Main See Main drive OPC belt photodeveloper cartridge drive service checkMotor Gear assembly Assembly Removal on Photodevelop Er cartridge Removal onController board removal On page 4-55. Does Operator panel service checkRIP board Removal on Board removal See Paper exit Output tray full service checkOn page 4-70. If Assembly 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 onDeveloper Retract solenoid Drive assembly Cam Removal on Toner feed service checkSee Developer Motor removal 4-35and Toner low/empty service checkOn page 4-70. Does error See Engine Sensor senderRegistration Transfer roller missing service checkHvps cage 4-62and5021-0XX Tray empty service check On page 4-70. If Paper guide Assembly removal on Paper guideSee Paper guide C Bottle holder removal on Waste toner bottle service checkWaste toner Bottle holderWaste toner feed service check Printer paper feed service check Paper feed service checksRegistration assembly removal on 5021-0XX Photodeveloper cartridge Print quality service checksBackground service check Background is smeared due to toner spreadBackside of paper is stained Back stain service checkBanding line appears in horizontal direction Banding service checkSee 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 checkCartridge removal on Jitter service checkMain motor assembly removal on Assembly. See Developer driveImage has missing or peeling toner at edge Missing image at edge service checkToner retract solenoid and cam Mixed color image service checkMixed color image appears Clutch removal onSee Transfer roller removal on Mottle service checkVoltage power supply Hvps Variation of optical density is found in imageSee Transfer belt cleaning roller Residual image service checkImage of preceding page appears on every other Light print occurs in right or left side of image Ribbing service checkSolenoid and cam removal on Removal on page 4-6 . Prior to Toner drop service checkAuger removal on Waste toner feeder removal onToner cartridge Replace faulty toner cartridge Vertical line appears in printed image Vertical line service checkLaser unit assembly printhead Vertical staggering image service checkPrinted image staggers in vertical direction White band appears in vertical direction of printed image Vertical white band service checkSee Clutch removal on White band service checkHorizontal white banding creates missing portion of image Transfer roller removal onPrint quality test pages on White line I service checkWhite line II service check White spot and black spot appear on paper White spot / black spot service checkBelt unit see Transfer belt unit System. See Toner retract solenoid White print service checkReinstall. See Transfer roller Removal on page 4-8 . EnsureWrinkle / 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 Print quality test pages Diagnostics menu structurePrint Quality Description Print registration Setting tray 2 left marginSelect Registration Select Left Margin Adj Menu Setting top marginPrint tests Select Registration Select Top MarginSelect Single or Continuous Hardware testsFollowing hardware tests can be selected from this menu Button test LCD testParallel wrap test ROM memory test Serial wrap test Dram memory testTransmit Data Interrupt Error Duplex left margin Duplex testsSelect Duplex Test Select Duplex Left Margin Device tests Disk test/cleanQuick disk test Flash test Select either Color Page Counts or Mono Page Counts Printer setupSetting the page count Viewing the permanent page countSerial number Setting configuration IDParallel strobe adjustment Viewing the error log Error logPrinting the error log Restore EP factory defaults Clearing the error logExiting diagnostic mode 5021-0XX Repair information Removal and cleaning precautionsDuring inspection During replacementHandling the printed circuit boards with MOS ICs During transportation/storageHandling Photodeveloper cartridgeParts 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 Board DCN18-Interlock switches Lvps ACN2-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 solenoidsBoard DCN8-Laser fan 5021-0XX Board DCN5-Photodeveloper OPC marker sensorBoard 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