Lexmark 5021-0XX User Manual

Revised March 24, 2006

Lexmark C510

• Table of Contents

•Start Diagnostics

5021-0XX

• Safety and Notices

• Trademarks

•Index

Lexmark and Lexmark with diamond
design are trademarks of Lexmark
International, Inc., registered in the
United States and/or other countries.

5021-0XX

Edition: March 24, 2006
The following paragraph does not apply to any country where such provisions are

inconsistent with local law: LEXMARK INTERNATIONAL, INC. PROVIDES THIS

PUBLICATION “AS IS” WITHOUT WARRANTY OF ANY KIND, EITHER EXPRESS OR
IMPLIED, INCLUDING, BUT NOT LIMITED TO, THE IMPLIED WARRANTIES OF
MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. Some states do
not allow disclaimer of express or implied warranties in certain transactions; therefore,
this statement may not apply to you.

This publication could include technical inaccuracies or typographical errors. Changes
are periodically made to the information herein; these changes will be incorporated in
later editions. Improvements or changes in the products or the programs described may
be made at any time.

Comments may be addressed to Lexmark International, Inc., Department D22A/032-2,
740 West New Circle Road, Lexington, Kentucky 40550, U.S.A or electronically mailed
(e-mail) to [e-mail]. Lexmark may use or distribute any of
the information you supply in any way it believes appropriate without incurring any
obligation to you.

Lexmark and Lexmark with diamond design are trademarks of Lexmark International,
Inc., registered in the United States and/or other countries.

ImageQuick, Optra Forms, and PrintCryption are trademarks of Lexmark International,
Inc.

PCL® is a registered trademark of the Hewlett-Packard Company.
PostScript® is a registered trademark of Adobe Systems Incorporated.
Other trademarks are the property of their respective owners.

© 2004 Lexmark International, Inc.
All rights reserved.

UNITED STATES GOVERNMENT RIGHTS

This software and any accompanying documentation provided under this agreement are
commercial computer software and documentation developed exclusively at private
expense.

P/N 12G9320

5021-0XX

Table of contents

Laser notices. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xi

Safety information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xxi

Preface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xxvi

Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xxvi

General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

Maintenance approach . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

Tools required for service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

Serial number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

Acronyms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

Resolution. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

Model differences . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

Technical specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

Physical specifications and weight . . . . . . . . . . . . . . . . . . . . . 1-5

Operating clearances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6

Packaging and shipping dimension s. . . . . . . . . . . . . . . . . . . . 1-6

Print speed and performance . . . . . . . . . . . . . . . . . . . . . . . . . 1-7

Time to first print . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7

Duty cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8

Printer memory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8

Paper and media specifications . . . . . . . . . . . . . . . . . . . . . . . 1-8

Media sizes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11

Output capacity by media and source. . . . . . . . . . . . . . . . . . 1-12

Media guidelines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12

Connectivity. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14

Power and electrical specifications. . . . . . . . . . . . . . . . . . . . 1-15

Environment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-16

Printer identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-17

Options identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-18

Printer theory of operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-19

Printer paper path . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-20

Printer systems description . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-21

Basic principles of color printing . . . . . . . . . . . . . . . . . . . . . . 1-21

Mechanical and electrical structures. . . . . . . . . . . . . . . . . . . 1-21

Printer component systems . . . . . . . . . . . . . . . . . . . . . . . . . 1-23

Basic process of color printing . . . . . . . . . . . . . . . . . . . . . . . 1-24

Print system and transfer system . . . . . . . . . . . . . . . . . . . . . 1-25

Structure of OPC belt (photo developer cartridge) . . . . . . . . 1-26

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5021-0XX

Basic structure of the print system. . . . . . . . . . . . . . . . . . . . .1-27

Details of the print system . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-29

Charging process. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-29

Exposing process. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-31

Developing process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-32

First transfer (drum) process . . . . . . . . . . . . . . . . . . . . . . . . .1-34

Belt discharge (erase lamp) process . . . . . . . . . . . . . . . . . . .1-35

Belt cleaning process. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-36

Details of the transfer system . . . . . . . . . . . . . . . . . . . . . . . . . . .1-38

Second transfer (paper) process . . . . . . . . . . . . . . . . . . . . . .1-38

Transfer belt cleaning process. . . . . . . . . . . . . . . . . . . . . . . .1-39

Details of the optical system . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-40

Details of the paper transportation system . . . . . . . . . . . . . . . . .1-42

Fusing unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-44

Fusing process. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-46

Control system structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-47

Electrical system and function . . . . . . . . . . . . . . . . . . . . . . . .1-47

Control of print process . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-48

Print sequence diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-49

Laser drive control circuit. . . . . . . . . . . . . . . . . . . . . . . . . . . .1-50

Interface control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-51

Diagnostic information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1

Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1

Service error codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-2

Operator messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-9

Paper jam messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-22

Symptom tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-25

Printer symptom table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-25

Print quality symptom table . . . . . . . . . . . . . . . . . . . . . . . . . .2-27

Printer service checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-29

901—Yellow developer clutch service check. . . . . . . . . . . . .2-29

902—Magenta developer clutch service check . . . . . . . . . . .2-31

903—Cyan developer clutch service check . . . . . . . . . . . . .2-33

904—Black developer clutch service check . . . . . . . . . . . . .2-35

905—Yellow toner retract solenoid service check . . . . . . . . .2-37

906—Magenta toner retract solenoid service check . . . . . . .2-39

907—Cyan toner retract solenoid service check . . . . . . . . . .2-41

908—Black toner retract solenoid service check. . . . . . . . . .2-43

910—Developer motor service check . . . . . . . . . . . . . . . . . .2-45

911—Main motor service check. . . . . . . . . . . . . . . . . . . . . . .2-48

912—Power supply fan service check . . . . . . . . . . . . . . . . . .2-51

913—Fuser fan service check . . . . . . . . . . . . . . . . . . . . . . . .2-52

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5021-0XX

914—Laser fan service check. . . . . . . . . . . . . . . . . . . . . . . . 2-53

915—Erase lamp service check . . . . . . . . . . . . . . . . . . . . . . 2-54

916—Toner empty sensor (sender-TPD) service check. . . . 2-56

917—Toner empty sensor (receiver-TTR) service check. . . 2-57

918—HVPS connection service check . . . . . . . . . . . . . . . . . 2-58

919—Lower feed unit (secondary paper assembly) service check

2-59

920—Fuser thermistor service check . . . . . . . . . . . . . . . . . . 2-60

921,922,923,924,925—Fuser assembly service check . . . . 2-61

930,931,932—Laser unit assembly service check . . . . . . . . 2-62

985—Duplex connection error 1 service check. . . . . . . . . . . 2-63

986—Duplex connection error 2 service check. . . . . . . . . . . 2-64

990—Transfer belt unit service check. . . . . . . . . . . . . . . . . . 2-65

991—Transfer roller clutch service check. . . . . . . . . . . . . . . 2-67

992—Transfer belt cleaning roller clutch service check . . . . 2-68

993—Fuser clutch service check . . . . . . . . . . . . . . . . . . . . . 2-69

994—OPC belt marker sensor service check. . . . . . . . . . . . 2-70

995—High voltage power supply (HVPS) service check . . . 2-72

996—Low voltage power supply (LVPS) service check . . . . 2-74

Cover open service check. . . . . . . . . . . . . . . . . . . . . . . . . . . 2-75

Incorrect media service check. . . . . . . . . . . . . . . . . . . . . . . . 2-78

Missing photodeveloper cartridge service check . . . . . . . . . 2-80

Missing toner cartridge service check. . . . . . . . . . . . . . . . . . 2-81

OPC belt (photodeveloper) cartridge dr iv e service check . . 2-83

Operator panel service check . . . . . . . . . . . . . . . . . . . . . . . . 2-84

Output tray full service check . . . . . . . . . . . . . . . . . . . . . . . . 2-85

Paper size sensing service check. . . . . . . . . . . . . . . . . . . . . 2-87

Printer no power service check. . . . . . . . . . . . . . . . . . . . . . . 2-89

Toner feed service check . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-91

Toner low/empty service check. . . . . . . . . . . . . . . . . . . . . . . 2-92

Transfer roller missing service check . . . . . . . . . . . . . . . . . . 2-93

Tray empty service check . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-95

Waste toner bottle service check . . . . . . . . . . . . . . . . . . . . . 2-97

Waste toner feed service check . . . . . . . . . . . . . . . . . . . . . . 2-98

Paper feed service checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-99

Printer paper feed service check . . . . . . . . . . . . . . . . . . . . . 2-99

Print quality service checks . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-101

Background service check . . . . . . . . . . . . . . . . . . . . . . . . . 2-101

Back stain service check . . . . . . . . . . . . . . . . . . . . . . . . . . 2-102

Banding service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-103

Black line service check . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-104

Color misregistration service check . . . . . . . . . . . . . . . . . . 2-105

Insufficient fusing service check . . . . . . . . . . . . . . . . . . . . . 2-107

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5021-0XX

Insufficient gloss service check . . . . . . . . . . . . . . . . . . . . . .2-108

Jitter service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-109

Missing image at edge service check . . . . . . . . . . . . . . . . .2-110

Mixed color image service check . . . . . . . . . . . . . . . . . . . .2-111

Mottle service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-112

Residual image service check . . . . . . . . . . . . . . . . . . . . . . .2-113

Ribbing service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-114

Toner drop service check . . . . . . . . . . . . . . . . . . . . . . . . . .2-116

Vertical line service check . . . . . . . . . . . . . . . . . . . . . . . . . .2-118

Vertical staggering image service check . . . . . . . . . . . . . . .2-119

Vertical white band service check . . . . . . . . . . . . . . . . . . . .2-120

White band service check . . . . . . . . . . . . . . . . . . . . . . . . . .2-121

White line I service check . . . . . . . . . . . . . . . . . . . . . . . . . .2-122

White line II service check . . . . . . . . . . . . . . . . . . . . . . . . . .2-123

White spot / black spot service check . . . . . . . . . . . . . . . . .2-124

White print service check . . . . . . . . . . . . . . . . . . . . . . . . . .2-125

Wrinkle / image migration service check . . . . . . . . . . . . . . .2-126

Uneven density (right and left). . . . . . . . . . . . . . . . . . . . . . .2-127

Spacing table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-129

Roller specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-129

Diagnostic aids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1

Disabling download emulations . . . . . . . . . . . . . . . . . . . . . . . . . .3-1

Paper jam sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-2

Diagnostic mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-4

Diagnostics menu structure . . . . . . . . . . . . . . . . . . . . . . . . . . .3-5

Print quality test pages. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-5

Print registration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-6

Setting tray 2 left margin . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-6

Setting top margin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-7

Print tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-7

Hardware tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-8

LCD test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-9

Button test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-9

Parallel wrap test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-9

ROM memory test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-10

DRAM memory test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-11

Serial wrap test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-11

Duplex tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-13

Duplex left margin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-13

Device tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-14

Quick disk test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-14

Disk test/clean . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-14

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5021-0XX

Flash test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15

Printer setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16

Setting the page count . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16

Viewing the permanent page count. . . . . . . . . . . . . . . . . . . . 3-16

Serial number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17

Setting configuration ID. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17

Parallel strobe adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18

Error log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19

Viewing the error log. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19

Printing the error log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19

Clearing the error log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20

Restore EP factory defaults . . . . . . . . . . . . . . . . . . . . . . . . . 3-20

Exiting diagnostic mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21

Repair information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

Removal and cleaning precautions . . . . . . . . . . . . . . . . . . . . . . . 4-1

Handling the printed circuit boards with

MOS ICs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

During transportation/storage:. . . . . . . . . . . . . . . . . . . . . . . . . 4-2

During replacement: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

During inspection:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

Photodeveloper cartridge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3

During transportation/storage . . . . . . . . . . . . . . . . . . . . . . . . . 4-3

Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3

Parts not to be touched. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3

Printer removal procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4

Precautions to take before maintenance work . . . . . . . . . . . . 4-4

CRU/FRU and supplies removals . . . . . . . . . . . . . . . . . . . . . . . . 4-5

Cleaning roller cover removal. . . . . . . . . . . . . . . . . . . . . . . . . 4-6

Transfer belt cleaning roller removal. . . . . . . . . . . . . . . . . . . . 4-6

Transfer belt unit removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7

Transfer roller removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8

Fuser assembly removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9

Waste toner bottle removal. . . . . . . . . . . . . . . . . . . . . . . . . . 4-10

Photodeveloper cartridge removal . . . . . . . . . . . . . . . . . . . . 4-11

Duplex unit assembly removal . . . . . . . . . . . . . . . . . . . . . . . 4-13

Secondary paper feed assembly removal. . . . . . . . . . . . . . . 4-16

Cover removals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17

Top cover assembly removal . . . . . . . . . . . . . . . . . . . . . . . . 4-18

Front cover assembly removal . . . . . . . . . . . . . . . . . . . . . . . 4-19

Right cover removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-22

Rear cover assembly removal. . . . . . . . . . . . . . . . . . . . . . . . 4-22

Left cover removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-24

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5021-0XX

Laser unit assembly (printhead) removal. . . . . . . . . . . . . . . .4-24

Laser unit fan assembly removal . . . . . . . . . . . . . . . . . . . . . .4-26

Erase lamp removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-27

Right side removals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-29

Front door interlock switch removal . . . . . . . . . . . . . . . . . . . .4-29

Front door interlock switch with bracket. . . . . . . . . . . . . . . . .4-31

Developer motor removal. . . . . . . . . . . . . . . . . . . . . . . . . . . .4-31

Waste toner bottle holder removal . . . . . . . . . . . . . . . . . . . . .4-32

Developer drive assembly removal . . . . . . . . . . . . . . . . . . . .4-32

Toner sensor (sender) removal . . . . . . . . . . . . . . . . . . . . . . .4-35

Cleaning roller clutch removal . . . . . . . . . . . . . . . . . . . . . . . .4-36

Main motor assembly removal . . . . . . . . . . . . . . . . . . . . . . . .4-38

Clutch removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-40

Main drive gear assembly removal. . . . . . . . . . . . . . . . . . . . .4-41

Waste toner feeder removal. . . . . . . . . . . . . . . . . . . . . . . . . .4-42

Rear removals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-44

RIP board removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-45

Bracket assembly removal. . . . . . . . . . . . . . . . . . . . . . . . . . .4-45

Paper guide assembly removal . . . . . . . . . . . . . . . . . . . . . . .4-46

Paper guide (C) assembly removal . . . . . . . . . . . . . . . . . . . .4-47

Paper feed roller removal. . . . . . . . . . . . . . . . . . . . . . . . . . . .4-48

Paper exit assembly removal. . . . . . . . . . . . . . . . . . . . . . . . .4-49

Registration assembly removal . . . . . . . . . . . . . . . . . . . . . . .4-52

Left side removals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-53

Operator panel cable removal . . . . . . . . . . . . . . . . . . . . . . . .4-54

Engine controller board removal . . . . . . . . . . . . . . . . . . . . . .4-55

RIP board cage removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-57

High voltage power supply (HVPS) removal . . . . . . . . . . . . .4-59

Low voltage power supply (LVPS) with cage removal . . . . . .4-60

HVPS cage removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-62

Toner present sensor remov al . . . . . . . . . . . . . . . . . . . . . . . .4-63

Toner sensor (receiver) removal . . . . . . . . . . . . . . . . . . . . . .4-64

Toner retract solenoid and cam removal . . . . . . . . . . . . . . . .4-64

Left tray guide assembly removal. . . . . . . . . . . . . . . . . . . . . .4-65

Top removals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-68

Marker sensor assembly removal . . . . . . . . . . . . . . . . . . . . .4-69

I/O board removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-70

Waste toner auger removal . . . . . . . . . . . . . . . . . . . . . . . . . .4-72

Waste toner agitator removal . . . . . . . . . . . . . . . . . . . . . . . . .4-73

Power supply fan removal . . . . . . . . . . . . . . . . . . . . . . . . . . .4-74

viii Service Manual

5021-0XX

Locations and connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3

Electronic components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4

Sensor locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4

Printer circuit board locations . . . . . . . . . . . . . . . . . . . . . . . . . 5-6

Fan/motor locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7

Interlock switch locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8

Solenoid/clutch locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9

Symbol and part name table . . . . . . . . . . . . . . . . . . . . . . . . 5-11

Wiring diagram / cable harness reference . . . . . . . . . . . . . . 5-14

RIP board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15

Engine controller board . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16

Input/output (I/O) board . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-17

Low voltage power supply (LVPS) board . . . . . . . . . . . . . . . 5-18

High voltage power supply (HVPS) board. . . . . . . . . . . . . . . 5-18

Printer cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-19

Cable 1 connector assignments . . . . . . . . . . . . . . . . . . . . . . 5-19

Cable 1 connector pin assignments . . . . . . . . . . . . . . . . . . . 5-19

Cable 2 connector assignments . . . . . . . . . . . . . . . . . . . . . . 5-22

Cable 2 connector pin assignments . . . . . . . . . . . . . . . . . . . 5-22

Cable 3 connector assignments . . . . . . . . . . . . . . . . . . . . . . 5-24

Cable 3 connector pin assignments . . . . . . . . . . . . . . . . . . . 5-24

Cable 4 connector assignments . . . . . . . . . . . . . . . . . . . . . . 5-26

Cable 5 connector assignments . . . . . . . . . . . . . . . . . . . . . . 5-27

Cable 6 connector assignments . . . . . . . . . . . . . . . . . . . . . . 5-32

Cable 6 connector pin assignments . . . . . . . . . . . . . . . . . . . 5-32

Cable 7 connector assignments . . . . . . . . . . . . . . . . . . . . . . 5-36

Cable 7 connector pin assignments . . . . . . . . . . . . . . . . . . . 5-36

Cable 9 connector assignments . . . . . . . . . . . . . . . . . . . . . . 5-42

Cable 9 connector pin assignments . . . . . . . . . . . . . . . . . . . 5-42

Cable 10 connector assignments . . . . . . . . . . . . . . . . . . . . . 5-44

Cable 10 connector pin assignments . . . . . . . . . . . . . . . . . . 5-44

Cable 11 connector assignments . . . . . . . . . . . . . . . . . . . . . 5-46

Cable 11 connector pin assignments . . . . . . . . . . . . . . . . . . 5-46

Cable 12 connector assignments . . . . . . . . . . . . . . . . . . . . . 5-47

Cable 12 connector pin assignments . . . . . . . . . . . . . . . . . . 5-47

Cable 13 connector assignments . . . . . . . . . . . . . . . . . . . . . 5-48

Cable 13 connector pin assignments . . . . . . . . . . . . . . . . . . 5-48

ix

5021-0XX

Preventive maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-1

Parts catalog . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-1

How to use this parts catalog . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-1

Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I-1

Part number index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I-5

x Service Manual

Laser notices

The following laser notice labels may be affixed to this printer as
shown:

Laser advisory label

5021-0XX

Laser notices xi

5021-0XX

Class 1 Laser statement label

xii Service Manual

5021-0XX

Laser notice

The printer is certified in the U.S. to conform to the requirements of
DHHS 21 CFR Subchapter J for Class I (1) laser products, and
elsewhere is certified as a Class I laser product conforming to the
requirements of IEC 60825-1.

Class I laser products are not considered to be hazardous. The
printer contains internally a Class IIIb (3b) laser that is nominally a 5
milliwatt gallium arsenide laser operating in the wa velength region of
770-795 nanometers. The laser system and printer are designed so
there is never any human access to laser radiation above a Class I
level during normal operation, user maint enance, or prescribed
service condition.

Laser

Der Drucker erfüllt gemäß amtlicher Bestätigung der USA die
Anforderungen der Bestimmung DHHS (Department of Health and
Human Services) 21 CFR Teil J für Laserprodukte der Klasse I (1).
In anderen Ländern gilt der Drucker als Laserprodukt der Klasse I,
der die Anforderungen der IEC (International Electrotechnical
Commission) 60825-1 gemäß amtlicher Bestätigung erfüllt.

Laserprodukte der Klasse I gelten als unschädlich. Im Inneren des
Druckers befindet sich ein Laser der Klasse IIIb (3b), bei dem es
sich um einen Galliumarsenlaser mit 5 Milliwatt handelt, der Wellen
der Länge 770-795 Nanometer ausstr ahlt. Das Lasersystem und der
Drucker sind so konzipiert, daß im Normalbetrieb, bei der Wartung
durch den Benutzer oder bei ordnungsgemäßer Wartung durch den
Kundendienst Laserbestr ahlung, die die Klasse I übersteigen würde,
Menschen keinesfalls erreicht.

Laser notices xiii

5021-0XX

Avis relatif à l’utilisation de laser

Pour les Etats-Unis : cette imprimante est certifiée conforme aux
provisions DHHS 21 CFR alinéa J concernant les produits laser de
Classe I (1). Pour les autres pays : cette imprimante répond aux
normes IEC 60825-1 relatives aux produits laser de Classe I.

Les produits laser de Classe I sont considérés comme des produits
non dangereux. Cette imprimante est équipée d’un laser de Classe
IIIb (3b) (arséniure de gallium d’une puissance nominale de 5
milliwatts) émettant sur des longueurs d’onde comprises entre 770
et 795 nanomètres. L’imprimante et son système laser sont conçus
pour impossible, dans des conditions normales d’utilisation,
d’entretien par l’utilisateur ou de révision, l’exposition à des
rayonnements laser supérieurs à des rayonnements de Classe I .

Avvertenze sui prodotti laser

Questa stampante è certificata negli Stati Uniti per essere conforme
ai requisiti del DHHS 21 CFR Sottocapitolo J per i prodotti laser di
classe 1 ed è certificata negli altri Paesi come prodotto laser di
classe 1 conforme ai requisiti della norma CEI 60825-1.

I prodotti laser di classe non sono considerati pericolosi. La
stampante contiene al suo interno un laser di classe IIIb (3b)
all’arseniuro di gallio della potenza di 5mW che opera sulla
lunghezza d’onda compresa tra 770 e 795 nanometri. Il sistema
laser e la stampante sono stati progettati in modo tale che le
persone a contatto con la stampante, durante il normale
funzionamento, le operazioni di servizio o quelle di assistenza
tecnica, non ricevano radiazioni laser superiori al livello della classe

1.

xiv Service Manual

5021-0XX

Avisos sobre el láser

Se certifica que, en los EE.UU., esta impresora cumple los
requisitos para los productos láser de Clase I (1) establecidos en el
subcapítulo J de la norma CFR 21 del DHHS (Departamento de
Sanidad y Servicios) y, en los demás países, reúne todas las
condiciones expuestas en la norma IEC 60825-1 para pr oductos
láser de Clase I (1).

Los productos láser de Clase I no se consideran peligrosos. La
impresora contiene en su interior un láser de Clase IIIb (3b) de
arseniuro de galio de funcionamiento nominal a 5 milivatios en una
longitud de onda de 770 a 795 nanómetros. El sistema láser y la
impresora están diseñados de forma que ninguna persona pueda
verse af ectada por ning ún tipo de radiaci ón láser superior al nivel de
la Clase I durante su uso normal, el mantenimiento realizado por el
usuario o cualquier otra situación de servicio técnico.

Declaração sobre Laser
A impressora está certificada nos E.U.A. em conformidade com os

requisitos da regulamentação DHHS 21 CFR Subcapítulo J para a
Classe I (1) de produtos laser. Em outros locais, está certificada
como um produto laser da Classe I, em conformidade com os
requisitos da norma IEC 60825-1.

Os produtos laser da Classe I não são considerados perigosos.
Internamente, a impressora contém um pr oduto laser da Classe IIIb
(3b), designado laser de arseneto de potássio, de 5 milliwatts
,operando numa faixa de comprimento de onda entre 770 e 795
nanómetros. O sistema e a impressora laser foram concebidos de
forma a nunca existir qualquer possiblidade de acesso humano a
radiação laser superior a um nível de Classe I durante a operação
normal, a manutenção feita pelo utilizador ou condições de
assistência prescritas.

Laser notices xv

5021-0XX

Laserinformatie

De printer voldoet aan de eisen die gesteld worden aan een
laserprodukt van klasse I. Voor de Verenigde Staten zijn deze eisen
vastgelegd in DHHS 21 CFR Subchapter J, voor andere landen in
IEC 60825-1.

Laserprodukten van klasse I worden niet als ongevaarlijk
aangemerkt. De printer is voorzien van een la ser van klasse IIIb
(3b), dat wil zeggen een gallium arsenide-laser van 5 milliwatt met
een golflengte van 770-795 nanometer. Het lasergedeelte en de
printer zijn zo ontworpen dat bij normaal gebruik, bij onderhoud of
reparatie conform de voorschriften, nooit blootstelling mogelijk is
aan laserstraling boven een niveau zoals voorgeschreven is voor
klasse 1.

Lasermeddelelse

Printeren er godkendt som et Klasse I-laserprodukt, i
overenstemmelse med kravene i IEC 60825-1.

Klasse I-laserprodukter betragtes ikke som farlige. Printeren
indeholder internt en Klasse IIIB (3b)-laser, der nominelt er en 5
milliwatt galliumarsenid laser, som arbejder på bølgelængdeområdet
770-795 nanometer. Lasersystemet og printeren er udformet
således, at mennesker aldrig udsættes f or en laserstråling over
Klasse I-niveau ved normal drift, brugervedligeholdelse eller
obligatoriske servicebetingelser.

xvi Service Manual

5021-0XX

Huomautus laserlaitteesta

Tämä kirjoitin on Yhdysvalloissa luokan I (1) laserlaitteiden DHHS
21 CFR Subchapter J -määrityksen mukainen ja muualla luokan I
laserlaitteiden IEC 60825-1 -määrityksen mukainen.

Luokan I laserlaitteiden ei katsota olevan vaarallisia käyttäjälle.
Kirjoittimessa on sisäinen luokan IIIb (3b) 5 milliwatin
galliumarsenidilaser, joka toimii aaltoalueella 770 - 795 nanometriä.
Laserjärjestelmä ja kirjoitin on suunniteltu siten, että käyttäjä ei
altistu luokan I määrityksiä voimakkaammalle säteilylle kirjoittimen
normaalin toiminnan, käyttäjän tekemien huoltotoimie n tai muiden
huoltotoimien yhteydessä.

VARO! Avattaessa ja suojalukitus ohitettaessa olet alttiina
näkymättömälle lasersäteilylle. Älä katso säteeseen.

VARNING! Osynlig laserstrålning när denna del är öppnad och
spärren är urkopplad. Betrakta ej strålen.

Laser-notis

Denna skrivare är i USA certifierad att motsvara krav en i DHHS 21
CFR, underparagraf J för laserprodukter av Klass I (1). I andra
länder uppfyller skrivaren kraven för laserprodukter av Klass I enligt
kraven i IEC 60825-1.

Laserprodukter i Klass I anses ej hälsovådliga. Skrivaren har en
inbyggd laser av Klass IIIb (3b) som består a v en laserenhet av
gallium-arsenid på 5 milliwatt som arbetar i våglängdsområdet 770­795 nanometer . Lasersystemet och skrivaren är utf ormade så att det
aldrig finns risk för att någon person utsätts för laserstrålning över
Klass I-nivå vid normal användning, underhåll som utförs av
användaren eller annan föreskriven serviceåtgärd.

Laser notices xvii

5021-0XX

Laser-melding

Skriveren er godkjent i USA etter kravene i DHHS 21 CFR,
underkapittel J, for klasse I (1) laserprodukter, og er i andre land
godkjent som et Klasse I-laserprodukt i samsvar med kravene i IEC
60825-1.

Klasse I-laserprodukter er ikke å betrakte som farlige. Skriveren
inneholder internt en klasse IIIb (3b)-laser, som består av en
gallium-arsenlaserenhet som avgir stråling i bølgelengdeområdet
770-795 nanometer. Lasersystemet og skriveren er utformet slik at
personer aldri utsettes for laserstråling ut over klasse I-nivå under
vanlig bruk, vedlikehold som utføres av brukeren, eller foreskrevne
serviceoperasjoner.

Avís sobre el Làser

Segons ha estat certificat als Estats Units, aquesta impressora
compleix els requisits de DHHS 21 CFR, apartat J, pels productes
làser de classe I (1), i segons ha estat certificat en altres llocs, és un
producte làser de classe I que compleix els requisits d’IEC 60825-1.

Els productes làser de classe I no es consideren perillosos. Aquesta
impressora conté un làser de classe IIIb (3b) d’arseniür de gal.li,
nominalment de 5 mil.liwats, i funciona a la regió de longitud d’ona
de 770-795 nanòmetres. El sistema làser i la impressora han sigut
concebuts de manera que mai hi hagi exposició a la radiació làser
per sobre d’un nivell de classe I durant una operació normal, durant
les tasques de manteniment d’usuari ni durant els serveis que
satisfacin les condicions prescrites.

xviii Service Manual

Japanese laser notice

Chinese laser notice

5021-0XX

Laser notices xix

5021-0XX

Korean laser notice

xx Service Manual

Safety information

• The safety of this product is based on testing and approvals of

the original design and specific components. The manufacturer
is not responsible for safety in the event of use of unauthorized
replacement parts.

• The maintenance information for this product has been

prepared for use by a professional service person and is not
intended to be used by others.

• There may be an increased risk of electric shock and personal

injury during disassembly and servicing of this product.
Professional service personnel should underst and this and tak e
necessary precautions.

• CAUTION: When you see this symbol, there is a

danger from hazardous voltage in the area of the
product where you are working. Unplug the product
before you begin, or use caution if the product must
receive power in order to perform the task.

Consignes de sécurité

5021-0XX

• La sécurité de ce produit repose sur des tests et des

agréations portant sur sa conception d'origine et sur des
composants particuliers. Le fabricant n'assume aucune
responsabilité concernant la sécurité en cas d'utilisation de
pièces de rechange non agréées.

• Les consignes d'entretien et de réparation de ce produit

s'adressent uniquement à un personnel de maintenance
qualifié.

• Le démontage et l'entretien de ce produit pouvant présenter

certains risques électriques, le person n el d'ent re tie n qualif i é
devra prendre toutes les précautions nécessaires.

• ATTENTION : Ce symbole indique la présence

d'une tension dangereuse dans la partie du produit
sur laquelle vous travaillez. Débranchez le produit
avant de commencer ou faites preuve de vigilance si
l'exécution de la tâche e xige que le produit reste sous
tension.

Safety information xxi

5021-0XX

Norme di sicurezza

• La sicurezza del prodotto si basa sui test e sull'approvazione

del progetto originale e dei componenti specifici. Il produttore
non è responsabile per la sicurezza in caso di sostituzione non
autorizzata delle parti.

• Le informazioni riguardanti la manutenzione di questo prodotto

sono indirizzate soltanto al personale di assistenza autorizzato.

• Durante lo smontaggio e la manutenzione di questo prodotto,

il rischio di subire scosse elettriche e danni alla persona è più
elevato. Il personale di assistenza autorizzato deve, quindi,
adottare le precauzioni necessarie.

• ATTENZIONE: Questo simbolo indica la presenza

di tensione pericolosa nell'area del prodotto.
Scollegare il prodotto prima di iniziare o usare cautela
se il prodotto deve essere alimentato per eseguire
l'intervento.

Sicherheitshinweise

• Die Sicherheit dieses Produkts basiert auf Tests und

Zulassungen des ursprünglichen Modells und bestimmter
Bauteile. Bei Verwendung nicht genehmigter Ersatzteile wird
vom Hersteller keine Verantwortung oder Haftung für die
Sicherheit übernommen.

• Die Wartungsinformationen für dieses Produkt sind

ausschließlich für die Verwendung durch einen
Wartungsfachmann bestimmt.

• Während des Auseinandernehmens un d de r War t u n g de s

Geräts besteht ein zusätzliches Risiko eines elektrischen
Schlags und körper lic her Verletzung. Das zuständige
Fachpersonal sollte entsprechende Vorsichtsmaßnahmen
treffen.

• ACHTUNG: Dieses Symbol weist auf eine

gefährliche elektrische Spannung hin, die in diesem
Bereich des Produkts auftreten kann. Ziehen Sie vor
den Arbeiten am Gerät den Netzstecker des Geräts,
bzw. arbeiten Sie mit großer Vorsicht, wenn das
Produkt für die Ausführung der Arbeiten an den
Strom angeschlossen sein muß.

xxii Service Manual

Pautas de Seguridad

• La seguridad de este producto se basa en pruebas y

aprobaciones del diseño original y componentes específicos.
El fabricante no es responsab le de la seguridad en caso de uso
de piezas de repuesto no autorizadas.

• La información sobre el mantenimiento de este producto está

dirigida exclusivamente al personal cualificado de
mantenimiento.

• Existe mayor riesgo de descarga eléctrica y de daños

personales durante el desmontaje y la reparación de la
máquina. El personal cualificado debe ser consciente de este
peligro y tomar las precauciones necesarias.

• PRECAUCIÓN: este símbolo indica que el voltaje

de la parte del equipo con la que está trabajando es
peligroso. Antes de empezar, desenchufe el equipo
o tenga cuidado si, para trabajar con él, debe
conectarlo.

Informações de Segurança

5021-0XX

• A segurança deste produto baseia-se em testes e aprovações

do modelo original e de componentes específicos. O fabricante
não é responsável pela segunrança, no caso de uso de peças
de substituição não autorizadas.

• As informações de segurança relativas a este produto

destinam-se a profissionais destes serviços e não devem ser
utilizadas por outras pessoas.

• Risco de choques eléctricos e ferimentos gr aves durante a

desmontagem e manutenção deste produto. Os profissionais
destes serviços devem estar avisados deste facto e tomar os
cuidados necessários.

• CUIDADO: Quando vir este símbolo, existe a

possível presença de uma potencial tensão perigosa
na zona do produto em que está a trabalhar. Antes
de começar , desligue o produto da tomada eléctrica
ou seja cuidadoso caso o produto tenha de estar
ligado à corrente eléctrica para realizar a tarefa
necessária.

Safety information xxiii

5021-0XX

Informació de Seguretat

• La seguretat d'aquest producte es basa en l'avaluació i

aprovació del disseny original i els components específics.
El fabricant no es fa responsable de les qüestions de
seguretat si s'utilitzen peces de recanvi no autoritzades.

• La informació pel manteniment d’aquest producte està

orientada exclusivament a professionals i no està destinada
a ningú que no ho sigui.

• El risc de xoc elèctric i de danys personals pot augmentar

durant el procés de desmunt atge i de servei d’aquest producte.
El personal professional ha d’estar-ne assabentat i prendre
les mesures convenients.

• PRECAUCIÓ: aquest símbol indica que el voltatge

de la part de l'equip amb la qual esteu treballant és
perillós. Abans de començar, desendolleu l'equip
o extremeu les precaucions si, per treballar amb
l'equip, l'heu de connectar.

xxiv Service Manual

5021-0XX

Safety information xxv

5021-0XX

Preface

This manual contains maintenance procedures for service
personnel. It is divided into the following chapters:

1. General information contains a general description of the
printer and the maintenance approach used to repair it. Special
tools and test equipment are listed, as well as general
environmental and safety instructions.

2. Diagnostic information contains an error indicator table,
symptom tables, and service checks used to isolate failing field
replaceable units (FRUs).

3. Diagnostic aids contains tests and checks used to locate or
repeat symptoms of printer pr oblems.

4. Repair information provides instructions for making printer
adjustments and removing and installing FRUs.

5. Connector locations uses illustrations to identify the connector
locations and test points on the printer.

6. Preventive maintenance contains the lubrication specifications
and recommendations to prevent problems.

7. Parts catalog contains illustrations and part numbers for
individual FRUs.

Definitions

Note: A note provides additional information.
Warning: A warning identifies something that might damage the

product hardware or software.
CAUTION: A caution identifies something that might cause a

servicer harm.

CAUTION: When you see this symbol, there is a
danger from hazardous voltage in the area of the
product where you are working. Unplug the product
before you begin, or use caution if the product must
receive power in order to perform the task.

xxvi Service Manual

5021-0XX

1. General information

This Lexmark™ C510 color laser printer is the ideal printer for
presentations, busin ess graphics, line art, and text. It uses laser
diode electrophotographic technology to deliver remarkable quality
print images and text. The printer can be used as a shared network
or desktop printer.

Maintenance approach

The diagnostic information in this manual leads you to the correct
field replaceable unit (FRU) or part. Use the error code charts,
symptom index, and service checks to determine the symptom and
repair the failure. See “Diagnostic information” on page 2-1, for
location of each section. You may find that the removals in the
Repair information chapter will help you identify parts. After you
complete the repair, perform tests as needed to verify the rep air.

Tools required for service

The removal and adjustment procedures described in this manual
require the following tools and equipment:

• Analog volt ohmmeter (a digital volt ohmmeter may also be

used)

• Flat-blade screwdrivers

• Needle nose pliers

• #1 Phillips screwdriver

• #2 Phillips screwdriver

• Slotted screwdriver #1

• Slotted clock screwdriver #1

• Tweezers, C-ring pliers

When you make voltage readings, always use frame ground unless
another ground is specified.

General information 1-1

5021-0XX

Serial number

Look for the label on the rear cover of your printer for serial number
information. The serial number is also listed in the menu settings
page and can be printed from the utilities menu.

1-2 Service Manual

Acronyms

ASIC Application-Specific Integrated Circuit
CS Customer Ordered
CSU Customer Setup
DRAM Dynamic Random Access Memory
EEPROM Electrically Erasable Programmable Read-Only

Memory
EP Electrophotographic Process
ESD Electrostatic Discharge
FRU Field Replaceable Unit
HV High Voltage
HVPS High Voltage Power Supply
LAN Local Area Network
LASER Light Amplification by Stimulated Emission of

Radiation
LCD Liquid Crystal Display
LED Light-Emitting Diode
LV Low Voltage
LVPS Low Voltage Power Supply
NVRAM Nonvolatile Random Access Memory
OEM Original Equipment Manufacturer
PICS Problem Isolation Charts
PIXEL Picture Element
POR Power-On Reset
POST Po wer-On Self Test
PQET Print Quality Enhancement Technology
RIP Raster Image Processor
ROS Read-Only Storage
SRAM Static Random Access Memory
UPR Used Parts Replacement
V AC Volts alternating current
VDC Volts direct current

5021-0XX

General information 1-3

5021-0XX

Specifications

Resolution

600 x 600 dpi
2400 image quality

Model differences

C510 C510n C510dtn

USB 2.0 X X X
Parallel X
Ethernet X X
Memory (MB) 64 128 128

Options available

530-sheet drawer
(tray 2)

Duplex X X
Hard disk X X X

Technical specifications

XX

Toner darkness

There are five settings to balance print darkness and toner savings.
The higher the setting, the darker the print. The toner darkness
default setting is 4.

The toner darkness setting is available through the operator panel
under the Color Menu, Toner Darkness menu.

Color correction settings

There are three settings to choose the type of color correction to be
applied when printing.

Auto (default): Applies different color correction to each object on
the printed page depending upon the type of object ( te xt, graphics or
image), and how the color for each object is specified.

Off: No color correction is implemented.

1-4 Service Manual

5021-0XX

Manual: Allows users to customize color correction output from the

operator panel. Setting selectab le from the driver.

Physical specifications and weight

The following table contains the dimensions and weights for each
printer model and option. This does not include packaging but does
include the print cartridge that ships with the printer.

Width Depth Height Weight
inch inch inch lb
mm mm mm kg

Printers

Lexmark C510

1

19.5 16.5 15.2 67.0
495 420 385 30.3

Lexmark C510n

2

19.5 16.5 15.2 67.0
495 420 385 30.3

Lexmark C510dtn

3

19.5 20.7 23.2 91.0
495 525 590 41.2

Paper options

Duplex unit 14.2 7.1 15.2 11.0

360 180 385 5.0

530-Sheet drawer 18.1 18.5 7.3 13.3

460 470 185 6.0

530-Sheet tray 11.2 14.4 4.5 4.2

285 365 115 1.9

Standard tray 10.8 13.0 2.2 2.2

275 330 55 1.0

Legal tray 10.8 15.9 2.2 2.5

275 405 55 1.1

1

Base model is the base printer with standard 250-sheet input tray and starter

cartridges.

2

Network model is the network-ready printer with standard input tray and starter

cartridges.

3

Duplex network model is the network-ready printer plus duplex option and 530-sheet

input tray.

4

Weight does not include packaging or pubs.

4

General information 1-5

5021-0XX

Operating clearances

Printer sides C510 & C510n C510 & C510n

Left side 8 in (203 mm) 8 in (203 mm) 8 in (203 mm) 8 in (203 mm)
Right side 20 in (508 mm) 20 in (508 mm) 20 in (508 mm) 20 in (508 mm)
Front 28 in (711 mm) 28 in (711 mm) 28 in (711 mm) 28 in (711 mm)
Rear 10 in (254 mm) 10 in (254 mm) 14 in (355 mm) 14 in (355 mm)
Top 23 in (584 mm) 29 in (736 mm) 25 in (635 mm) 29 in (736 mm)

with 530-sheet
tray

C510 & C510n
with duplex
unit

C510dtn with
530-sheet tray

Packaging and shipping dimensions

Width Depth Height Weight

Printers

C510 22.6 20.9 22.4 80

C510n 22.6 20.9 22.4 80

C510dtn

Options
Duplex 18.0 20.8 12.0 16.1

530-Sheet drawer 21.9 22.4 10.9 18.7

530-Sheet tray 17.7 15.1 7.9 6.4

250-Sheet tray 13.2 16.2 5.5 3.3

Legal tray 13.2 19.0 5.7 5.5

1
2

1

in in in lb
mm mm mm kg

574 530 570 36.4

574 530 570 36.4

2

23.4 23.6 46.2 112.2

594.36 599.44 1173.48 51.0

456 528 305 7.3

556 570 277 8.5

450 384 200 2.9

335 412 140 1.5

335 483 144 2.5
Includes start-up kit (supplies)
C510dtn ships printer, duplex and 1 tray bundled on a pallet.

1-6 Service Manual

5021-0XX

Print speed and performance

Simplex printing Duplex printing

pages/minute) (sides/minute)

Media size Standard tray Standard tray

Letter 30 8 15 4
A4 308154
Legal 16 8 5 4
Transparencies 3 2 N/S N/S
Thick card stock 3 2 N/S N/S
Labels (letter &

A4)
Medium thick card

stock (letter & A4)
Envelopes 5 3 N/S N/S
N/S - Media size not supported in this tray
Note: For media size A4 duplex mode with custom paper sizes, size sensing is

turned off.

53N/SN/S

43N/SN/S

Time to first print

Simplex Duplex

Time from standby mode 13 seconds 19 seconds 19 seconds 27 seconds
Time from power saver

mode

Note: Time to first page (TTFP) is the time from the moment when the host sends the
print signal until the moment the trailing edge of the first page leaves the exit feed rollers .
TTFP is measured using a simple text (single character) page.

Note: Warm up time, 45 seconds maximum, is the time elapsed from when the power is
turned on to when the ready status is reached.

45 seconds 45 seconds 45 seconds 45 seconds

Processor

500 MHz

General information 1-7

5021-0XX

Duty cycle

Maximum duty cycle-35,000 pages (one month's usage)
Machine life-120,000 pages/300,000 images

Printer memory

Memory configuration

C510 C510n C510dtn

Standard DRAM 64MB 128MB 128MB
Max DRAM 320MB

Available memory options

Optional 64MB and 128MB SDRAM DIMMs are available.

Flash memory options

Optional 16MB and 32MB DIMMs are available from Lexmark.

Memory and expansion slots

1

100pin DIMM slots (1-2 SDRAM, 1 Flash
PCI Slots (for optional interface cards) 1 1 1
Firmware card slot 1 1 1
User flash card slot 1 1 1

1

Only one Flash card may be installed.

Only one DLE/Firmware card is supported at a time, as well as only one User Flash card
is supported at a time.

)211

C510 C510n C510dtn

Paper and media specifications

Print area

The C510 printable area is up to 4.0 m m (0.158 in.) f rom the top a nd
bottom of the media, and up to 3.0 mm (0.1 18 in.) fr om the left an d
right edges. Any information placed outside this specified printable
area will not print. Note: For envelopes, the printable area is up to

4.0 mm (0.158 in.) of the left and right edge s , and 3.0 mm(0. 118 in .)
of the top and bottom edges.

1-8 Service Manual

5021-0XX

Input and output configurations

The following table shows the standard number of input sources and
output destinations, as well as the estimated capacity of each.
Capacity may v a ry and is subject to media specification s and printer
operating environment. The capacities listed are based on plain
paper at 75 g/m

2

.

Sources and capacities C510/C510n C510dtn

Input sources
Number of standard sources 1 2
Number of optional input drawers 1 0
Maximum number of input sources

Standard input
Primary tray 250 250
Second tray 530
Total standard 250 780
Optional input
Optional legal tray 250 250
Optional tray 1 250 250
Optional tray 2 530 530

Number of standard destinations 1 1
Output capacities
Standard output bin capacity (top)
Media up to 20 lb paper 250 250
Other
Duplex unit Yes Standard

1

Optional input drawer is a 530-sheet capacity drawer. Only one optional drawer

may be installed at any time.

2

The printer supports top output (face down) as standard. No additional output

options are available.

3

Includes optional 530-sheet drawer.

Note: All capacities are based on use of 20 lb paper.

1

Input capacities

Output destinations

2

22

3

General information 1-9

5021-0XX

Media input types and weights

Source Type Standard

1,2

Paper
(grain long)

Xerographic
or bond
paper

Xerographic
or bond
paper

100%
Cotton

Card stock Index 163 g/m

Index 164- 210

Transparency

3

tray Legal
tray

60-74
g/m
(16-19 lb)

75-120
g/m
32 lb)

75-120
g/m
(24-32 lb)

(90 lb)

g/m
(91-110
lb)

PN
12A5940
PN

530­Sheet
tray

Duplex Printer menu Item

Paper

60-74

2

g/m
(16-19 lb)

75-120

2

(20-

g/m2 (20­32 lb)

75-120

2

g/m
(24-32 lb)

2

N/A N/A Card stock Normal

N/A N/A Card stock Heavy

2

60-74

2

g/m

Plain paper Light

2

(16-19 lb)
75-120

g/m2 (20­32 lb)

75-120

2

g/m
(24-32 lb)

Plain paper Normal

Plain paper Heavy

2

N/A N/A Transparency

type

12A5941

2

Labels
Envelopes 75-90

g/m

N/A N/A Label
N/A N/A Envelope Normal

2

(20-24lb)

1

Punched, embossed, water-marked, perforated, punched, inkjet paper or plastic-

coated media should not be used.

2

Only occasional use of paper labels in an office environment is supported.

3

Only PN 12A5940 and 12A5941 should be used.

Paper

weight

1-10 Service Manual

5021-0XX

Media sizes

Media sizes Dimensions Input Output

Standard 250-sheet tray 1

Optional legal tray

Optional 530-sheet tray 2

Optional duplex unit

Standard 250-sheet bin

mm in.
A4 210 x 297 8.27 x 11.7 X X X X X
A5 148 x 210 5.83 x 8.27 X X X

3

JIS B5
Letter 216 x 279.4 8.5 x 11 X X X X X
Legal 216 x 356 8.5 x 14 X X X
Executive 184.2 x 266.7 7.25 x 10.5 X X X X X
Folio 216 x 330 8.5 x 13 X X X
Statement 139.7 x 215.9 5.5 x 8.5 X X X
Universal

1

Standard 250-sheet
letter tray

Optional 250-sheet
legal tray

Optional duplex 148x210 to

Envelope sizes Dimensions Dimensions
9 Envelope

2

COM 10 Envelope 104.8 x 241.3 4.12 x 9.5 X X X
DL Envelope 110 x 220 4.33 x 8.66 X X X
C5 Envelope
B5 Envelope

1

Select Universal when using a non-standard size sheet of print material. The printer
formats the page for the maximum size 8.5 X 14 in.(215.9 X 355.6 mm). Set the actual
size from your software application.

2

Supported through the driver.

3

B5 may be supported in optional tray 1, but size sensing must be turned off.

2

2

182 x 257 7.17 x 10.1 X X X X

XX X X

104.8x210 to

215.9x297

104.8x210 to

215.9x355.6

4.125x8.27 to

8.5x11.7

4.125x8.27 to

8.5x14

5.83x8.27 to

215.9x355.6

8.5x14

98.4x225.4 3.875 x 8.9 X X X

162 x 229 6.38 x 9.01 X X X
176 x 250 6.93 x 9.84 X X X

General information 1-11

5021-0XX

Output capacity by media and source

Source Media Capacity Orientation

Standard output
bin (top)¹

Supports all sizes listed in
the "Media sizes" table

250 sheets (20 lb
paper)
50 Transparencies

Collated
Face down

Media guidelines

With the Lexmark C510 print technology, paper designed for use
with xerographic copiers should provide satisfactory print quality and
feed reliability. Other media types may be suitable. We recommend
that users test any particular brand for suitability to their
applications. Refer to the printer User's Reference for additional
media specifications.

Paper

• Rough, highly textured, limp, or pre-curled papers will result in

lower print quality and more frequent paper feed f ailures.

• Colored papers must be able to withstand 338°F ( 170°C) fusing

temperature.

• Preprinted forms and letterheads should be selected using

guidelines in the printer User's Reference. The chemical
process used in preprinting may render some papers unsuitable
for use with the printer.

• Unsuitable papers include punched, embossed, water-marked,

perforated media, any kind of inkjet paper or plastic-coated
paper.

• Recycled paper less than 75 g/m

unacceptable results.

The laser printing process heats paper to high temperatures of
170°C (338°F). Use only paper able to withstand these
temperatures without discoloring, bleeding, or releasing hazardous
emissions. Check with the man ufacturer or vendor to determine
whether the paper you have chosen is acceptable for laser printers.

Envelopes

Should be fed with short edge first, flap down and to the right.

1-12 Service Manual

2

(20 lb) may cause

5021-0XX

• If envelope wrinkling occurs, refer to the User's Reference for

correct loading and stacking of envelopes.

• All envelopes should be new, unused, and without damage.

• Envelopes with excessive curl or twist e xceeding 6.0 mm, those

stuck together, those with bent corners or nicked edges, or
those that interlock should not be used.

• Minimum weight: 90 g/m

2

(24 lb).

• The following envelopes should not be used:

– Envelopes with windows, holes, perforations, cutouts, or

deep embossing

– Envelopes with metal clasps, string ties, or metal folding

bars

– Envelopes with e xposed f lap adhesiv e when th e flap is in the

closed position

– Self-seal envelopes

• Under high humidity conditions (over 60%), the env elopes may

seal during printing.

• For best results, print on new 90 g/m

cotton-bond envelope.

2

(24 lb) sulfite or 25%

Transparencies

• Use letter (12A5940) or A4-size (12A5941) sheets only.

• Transparencies are only supported in tray 1 (standard or legal

trays).

Labels

• Labels should be selected using guidelines f ound in the User's

Reference, Complete Printer Reference, or the Card stock &
Label Guide (located at www.lexmark.com), and tested for
acceptability.

• Vinyl labels are not supported.

• Labels are only supported in tray 1 (standard or legal trays).

Glossy Paper

• Use letter (12A5950) or A4-size (12A5951) sheets only.

General information 1-13

5021-0XX

• Glossy paper is only supported from tray 1 (standard or legal

trays).

Connectivity

Cables

Personal comput ers

• A parallel printer cable is required for attachment of the printer

and must be ordered separately.

• For serial attachment, optional RS-232C serial interface card

(P/N 11K4602) should be ordered.

• For USB attachment a USB cable is required and must be

ordered separately.

IBM AS/400

• For parallel attachment, a parallel cable is required.

• For serial attachment, optional RS-232C serial interface card

(P/N 11K4602) should be ordered.

• For serial attachment to the IBM AS/400 ASCII Workstation

Controller, refer to the IBM AS/400 ASCII Workstation
Reference and Example manual (SA41-9922) for specific cable
information. The printer require s th e op tio na l RS -2 32 C serial
interface card (P/N 11K4602).

Connections

C510 C510n C510dtn

Standard local connections Parallel & USB 2.0 Ether net & USB

Standard network
connections

Optional local connections RS-232 Serial/Parallel IEEE 1284-C Interface Card
Optional network

connections

N/A 10/100 Base-TX

10/100Base TX Ethernet, Token-Ring, 802.11b
Wireless

2.0

Ethernet

Ethernet & USB

2.0
10/100 Base-TX

Ethernet

1-14 Service Manual

5021-0XX

Power and electrical specifications

Printing states C510 C510n C510dtn

Off 0 W O W O W

Average power while printing

Continuous mono printing 550 W 550 W 550 W
Continuous color printing 370 W 370 W 370 W

Power consumption, standby

Power saver on 12 W 13 W 13 W
Power saver off 150 W 150 W 150 W

Maximum current while printing

100 Volts 8.1 A
115 Volts 7.2 A
230 Volts 2.83 A

Average curre nt while printing

100 Volts 6.9 A
115 Volts 5.6 A
230 Volts 3.0 A

General information 1-15

5021-0XX

Environment

Environment Specifications

Operating
Air temperature - product operating 10 to 32.5°C (50 to 90.5°F)
Air temperature - product power off 5 to 35°C (41 to 95°F)
Air relative humidity 15 to 80%
Altitude 0 - 2,500 m (0 - 8,200 ft.)

Ship / Storage
Temperature-printer and supplies 0 to 35°C (32 to 95°F)
Relative humidity 10 to 90% RH
Atmospheric pressure 613 to 16057 hPa (460 to 800 mm Hg)

1

Severe High 35 to 40°C (95 to 104°F), Se vere Low -10 to 0°C (14 to 32°F). The period
under severe shall not be deemed to be continuous, but rather a total of such
intermittent periods (48 hours at most for any one period).

1

1-16 Service Manual

Printer identification

5021-0XX

General information 1-17

5021-0XX

Options identification

1-18 Service Manual

Printer theory of operation

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

5021-0XX

General information 1-19

5021-0XX

Printer paper path

The following illustration shows the paper path and the associated
paper jam messages for jams at specific points in the paper path.
The printer depicted in the illustration has a duplex unit and
secondary paper feed assembly installed:

1-20 Service Manual

5021-0XX

Printer systems description

See the illustration “Printer component systems” on page 1-23,
for more information.

Basic principles of color printing

Color printing is made through the subtractive process of combining
the three primary colors: yellow, magenta, and cyan.

Mechanical and electrical structures

This color laser printer consists of five engineering systems: print,
transfer, optical, paper transport, and control system.

Print system

The print system consists of six functional parts located around the
optical photoconductor (OPC) belt and forms a toner image on the
OPC belt: charge, expose, develop, first transfer, discharge, and
clean.

Transfer system

The transfer system consists of three functional parts that transfers
the toner image formed on the transfer belt to paper: transfer belt
unit, second transfer, and cle aning roller.

Optical system

The optical system consists of two functional parts that forms an
electrostatic latent image on the OPC belt using a laser light: optical
unit and scanner motor (SCM).

Paper transport system

The paper transport system consists of five functional parts that
picks up paper from the paper tray, separates the transported paper
from the transfer be lt, and exits it from the printer after fusing the
toner image on the paper: paper tray, transport, fuser, and paper
exit.

General information 1-21

5021-0XX

Control system

The control system consists of four control parts and runs the printer
by processing the interface signals transmitted from the computer
and the other printer systems such as the print, transfer , optical, and
transport system: sequence control, laser control, fusing
temperature control, and interface control.

1-22 Service Manual

Printer component systems

5021-0XX

General information 1-23

5021-0XX

Basic process of color printing

1. This printer has a toner cartridge for each color — yellow,
magenta, cyan, and black.

2. The toner image is developed with primary colors and then
transferred to the transfer belt for color combination.

3. The toner image formed on the tr ansfer belt is transferred to
paper.

4. The toner is fused to the paper by the thermal fuser unit. During
the fusing process, the primary colors mix, yielding the desired
color.

1-24 Service Manual

5021-0XX

Print system and transfer system

This illustration shows the basic structure of the print system having
the OPC belt as a main function, and the transfer system including
the transfer belt . A color print is accomplished by actuating each
process in the print system and the transfer system.

General information 1-25

5021-0XX

Structure of OPC belt (photo developer cartridge)

The OPC belt consists of a surface layer having an optical
photoconductor (OPC) of organic material, the inner layer consists
of an insulator material (PET), and the aluminum deposit layer in
between. The OPC belt is a main part of the print system.

1-26 Service Manual

Basic structure of the print system

The print system process consists of the following:

1. The OPC belt is biased to the -CBV(V) by power supply CBV.

2. The OPC belt is then evenly charged to the negative hig h
voltage by the OPC charging system. The charging system
consists of a charging brush that is biased by power supply
CHV and a discharge roller that is biased by pow er su pply DCV.

3. The developer roller in the toner cartridge is biased to

-DBV(V) by power supply DBV.

4. Frame potential of transfer drum is GND.

5021-0XX

General information 1-27

5021-0XX

5. Variation of the OPC belt potential:
a. The OPC belt is biased to -CBV(V).

b. The OPC belt surface is evenly charged to -Vo(V) during the

charging process.

c. During the exposing process , the optical unit emits a laser

beam that strikes the OPC belt surface forming an
electrostatic image. The electrostatic image is at -VR(V)
potential.

d. The negatively charged toner is moved to the OPC belt in

the dev elopment process due to the differe nce between

-VR(V) and -DBV(V). A visible image is the result.

e. The negatively charged toner on the OPC belt is moved to

the transfer belt because the potential GND of the transfer
belt is greater than -VR(V) of the OPC belt.

f. The OPC belt is discharged by the erase lamp radiating on

the OPC belt.

Latent image

-V0

-V0

TEST

-V0

PRINT

-V0

Laser diode
exposing

2

Developer roller

-V0

-V0

OPC belt

0V

-CBV

-CBV

-CBV

-CBV

-CBV

-CBV

Charging

1

OPC belt surface

-V0
Charge brush

-CHV
(-BRV)

-V0

-V0

-V0

-V0

-V0

-V0

-V0

-V0

-VR

Discharge roller

OPC charging system

DCV

-V0

-V0

-V0

-V0

KY

Developing

3

-V0

-V0

-V0

-V0

Toner image

-V0

TEST

PRINT

-V0

M

C

-DBV

-DBV

-V0

-V0

-V0

PRINT

Transfer belt

4

(M)toner

TEST

-CBV

-CBV

-CBV

-CBV

Erase lamp

5

Blade
6

1-28 Service Manual

5021-0XX

Details of the print system

Charging process

In the charging process, the OPC belt is evenly charged by the
charger. See “Printer theory of operation” on page 1-19 for
charger unit location.

The charger unit consists of a charg ing brush and a discharge roller.

1. The charge brush charges the OPC belt surface to

-Vo(V) potential. The charge on the surface of the OPC belt is
then smoothed to an even -Vo(V) by the discharge roller.

2. The charger unit controls the grid to a constant v oltage of ZD(V)
for even charging.

General information 1-29

5021-0XX

3. Before charging, the OPC belt surface is -CBV(V).
The charger unit evenly charges the OPC belt surface to -Vo(V)

by generating a negative charge.

1-30 Service Manual

Exposing process

In the exposing process, the OPC belt surface is exposed to the
laser light which forms an electrostatic latent image.

The luminous source of the laser is a semiconductor laser. See
“Printer theory of operation” on page 1-19 for optical unit
location.

The laser light scans the OPC belt, forming an electrostatic late nt
image.

1. The OPC belt surface is charged to -Vo(V) potential.
a. The laser scans the OPC belt in a rectangular pattern during

forward movement of the OPC belt.

b. High speed switching of the laser matches the transmitted

image data.

c. The charge of the areas radiated by the laser light is

discharged, creating a -VR(V) potential.

d. An electrostatic latent image is formed (invisible) on the

OPC belt.

5021-0XX

General information 1-31

5021-0XX

Developing process

In the developing process, an electrostatic latent image attracts
printer toner and becomes visible on the OPC belt.

There are four toner cartridges. See “Printer theory of operation”
on page 1-19 for toner cartridges location. The toner cartridges are
located in the printer from top to bottom in the order of black, yello w,
magenta, and cyan.

1. Toner adheres to the developer roller.
The deve loper roller makes contact with the surf ace of the OPC

belt which begins the developing process.

2. The developer roller has been biased to -DBV(V) potential.

1-32 Service Manual

5021-0XX

The first illustration shows the relationship between the toner, the

-Vo(V) at the non-exposed area of the OPC belt and the -VR(V) at
the exposed area of t he OPC belt.

Dev. roller

(-CBV)+(-DBV)

Toner

(-CBV)

OPC belt

DBV

CBV

3. Developing is pr ocessed by toner adhering to the OPC belt due
to the attraction betw een the toner and the -VR(V) cha rge at the
exposed area of OPC belt. The toner image becomes visib le on
the OPC belt.

Note: No developing takes place on the non-ex posed area
because the potential of toner and that of the non-e xposed area
of the OPC belt is an identical pole and therefore, repels.

General information 1-33

5021-0XX

First transfer (drum) process

The first transfer process consists of toner images on the OPC belt
being transferred to the transfer belt. The transfer belt is composed
of a special rubber. See “Printer theory of operation” on
page 1-19 for transfer belt location.

1. After the development process, the OPC belt rotates making
contact and synchronizing with the transfer belt and the
aluminum drum.

Transfer belt

Aluminum drum tube

Aluminum drum tube

Film (transfer belt)

2. The OPC belt has been biased to -CBV(V) potential. The
potential of the transfer belt and drum is nearly GND.

3. Toner on the OPC belt is moved to the tran sf er be lt. This occurs
because of the diff erence of pot ential between t he OPC belt and
the transfer belt. Toner that has been developed, in each color,
is moved from the OPC belt to the transfer belt and the two
color toner image is overlapped on th e transfer belt.

1-34 Service Manual

4. The toner image is then transferred to paper.

Belt discharge (erase lamp) process

5021-0XX

Electrical belt cleaning is accomplished by an erase lamp radiating
on the OPC belt. Radiation discharges the residual charge -VR(V)
remaining on the belt after the first transfer process. Electrical
cleaning occurs after each toner color transfer. The erase lamp is a
luminous source consisting of 24 light emitting diodes. Aft er the
electrical belt cleaning, the OPC belt is cleaned with a mechanical
blade.

General information 1-35

5021-0XX

OPC belt

OPC belt cleaning
(blade)

First transfer

OPC belt discharging
(erase lamp)

Belt cleaning process

In the belt cleaning process, residual toner adhering to the OPC b elt
surface is mechanically removed by a blade edge.

1-36 Service Manual

5021-0XX

The residual toner is collected in a waste toner container located by
the waste toner feeder.

OPC belt

OPC belt cleaning
(blade)

First transfer

OPC belt discharging
(erase lamp)

General information 1-37

5021-0XX

Details of the transfer system

Second transfer (paper) process

In the second transfer process, the toner image on the transfer belt
is transferred to paper. See “Printer theory of operation” on
page 1-19 for second transfer roller location.

The transfer roller, normally separated from the transfer belt, is
positively biased by the power supply THV. The transfer roller
contacts the transfer belt as paper passes between the transfer
roller and the transf er belt. The positive bias of the transfer roller
causes the toner to release from the transfer belt and adhere to the
paper.

1-38 Service Manual

5021-0XX

Transfer belt cleaning process

The residual toner on the surface of the transfer belt is removed
after the paper transfer process. See “Printer theory of operation”
on page 1-19 for transfer belt cleaner unit location.

The belt cleaner brush is a semiconductor-type fur brush. The
cleaning roller is charged by voltage FCBV. The resistance of the
cleaning brush against the cleaning roller charges the brush. The
brush in turn contacts the surface of the rotating tr ansfer belt. The
negatively charged toner adheres to the positively charged (FCBV)
brush, which cleans the transfer belt. The cleaning brush does not
contact the transfer belt during the imaging process.

Waste toner, adhering to the surface of the cleaning roller, is
removed by the cleaning blade, routed by the waste toner feeder to
the waste toner container wh ere it is deposited.

General information 1-39

5021-0XX

Details of the optical system

In the optical system process, the printer utilizes a semiconductor
laser diode as a light source. This laser diode is controlled by fast
switching which matches the transmitted image data (video signal).

The generated laser light scans the OPC belt through a polygon
mirror and lens. The electrostatic latent images are formed on the
OPC belt.

The Optical printhead unit consists of following parts:

No. Description

1

2

3

4

5

6

7

PD: photo detector

Polygon mirror: hexahedral mirror that reflects the laser
beam

Cylinder lens: laser beam condenser

Laser unit: laser diode light emitting source

LDC: laser diode control circuit

BTD mirror: beam timing detector mirror to guide the
laser beam to PD

Scanner motor: rotates the polygon mirror

1-40 Service Manual

No. Description

F-lens: laser beam focus lens

8

Mirror: laser beam path reflecting mirror

9

5021-0XX

General information 1-41

5021-0XX

Details of the paper transportation system

In the paper transportation process, paper is automatically fed by
the pick-up roller and transported to the registration roller. The
registration roller synchronizes with the transfer belt. The
registration roller transports the paper to the transfer roller. During
the transfer process, the transfer roller forwards the paper to the
fuser rollers. During the fusing process, the fuser rollers transport
the fused paper to the exit roller and the exit roller pushes the final
paper out of the rear cover assembly.

The paper transportation system consists of the following parts:

No. Part Function

Paper tray Accommodates paper to be automatically fed

1

Pick-up roller Feeds paper one by one, preventing multi-feed.

2

Registration

3

roller

through the printer.

Transports and synchronizes paper with the
transfer belt.

1-42 Service Manual

No. Part Function

Transfer roller Works in conjunction with the transfer belt to

4

Fuser unit Utilizes a heat roller to fuse the toner image to

5

transfer the image to paper and to transport the
paper to the fuser.

the paper.

5021-0XX

6

Paper exit
roller

Exits the fused paper from the printer.

General information 1-43

5021-0XX

Fusing unit

The fusing unit utilizes a thermal fusing system that contains a
heated fusing roller and a belt-like backup roller. The heated roller
contains an inner heating element. The backup roller contains three
pressure members located behind the belt. Paper carrying a toner
image passes between the rollers where heat and pressure are
applied to the paper to fuse the toner to the paper.

The fusing unit consists of the following components:

No. Part Function

Fusing roller Used for fusing, containing a heater.

1

Back-up roller Pressure roller.

2

Fusing heater Heating device heated by a halogen lamp.

3

1-44 Service Manual

No. Part Function

Thermistor Sensor that detects the temperature of the

4

Thermal fuse Protective device that prevents the fuser roller

5

fuser roller’s surf ace.

from being excessively heated.

5021-0XX

General information 1-45

5021-0XX

Fusing process

1. When the paper reaches the fuser, the toner image is
transferred on the paper, but not yet fused to the paper.

2. The transported paper passes between the heated roller and
the back-up roller. The heated roller’s temperature is
approximately 338°F (170°C).

3. When the paper with toner image passes between the heated
roller and the backup rolle r, the heat from the heated roller in
combination with the pressure between the two rollers, melts
the toner, fusing it to the paper.

4. The fused paper then separates from the rollers and is
transported out of the printer into the output bin or is routed
back into the printer for printing on the other side of the duplex
print.

1-46 Service Manual

Control system structure

Electrical system and function

The engine board controls most of the main electrical parts in this
printer.

No. Control process Function

5021-0XX

1 Print process

control

2 Laser output

control

3 Fuser

temperature
control

4 Toner sensing

control

5 Interface control

(video signal)

6 Operator panel

indicator

7 Error control Controls safe stop procedures when errors

Controls print process from paper feed
through paper exit.

Automatically controls laser output to the
default.

Controls fuser heater, allowing heated
roller to reach default temperature.

Controls sensing of toner empty status.

Processes the input and output signal with
external controller computer.

Displays printer operation status.

occur.

General information 1-47

5021-0XX

Control of print process

Control block diagram

No. Control process Function

1 Sequence control Controls print sequence of printer.

2 Temperature

control

3Consumables’ life

control

4 Operator panel

control

5 Error processing

control

6 Interface control Controls receipt and transmission of interface

7 Laser control Controls laser scanning and laser power.

Controls temperature of fuser unit.

Controls toner empty status for each toner
cartridge and life of periodic replacement
parts.

Controls operator panel indication and
operator signals.

Senses errors occurring as well as stop
procedures.

signals from external controller.

Note: A micro CPU mounted on the engine board controls the print
processes.

1-48 Service Manual

Print sequence diagram

5021-0XX

General information 1-49

5021-0XX

Laser drive control circuit

The laser drive control circuit (LDC) consists of a video signal input
circuit, laser drive circuit, laser diode, output sensing circuit, and
output control circuit. See the illustration.

1. When the video signal is received, the laser drive control circuit
switches the laser diode s witch on and ra diates according to the
video signal.

2. The radiated laser beam senses the photo detector (PD). The
detected signal is returned to the output control circuit.

3. The output control circuit controls the radiated output to a
constant, by comparing the laser output default with the
feedback value transmitted from the output sensing circuit.

4. The laser beam, scanned by the scanner motor, is sensed by
the beam detector (PD), and then outputs the beam detecting
timing (BDT) signal.

1-50 Service Manual

5021-0XX

Interface control

Interface type

Through the video interface, the RIP controls the printer and
operator panel using command/status communication and tr ansmits
the synchronized video data to the printer laser diode. The operator
panel is physically resident on the engine.

Interface connection

The interface connector of the laser printer is connect ed to the ho st
system as shown in the following illustration.

General information 1-51

5021-0XX

1-52 Service Manual

5021-0XX

2. Diagnostic information

Start

CAUTION: Remove power from the printer before you connect or

disconnect any cable, electr onic board or assembly, for personal
safety and to prevent damage to the printer. Always use the hand
grips on the side of the printer and be sur e your fingers are not
under the printer when you set the printer down.

Use the service error codes, user status messages, user error
messages, symptom tables, service checks, and diagnostic aids, to
determine the corrective action necessary to repair a malfunctioning
printer.

Service error codes are indicated by a three-digit error code. If a
service error code displays, go to the “Service er ror codes” on

page 2-2.

User status messages provide the user with information on the
current status of the printer. “Ready” displays on the first line of the
display unless Power Saver is invoked, then Power Saver is
displayed. If a user status message displays, go to the “Operator

messages” on page 2-9.

User error messages are indicated b y a tw o- or three-digit error code
which provides the user with inf ormation e xplaining a prob lem with a
print cartridge, paper jam, option, port, and so on. If a user error
message displays, go to the“Operator messages” on page 2-9.

The User Messages section sometimes allows a servicer to isolate
printer problems. This section also gives actions to be taken when
they do not set or clear.

If you have a failing symptom, go to the “Symptom tables” on

page 2-25. Locate your symptom and take the appropriate action.

If a service error code appears while you are working on the printer,
go to the “Service error codes” on page 2-2 and take the
appropriate action.

Diagnostic information 2-1

5021-0XX

Service error codes

Error code Action

900
RIP Software

901
Yellow developer

clutch error (DCLY)
902

Magenta developer
clutch error (DCLM)

903
Cyan developer

clutch error (DCLC)
904

Black developer
clutch error (DCLK)

905
Yellow toner retract

solenoid error
(DSLY)

906
Magenta toner retract

solenoid error
(DSLM)

Contact customer service center, or Lexmark support
center

Go to “901—Yellow developer clutch service

check” on page 2-29.

Go to “902—Magenta developer clutch service

check” on page 2-31.

Go to “903—Cyan developer clutch service

check” on page 2-33.

Go to “904—Black developer clutch service

check” on page 2-35.

Go to “905—Y ellow toner retract solenoid service

check” on page 2-37.

Go to “906—Magenta toner retract solenoid

service check” on page 2-39.

907
Cyan toner retract

solenoid error
(DSLC)

908
Black toner retract

solenoid error
(DSLK)

2-2 Service Manual

Go to “907—Cyan toner retract solenoid service

check” on page 2-41.

Go to “908—Black toner retract solenoid service

check” on page 2-43.

Error code Action

5021-0XX

910
Developing motor

(DM) error
911

Main motor (MM)
error

912
Power supply fan

(PSFAN) error
913

Fuser fan (FUFAN)
error

914
Laser fan error

915
Erase lamp error

916
Toner empty sensor

connection error 1
(TPD)

Go to “910—Developer motor service check” on

page 2-45.

Go to “911—Main motor service check” on

page 2-48.

Go to “912—Power supply fan service check” on

page 2-51.

Go to “913—Fuser fan service check” on

page 2-52.

Go to “914—Laser fan service check” on

page 2-53.

Go to “915—Erase lamp service check” on

page 2-54.

Go to “916—Toner empty sensor (sender-TPD)

service check” on page 2-56.

917
Toner empty sensor

connection error 2
(TTR)

918
High voltage power

supply connection
error

919
Secondary paper

feed assembly error

Go to “917—Toner empty sensor (receiver-TTR)

service check” on page 2-57.

Go to “918—HVPS connection service check” on

page 2-58.

Go to “919—Lower feed unit (secondary paper

assembly) service check” on page 2-59.

Diagnostic information 2-3

5021-0XX

Error code Action

920
Fuser thermistor

error
921/922/923/924/925

Fuser temperature
error

92X
Fuser exhausted

930
Laser power error

931
Beam detector error

(BDT)

932
Scanner motor error

(SM)

Go to “920—Fuser thermistor service check” on

page 2-60.

Go to “921,922,923,924,925—Fuser assembly

service check” on page 2-61.

Fuser is in a maintenance state and needs to be
replaced before any other action can be taken.

Replace fuser assembly (see “Fuser assembly

removal” on page 4-9) and note whether any error

code exists.
Note: Fuser is a customer-order supply.

Indicates that printhead laser output is low.
Go to “930,931,932—Laser unit assembly service

check” on page 2-62.

Indicates that printhead laser scanning beam is not
detected by the beam sensor.

Go to “930,931,932—Laser unit assembly service

check” on page 2-62.

Indicates abnormal rotation of printhead scanner
motor.

Go to “930,931,932—Laser unit assembly service

check” on page 2-62.

939
RIP to engine

communication

945
Engine board

NVRAM error

2-4 Service Manual

Indicates that the RIP board processor cannot
communicate with processor. Remove and reinstall
RIP board. Go to “RIP board removal” on

page 4-45. Ensure RIP board makes proper

connection with engine controller board connector.
Ensure engine controller board is properly installed.
If error persists, replace RIP board. If error still
persists, replace engine controller board. See

“Engine controller board removal” on page 4-55.

Turn power off and then back on.
If error still exists, replace engine controller board.

Go to “Engine controller board removal” on

page 4-55.

Error code Action

5021-0XX

946
Engine controller

hardware error

947
Process timing clock

error

953
NVRAM chip failure

954
NVRAM CRC failure

955
Code CRC

955
Code ECC

956
Processor failure

Turn power off and then back on.
If error still exists, replace engine controller board.

Go to “Engine controller board removal” on

page 4-55.

Indicates synchronization signal from main motor
(MM) is not inputted.

Go to “911—Main motor service check” on

page 2-48.

Indicates engine board NVRAM failed.
Replace engine controller board. Go to “Engine

controller board removal” on page 4-55.

Indicates the operator panel failed CRC check.
Replace the operator panel cable. Go to “Operator

panel cable removal” on page 4-54.

Indicates that on-board NAND flash located on RIP
board has failed CRC check. Replace RIP board. Go
to “RIP board removal” on page 4-45.

Indicates that on-board NAND flash located on RIP
board has failed CRC check. Replace RIP board. Go
to “RIP board removal” on page 4-45.

Indicates a problem with RIP board processor.
Replace RIP board. Go to “RIP board removal” on

page 4-45.

957
ASIC failure

958
NAND failure

959
SRAM failure

960
Memory error

Indicates a problem with RIP board ASIC. Replace
RIP board. Go to “RIP board removal” on

page 4-45.

Indicates that on-board NAND flash located on RIP
board has failed. Replace RIP board. Go to “RIP

board remova l ” on page 4-45.

Indicates a problem with RIP board SRAM. Replace
RIP board. See “RIP board removal” on page 4-45.

Indicates that RIP board soldered RAM is bad.
Replace RIP board. Go to “RIP board removal” on

page 4-45.

Diagnostic information 2-5

5021-0XX

Error code Action

961
Memory error

962
Memory error

964
Emulation error

975
Unrecognizable

network port

976
Unrecognizable

software error in
network port

Indicates RAM in slot 1 is bad. Replace memory in
slot 1. If error persists, replace RIP board. Go to “RIP

board removal” on page 4-45.

Indicates RAM in slot 2 is bad. Replace memory in
slot 2. If error persists, replace RIP board. Go to “RIP

board removal” on page 4-45.

Indicates a failure within a download emulation that is
programmed into the firmware card. To troubleshoot,
perform the following:

1. Disable download emulation. Go to “Disabling

download emulations” on page 3-1.

2. Reprogram download emulation into the firmware
card.

3. If 964 error is still present, replace firmware card
and download emulation again.

Indicates a problem with the network port.

• Network printer

Replace RIP board. Go to “RIP board removal” on

page 4-45.

• Standard printer with INA

Replace INA. If error persists, replace RIP board. Go
to “RIP board removal” on page 4-45.

Indicates a problem with network port.
Network printer
Replace RIP board. Go to “RIP board removal” on

page 4-45.

• Standard printer with INA

Replace INA. If error persists, replace RIP board. Go
to “RIP board removal” on page 4-45.

978
Bad checksum while

programming
network port

2-6 Service Manual

Indicates a problem with the network port.

• Network printer

Replace RIP board. Go to “RIP board removal” on

page 4-45.

• Standard printer with INA

Replace INA. If error persists, replace RIP board. Go
to “RIP board removal” on page 4-45.

Error code Action

5021-0XX

979
Flash parts failed

while programming
network port

980
Duplex controller

hardware error 1

982
Duplex controller

hardware error 1

983
Duplex motor error

Indicates a problem with the network port.

• Network printer

Replace RIP board. Go to “RIP board removal” on

page 4-45.

• Standard printer with INA

Replace INA. If terror persists, replace RIP board. Go
to “RIP board removal” on page 4-45.

Indicates a communication problem between engine
controller board and duplex unit.

• Ensure that duplex cable is connected.

• If cable is connected and error persists, replace

duplex unit.

• If replacing duplex unit does not clear error,
replace engine controller board. Go to “Engine

controller board removal” on page 4-55.

Indicates a communication problem between engine
controller board and duplex unit.

• Ensure that duplex cable is connected.

• If cable is connected and error persists, replace

duplex unit.

• If replacing duplex unit does not clear error,
replace engine controller board. Go to “Engine

controller board removal” on page 4-55.

Indicates a blown motor-protective current fuse
located on DCTL board in duplex unit. Replace
duplex unit.

984
Outer pass select

solenoid error
985

Duplex connection
error 1

986
Duplex connection

error 2

Indicates a duplex solenoid problem. Replace duplex
unit.

Indicates that there is a connection problem between
the duplex unit and the low voltage power supply.

Go to “985—Duplex connection error 1 service

check” on page 2-63.

Indicates that there is a connection problem between
the duplex unit and engine controller board.

Go to “986—Duplex connection error 2 service

check” on page 2-64.

Diagnostic information 2-7

5021-0XX

Error code Action

990
Transfer belt (transfer

unit) error

991
Transfer roller clutch

error

992
Cleaning roller clutch

error

993
Fuser clutch error

994
OPC belt marker

sensor error

995
Charger HV unit error

Indicates unstable transfer belt rotation; color
matching cannot be secured.

Go to “990—Transfer belt unit service check” on

page 2-65.

Indicates a problem with transfer roller cable
connection.

Go to “991—Transfer roller clutch service check”

on page 2-67.

Indicates a problem with transfer unit cleaning roller
clutch cable connection.

Go to “992—Transfer belt cleaning roller clutch

service check” on page 2-68.

Indicates a problem with fuser clutch cable
connection.

Go to “993—Fuser clutch service check” on

page 2-69.

Indicates marker on OPC belt (photodeveloper
cartridge) is not being properly detected by marker
sensor.

Go to “994—OPC belt marker sensor service

check” on page 2-70.

Indicates a problem with HVPS charging voltage
supplied to the OPC (photodeveloper cartridge)
charging unit.

Go to “995—High voltage power supply (HVPS)

service check” on page 2-72.

996
LVPS error

2-8 Service Manual

Go to “996—Low voltage power supply (LVPS)

service check” on page 2-74.

Operator messages

Message Description Action

5021-0XX

Change Tray <x>
<type> <size>

Close Duplex Door Duplex door is

Close Front Cover Front cover is open. Open and reclose front cover.

Printer is requesting
different media than
what is loaded in
specified tray or
defined by paper
size or paper type
settings for tray.

open.

Ensure tray contains proper
type and size of media for job.

Remove tray from machine.
Remove paper from tray.
Change paper size length.

Observe paper size sensor
actuator, located on the side of
the tray, movement as you
change to various paper sizes.
Actuator should move back
and forth. If actuator does not
move back and forth, replace
paper tray.

If problem persists, go to

“Paper size sensing service
check” on page 2-87.

Ensure that strap connecting
front cover to printer is
attached to printer.

If problem persists, go to

“Cover open service check”
on page 2-75.

Close Rear Cover Rear cover

assembly is open.

Close Top Cover Top cover is open. Open and reclose top cover.

Open and close rear cover
assembly.

If problem persists, go to

“Cover open service check”
on page 2-75.

If problem persists, go to

“Cover open service check”
on page 2-75.

Diagnostic information 2-9

5021-0XX

Message Description Action

Did you replace
Fuser?

Did you replace the
Photodev Cart?

Fuser page counter
has exceeded fuser
page limit.

This message
appears when the
top door is closed or
when you answer
another
replacement
message, and
photodeveloper
cartridge is either in
a warning or
exhausted state
requiring that you
replace it.

Secondary
message appears
with instructions.

Replace fuser.
Note: This is a customer

ordered part.
Pressing Select clears

maintenance counter.
Press Stop to continue

printing. This does not clear
maintenance counter. Fuser
remains in warning state, and
message appears again each
time rear cover is opened.

Replace photodeveloper
cartridge and press Go.
Pressing Go clears
maintenance counter.

Press Stop to continue
printing. This does not clear
maintenance counter.
Message 83 Photodev
Exhausted returns after
pressing Stop. Photode veloper
cartridge remains in warning
state, and this message
appears again each time top
cover is opened.

2-10 Service Manual

Message Description Action

5021-0XX

Menus Disabled Printer menus have

been disabled. This
occurs when
<Menu> is pressed
while printer is
Ready and menu
lockout is active.

The printer display
shows this
message for one
second and then
returns to Ready
message.

No button actions
are possible while
this message is
displayed.

Not Ready Printer is in not

ready state, which
means it is not
ready to receive or
process data.

This message
displays when Stop
is pressed during a
print job.

If operator has disabled menu
and you want to run operator
print tests, turn machine Off
and then press Return and
Select as you turn machine
on.

Press Go to take the printer
out of the not ready state.

Perf orming Self Test Printer is running

normal series of
start-up tests after it
is powered on.
When tests are
complete, printer
returns to Ready.

No button actions
are possible while
this message is
displayed.

Printer performs self-test.

Diagnostic information 2-11

5021-0XX

Message Description Action

Power Saver Printer is ready to

receive and process
data. If printer
remains inactive for
period of time
specified in Power
Saver menu item
(20 minutes is
factory default),
Power Saver
message replaces
Ready message on
display.

Remove paper
Standard bin

Supplies At least one printer

TMA Toner mass

Output bin is full.
Bin full warning is
cleared when
output level
reported by bin is
no longer full.

supply requires
attention.

adjustment.
Printer is

performing a toner
mass adjustment.
This is a secondary
message that
appears on second
line of operator
panel when Engine

Warming and
Performing Self
Test messages

appear.

Send a job to print.
Press Go to quickly warm

printer to normal operating
temperature and display
Ready message.

Go to “Output tray full

service check” on page 2-85.

Press Menu to open Supplies
Menu and identify which
supply item needs replacing.

Replace appropriate printer
supply.

Wait for message to clear.

2-12 Service Manual

5021-0XX

Message Description Action

Tray <x> Empty I nput tray is empty. Load media of size and type

requested in second line of
display in specified tray. Printer
automatically clears message
and continues printing job. If
problem persists, go to “Tray

empty service check” on
page 2-95.

Tray <x> missing Specified tray is

30 <color> Toner
Cart Missing

32 Unsupported
Print Cartridge

34 Incorrect Media Printer has detected

34 Short Paper Printer has

either missing or
not fully inserted.

Specified cartridge
(Cyan, Magenta,
Yellow, or Black) is
not installed in the
printer.

Unsupported print
cartridge has been
installed in printer.

a mismatch in
requested media
type and type
loaded.

determined that
length of paper in
source specified on
second line of
display is too short
to print formatted
data.

Ensure tray is fully inserted in
printer. If problem persists, go
to “Paper size sensing

service check” on page 2-87.

Insert cartridge and close front
cover to clear message. If
message persists, go to

“Missing toner cartridge
service check” on page 2-81.

Remove print cartridge and
insert a supported print
cartridge. If problem persists,
go to “Missing toner

cartridge service check” on
page 2-81.

Remove paper tray. Ensure
media selected for print job is
in tray. If problem persists, go
to “Incorrect media service

check” on page 2-78.

Press Go to clear message.
Ensure paper size setting in
paper menu is correct for
paper size. If problem persists,
go to “Paper size sensing

service check” on page 2-87.

Diagnostic information 2-13

5021-0XX

Message Description Action

35 Res Save Off
Deficient Memory

37 Insufficient
Collation Area

37 Insufficient
Defrag Memory

Printer lacks
memory needed to
enable Resource
Save. This
message usually
indicates too much
memory is allocated
for one or more of
printer link buffers.

Printer memory (or
hard disk, if
installed) does not
have free space
necessary to collate
print job.

Printer cannot
defragment flash
memory, because
printer memory
used to store
undeleted flash
resources is full.

Press Go to disable Resource
Save and continue printing.

To enable Resource Save after
you get this message:

• Make sure link buffers are
set to Auto, and exit menus
to activate link buffer
changes.

• When Ready is displayed,
enable Resource Save from
the Setup Menu.

Install additional memory.
Press Go to print portion of job

already stored and begin
collating rest of job.

Press Menu to open Job Menu
and cancel current job.

Delete fonts, macros, and
other data in printer memory.

Install additional printer
memory.

2-14 Service Manual

Message Description Action

5021-0XX

37 Insufficient
Memory

38 Memory Full Printer is

Printer memory is
full and cannot
continue processing
current print jobs.

processing data,
but memory used to
store pages is full.

Press Go to clear message
and continue current print job.
Printer frees memory by
deleting oldest held job and
continues deleting held jobs
until there is enough printer
memory to process job.

Press Stop to clear message
without deleting any held jobs.
Current job may not print
correctly.

Press Menu to open Job Menu
and cancel current job.

To avoid this error in future:

• Delete fonts, macros, and
other data in printer
memory.

• Install additional printer
memory.

Note: Messages 37

Insufficient Memory and Held
Jobs May Be Lost alternate on

display.
Press Go to clear message

and continue printing job. Job
may not print correctly.

Press Menu to open Job Menu
and cancel current job.

To avoid this error in future:

• Simplify print job by
reducing amount of tex t or
graphics on a page and
deleting unnecessary
downloaded fonts or
macros.

• Install additional printer
memory.

Diagnostic information 2-15

5021-0XX

Message Description Action

39 Complex Page Page may not print

correctly because
print information on
page is too
complex.

51 Defective Flash Printer detects

defective flash
memory.

52 Flash Full There is not enough

free space in flash
memory to store
data you are trying
to download.

Press Go to clear message
and continue printing job. Job
may not print correctly.

Press Menu to open Job Menu
and cancel current job.

To avoid this error in future:

• Reduce complexity of page
by reducing amount of text
or graphics on page and
deleting unnecessary
downloaded fonts or
macros.

• Set Page Protect to On in
Setup Menu.

• Install additional printer
memory.

Press Go to clear message
and continue printing. You
must install different flash
memory before you can
download any resources to
flash.

Press Go to clear message
and continue printing.
Downloaded fonts and macros
not previously stored in flash
memory are deleted.

Delete fonts, macros, and
other data stored on flash
memory.

Install flash memory with more
storage capacity.

53 Unformatted
Flash

2-16 Service Manual

Printer detects
unformatted flash
memory.

Press Go to clear message
and continue printing. You
must format flash memory
before you can store any
resources on it.

If error message remains, flash
memory may be defective and
require replacing.

Message Description Action

5021-0XX

54 Serial Option
<x> Error

54 Standard Serial
Error

54 Network <x>
Software Error

54 Std Network
Software Error

54 Std Par ENA
Connection Lost

54 Par <x> ENA
Connection Lost

Printer has detected
a serial interface
error on a serial
port.

Printer cannot
establish
communications
with an installed
network port.

Printer has lost
connection to an
external print server
(also called an
external network
adapter or ENA).

Make sure serial link is set up
correctly and you are using
appropriate cable.

Press Go to clear message
and continue printing. Job may
not print correctly.

Press Menu to open Job Menu
and reset printer.

Press Go to clear message
and continue printing. Job may
not print correctly.

Program new firmware for
network interface by way of
parallel port.

Press Menu to open Job Menu
and reset printer.

Make sure cable connecting
ENA and printer is securely
attached. Turn printer off and
then on to reset printer.

Press Go to clear the
message. Printer erases any
reference to ENA and then
resets.

55 Unsupported
Option in Slot <x>

55 Unsupported
Flash in Slot <x>

56 Serial Port <x>
Disabled

An unsupported
option card is
installed in one of
ports or an
unsupported flash
DIMM is installed in
a memory slot.

Data has been sent
to printer through a
serial port, but
serial port is
disabled.

Turn off and unplug printer.
Remove unsupported option.
Plug in printer and turn it on.

Press Go to clear message.
Printer discards any data
received through serial port.

Make sure Serial Buffer menu
item in Serial Menu is not set
to Disabled.

Diagnostic information 2-17

5021-0XX

Message Description Action

56 Parallel P ort <x>
Disabled

56 Std Parallel Port
Disabled

57 Configuration
Change

58 Too Many Flash
Options

61 Defective Disk Printer detects a

62 Disk Full There is not enough

Data has been sent
to printer through a
parallel port, but
parallel port is
disabled.

Printer cannot
restore confidential
or held jobs on hard
disk because print
configuration has
changed.

Too many flash
memory options are
installed on printer.

defective hard disk.

memory on hard
disk to store data
sent to printer.

Press Go to clear message.
Printer discards any data
received through parallel port.

Make sure Parallel Buffer
menu item in Parallel Menu is
not set to Disabled.

Press Go to clear message.
Note: Messages 57

Configuration Change and
Held Jobs May Not Be
Restored alternate on display.

Turn off and unplug printer.
Remove excess flash memory.
Plug in printer and turn it on.

Press Go to clear message
and continue printing.

Install a different hard disk
before you perform any
operations that require one.

Press Go to clear message
and continue processing. Any
information not previously
stored on hard disk is deleted.

Delete fonts, macros, and
other data stored on hard disk.

63 Unformatted
Disk

2-18 Service Manual

Printer detects an
unformatted hard
disk.

Press Go to clear message
and continue printing.

Format disk before performing
any disk operations. To format
disk, select Format Disk from
Utilities Menu.

If error message remains, hard
disk may be defective and
require replacing. Install a new
hard disk and format it.

Message Description Action

5021-0XX

64 Unsupported
Disk Format

80 Transfer Roller
Missing

82 Waste Bottle
Nearly Full

82 Waste Toner
Bottle Full or
Missing

83 Photodev Cart
Exhausted

83 Photodev Cart
Life Warning

Printer detects an
unsupported disk
format.

Transfer roller is
missing or not
properly installed.

Toner waste bottle
is almost full.

Waste toner bottle
is full or missing.

Photodeveloper
cartridge is
completely used.

Photodeveloper
cartridge is nearing
end of life.

Press Go to clear message.
Format disk.
Note: Disk operations are not

allowed until disk is formatted.
Ensure transfer roller is

properly installed. If problem
persists, go to “T ransfer roller

missing service check” on
page 2-93.

Press Go to clear message
and continue printing.

Replace waste toner bottle. If
message does not clear, go to

“Waste toner bottle service
check” on page 2-97.

Replace waste toner bottle and
press Go to clear message.

“Waste toner bottle service
check” on page 2-97.

Replace photodeveloper
cartridge.

Press Go to clear message
and continue printing.

Replace photodeveloper
cartridge.

83 Photodev Cart
Missing

Photodeveloper
cartridge is either
missing or
incorrectly installed.

Correctly install
photodeveloper cartridge to
clear message and continue
printing.

Diagnostic information 2-19

5021-0XX

Message Description Action

87 Fuser Exhausted Fuser is completely

used.

87 Fuser Life
Warning

Fuser is nearing
end of life.

Replace fuser.
If problem persists, check

cable for co nt inuity that
connects engine controller
board connector FUCN and
fuser. If cable is bad, replace
cable. Otherwise, replace
engine controller board. Go to

“Engine controller board
removal” on page 4-55.

Press Go to clear message
and continue printing.

Replace fuser. Go to “Fuser

assembly removal” on
page 4-9.

Note: Fuser is a customer

ordered part.
If problem persists, check

cable for co nt inuity that
connects engine controller
board connector FUCN and
fuser. If cable is bad, replace
cable. Otherwise, replace
engine controller board. Go to

“Engine controller board
removal” on page 4-55.

87 Fuser Missing Fuser is either

missing or
incorrectly installed.

2-20 Service Manual

Correctly install fuser. Go to

“Fuser assembly removal”
on page 4-9.

If problem persists, check
cable for co nt inuity that
connects engine controller
board connector FUCN and
fuser. If cable is bad, replace
cable. Otherwise, replace
engine controller board. Go to

“Engine controller board
removal” on page 4-55.

Message Description Action

5021-0XX

88 <color> Toner
Empty

88 <color> Toner
Low

Printer has ceased
operating because
specified toner
cartridge is empty.

Printer has detected
that toner supply in
specified cartridge
is low.

Replace specified toner
cartridge. If problem persists,
go to “Toner low/empty

service check” on page 2-92.

Replace specified toner
cartridge. If problem persists,
go to “Toner low/empty

service check” on page 2-92.

Diagnostic information 2-21

5021-0XX

Paper jam me ssages

The following illustration lists paper jam messages indicating where
paper jam occurred.

CAUTION: When clearing paper jams, inside of the printer may be
hot. Allow printer to cool bef ore touching any internal components.

2-22 Service Manual