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Revised March 24, 2006
Lexmark C510
5021-0XX
· Table of Contents · Start Diagnostics · 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 [email protected]. 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 dimensions. . . . . . . . . . . . . . . . . . . . 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 drive 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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Printer setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Setting the page count . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Viewing the permanent page count. . . . . . . . . . . . . . . . . . . . Serial number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Setting configuration ID. . . . . . . . . . . . . . . . . . . . . . . . . . . . . Parallel strobe adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . Error log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Viewing the error log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Printing the error log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Clearing the error log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Restore EP factory defaults . . . . . . . . . . . . . . . . . . . . . . . . . Exiting diagnostic mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15 3-16 3-16 3-16 3-17 3-17 3-18 3-19 3-19 3-19 3-20 3-20 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 removal . . . . . . . . . . . . . . . . . . . . . . . .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
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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
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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
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Laser notices
The following laser notice labels may be affixed to this printer as shown:
Laser advisory label
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Class 1 Laser statement label
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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 wavelength 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 maintenance, 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 ausstrahlt. Das Lasersystem und der Drucker sind so konzipiert, daß im Normalbetrieb, bei der Wartung durch den Benutzer oder bei ordnungsgemäßer Wartung durch den Kundendienst Laserbestrahlung, die die Klasse I übersteigen würde, Menschen keinesfalls erreicht.
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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.
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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 productos 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 afectada por ningún tipo de radiación 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 produto 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.
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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 laser 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 for en laserstråling over Klasse I-niveau ved normal drift, brugervedligeholdelse eller obligatoriske servicebetingelser.
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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 huoltotoimien 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 kraven 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 av en laserenhet av gallium-arsenid på 5 milliwatt som arbetar i våglängdsområdet 770795 nanometer. Lasersystemet och skrivaren är utformade 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.
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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.
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Japanese laser notice
Chinese laser notice
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Korean laser notice
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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 understand this and take 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
· 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 personnel d'entretien qualifié 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 exige que le produit reste sous tension.
· · ·
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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.
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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 und der Wartung des Geräts besteht ein zusätzliches Risiko eines elektrischen Schlags und körperlicher 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.
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Pautas de Seguridad
· La seguridad de este producto se basa en pruebas y
aprobaciones del diseño original y componentes específicos. El fabricante no es responsable 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.
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Informações de Segurança
· 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 graves 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.
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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 desmuntatge 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.
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Safety information xxv
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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 problems. 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.
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1. General information
This LexmarkTM C510 color laser printer is the ideal printer for presentations, business 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 repair.
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
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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.
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Acronyms
ASIC CS CSU DRAM EEPROM EP ESD FRU HV HVPS LAN LASER LCD LED LV LVPS NVRAM OEM PICS PIXEL POR POST PQET RIP ROS SRAM UPR VAC VDC Application-Specific Integrated Circuit Customer Ordered Customer Setup Dynamic Random Access Memory Electrically Erasable Programmable Read-Only Memory Electrophotographic Process Electrostatic Discharge Field Replaceable Unit High Voltage High Voltage Power Supply Local Area Network Light Amplification by Stimulated Emission of Radiation Liquid Crystal Display Light-Emitting Diode Low Voltage Low Voltage Power Supply Nonvolatile Random Access Memory Original Equipment Manufacturer Problem Isolation Charts Picture Element Power-On Reset Power-On Self Test Print Quality Enhancement Technology Raster Image Processor Read-Only Storage Static Random Access Memory Used Parts Replacement Volts alternating current Volts direct current
General information 1-3
5021-0XX
Specifications
Resolution
600 x 600 dpi 2400 image quality
Model differences
C510 USB 2.0 Parallel Ethernet Memory (MB) 530-sheet drawer (tray 2) Duplex Hard disk 64 X X X X X X 128 X X X X Options available X 128 C510n X C510dtn X
Technical specifications
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 (text, 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 selectable 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 inch mm Printers Lexmark C5101 Lexmark C510n2 Lexmark C510dtn3 Paper options Duplex unit 530-Sheet drawer 530-Sheet tray Standard tray Legal tray
1 2 3 4
Depth inch mm
Height inch mm
Weight4 lb kg
19.5 495 19.5 495 19.5 495
16.5 420 16.5 420 20.7 525
15.2 385 15.2 385 23.2 590
67.0 30.3 67.0 30.3 91.0 41.2
14.2 360 18.1 460 11.2 285 10.8 275 10.8 275
7.1 180 18.5 470 14.4 365 13.0 330 15.9 405
15.2 385 7.3 185 4.5 115 2.2 55 2.2 55
11.0 5.0 13.3 6.0 4.2 1.9 2.2 1.0 2.5 1.1
Base model is the base printer with standard 250-sheet input tray and starter cartridges. Network model is the network-ready printer with standard input tray and starter cartridges. Duplex network model is the network-ready printer plus duplex option and 530-sheet input tray. Weight does not include packaging or pubs.
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Operating clearances
Printer sides C510 & C510n C510 & C510n C510 & C510n with 530-sheet with duplex tray unit 8 in (203 mm) 20 in (508 mm) 28 in (711 mm) 10 in (254 mm) 29 in (736 mm) 8 in (203 mm) 20 in (508 mm) 28 in (711 mm) 14 in (355 mm) 25 in (635 mm) C510dtn with 530-sheet tray 8 in (203 mm) 20 in (508 mm) 28 in (711 mm) 14 in (355 mm) 29 in (736 mm)
Left side Right side Front Rear Top
8 in (203 mm) 20 in (508 mm) 28 in (711 mm) 10 in (254 mm) 23 in (584 mm)
Packaging and shipping dimensions
Width Printers1 C510 C510n C510dtn2 Options Duplex 530-Sheet drawer 530-Sheet tray 250-Sheet tray Legal tray
1 2
Depth in mm 20.9 530 20.9 530 23.6 599.44 20.8 528 22.4 570 15.1 384 16.2 412 19.0 483
Height in mm 22.4 570 22.4 570 46.2 1173.48 12.0 305 10.9 277 7.9 200 5.5 140 5.7 144
Weight lb kg 80 36.4 80 36.4 112.2 51.0 16.1 7.3 18.7 8.5 6.4 2.9 3.3 1.5 5.5 2.5
in mm 22.6 574 22.6 574 23.4 594.36 18.0 456 21.9 556 17.7 450 13.2 335 13.2 335
Includes start-up kit (supplies) C510dtn ships printer, duplex and 1 tray bundled on a pallet.
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Print speed and performance
Simplex printing pages/minute) Media size Letter A4 Legal Transparencies Thick card stock Labels (letter & A4) Medium thick card stock (letter & A4) Envelopes Standard tray 30 30 16 3 3 5 4 5 8 8 8 2 2 3 3 3 Duplex printing (sides/minute) Standard tray 15 15 5 N/S N/S N/S N/S N/S 4 4 4 N/S N/S N/S 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.
Time to first print
Simplex Time from standby mode Time from power saver mode 13 seconds 45 seconds 19 seconds 45 seconds Duplex 19 seconds 45 seconds 27 seconds 45 seconds
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.
Processor 500 MHz
General information 1-7
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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 Standard DRAM Max DRAM 64MB C510n 128MB 320MB C510dtn 128MB
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
C510 100pin DIMM slots (1-2 SDRAM, 1 Flash1) PCI Slots (for optional interface cards) Firmware card slot User flash card slot
1Only
C510n 1 1 1 1
C510dtn 1 1 1 1
2 1 1 1
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.
Paper and media specifications
Print area The C510 printable area is up to 4.0 mm (0.158 in.) from the top and bottom of the media, and up to 3.0 mm (0.118 in.) from the left and 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 edges, and 3.0 mm(0.118 in.) of the top and bottom edges.
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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 vary and is subject to media specifications and printer operating environment. The capacities listed are based on plain paper at 75 g/m2.
Sources and capacities Number of standard sources Number of optional input drawers Maximum number of input sources1 Input capacities2 Standard input Primary tray Second tray Total standard Optional input Optional legal tray Optional tray 1 Optional tray 2 Number of standard destinations Output capacities Standard output bin capacity (top) Media up to 20 lb paper Other Duplex unit
1 2 3
C510/C510n Input sources 1 1 2
C510dtn3 2 0 2
250 250 250 250 530 Output destinations 1
250 530 780 250 250 530 1
250 Yes
250 Standard
Optional input drawer is a 530-sheet capacity drawer. Only one optional drawer may be installed at any time. The printer supports top output (face down) as standard. No additional output options are available. Includes optional 530-sheet drawer. Note: All capacities are based on use of 20 lb paper.
General information 1-9
5021-0XX Media input types and weights
Source Type Standard 530tray Legal Sheet tray tray Duplex Printer menu Item
Paper type Paper1,2 (grain long) Xerographic 60-74 60-74 60-74 Plain paper or bond g/m2 g/m2 g/m2 paper (16-19 lb) (16-19 lb) (16-19 lb) 75-120 75-120 Plain paper Xerographic 75-120 or bond g/m2 (20- g/m2 (20- g/m2 (2032 lb) 32 lb) 32 lb) paper 100% Cotton Card stock Index Index 75-120 75-120 Plain paper 75-120 g/m2 g/m2 g/m2 (24-32 lb) (24-32 lb) (24-32 lb) 163 g/m2 (90 lb) 164- 210 g/m2 (91-110 lb) PN 12A5940 PN 12A5941 75-90 g/m2 (20-24lb) N/A N/A N/A N/A Card stock Card stock
Paper weight Light
Normal
Heavy
Normal Heavy
Transparency
3
N/A
N/A
Transparency
Labels2 Envelopes
1
N/A N/A
N/A N/A
Label Envelope Normal
Punched, embossed, water-marked, perforated, punched, inkjet paper or plasticcoated media should not be used. occasional use of paper labels in an office environment is supported. Only PN 12A5940 and 12A5941 should be used.
2 Only 3
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Media sizes
Media sizes Dimensions Standard 250-sheet tray 1 Input Optional 530-sheet tray 2 Output Standard 250-sheet bin X X X X X X X X X X X X X X
mm A4 A5 JIS B53 Letter Legal Executive Folio Statement Universal1 210 x 297 148 x 210 182 x 257 216 x 279.4 216 x 356 216 x 330
in. 8.27 x 11.7 5.83 x 8.27 7.17 x 10.1 8.5 x 11 8.5 x 14 X X X X X 8.5 x 13 X X X X X X X X X X X X X X X X X X X X X
184.2 x 266.7 7.25 x 10.5 139.7 x 215.9 5.5 x 8.5
Standard 250-sheet 104.8x210 to 4.125x8.27 to letter tray 215.9x297 8.5x11.7 Optional 250-sheet legal tray Optional duplex Envelope sizes 9 Envelope2 COM 10 Envelope DL Envelope C5
1
104.8x210 to 4.125x8.27 to 215.9x355.6 8.5x14 148x210 to 215.9x355.6 Dimensions 98.4x225.4 110 x 220 162 x 229 176 x 250 5.83x8.27 to 8.5x14 Dimensions 3.875 x 8.9 4.33 x 8.66 6.38 x 9.01 6.93 x 9.84 X X X X X X X X X X
104.8 x 241.3 4.12 x 9.5
Envelope2
B5 Envelope2
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. through the driver. B5 may be supported in optional tray 1, but size sensing must be turned off.
2 Supported 3
General information 1-11
Optional duplex unit
Optional legal tray
5021-0XX
Output capacity by media and source
Source Standard output bin (top)¹ Media Supports all sizes listed in the "Media sizes" table Capacity 250 sheets (20 lb paper) 50 Transparencies Orientation 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 failures.
· 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/m2 (20 lb) may cause
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 manufacturer 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.
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· 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 exceeding 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/m2 (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 exposed flap adhesive when the flap is in the closed position Self-seal envelopes
· Under high humidity conditions (over 60%), the envelopes may
seal during printing.
· For best results, print on new 90 g/m2 (24 lb) sulfite or 25%
cotton-bond envelope. 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 found 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.
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· Glossy paper is only supported from tray 1 (standard or legal
trays).
Connectivity
Cables Personal computers
· 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 requires the optional RS-232C serial interface card (P/N 11K4602). Connections
C510 Standard local connections Standard network connections Optional local connections Optional network connections C510n C510dtn Ethernet & USB 2.0
Parallel & USB 2.0 Ethernet & USB 2.0 N/A
10/100 Base-TX 10/100 Base-TX Ethernet Ethernet
RS-232 Serial/Parallel IEEE 1284-C Interface Card 10/100Base TX Ethernet, Token-Ring, 802.11b Wireless
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Power and electrical specifications
Printing states Off C510 0W C510n OW C510dtn OW
Average power while printing Continuous mono printing 550 W Continuous color printing 370 W Power consumption, standby Power saver on Power saver off 12 W 150 W 13 W 150 W 13 W 150 W 550 W 370 W 550 W 370 W
Maximum current while printing 100 Volts 115 Volts 230 Volts Average current while printing 100 Volts 115 Volts 230 Volts 6.9 A 5.6 A 3.0 A 8.1 A 7.2 A 2.83 A
General information 1-15
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Environment
Environment Air temperature - product operating Air temperature - product power off Air relative humidity Altitude Temperature-printer and supplies Relative humidity Atmospheric pressure
1Severe
Specifications Operating 10 to 32.5°C (50 to 90.5°F) 5 to 35°C (41 to 95°F) 15 to 80% 0 - 2,500 m (0 - 8,200 ft.) Ship / Storage 0 to 35°C (32 to 95°F)1 10 to 90% RH 613 to 16057 hPa (460 to 800 mm Hg)
High 35 to 40°C (95 to 104°F), Severe 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).
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Printer identification
General information 1-17
5021-0XX
Options identification
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Printer theory of operation
The following diagram shows the major parts of the printer and paper path.
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:
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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 cleaning 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 belt, 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.
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Printer component systems
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 transfer 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.
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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.
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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 high 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 power supply 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.
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 development process due to the difference 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 -CBV -CBV -CBV -CBV OPC belt K Y M C Developing 3 -V0 -V0 -V0 -V0 -V0 -V0 -V0 -V0 -V0 -V0 -V0 -V0 -V0 TE