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Lexmark C510 Service Manual - Page 271

Main drive gear assembly removal, Remove transfer roller clutch. See

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5021-0XX Main drive gear assembly removal 1. Remove cleaning roller clutch. See "Toner sensor (sender) removal" on page 4-35. 2. Remove main motor assembly. See "Main motor assembly removal" on page 4-38. Note: If you are removing the main drive gear assembly to get to the waste toner feeder you do not have to remove the fuser, transfer roller, registration, or paper feed clutch. The clutches are removed at the first of this procedure because the main drive gear assembly FRU does not include the clutches. 3. Remove fuser clutch. See "Clutch removal" on page 4-40. 4. Remove transfer roller clutch. See "Clutch removal" on page 4-40. 5. Remove registration clutch. See "Clutch removal" on page 4-40. 6. Remove paper feed clutch. See "Clutch removal" on page 4-40. 7. Remove five screws (A) that secure main drive gear assembly to printer. A Repair information 4-41

Section	Page
Table of contents	3
Laser notices	11
Laser advisory label	11
Class 1 Laser statement label	12
Laser notice	13
Laser	13
Avis relatif à l’utilisation de laser	14
Avvertenze sui prodotti laser	14
Avisos sobre el láser	15
Laserinformatie	16
Lasermeddelelse	16
Huomautus laserlaitteesta	17
Laser-notis	17
Laser-melding	18
Avís sobre el Làser	18
Japanese laser notice	19
Chinese laser notice	19
Korean laser notice	20
Safety information	21
Consignes de sécurité	21
Norme di sicurezza	22
Sicherheitshinweise	22
Pautas de Seguridad	23
Informações de Segurança	23
Informació de Seguretat	24
Preface	26
Definitions	26
1. General information	27
Maintenance approach	27
Tools required for service	27
Serial number	28
Acronyms	29
Specifications	30
Resolution	30
Model differences	30
Technical specifications	30
Physical specifications and weight	31
Operating clearances	32
Packaging and shipping dimensions	32
Print speed and performance	33
Time to first print	33
Duty cycle	34
Printer memory	34
Paper and media specifications	34
Media sizes	37
Output capacity by media and source	38
Media guidelines	38
Connectivity	40
Power and electrical specifications	41
Environment	42
Printer identification	43
Options identification	44
Printer theory of operation	45
Printer paper path	46
Printer systems description	47
Basic principles of color printing	47
Mechanical and electrical structures	47
Printer component systems	49
Basic process of color printing	50
Print system and transfer system	51
Structure of OPC belt (photo developer cartridge)	52
Basic structure of the print system	53
Details of the print system	55
Charging process	55
Exposing process	57
Developing process	58
First transfer (drum) process	60
Belt discharge (erase lamp) process	61
Belt cleaning process	62
Details of the transfer system	64
Second transfer (paper) process	64
Transfer belt cleaning process	65
Details of the optical system	66
Details of the paper transportation system	68
Fusing unit	70
Fusing process	72
Control system structure	73
Electrical system and function	73
Control of print process	74
Print sequence diagram	75
Laser drive control circuit	76
Interface control	77
2. Diagnostic information	79
Start	79
Service error codes	80
Operator messages	87
Paper jam messages	100
Symptom tables	103
Printer symptom table	103
Print quality symptom table	105
Printer service checks	107
901-Yellow developer clutch service check	107
902-Magenta developer clutch service check	109
903-Cyan developer clutch service check	111
904-Black developer clutch service check	113
905-Yellow toner retract solenoid service check	115
906-Magenta toner retract solenoid service check	117
907-Cyan toner retract solenoid service check	119
908-Black toner retract solenoid service check	121
910-Developer motor service check	123
911-Main motor service check	126
912-Power supply fan service check	129
913-Fuser fan service check	130
914-Laser fan service check	131
915-Erase lamp service check	132
916-Toner empty sensor (sender-TPD) service check	134
917-Toner empty sensor (receiver-TTR) service check	135
918-HVPS connection service check	136
919-Lower feed unit (secondary paper assembly) service check	137
920-Fuser thermistor service check	138
921,922,923,924,925-Fuser assembly service check	139
930,931,932-Laser unit assembly service check	140
985-Duplex connection error 1 service check	141
986-Duplex connection error 2 service check	142
990-Transfer belt unit service check	143
991-Transfer roller clutch service check	145
992-Transfer belt cleaning roller clutch service check	146
993-Fuser clutch service check	147
994-OPC belt marker sensor service check	148
995-High voltage power supply (HVPS) service check	150
996-Low voltage power supply (LVPS) service check	152
Cover open service check	153
Incorrect media service check	156
Missing photodeveloper cartridge service check	158
Missing toner cartridge service check	159
OPC belt (photodeveloper) cartridge drive service check	161
Operator panel service check	162
Output tray full service check	163
Paper size sensing service check	165
Printer no power service check	167
Toner feed service check	169
Toner low/empty service check	170
Transfer roller missing service check	171
Tray empty service check	173
Waste toner bottle service check	175
Waste toner feed service check	176
Paper feed service checks	177
Printer paper feed service check	177
Print quality service checks	179
Background service check	179
Back stain service check	180
Banding service check	181
Black line service check	182
Color misregistration service check	183
Insufficient fusing service check	185
Insufficient gloss service check	186
Jitter service check	187
Missing image at edge service check	188
Mixed color image service check	189
Mottle service check	190
Residual image service check	191
Ribbing service check	192
Toner drop service check	194
Vertical line service check	196
Vertical staggering image service check	197
Vertical white band service check	198
White band service check	199
White line I service check	200
White line II service check	201
White spot / black spot service check	202
White print service check	203
Wrinkle / image migration service check	204
Uneven density (right and left)	205
Spacing table	207
Roller specifications	207
3. Diagnostic aids	209
Disabling download emulations	209
Paper jam sequence	210
Diagnostic mode	212
Diagnostics menu structure	213
Print quality test pages	213
Print registration	214
Setting tray 2 left margin	214
Setting top margin	215
Print tests	215
Hardware tests	216
LCD test	217
Button test	217
Parallel wrap test	217
ROM memory test	218
DRAM memory test	219
Serial wrap test	219
Duplex tests	221
Duplex left margin	221
Device tests	222
Quick disk test	222
Disk test/clean	222
Flash test	223
Printer setup	224
Setting the page count	224
Viewing the permanent page count	224
Serial number	225
Setting configuration ID	225
Parallel strobe adjustment	226
Error log	227
Viewing the error log	227
Printing the error log	227
Clearing the error log	228
Restore EP factory defaults	228
Exiting diagnostic mode	229
4. Repair information	231
Removal and cleaning precautions	231
Handling the printed circuit boards with MOS ICs	232
During transportation/storage:	232
During replacement:	232
During inspection:	232
Photodeveloper cartridge	233
During transportation/storage	233
Handling	233
Parts not to be touched	233
Printer removal procedures	234
Precautions to take before maintenance work	234
CRU/FRU and supplies removals	235
Cleaning roller cover removal	236
Transfer belt cleaning roller removal	236
Transfer belt unit removal	237
Transfer roller removal	238
Fuser assembly removal	239
Waste toner bottle removal	240
Photodeveloper cartridge removal	241
Duplex unit assembly removal	243
Secondary paper feed assembly removal	246
Cover removals	247
Top cover assembly removal	248
Front cover assembly removal	249
Right cover removal	252
Rear cover assembly removal	252
Left cover removal	254
Laser unit assembly (printhead) removal	254
Laser unit fan assembly removal	256
Erase lamp removal	257
Right side removals	259
Front door interlock switch removal	259
Front door interlock switch with bracket	261
Developer motor removal	261
Waste toner bottle holder removal	262
Developer drive assembly removal	262
Toner sensor (sender) removal	265
Cleaning roller clutch removal	266
Main motor assembly removal	268
Clutch removal	270
Main drive gear assembly removal	271
Waste toner feeder removal	272
Rear removals	274
RIP board removal	275
Bracket assembly removal	275
Paper guide assembly removal	276
Paper guide (C) assembly removal	277
Paper feed roller removal	278
Paper exit assembly removal	279
Registration assembly removal	282
Left side removals	283
Operator panel cable removal	284
Engine controller board removal	285
RIP board cage removal	287
High voltage power supply (HVPS) removal	289
Low voltage power supply (LVPS) with cage removal	290
HVPS cage removal	292
Toner present sensor removal	293
Toner sensor (receiver) removal	294
Toner retract solenoid and cam removal	294
Left tray guide assembly removal	295
Top removals	298
Marker sensor assembly removal	299
I/O board removal	300
Waste toner auger removal	302
Waste toner agitator removal	303
Power supply fan removal	304
5. Locations and connectors	305
Printer	305
Options	307
Electronic components	308
Sensor locations	308
Printer circuit board locations	310
Fan/motor locations	311
Interlock switch locations	312
Solenoid/clutch locations	313
Symbol and part name table	315
Wiring diagram / cable harness reference	318
RIP board	319
Engine controller board	320
Input/output (I/O) board	321
Low voltage power supply (LVPS) board	322
High voltage power supply (HVPS) board	322
Printer cables	323
Cable 1 connector assignments	323
Cable 1 connector pin assignments	323
Cable 2 connector assignments	326
Cable 2 connector pin assignments	326
Cable 3 connector assignments	328
Cable 3 connector pin assignments	328
Cable 4 connector assignments	330
Cable 5 connector assignments	331
Cable 6 connector assignments	336
Cable 6 connector pin assignments	336
Cable 7 connector assignments	340
Cable 7 connector pin assignments	340
Cable 9 connector assignments	346
Cable 9 connector pin assignments	346
Cable 10 connector assignments	348
Cable 10 connector pin assignments	348
Cable 11 connector assignments	350
Cable 11 connector pin assignments	350
Cable 12 connector assignments	351
Cable 12 connector pin assignments	351
Cable 13 connector assignments	352
Cable 13 connector pin assignments	352
6. Preventive maintenance	355
7. Parts catalog	357
How to use this parts catalog	357
Assembly 1: Base printer	358
Assembly 2: Covers	360
Assembly 3: Front	362
Assembly 4: Right	364
Assembly 5: Rear	366
Assembly 6: Left	368
Assembly 7: Top	370
Assembly 8: RIP board	372
Assembly 9: Miscellaneous/Options	374
Index	377
Part number index	381