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Lexmark MS510 - Service Manual
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MS510, MS610, M1145, & M3150
Machine Type 4514-630, -635, -646, -638,
-639, -649
Service Manual
•
Star
t diag
nos
tics
•
Maintenance
•
Safety and notices
•
Trad
emarks
•
Index
December 04, 2014
www.lexmark
.com
P/N 12G2826
2
Table of Contents
Main Page
Default Chapter
1
Service Manual
1
Product Information
2
Edition Notice
2
December
2
Table of Contents
3
Notices and Safety Information
13
Laser Notices
13
Safety Information
16
Preface
21
Service Manual Conventions
21
Change History
21
General Information
25
Media Guidelines
25
Paper Guidelines
25
Moisture Content
26
Unacceptable Paper
26
Using Recycled Paper and Other Office Papers
27
Using Specialty Media
28
Tips on Using Transparencies
29
Supported Paper Sizes, Types, and Weights
30
Supported Paper Types and Weights
31
Data Security Notice
32
Tools Required for Service
33
Diagnostic Information
35
Troubleshooting Overview
35
Performing the Initial Troubleshooting Check
35
Power-On Reset (POR) Sequence
35
Fixing Print Quality Issues
36
Initial Print Quality Check
36
Gray Background or Toner Fog Check
36
Blank Pages Check
37
Solid Black Pages Check
38
Repeating Defects Check
39
Shadow Images Check
39
Skewed Print Check
40
Streaked Horizontal or Vertical Lines Appear on Prints Check
42
Toner Smear Check
42
Toner Specks Appear on Prints Check
43
Paper Jams
44
Avoiding Jams
44
Understanding Jam Messages and Locations
45
200 Paper Jams
47
Main Drive Motor Control Jam Service Check
54
201 Paper Jams
55
202 Paper Jams
56
23Y Paper Jams
59
Duplex Service Check
61
241 Paper Jams
62
242-244 Paper Jams
66
25Y Paper Jams
72
Understanding the Printer Messages
74
Cartridge, Imaging Unit Mismatch [41.Xy]
74
Cartridge Low [88.Xy]
74
Cartridge Nearly Low [88.Xy]
74
Cartridge very Low, [X] Estimated Pages Remain [88.Xy]
74
Change [Paper Source] to [Custom Type Name] Load [Orientation]
74
Change [Paper Source] to [Custom String] Load [Paper Orientation]
75
Change [Paper Source] to [Paper Size] Load [Orientation]
75
Change [Paper Source] to [Paper Type] [Paper Size] Load [Orientation]
75
Close Front Door
75
Complex Page, some Data May Not Have Printed [39]
75
Configuration Change, some Held Jobs Were Not Restored [57]
75
Defective Flash Detected [51]
76
Error Reading USB Drive. Remove USB
76
Error Reading USB Hub. Remove Hub
76
Imaging Unit Low [84.Xy]
76
Imaging Unit Nearly Low [84.Xy]
76
Imaging Unit very Low, [X] Estimated Pages Remain [84.Xy]
76
Incorrect Paper Size, Open [Paper Source] [34]
77
Insert Tray [X]
77
Insufficient Memory to Support Resource Save Feature [35]
77
Insufficient Memory to Collate Job [37]
77
Insufficient Memory for Flash Memory Defragment Operation [37]
77
Insufficient Memory, some Held Jobs Were Deleted [37]
77
Insufficient Memory, some Held Jobs will Not be Restored [37]
78
Load [Paper Source] with [Custom String] [Paper Orientation]
78
Load [Paper Source] with [Custom Type Name] [Paper Orientation]
78
Load [Paper Source] with [Paper Size] [Paper Orientation]
78
Load [Paper Source] with [Paper Type] [Paper Size] [Paper Orientation]
79
Load Manual Feeder with [Custom Type Name] [Paper Orientation]
79
Load Manual Feeder with [Custom String] [Paper Orientation]
79
Load Manual Feeder with [Paper Size] [Paper Orientation]
79
Load Manual Feeder with [Paper Type] [Paper Size] [Paper Orientation]
80
Maintenance Kit Low [80.Xy]
80
Maintenance Kit Nearly Low [80.Xy]
80
Maintenance Kit very Low, [X] Estimated Pages Remain [80.Xy]
80
Memory Full [38]
80
Network [X] Software Error [54]
80
Non-Lexmark [Supply Type], See User's Guide [33.Xy]
81
Not Enough Free Space in Flash Memory for Resources [52]
81
Printer Had to Restart. Last Job May be Incomplete
81
Reinstall Missing or Unresponsive Cartridge [31.Xy]
82
Reinstall Missing or Unresponsive Imaging Unit [31.Xy]
82
Remove Paper from Standard Output bin
82
Replace Cartridge, 0 Estimated Pages Remain [88.Xy]
82
Replace Cartridge, Printer Region Mismatch [42.Xy]
82
Replace Imaging Unit, 0 Estimated Pages Remain [84.Xy]
83
Replace Maintenance Kit, 0 Estimated Pages Remain [80.Xy]
83
Replace Unsupported Cartridge [32.Xy]
83
Replace Unsupported Imaging Unit [32.Xy]
83
Serial Option [X] Error [54]
83
SMTP Server Not Set Up. Contact System Administrator
84
Standard Network Software Error [54]
84
Standard Parallel Port Disabled [56]
84
Standard USB Port Disabled [56]
84
Too Many Flash Options Installed [58]
84
Too Many Trays Attached [58]
85
Unformatted Flash Detected [53]
85
Unsupported Option in Slot [X] [55]
85
Weblink Server Not Set Up. Contact System Administrator
85
User Attendance Messages (0-99.99)
86
Toner Cartridge Smart Chip Contact Service Check
87
Imaging Unit Smart Chip Contact Service Check
88
Toner Smart Chip Compatibility Service Check
88
Imaging Chip Compatibility Service Check
89
Media Size Mismatch Service Check
89
Insufficient Memory Service Check
91
Printer/Cartridge Mismatch Service Check
91
Flash Full Service Check
92
Maintenance Kit Service Check
92
Imaging Unit Low Service Check
92
Toner Cartridge Low Service Check
93
Printer Hardware Errors
94
111 Errors
94
Errors
96
Errors
97
132 Errors
98
Errors
99
Errors
100
Errors
101
Errors
102
Errors
103
ACM Service Check
104
Steps before Starting the 9Yy Service Checks
104
900 Errors
106
Errors
111
94Y Errors
111
Errors
112
Errors
114
96Y Errors
115
97Y Errors
116
99Y Errors
117
Base Printer Symptoms
117
Dead Machine Service Check
117
Controller Board Service Check
118
Control Panel Button Service Check
119
Control Panel Service Check
120
Toner Starvation Service Check
120
USB Print Service Check
121
Network Service Check
122
Input Option Hardware Errors
125
3Yy Error Messages
125
Option Tray Pick/Lift Motor Service Check
127
Option Tray Separator/Pass through Motor Service Check
127
Option Tray ACM Motor Service Check
128
Option Tray Controller Card Service Check
128
Service Menus
129
Understanding the Printer Control Panel
129
Using the Printer Control Panel
129
Understanding the Colors of the Indicator and Sleep Button Lights
130
Menus List
131
Diagnostics Menu
132
Entering the Diagnostics Menu
132
Registration
132
Print Tests
133
Print Quality Pages
133
Hardware Tests
134
Duplex Tests
135
Top Margin
136
Left Margin
136
Input Tray Tests
137
Output bin Tests
138
Base Sensor Test
139
Device Tests
139
Printer Setup
140
Printed Page Count
141
Permanent Page Count
141
EP Setup
142
Print Contrast
143
Gap Adjust
143
Auto Dark Adj
143
Reports
144
Event Log
144
Exit Diags
145
Configuration Menu
145
Entering the Configuration Menu
145
Maintenance Counter Value
146
Reset Maintenance Counter
146
Print Quality Pages
146
Reports
147
Panel Menus
147
PPDS Emulation
147
Download Emuls
147
Safe Mode
147
Factory Defaults
148
Energy Conserve
148
Paper Prompts
148
Envelope Prompts
149
Action for Prompts
149
Jobs on Disk
150
Disk Encryption
150
Wipe All Settings
150
Font Density
150
Font Sharpening
150
Reduced Curl
151
Require Standby
151
A5 Loading
151
UI Automation
152
Key Repeat Initial Delay
152
Key Repeat Rate
152
Clear Supply Usage History
153
Clear Custom Status
153
USB Speed
153
Automatically Display Error Screens
153
USB Pnp
153
Restore Factory Defaults
154
Entering Invalid Engine Mode
154
Entering Recovery Mode
155
Accessing the Network SE Menu
155
Service Engineer Menu
155
Accessing the Service Engineer (SE) Menu
155
Service Engineer (SE) Menu
155
Repair Information
157
Removal Precautions
157
Data Security Notice
157
Handling ESD-Sensitive Parts
157
Controller Board/Control Panel Replacement
158
Restoring the Printer Configuration after Replacing the Controller Board
159
Restoring Solutions, Licenses, and Configuration Settings
161
Updating the Printer Firmware
162
Backing up Esf Solutions and Settings
163
Ribbon Cable Connectors
164
Zero Insertion Force (ZIF) Connectors
164
Horizontal Top Contact Connector
165
Horizontal Bottom Contact Connector
168
Vertical Mount Contact Connector
171
Horizontal Sliding Contact Connector
174
Low Insertion Force (LIF) Connector
177
Printhead Assembly Adjustments
178
Removal Procedures
181
Left Side Removals
181
Left Cover Removal
181
Main Drive Gearbox Removal
182
MPF Solenoid Removal
184
MPF Gearbox Removal
187
Reverse Solenoid Removal
190
Cartridge Gearbox Removal
191
Duplex Gear Assembly Removal
192
Right Side Removals
194
Right Cover Removal
194
Right Cover Removal (Ms610De)
194
Tray Present Sensor Removal
195
Cooling Fan Duct Removal
196
Cooling Fan Removals
196
Cooling Fan Mount Removal (Ms610De)
198
Controller Board Shield Removal (Ms610De)
200
Controller Board Removals
200
Toner Cartridge Smart Chip Contact Removal
204
Front Removals
206
Left Front Mount Removal
206
Right Front Mount Removal
208
Transfer Roll Removal
210
Cartridge Plunger Removal
211
Bezel Removals
214
Nameplate Removals
216
Control Panel Assembly Removals
218
UICC Removals
222
Control Panel USB Port Removal (Ms610Dn)
225
Speaker and Control Panel USB Port Removal (Ms610De)
226
MPF Assembly Removal
227
MPF Pick Roller Cover Removal
230
MPF Pick Roller Removal
230
Bail Removal
231
Jam Access Cover Removal
231
Front Door Removal
232
Front Access Cover Removal
235
Front Door Sensor Removal
235
Front Input Guide Removal
236
Separator Pad Removal
238
Bottom Removals
240
Power Supply Removal
240
Power Supply Shield Removal
241
Duplex Removal
242
Duplex Sensor and Input Sensor Removal
243
Index Sensor Removal
246
Toner Density Sensor Removal
246
Media Present Sensor Removal
247
Trailing Edge Sensor Removal
249
Media Present Sensor Flag Removal
249
ACM Assembly Removal
253
Pick/Lift Motor Gearbox Removal
255
Rear Side Removals
257
Dust Cover Removal
257
Rear Door and Cover Removal
257
Narrow Media/Bin Full Sensor Removal
258
Redrive Assembly Removal
260
Redrive Shaft Removal
261
Fuser Removal
263
Top Side Removals
264
Top Cover Removal
264
Laser Scanning Unit (LSU) Removal
265
250/550-Sheet Option Tray Removals
267
Pick Roller Removal
267
Separator Roll Assembly Removal
268
ACM Assembly Removal
270
Component Locations
273
Exterior Locations
273
Ms510Dn and Ms610Dn Exterior Locations
273
Rear View
274
Ms610De Exterior Locations
275
Maintenance
277
Inspection Guide
277
Scheduled Maintenance
278
Maintenance Kits
278
Resetting the Maintenance Counter
279
Lubrication Specification
279
Cleaning the Printer
280
Parts Catalog
282
Legend
282
Assembly 1: Covers
283
Assembly 2: Electronics 1
287
Assembly 3: Electronics 2
289
Assembly 4: Frame
292
Assembly 5: Option Trays
295
Assembly 6: Maintenance Kits
297
Assembly 7: Power Cords
299
Assembly 8: Miscellaneous
301
Appendix A: Printer Specifications
303
Product Power Consumption
303
Electrical Specifications
303
Operating Clearances
304
Acoustics
304
Operating Environment
305
Appendix B: Options and Features
307
Available Internal Options
307
Media Handling Options
307
Appendix C: Theory of Operation
309
POR Sequence
309
Printer Control
309
Paper Path Information
309
Input Tray
309
Multipurpose Feeder (MPF)
310
Simplex Printing
310
Duplex Printing
311
Media Handling Components
312
Main Drive Gearbox
312
Autocompensator Mechanism (ACM)
312
Key Components
313
Sensors
313
Other Key Components
314
Electrophotographic Process (EP Process)
316
Appendix D: Acronyms
321
Index
323
Part Number Index
331
Part Name Index
337
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Paper Guide
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