Page 1: Service Manual
MS510, MS610, M1145, & M3150 Machine Type 4514-630, -635, -646, -638, -639, -649 Service Manual • Start diagnostics • Maintenance • Safety and notices • Trademarks • Index December 04, 2014 www.lexmark.com P/N 12G2826...
Page 2: Product Information
December 04, 2014 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.
Page 3: Table Of Contents
4514-6xx Table of contents Product information..................2 Edition notice....................2 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 Using recycled paper and other office papers ....................27 Using specialty media ............................28 Supported paper sizes, types, and weights ......................30 Data security notice..........................32 Tools required for service........................33...
Page 4 4514-6xx Understanding jam messages and locations.....................45 200 paper jams ..............................47 201 paper jams ..............................55 202 paper jams ..............................56 23y paper jams ..............................59 241 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...
Page 5 4514-6xx 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...
Page 6 4514-6xx 155 errors ...............................102 171 errors ...............................103 ACM service check ............................104 Steps before starting the 9yy service checks ....................104 900 errors ...............................106 912 errors ...............................111 94y errors................................111 950–958 errors ...............................112 959 errors ...............................114 96y errors................................115 97y errors................................116 98y errors................................116 99y errors................................117 Base printer symptoms...........................117 Dead machine service check...........................117 Controller board service check ........................118...
Page 7 4514-6xx Printer Setup..............................140 EP Setup................................142 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...
Page 8 4514-6xx 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...
Page 9 4514-6xx 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...
Page 10 4514-6xx Component locations................273 Exterior locations..........................273 MS510dn and MS610dn exterior locations ....................273 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...
Page 11 4514-6xx 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...
Page 12 4514-6xx Table of contents...
Page 13: Notices And Safety Information
4514-6xx Notices and safety information Laser notices Laser notice The printer is certified in the U.S. to conform to the requirements of DHHS 21 CFR, Chapter I, 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.
Page 14 4514-6xx Aviso de láser Esta impresora se ha certificado en EE. UU. de conformidad con los requisitos de DHHS 21 CFR, capítulo I, subcapítulo J, para los productos láser de Clase I (1), y en otros países está certificada como un producto láser de Clase I de acuerdo con los requisitos de IEC 60825-1.
Page 15 4514-6xx Luokan I lasertuotteita ei pidetä haitallisina. Tulostimen sisällä on luokan IIIb (3b) laser, joka on nimellisteholtaan 7 mW:n galliumarsenidilaser ja toimii 655–675 nanometrin aallonpituuksilla. Laserjärjestelmä ja tulostin ovat rakenteeltaan sellaisia, että käyttäjä ei joudu alttiiksi luokkaa 1 suuremmalle säteilylle normaalin käytön, ylläpidon tai huollon aikana.
Page 16: Safety Information
4514-6xx Class I 레이저 제품은 위험한 제품으로 간주되지 않습니다. 프린터에는 655-675 나노미터의 파장 영역에서 작동 하는 공칭 7 밀리와트 갈륨 비소 레이저인 클래스 IIIb(3b) 레이저가 내부에 포함되어 있습니다. 레이저 시스템 과 프린터는 정상적인 작동, 사용자 유지 관리 또는 사전 설명된 서비스 조건에는 사람에게 클래스 I 수준 이상 의...
Page 17 4514-6xx AVERTISSEMENT—RISQUE DE BLESSURE La batterie lithium de ce produit n'est pas destinée à être remplacée. Il existe un risque d'explosion si une batterie lithium est placée de façon incorrecte. Ne rechargez pas, ne démontez pas et n’incinérez pas une batterie lithium.
Page 18 4514-6xx 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.
Page 19 4514-6xx 当心一可能的伤害：本产品中的锂电池不可更换。如果不正确更换锂电池，可能会有爆炸危险。不要再充电、拆解或焚烧锂电池。丢弃旧的锂电池时应按照制造商的指导及当地法规进行处理。 Notices and safety information...
Page 20 4514-6xx...
Page 21: Preface
4514-6xx Preface This manual contains maintenance procedures for service personnel. It is divided into the following chapters: • General information contains a general description of the printer. Special tools and test equipment are discussed. • Diagnostic information contains diagnostic aids you can use to isolate failing FRUs. These diagnostic aids include error code tables, symptom tables, and service checks.
Page 22 4514-6xx October 9, 2014 • Updated the illustration of Electronics 2 parts catalog assembly to show the correct toner cartridge smart chip contact. September 22, 2014 • Replaced part number 40X8274 with 40X9181. August 15, 2014 Updated the following service checks: •...
Page 23 4514-6xx • Updated the error code mapping for the paper jams. October 22, 2013 • Added part number 40X9654. • Deleted part numbers 40X8525 and 40X8526. September 19, 2013 • Added part number 40X9651. August 13, 2013 • Added “Restoring the printer configuration after replacing the controller board” under Removal precautions. •...
Page 24 4514-6xx...
Page 25: General Information
General information The Lexmark MS510, MS610, M1145, and M3150 are network‑capable, multi‑function laser printers that print monochrome print jobs. All information in this service manual pertains to all models unless explicitly noted. The printers are available in the following models:...
Page 26: Moisture Content
4514-6xx Curl Curl is the tendency for paper to curl at its edges. Excessive curl can cause paper feeding problems. Curl can occur after the paper passes through the printer, where it is exposed to high temperatures. Storing paper unwrapped in hot, humid, cold, or dry conditions, even in the trays, can contribute to paper curling prior to printing and can cause feeding problems.
Page 27: Using Recycled Paper And Other Office Papers
Lexmark consistently tests its printers with recycled paper (20–100% post-consumer waste) and a variety of test paper from around the world, using chamber tests for different temperature and humidity conditions. Lexmark has found no...
Page 28: Using Specialty Media
4514-6xx reason to discourage the use of today's recycled office papers, but generally the following property guidelines apply to recycled paper. • Low moisture content (4–5%) • Suitable smoothness (100–200 Sheffield units, or 140–350 Bendtsen units, European) Note: Some much smoother papers (such as premium 24 lb laser papers, 50–90 Sheffield units) and much rougher papers (such as premium cotton papers, 200–300 Sheffield units) have been engineered to work very well in laser printers, despite surface texture.
Page 29: Tips On Using Transparencies
Print samples on the labels being considered for use before buying large quantities. Note: Use only paper label sheets. Vinyl, pharmacy, and two‑sided labels are not supported. For more information on label printing, characteristics, and design, see the Card Stock & Label Guide available at http://support.lexmark.com. When printing on labels: •...
Page 30: Supported Paper Sizes, Types, And Weights
4514-6xx • Use transparencies designed specifically for laser printers. Transparencies must be able to withstand temperatures up to 185°C (365°F) without melting, discoloring, offsetting, or releasing hazardous emissions. Note: If the transparency weight is set to Heavy and the transparency texture is set to Rough in the Paper menu, then transparencies can be printed at a temperature up to 195°C (383°F).
Page 31: Supported Paper Types And Weights
4514-6xx Paper size Standard tray Optional 250‑ or Multipurpose feeder Duplex mode 550‑sheet tray Universal 76.2 x 127 mm (3 x 5 in.) up to 216 x 356 mm (8.5 x 14 in.) 7 3/4 Envelope (Monarch) 98 x 191 mm (3.9 x 7.5 in.) 9 Envelope 98 x 225 mm (3.9 x 8.9 in.) 10 Envelope...
Page 32: Data Security Notice
4514-6xx Paper type 250‑ or 550‑sheet tray Multipurpose feeder Duplex mode Bond Envelope Rough envelope Letterhead Preprinted Colored Paper Light Paper Heavy Paper Rough/Cotton One‑sided paper labels designed for laser printers are supported for occasional use. It is recommended to print 20 or fewer pages of paper labels per month.
Page 33: Tools Required For Service
4514-6xx After removing the old part, return it to your next level of support. Tools required for service • Flat-blade screwdrivers, various sizes • #0 Phillips screwdriver, magnetic • #1 Phillips screwdriver, magnetic • #2 Phillips screwdriver, magnetic • #2 Phillips screwdriver, magnetic short-blade •...
Page 34 4514-6xx...
Page 35: Diagnostic Information
4514-6xx Diagnostic information CAUTION—SHOCK HAZARD: For personal safety and to prevent damage to the printer, remove the power cord from the electrical outlet before you connect or disconnect any cable, electronic board or assembly. CAUTION—HOT SURFACE: The inside of the printer might be hot. To reduce the risk of injury from a hot component, allow the surface to cool before touching it.
Page 36: Fixing Print Quality Issues
4514-6xx The exit rollers turn. The control panel indicator light blinks (MS610de only). Ready appears on the display. If no error code is displayed, but a symptom is present, go to “Base printer symptoms” on page 117. Fixing print quality issues The symptoms described in this chapter might require replacement of one or more CRUs (Customer Replaceable Units) designated as supplies or maintenance items, which are the responsibility of the customer.
Page 37: Blank Pages Check
4514-6xx Actions Step 1 Go to step 2. Replace the cartridge plunger. See “Cartridge Check the cartridge plunger. plunger removal” on page 211. Is the cartridge plunger properly attached to the front door, and is the spring functioning properly? Step 2 Go to step 3.
Page 38: Solid Black Pages Check
4514-6xx Actions Step 3 Go to step 4. Replace the imaging unit. Check the imaging unit for wear or damage. Is it free of wear or damage? Step 4 Go to step 5. Replace the transfer roll. See “Transfer roll Check the transfer roll for surface contamination or excessive wear.
Page 39: Repeating Defects Check
4514-6xx Repeating defects check Actions Step 1 Replace the imaging Go to step 2. unit. Measure the distance between defects. Is the distance between defects equal to any of the following? • 3.82 in. (97 mm) • 1.85 in. (47 mm) •...
Page 40: Skewed Print Check
4514-6xx Actions Step 4 Go to step 5. Replace the fuser. See “Fuser removal” on Check the following fuser components for wear or damage: page 263. • Gears • Exit rollers • Belt fuser Are they free of damage? Step 5 The problem is solved.
Page 41 4514-6xx Actions Step 4 Go to step 5. Replace the pick tires. Make sure the pick tires are free of debris. Check for wear or damage. Are they free of wear or damage? Step 5 Go to step 11. Replace the input tray. Check the lift plate on the input tray for damage.
Page 42: Streaked Horizontal Or Vertical Lines Appear On Prints Check
4514-6xx Streaked horizontal or vertical lines appear on prints check Actions Step 1 Go to step 2. Replace the imaging unit. Check the imaging unit for wear or damage. Is it free of wear or damage? Step 2 Go to step 3. The problem is solved.
Page 43: Toner Specks Appear On Prints Check
4514-6xx Actions Step 1 Go to step 2. Tighten the screws. Check if the fuser screws are tightly fastened. Are they tightly fastened? Step 2 Go to step 3. Replace the fuser. See “Fuser removal” on Turn off the printer. page 263.
Page 44: Paper Jams
4514-6xx Actions Step 3 Go to step 4. Replace the transfer roll. See “Transfer roll Check the transfer roll for contamination or excessive wear. removal” on page 210. Is it free of contamination or wear? Step 4 Go to step 5. Replace the fuser.
Page 45: Understanding Jam Messages And Locations
4514-6xx • Make sure that the paper guides are properly positioned. • Push the tray firmly into the printer after loading paper. Use recommended paper • Use only recommended paper or specialty media. • Do not load wrinkled, creased, damp, bent, or curled paper. •...
Page 46 4514-6xx Area Printer control panel message What to do Standard bin [x]‑page jam, clear standard Remove the jammed paper. bin. [20y.xx] Rear door [x]‑page jam, open rear Open the rear door, and then remove the jammed paper. door. [20y.xx] Tray 1 [x]‑page jam, remove tray 1 to Pull tray 1 completely out, then push the front duplex flap clear duplex.
Page 47: 200 Paper Jams
4514-6xx 200 paper jams [x]‑page jam, open front door. [20y.xx] CAUTION—HOT SURFACE: The inside of the printer might be hot. To reduce the risk of injury from a hot component, allow the surface to cool before touching it. Press the button on the right side of the printer, and then open the front door. Pull the toner cartridge out using the handle.
Page 48 4514-6xx Warning—Potential Damage: Do not touch the shiny blue photoconductor drum under the imaging unit. Doing so may affect the quality of future print jobs. Lift the green flap in front of the printer. Place the imaging unit aside on a flat, smooth surface. Warning—Potential Damage: Do not expose the imaging unit to direct light for more than 10 minutes.
Page 49 4514-6xx Insert the imaging unit by aligning the arrows on the side rails of the unit with the arrows on the side rails inside the printer, and then insert the imaging unit into the printer. Insert the toner cartridge by aligning the side rails of the cartridge with the arrows on the side rails inside the printer, and then insert the cartridge into the printer.
Page 50 4514-6xx 200 paper jam messages Error code Description Action 200.01 Input sensor covered during warm-up sequence. Go to “Sensor (input) static jam service check” on page 200.02 Input sensor covered too quickly. Go to “Sensor (input) early/late arriving service check” on page 200.03 Page did not reach input sensor or was late reaching Go to...
Page 51 4514-6xx Error code Description Action 200.30 Invalid printhead NVRAM. Go to “Sensor (input) image jam service check” on page 200.31 Paper, in the middle of a job, at input sensor before Go to “Sensor (input) early/late arriving service interrupt occurred. check”...
Page 52 4514-6xx Action Step 4 Go to step 5. Replace the input sensor. See “Duplex POR into the Diagnostics menu and perform a sensor test: sensor and input Diagnostics Menu > Base Sensor Test > Input. sensor removal” on page 243. Does the sensor state on the control panel display change when it is toggled? Step 5...
Page 53 4514-6xx Action Step 6 Go to step 7. Replace either the media present sensor Check the media present sensor and media present sensor flag for: or media present • Proper operation sensor flag, or both. • Wear or damage See: •...
Page 54: Main Drive Motor Control Jam Service Check
4514-6xx Action Step 4 Go to step 5. Replace the LSU. See “Laser scanning unit POR into the Diagnostics menu and perform a feed test: (LSU) removal” on Diagnostics Menu > Input Tray Tests > Feed Tests > Tray 1 page 265.
Page 55: 201 Paper Jams
4514-6xx Action Step 4 Replace the controller Replace the fuser. See board. See “Controller “Fuser removal” on Check the fuser gear for damage or toner contamination. board removals” on page 263. page 200. Is it free of damage and contamination? 201 paper jams [x]‑page jam, clear standard bin.
Page 56: 202 Paper Jams
4514-6xx Sensor (narrow media) jam service check Action Step 1 Go to step 2. Reseat the cable. Check the narrow media sensor cable JNRW1 for proper connection. Is it properly connected? Step 2 Go to step 3. Replace the narrow media sensor.
Page 57 4514-6xx Firmly grasp the jammed paper on each side, and then gently pull it out. Note: Make sure all paper fragments are removed. Close the rear and front doors. From the printer control panel, press to clear the message and continue printing. 202 paper jam messages Error code Description...
Page 58 4514-6xx Error code Description Action 202.13 Restart attempted after an internal jam without cover Go to “Sensor (fuser exit) jam service check” on open. Close event. Likely that the jam was not actually page cleared. 202.14 Expected banner sheet ( assumed wide ) not detected Go to “Sensor (fuser exit) jam service check”...
Page 59: 23Y Paper Jams
4514-6xx Action Step 4 Go to step 5. Replace the fuser. See “Fuser removal” on Check the fuser gears and rollers for damage. page 263. Are they free of damage? Step 5 Contact the next level The problem is solved. of support.
Page 60 4514-6xx Locate the blue lever, and then pull it down to release the jam. Firmly grasp the jammed paper on each side, and then gently pull it out. Note: Make sure all paper fragments are removed. Insert the tray. From the printer control panel, touch to clear the message and continue printing.
Page 61: Duplex Service Check
4514-6xx 23y paper jam messages Error code Description Action 230.01 Sheet covering internal duplex sensor during warm Go to “Duplex service check” on page 230.02 Paper jam around internal duplex. Go to “Duplex service check” on page 230.03 Internal duplex sensor never made by leading edge of Go to “Duplex service check”...
Page 62: 241 Paper Jams
4514-6xx Action Step 4 Go to step 5. Replace the duplex. “Duplex removal” From under the printer, check the duplex, belt, and roller for wear and on page 242. damage. Are they free of wear and damage? Step 5 Go to step 6. Replace the duplex sensor.
Page 63 4514-6xx Insert the tray. From the printer control panel, select Next > > Clear the jam, press OK > 241 paper jam messages Error code Description Action 241.01 Paper over tray 1 pass through sensor on warmup. Go to “Tray 1 jam service check” on page 241.02 Sensor (input) early arriving jam.
Page 64 4514-6xx Error code Description Action 241.32 Media tray not ready. Go to “Tray 1 jam service check” on page 241.33 The media tray was pulled during the media pick Go to “Tray 1 jam service check” on page process. 241.41 Media feeder motor stall in tray 1.
Page 65 4514-6xx Action Step 5 Go to step 6. Replace the front input guide. See “Front input Check the front input guide. guide removal” on page 236. Is it free of damage? Step 6 Go to step 8. Go to step 7. POR into the Diagnostics menu and perform a feed test: Diagnostics Menu >...
Page 66: 242-244 Paper Jams
4514-6xx 242–244 paper jams [x]‑page jam, open tray [x]. [24y.xx] Pull the tray completely out of the printer. Note: The message on the printer display indicates the tray where the jammed paper is located. Firmly grasp the jammed paper on each side, and then gently pull it out. Note: Make sure all paper fragments are removed.
Page 67 4514-6xx Error code Description Action 242.03 Tray 2 pass through sensor never became covered Go to “Option tray jam service check” on page when feeding a sheet from an option below. 242.05 Option tray 2 pass through sensor never became Go to “Option tray jam service check”...
Page 68 4514-6xx Error code Description Action 242.46 Motor 2 (Separator/Passthrough) motor ramp (end Go to “Option tray jam service check” on page ramp - did not reach speed, typical pack feed paper jam). 242.47 Motor 3 motor stalled. Go to “Option tray jam service check” on page 242.48 Motor 3 motor PWM overflow error (underspeed).
Page 69 4514-6xx Error code Description Action 243.20 Took too long to ramp up dc feed motor in tray 3. Go to “Option tray jam service check” on page 243.21 Pick motor stall in tray 3. Go to “Option tray jam service check” on page 243.22 Tray 3 pick motor underspeed.
Page 70 4514-6xx Error code Description Action 244.09 Tray 4 pick motor lost encoder. Go to “Option tray jam service check” on page 244.11 Autocomp Pick / Lift Motor - Encoder Never Detected Go to “Option tray jam service check” on page in tray 4.
Page 71 4514-6xx Error code Description Action 244.49 Motor 3 motor ramp (end ramp - did not reach speed, Go to “Option tray jam service check” on page typical pack feed paper jam). Option tray jam service check Action Step 1 Replace the option Go to step 2.
Page 72: 25Y Paper Jams
4514-6xx Action Step 9 Contact the next level The problem is solved. of support. Does the error remain? 25y paper jams [x]‑page jam, clear manual feeder. [25y.xx] From the multipurpose feeder, firmly grasp the jammed paper on each side, and then gently pull it out. Note: Make sure all paper fragments are removed.
Page 73 4514-6xx 250 paper jam messages Error code Description Action 250.06 Input sensor did not detect sheet picked from Go to “MPF service check” on page MPF. No other sheets should be in the path. MPF service check Action Step 1 Go to step 2.
Page 74: Understanding The Printer Messages
Check if the toner cartridge and imaging unit are both MICR (Magnetic Imaging Content Recording) or non-MICR supplies. Note: For a list of supported supplies, see the “Ordering supplies” section of the User's Guide or visit www.lexmark.com. Change the toner cartridge or imaging unit so that both are MICR or non‑MICR supplies. Notes: •...
Page 75: Change [Paper Source] To [Custom String] Load [Paper Orientation]
4514-6xx Change [paper source] to [custom string] load [paper orientation] Try one or more of the following: • Load the correct size and type of paper in the tray, then verify that the paper size and type settings are specified in the Paper menu on the printer control panel, and then select Finished changing paper.
Page 76: Defective Flash Detected [51]
4514-6xx • The print job is sent from a flash drive that is no longer attached to the USB port. • The printer hard disk contains print jobs that were stored when the hard disk was installed in a different printer model.
Page 77: Incorrect Paper Size, Open [Paper Source] [34]
4514-6xx Incorrect paper size, open [paper source] [34] Try one or more of the following: • Load the correct size of paper in the tray. • From the printer control panel, select Continue to clear the message and print using a different tray. For non‑touch‑screen printer models, press to confirm.
Page 78: Insufficient Memory, Some Held Jobs Will Not Be Restored [37]
4514-6xx Insufficient memory, some held jobs will not be restored [37] Try one or more of the following: • From the printer control panel, select Continue to clear the message. For non-touch-screen printer models, press to confirm. • Delete other held jobs to free up additional printer memory. Load [paper source] with [custom string] [paper orientation] Try one or more of the following: •...
Page 79: Load [Paper Source] With [Paper Type] [Paper Size] [Paper Orientation]
4514-6xx Load [paper source] with [paper type] [paper size] [paper orientation] Try one or more of the following: • Load the tray or feeder with the correct size and type of paper. • To use the tray or feeder that has the correct size and type of paper, select Finished loading paper on the printer control panel.
Page 80: Load Manual Feeder With [Paper Type] [Paper Size] [Paper Orientation]
Maintenance kit low [80.xy] You may need to order a maintenance kit. For more information, contact customer support at http://support.lexmark.com or your service representative. If necessary, select Continue to clear the message and continue printing. For non‑touch‑screen printer models, press to confirm.
Page 81: Non-Lexmark [Supply Type], See User's Guide [33.Xy]
The printer has detected a non‑Lexmark supply or part installed in the printer. Your Lexmark printer is designed to function best with genuine Lexmark supplies and parts. Use of third-party supplies or parts may affect the performance, reliability, or life of the printer and its imaging components.
Page 82: Reinstall Missing Or Unresponsive Cartridge [31.Xy]
“Replacing supplies” section of the User’s Guide. Note: If you do not have a replacement cartridge, then see the “Ordering supplies” section of the User’s Guide or visit www.lexmark.com. Replace cartridge, printer region mismatch [42.xy] Install a toner cartridge that matches the region number of the printer.
Page 83: Replace Imaging Unit, 0 Estimated Pages Remain [84.Xy]
“Replacing supplies” section of the User’s Guide. Note: If you do not have a replacement imaging unit, then see the “Ordering supplies” section of the User’s Guide or visit www.lexmark.com. Replace maintenance kit, 0 estimated pages remain [80.xy] Contact customer support at http://support.lexmark.com...
Page 84: Smtp Server Not Set Up. Contact System Administrator
4514-6xx • From the printer control panel, select Continue to continue printing. For non‑touch‑screen printer models, press to confirm. • Turn off the printer, and then turn it back on. SMTP server not set up. Contact system administrator. From the printer control panel, select Continue to clear the message. For non‑touch‑screen printer models, press to confirm.
Page 85: Too Many Trays Attached [58]
4514-6xx Connect the power cord to a properly grounded electrical outlet. Turn the printer back on. Too many trays attached [58] Turn off the printer. Unplug the power cord from the electrical outlet. Remove the extra trays. Connect the power cord to a properly grounded electrical outlet. Turn the printer back on.
Page 86: User Attendance Messages (0-99.99)
4514-6xx User attendance messages (0–99.99) User attendance messages (0‑99.99) Error code Description Action 31.21 Capactive Toner Level Sensing (CTLS) reading out of Go to “CTLS service check” on page 100. range. 31.22 Excessive CTLS noise. Go to “CTLS service check” on page 100.
Page 87: Toner Cartridge Smart Chip Contact Service Check
4514-6xx Error code Description Action 32.05 OEM Mismatch. The supplies OEM ID is not Go to “Toner smart chip compatibility service check” compatible with the printer's machine class. on page 32.10 Toner cartridge smart chip compatibility error Go to “Toner smart chip compatibility service check” on page 32.11 Imaging unit smart chip compatibility error...
Page 88: Imaging Unit Smart Chip Contact Service Check
4514-6xx Action Step 2 Go to step 3. Reseat the cable. Check the cable JARW1 for proper connection to the controller board. Is it properly connected? Step 3 Replace the controller Replace the toner board. See “Controller cartridge smart chip Check the toner cartridge smart chip contact for damaged pins.
Page 89: Imaging Chip Compatibility Service Check
4514-6xx Action Step 3 Contact the next level The problem is solved. of support. Update the firmware. Note: Contact the next level of support for the correct firmware level. Does the error remain? Imaging chip compatibility service check Action Step 1 Go to step 3.
Page 90 4514-6xx Action Step 3 Go to step 4. Replace the index sensor. See “Index Make sure the index sensor is free of debris. sensor removal” on Check it for damage. page 246. Is it free of damage? Step 4 Go to step 5. Replace the trailing edge sensor.
Page 91: Insufficient Memory Service Check
4514-6xx Insufficient memory service check Action Step 1 Go to step 2. The problem is solved. Disable the Resource save feature: Settings > Print Settings > Setup Menu > Resource Save > Off Does the problem remain? Step 2 Go to step 3. Reseat the memory card.
Page 92: Flash Full Service Check
4514-6xx Flash full service check Action Step 1 Go to step 2. The problem is solved. Format the flash memory. Navigate to Settings > Print Settings > Utilities, then select Format Flash. Does the error remain? Step 2 Go to step 3. Replace the memory card.
Page 93: Toner Cartridge Low Service Check
4514-6xx Toner cartridge low service check Action Step 1 Go to step 2. The problem is solved. Replace the toner cartridge. Does the problem remain? Step 2 Go to step 3. The problem is solved. Make sure the toner cartridge smart chip contact cable JARW1 is properly connected to the controller board.
Page 94: Printer Hardware Errors
4514-6xx Printer hardware errors 111 errors 111 error messages Error code Description Action 111.00 Pel clock check failed. Go to “LSU service check” on page 111.01 Downlevel ASIC detected. 111.31 Printhead never delivered HSYNCs. 111.32 Printhead lost HSYNCs. 111.40 Wrong printhead installed 111.50 Open-loop printhead error, open-loop sweep state.
Page 95 4514-6xx Error code Description Action 111.60 Closed-loop printhead sweep error, check sweep Go to “LSU service check” on page accuracy state. 111.61 Printhead drive control out of range due to an external event beyond what the control is designed to handle. 111.62 Closed-loop printhead error, off-resonant PI effort state.
Page 96: Errors
4514-6xx 121 errors 121 error messages Error code Description Action 121.07 Fuser has been on for more than allowed after a gap Go to “Fuser service check” on page blowout, and the temperature is still too cold. 121.08 Fuser was under temp when page was in fuser. 121.20 Fuser undertemp during steady state control.
Page 97: Errors
4514-6xx Action Step 2 Go to step 3. Reseat the cables. • Check the fuser cables JTHERM1 and JEXIT for proper connection to the controller board. • Check the cable PCN5 for proper connection to the power supply. Are they properly connected? Step 3 Go to step 4.
Page 98: 132 Errors
4514-6xx LVPS service check Action Step 1 Go to step 2. The problem is solved. Check the power cord for continuity. If necessary, replace. Make sure the nominal voltage source is within specification. See “Electrical specifications” on page 303. Does the problem remain? Step 2 Go to step 3.
Page 99: Errors
4514-6xx Toner density sensor service check Action Step 1 Go to step 2. Clean the sensor. Remove the transfer roll, and check for loose toner blocking the toner density sensor. Is it free of loose toner? Step 2 Go to step 3. Reinstall the wiper properly.
Page 100: Errors
4514-6xx CTLS service check Action Step 1 Go to step 2. Clean the CTLS. Check for loose toner blocking the CTLS. Is it free of any loose toner? Step 2 Go to step 3. Reseat the cables. • Check the cable PCN3 for proper connection to the power supply. •...
Page 101: Errors
4514-6xx Action Step 3 Replace the controller Replace the main drive board. See “Controller gearbox. See “Main Check the main drive motor for proper operation: board removals” on drive gearbox Remove the main drive gearbox. page 200. removal” on page Note: Do not disconnect the main drive gearbox cable.
Page 102: Errors
4514-6xx Action Step 4 The problem is solved. Contact the next level of support. Replace the controller board. Does this fix the problem? 155 errors 155 error messages Error code Description Action 155.00 No encoder received from auger motor. Go to “Cartridge gearbox service check”...
Page 103: Errors
4514-6xx Action Step 4 Go to step 5. The problem is solved. Run a print test. Does the problem remain? Step 5 Go to step 6. The problem is solved. Replace the toner cartridge Does the problem remain? Step 6 Go to step 7.
Page 104: Acm Service Check
4514-6xx Cooling fan service check Action Step 1 Go to step 2. Replace the cooling fan. See “Cooling fan Make sure that the cable JFAN1 is properly connected to the controller removals” on board. page 196. Check if the cooling fan is rotating properly. Is it rotating properly? Step 2 Go to step 3.
Page 105 4514-6xx Note: Not all of the items can be retrieved from the printer you are working on. A. Collecting the history information from the SE menu Note: Make sure your printer is connected to a network or to a print server. From a Web browser, type http://printer_IP_address/se, and then press Enter.
Page 106: 900 Errors
104. Determine the operating system used when the error occurred. If possible determine whether a PostScript or PCL file was sent to the device when the error occurred. Ask the customer which Lexmark Solutions applications are installed on the device.
Page 107 4514-6xx Action Step 1 Go to step 2. The problem is solved. POR the printer. Does the error remain? Step 2 Go to step 3. Go to step 6. Write down the exact 900.xx error code displayed on the device. Turn off the printer.
Page 108 4514-6xx Action Step 7 Go to step 8. Go to step 10. Note: Before performing this step, write down the following information about the file being sent to the printer: • Application used • Operating system • Driver type • File type (PCL, PostScript, XPS, etc.) Reattach the communications cable.
Page 109 4514-6xx Action Step 15 Go to step 31. The problem is solved. Install a Lexmark recommended memory option. Send a print job to the printer. Does the error remain? Step 16 Go to step 17. Go to step 21. Is there a modem installed? Step 17 Go to step 18.
Page 110 4514-6xx Action Step 24 Go to step 25. The problem is solved. Upgrade the firmware if it was not upgraded in a previous step. Note: Contact your next level of support for the correct firmware level to use. POR the printer. Send the printer a print job.
Page 111: Errors
4514-6xx Action Step 31 Contact your next level of support. You will need the following information: • Exact 900.xx error digits and complete error message • Printed menu settings page • Printed network settings page • Device error log • A sample print file if the error appears to be isolated to a single file •...
Page 112: Errors
4514-6xx 950–958 errors 950–958 error messages Error code Description Action 950.xx NVRAM mismatch failure—mismatch between Go to “NVRAM mismatch failure service check” on controller board EEPROM and control panel mirror. page 112. ".xx" codes: • 00-29— mismatch between system and mirror •...
Page 113 4514-6xx Warning—Potential Damage: These components can be used as a method of troubleshooting as long as the machine is booted into diagnostic mode or is operating in diagnostic mode. Once a component has been installed in a machine and powered up into user mode, it cannot be used in another machine. It must be returned to the manufacturer.
Page 114: Errors
4514-6xx 959 errors 959 error messages Error code Description Action 959.01 Controller verification failure of pensive boot code Go to “Invalid firmware/controller board service check” on page 115. 959.02 Failure to authenticate Signature Verification Code 959.03 Signature Verification Code failed to authenticate a code partition 959.04 Jump to unverified address...
Page 115: 96Y Errors
4514-6xx Invalid firmware/controller board service check Action Update the firmware. Replace the controller The problem is solved. board. See “Controller Note: Contact the next level of support for the correct firmware level. board removals” on page 200. Does the error remain? 96y errors 96y error messages Error code...
Page 116: 97Y Errors
4514-6xx 97y errors 97y error messages Error code Description Action 975.xx Network Error—unrecognizable network port Call the next level of support. Call the next level of support. 976.xx Network Error—unrecoverable software error in network port Call the next level of support. 978.xx Network Error—bad checksum while programming network port...
Page 117: 99Y Errors
4514-6xx 99y errors 99y error messages Error code Description Action 990.xx An equipment check condition has occurred in the Call the next level of support. specified device, but the device is unable to identify the exact component failure—device can be: •...
Page 118: Controller Board Service Check
4514-6xx Action Step 2 Go to step 3. Reseat the cables. Check if the power supply cable is properly connected to the controller board. Are they properly connected? Step 3 Go to “Controller Replace the power board service check” supply. See “Power Turn off the printer.
Page 119: Control Panel Button Service Check
4514-6xx Action Step 5 Go to step 7. Go to step 6. Unplug the cable JPS1 from the controller board, and verify the following voltages from the cable: • +5 V at pins 11, 12, 13, 14, 15, 16 • GND at pins 18, 20 Are the voltages correct? Step 6...
Page 120: Control Panel Service Check
4514-6xx Action Step 4 The problem is solved. Contact the next level of support. Replace the controller board. Go to “Controller board removals” on page 200. Did this fix the problem? Control panel service check Warning—Potential Damage: Do not replace the operator panel and controller board at the same time. Each card contains the printer settings.
Page 121: Usb Print Service Check
4514-6xx Action Step 3 The problem is solved. Go to step 4. Install a new cartridge plunger and spring. See “Cartridge plunger removal” on page 211. Print some pages. Did this fix the problem? Step 4 Go to “Cartridge Go to step 5. gearbox service check”...
Page 122: Network Service Check
Have the network administrator verify that the device is using the correct SSID, and wireless security protocols. For more network troubleshooting information, consult the Lexmark Network Setup Guide. Actions Step 1 Go to step 3.
Page 123 4514-6xx Actions Step 3 Go to step 5. Go to step 4. Check the printer’s online status under Printers and Faxes on the host computer. Delete all print jobs in the print queue. Is the printer online and in a Ready state? Step 4 The problem is solved.
Page 124 4514-6xx Actions Step 13 The problem is solved. Go to step 14. Try using a different Ethernet cable. Did this fix the problem? Step 14 Replace the controller Contact the network board. See “Controller administrator. Have the network administrator check the network drop for activity. board removals”...
Page 125: Input Option Hardware Errors
4514-6xx Actions Step 24 The problem is solved. Go to step 25. Replace the wireless card. Did this fix the problem? Step 25 The problem is solved. Contact the next level of support. Replace the controller board. See “Controller board removals” on page 200.
Page 126 4514-6xx Error code Description Action 331.51 Motor 1 (Pick/Lift) motor no first encoder Go to “Option tray pick/lift motor service check” on page 127. 331.52 Motor 1 (Pick/Lift) motor stop error Go to “Option tray pick/lift motor service check” on page 127.
Page 127: Option Tray Pick/Lift Motor Service Check
4514-6xx Error code Description Action 344.59 Motor 3 PWM underflow (motor overspeed) Go to “Option tray ACM motor service check” on page 128. Option tray pick/lift motor service check Action Step 1 Go to step 2. Replace the tray insert. Remove the option tray insert.
Page 128: Option Tray Acm Motor Service Check
4514-6xx Action Step 3 Contact the next level Replace the separator of support. roll assembly. See Check the separator roll assembly for wear or damage. “Separator roll assembly removal” on Is it free of wear or damage? page 268. Option tray ACM motor service check Action Step 1 Go to step 2.
Page 129: Service Menus
4514-6xx Service menus Understanding the printer control panel Using the printer control panel MS510dn and MS610dn Use the Display View the printer status and messages. Set up and operate the printer. Left arrow button Scroll to the left. Select button Select menu options.
Page 130: Understanding The Colors Of The Indicator And Sleep Button Lights
4514-6xx Use the Stop or cancel button Stop all printer activities. Back button Return to the previous screen. Down arrow button Scroll down. Home button Go to the home screen. Indicator light Check the status of the printer. MS610de Use the Display View the printer status and messages.
Page 131: Menus List
4514-6xx Indicator light Printer status The printer is off or in Hibernate mode. Blinking green The printer is warming up, processing data, or printing. Solid green The printer is on, but idle. Blinking red The printer requires user intervention. Sleep button light Printer status The printer is idle or in Ready state.
Page 132: Diagnostics Menu
4514-6xx Security Settings Help General Settings Print All Guides Miscellaneous Security Settings Print Quality Confidential Print Flash Drive Menu Media Guide Print Settings Disk Wiping Print Defects Guide Security Audit Log Menu Map Set Date and Time Information Guide Connection Guide Moving Guide Supplies Guide This menu appears only in touch‑screen printer models.
Page 133: Print Tests
4514-6xx Top Margin -16 to +16 Increasing the value moves the image down the page. Always adjust the top before the bottom margin. Bottom Margin -20 to +20 Increasing the value moves the image toward the top of the page. ‑25 to +25 Left Margin Increasing the value moves the image toward the right margin.
Page 134: Hardware Tests
4514-6xx Hardware Tests If the hardware test fails, replace the failing part. Panel Test This test verifies the function of the control panel display. Enter the Diagnostics menu, and then navigate to: Hardware Tests > Panel Test Exit the test. Button Test This test verifies the control panel button function except for the Sleep button.
Page 135: Duplex Tests
4514-6xx After the printer resets, the results of the test appear: DRAM Test [x] P:###### F:######. • [x] represents the size of the installed DRAM. • P:###### represents the number of times the memory test passed and finished successfully. The maximum pass count is 999,999. •...
Page 136: Top Margin
4514-6xx The Quick test page contains the following information: • Printer registration settings • Code levels • Alignment diamonds at the top, bottom, and each side • Horizontal lines for skew adjustment • General printer information, including current page count, installed memory, processor speed, serial number, engine ID, and controller board ID Check the Quick test page for the correct offset between the placement of the first scan line on the front and back side of a duplexed sheet.
Page 137: Input Tray Tests
4514-6xx To run this test: From the Diagnostics menu, navigate to: Duplex Tests > Sensor Test Testing… appears while the printer is verifying the state of the sensor. The control panel displays the current state of the sensor. Manually actuate the sensor to make it toggle between Open and Closed. If the sensor does not toggle, then it is malfunctioning.
Page 138: Output Bin Tests
4514-6xx Sensor Test Use this test to determine if the input tray sensors are working correctly. From the Diagnostics menu, navigate to: Input Tray Tests > Sensor Test Select the input source. All installed sources appear. Not all sensors appear for all trays. The following table indicates which tray sensors are available for each input source: Input source Tray empty sensor Pass through sensor...
Page 139: Base Sensor Test
4514-6xx Press X to exit the test. BASE SENSOR TEST Use the Base Sensor Test to determine that the sensors located inside the printer are operating correctly. The following sensors can be checked using this test: • Narrow Media • Input •...
Page 140: Printer Setup
4514-6xx Disk Test/Clean Warning—Potential Damage: This test destroys all data on the disk and should not be attempted on a good disk. This test may run approximately 1.5 hours, depending on the disk size. Note: This test is available only on the MS610de model. From the Diagnostics menu, navigate to: DEVICE TESTS >...
Page 141: Printed Page Count
4514-6xx Printer default values U.S. value Non-U.S. value Paper Sizes setting in the General Settings menu U.S. Metric Default Paper Size (paper feeding sources which do not Letter have hardware size sensing capabilities) Default Envelope Size (envelope feeding sources which do 10 Envelope DL Envelope not have hardware size sensing capability)
Page 142: Ep Setup
4514-6xx Par S Strobe Adj This setting adjusts the factory setting for the amount of time the strobe is sampled to determine that valid data is available on the parallel port. Each time the value is increased by one, the strobe is sampled 50 nanoseconds longer. Each time the value is decreased by 1, the strobe is sampled 50 nanoseconds less than the default value.
Page 143: Print Contrast
4514-6xx Print Contrast This setting controls the developer voltage offset. To adjust this setting: From the Diagnostics menu, navigate to: EP Setup > Print Contrast Press OK or touch to save any changes. Charge Roll This setting controls the charge roll voltage. To adjust this setting: From the Diagnostics menu, navigate to: EP Setup >...
Page 144: Reports
4514-6xx Note: No messages are displayed on the control panel to give any indication that this test is running. The device stores the results of its most recent process in the Auto dark adj field on the Menu settings page report. When deactivated, the printer disables and never executes this process.
Page 145: Exit Diags
4514-6xx • USB setup pkt info entries • Supply event entries To print the Event log: From the Diagnostics menu, navigate to Event Log > Print Log. Clear Log Use this to remove all the current information in the Event log. This affects both the viewed log and the printed log information.
Page 146: Maintenance Counter Value
4514-6xx Maintenance Counter Value When this is selected, the printer displays the current value for the maintenance kit counter. This counter tracks printer usage. A print job containing a single page increments the counter by one, while a duplex print job increments the counter by two.
Page 147: Reports
4514-6xx Reports Menu Settings Page This report generates a list of the Configuration menu settings and the value of each setting. To print the Menu settings page from the Configuration menu: From the Configuration menu, navigate to: Reports > Menu Settings Page Depending on the printer model, press OK or touch to print the page, or press X to return to the Configuration menu.
Page 148: Factory Defaults
4514-6xx Available options: • • Factory Defaults Warning—Potential Damage: This operation cannot be undone. This setting enables a user to restore all of the printer settings to either the network settings (on network models only) or to the base printer settings. To restore Factory Default settings: From the Configuration Menu, navigate to Factory Defaults.
Page 149: Envelope Prompts
4514-6xx When it is set to Auto, the emulator selected to print the job determines which of the installed input sources will receive the change prompt. When set to a value other than Auto, the selected source always receives this type of prompt. Envelope Prompts This controls which tray a change prompt is directed to when the envelopes are sensed to be the wrong size.
Page 150: Jobs On Disk
4514-6xx Jobs on Disk This setting appears only if a hard disk is installed. It allows buffered jobs to be deleted from the disk. This does not affect Print and Hold or parked jobs. To change the setting: From the Configuration menu, navigate to Jobs on Disk. Select from the available options to change the setting: •...
Page 151: Reduced Curl
4514-6xx Available options: • • Reduced Curl When on, this setting significantly reduces throughput and should be activated only as a last resort to solve paper curl problems. The printer uses this mode only when the media type is set to Paper. Available options: •...
Page 152: Ui Automation
4514-6xx UI Automation Once enabled, this setting creates an ENABLE_UI_AUTOMATION file in the /var/fs/shared/ directory. As long as this file exists, the printer permits external developers to test the stability of their applications against the printer to make sure that their applications have an appropriate level of stability. Disabling this setting deletes the file and prohibits automated testing.
Page 153: Clear Supply Usage History
4514-6xx Clear Supply Usage History This setting reverts the supply usage history (number of pages and days remaining) to the factory shipped level. To clear the supply usage history: From the Configuration menu, navigate to Clear Supply Usage History. Depending on the printer model, press OK or touch Clear Supply Usage History to proceed. Clear Custom Status Executing this operation erases any strings that have been defined by the user for the default or alternate custom messages.
Page 154: Restore Factory Defaults
4514-6xx Available options: • • Restore Factory Defaults Restore Settings This setting enables a user to restore all of the printer settings to either the network settings (on network models only) or to the base printer settings. To restore the settings: From the Configuration menu, navigate to Restore Factory Defaults >...
Page 155: Entering Recovery Mode
4514-6xx Entering Recovery mode This mode will allow the printer to boot from a secondary set of instructions to allow a code flash to the printer. Code can be flashed from a PC by USB. Turn off the printer. Press and hold 7, 2, and 8 simultaneously. Turn on the printer.
Page 156 4514-6xx Top level menu Intermediate menu NVRAM • Dump NVRAM • Reinit NVRAM TCP/IP • netstat‑r • arp‑a • Allow SNMP Set • • Meditech Mode • RAW LPR Mode • Gather Debug • Enable Debug Service menus...
Page 157: Repair Information
4514-6xx Repair information Removal precautions CAUTION—SHOCK HAZARD: For personal safety and to prevent damage to the printer, remove the power cord from the electrical outlet before you connect or disconnect any cable, electronic board or assembly. Data security notice This printer contains various types of memory that are capable of storing device and network settings, information from embedded solutions, and user data.
Page 158: Controller Board/Control Panel Replacement
4514-6xx • Put the ESD wrist strap on your wrist. Connect the wrist band to the system ground point. This discharges any static electricity in your body to the machine. • Hold the ESD-sensitive part by its edge connector shroud (cover); do not touch its pins. If you are removing a pluggable module, use the correct tool.
Page 159: Restoring The Printer Configuration After Replacing The Controller Board
Note: The software bundle contains the latest version of the firmware, applications, and software licenses from the Lexmark Virtual Solutions Center (VSC). The printer firmware may be at a different level from what was used before replacing the controller board.
Page 160 4514-6xx Note: Make sure that the serial number in the zip file matches the serial number of the printer being restored. Extract the contents of the zip file, open the Readme file, and then follow the instructions in the file. Notes: •...
Page 161: Restoring Solutions, Licenses, And Configuration Settings
4514-6xx Notes: • If you are unable to access the administrative menus to verify that the printer is restored, then ask the customer for access rights. • If a 10.00 error is displayed after you restart the printer, then contact the next level of support. Restoring solutions, licenses, and configuration settings To load the zip files that are extracted from the Service Restore Tool, do the following: Open a Web browser, and then type the printer IP address.
Page 162: Updating The Printer Firmware
4514-6xx Click Import. Repeat steps 3 to 5 for the other zip files that are included in the expanded zip file. Updating the printer firmware Warning—Potential Damage: Before updating the printer firmware, ask the next level of support for the correct code.
Page 163: Backing Up Esf Solutions And Settings
4514-6xx Using a network computer Using the File Transfer Protocol (FTP) Make sure that the printer is in ready state before flashing the printer. Turn on the printer. Obtain the IP address: • From the home screen • From the TCP/IP section of the Network/Ports menu From the command prompt of a network computer, open an FTP session to the printer IP address.
Page 164: Ribbon Cable Connectors
4514-6xx Importing eSF solutions and settings file After replacing the controller board, import back to the printer the eSF solutions and settings that were exported. POR the printer into Invalid engine mode. See “Entering Invalid engine mode” on page 154. Open a Web browser, and then type the printer IP address.
Page 165: Horizontal Top Contact Connector
4514-6xx Horizontal top contact connector This FRU contains a horizontal top contact cable connector. Read the instructions before proceeding. The horizontal top contact connector uses a back flip locking actuator to lock the ribbon cable into the Zero Insertion Force (ZIF) connector. The cable is inserted horizontally into the connector. Warning—Potential Damage: When opening or closing this type of actuator, gently lift or close the two tabs located on each end of the actuator.
Page 166 4514-6xx Inserting a cable into the horizontal top contact connector When installing the cable, check the locking actuator to ensure it is in the unlocked position. The tabs on the ends of the actuator are vertical when the actuator is unlocked. Insert the cable with the contacts on the cable facing up.
Page 167 4514-6xx Rotate the locking actuator to the locked position. The cable should not move while this step is performed. If the cable moves, open the actuator, reposition the cable, and then close the actuator to the down position. Repair information...
Page 168: Horizontal Bottom Contact Connector
4514-6xx Horizontal bottom contact connector This FRU contains a horizontal bottom contact cable connector. Read the instructions before proceeding. The horizontal bottom contact connector uses a flip locking actuator to lock the ribbon cable into the Zero Insertion Force (ZIF) connector. The cable is inserted horizontally into the connector. Warning—Potential Damage: When opening or closing this type of actuator, gently lift the center of the actuator using your finger.
Page 169 4514-6xx Inserting a cable into the horizontal bottom contact connector Check the actuator to verify it is in the open position. Insert the cable into the ZIF connector with the contacts facing downward and away from the locking actuator. The cable needs to be inserted below the actuator.
Page 170 4514-6xx Place your finger in the middle of the actuator, and then rotate the locking actuator to the locked position. Repair information...
Page 171: Vertical Mount Contact Connector
4514-6xx Vertical mount contact connector This FRU contains a vertical mount contact connector. Read the instructions before proceeding. The vertical mount contact connector uses a back flip locking actuator to lock the ribbon cable into the Zero Insertion Force (ZIF) connector. The cable is inserted vertically into the connector. Warning—Potential Damage: When opening or closing this type of actuator, gently lift the center of the actuator using your finger.
Page 172 4514-6xx Inserting a cable into the vertical mount contact connector When installing the cable, check the locking actuator to verify it is in the open position. Insert the cable with the contacts on the cable away from the locking actuator. Insert the cable on top of the actuator. Note: Verify that the cable is installed squarely into the connector.
Page 173 4514-6xx Rotate the locking actuator to the locked position by pressing down on both ends of the actuator. The cable should not move when this step is performed. If the cable moves, open the actuator, reposition the cable, and then close the actuator to the down position.
Page 174: Horizontal Sliding Contact Connector
4514-6xx Horizontal sliding contact connector This FRU contains a horizontal sliding contact connector. Read the instructions before proceeding. The horizontal sliding contact connector uses a slide locking actuator to lock the ribbon cable into the Zero Insertion Force (ZIF) connector. The cable is inserted horizontally into the connector. Warning—Potential Damage: When opening or closing this type of actuator, gently push or pull the two tabs located on each end of the actuator.
Page 175 4514-6xx Inserting a cable into the horizontal sliding contact connector When installing the cable, check the locking actuator to verify it is in the open position. If you are opening the connector, pull back on both end tabs using equal force to avoid breaking the connector. Insert the cable with the contacts on the cable facing away from the locking actuator.
Page 176 4514-6xx Slide the locking actuator towards the connector, locking the cable into place. The cable should not move when this step is performed. If the cable moves, open the actuator, reposition the cable, and then close the actuator to the down position. Repair information...
Page 177: Low Insertion Force (Lif) Connector
4514-6xx Low Insertion Force (LIF) connector This FRU contains a Low Insertion Force (LIF) connector. Read the instructions before proceeding. Warning—Potential Damage: When installing a cable into an LIF connector, care must be taken to avoid bending the edges of the cables and damaging the contacts on the cables. Inserting a cable into the LIF connector Looking at the connector, take note on which side the contacts are located.
Page 178: Printhead Assembly Adjustments
4514-6xx Printhead assembly adjustments Printhead assembly mechanical adjustment A printhead needs to be correctly positioned after it has been removed. Use a sharp pencil or a small, flat-blade screwdriver to mark the location of the old printhead on the printer frame. Align the new printhead relative to the location of the old printhead.
Page 179 4514-6xx If the grid lines of the right flap align below the corresponding lines on the left flap, then adjust the printhead clockwise relative to the printer, and recheck. If the grid lines of the left flap align below the corresponding lines of the right side, then adjust the printhead counterclockwise.
Page 180 4514-6xx Sample Quick test page. Use the actual sheet. From the Registration menu, select the Right margin setting: Diagnostics Menu > Registration > Right Margin To determine the Right margin setting: Choose the value of the darkest bar on the right side of the Quick test page. Add that value to the current Right margin setting found on the left side of the Quick test page.
Page 181: Removal Procedures
4514-6xx Removal procedures Keep the following tips in mind as you replace parts: • Some removal procedures require removing cable ties. You must replace cable ties during reassembly to avoid pinching wires, obstructing the paper path, or restricting mechanical movement. •...
Page 182: Main Drive Gearbox Removal
4514-6xx Main drive gearbox removal Remove the left cover. See “Left cover removal” on page 181. Squeeze the latch, and then detach the link from the front door. Repair information...
Page 183 4514-6xx Remove the 4 screws (A), and then remove the main drive gearbox. Disconnect the cable from the main drive gearbox. Repair information...
Page 184: Mpf Solenoid Removal
4514-6xx Remove the spring (B) and the fuser gear (C). MPF solenoid removal Remove the left cover. See “Left cover removal” on page 181. Remove the right cover. See “Right cover removal” on page 194. Remove the rear door and cover. See “Rear door and cover removal”...
Page 185 4514-6xx Cut the cable (B). Remove the other half of the cable from the printer. Installation notes: Install the MPF solenoid. Secure the cable to the holder (A). Repair information...
Page 186 4514-6xx Insert the cable into the hole (B). Route the cable using the new path. Repair information...
Page 187: Mpf Gearbox Removal
4514-6xx Secure the cable at the pick/lift motor gearbox using cable ties. Cut off any excess cable tie. MPF gearbox removal Remove the left cover. See “Left cover removal” on page 181. Remove the main drive gearbox. See “Main drive gearbox removal” on page 182.
Page 188 4514-6xx Disconnect the spring (A) from the printer. Remove the three screws (B), and then remove the left front mount. Repair information...
Page 189 4514-6xx Remove the three screws (C), and then remove the MPF gearbox. Release the two latches (D), and then remove the main input drive gears. Repair information...
Page 190: Reverse Solenoid Removal
4514-6xx Remove the E-clip (E), and then remove the MPF sector gear (F). Reverse solenoid removal Remove the right cover. See “Right cover removal” on page 194. Remove the left cover. See “Left cover removal” on page 181. Remove the rear door and cover. See “Rear door and cover removal”...
Page 191: Cartridge Gearbox Removal
4514-6xx Remove the two screws (A) securing the reverse solenoid. Cartridge gearbox removal Remove the left cover. See “Left cover removal” on page 181. Remove the four screws (A) securing the cartridge gearbox. Disconnect the cable from the cartridge gearbox. Repair information...
Page 192: Duplex Gear Assembly Removal
4514-6xx Duplex gear assembly removal Remove the left cover. See “Left cover removal” on page 181. Remove the rear door and cover. See “Rear door and cover removal” on page 257. Remove the power supply. See “Power supply removal” on page 240.
Page 193 4514-6xx From behind the three gears, remove the duplex coupling (D). Remove the duplex link (E) from the duplex. Repair information...
Page 194: Right Side Removals
4514-6xx Right side removals Right cover removal Open the front door. Position the printer so that it sits on its left side. Remove the two screws (A) securing the right cover. Release the latches (B) to remove the right cover. Right cover removal (MS610de) Open the controller board access door.
Page 195: Tray Present Sensor Removal
4514-6xx Release the latches (C) to remove the right cover. Tray present sensor removal Remove the right cover. See “Right cover removal” on page 194. Disconnect the cable (A) from the tray present sensor. Pry to remove the sensor retainer (B). Note: The retainer is secured to the sensor by an adhesive.
Page 196: Cooling Fan Duct Removal
4514-6xx Cooling fan duct removal Note: This is not a FRU. Remove the right cover. See “Right cover removal” on page 194. Remove the screw (A), and then remove the cooling fan duct. Cooling fan removals Cooling fan removal (MS510dn and MS610dn) Remove the right cover.
Page 197 4514-6xx Remove the two screws (B) securing the fan to the fan mount. Cooling fan removal (MS610de) Remove the right cover. See “Right cover removal” on page 194. Disconnect the cable JFAN1 from the controller board. Repair information...
Page 198: Cooling Fan Mount Removal (Ms610De)
4514-6xx Remove the two screws (A), and then remove the fan. Cooling fan mount removal (MS610de) Note: This is not a FRU. Remove the right cover. See “Right cover removal” on page 194. Remove the cooling fan. See “Cooling fan removals” on page 196.
Page 199 4514-6xx Remove two screws (A), and then remove the cooling fan mount. Repair information...
Page 200: Controller Board Shield Removal (Ms610De)
4514-6xx Controller board shield removal (MS610de) Note: This is not a FRU. Remove the right cover. See “Right cover removal” on page 194. Remove the four screws (A) securing the controller board shield. Controller board removals Note: Before replacing the controller board, export the eSF solutions and settings from the printer. For more information, see “Backing up eSF solutions and settings”...
Page 201 4514-6xx Remove the screw (A) from the rear side of the printer. Remove the five screws (B) securing the controller board. Installation note: After installing a new controller board, perform the printer configuration restoration. See “Restoring the printer configuration after replacing the controller board” on page 159.
Page 202 4514-6xx Controller board removal (MS610de) Remove the right cover. See “Right cover removal” on page 194. Remove the controller board shield. See “Controller board shield removal (MS610de)” on page 200. Disconnect all cables from the controller board. Release the toroid from the holder. Repair information...
Page 203 4514-6xx Remove the screw (A) from the rear side of the printer. Remove the seven screws (B) securing the controller board. Repair information...
Page 204: Toner Cartridge Smart Chip Contact Removal
4514-6xx Installation note: After installing a new controller board, perform the printer configuration restoration. See “Restoring the printer configuration after replacing the controller board” on page 159. Toner cartridge smart chip contact removal Remove the right cover. See “Right cover removal” on page 194.
Page 205 4514-6xx From behind the right cartridge guide, release the 4 latches (C) to detach the toner cartridge smart chip contact. Note: Pay attention to the original position of the spring and the actuators. Repair information...
Page 206: Front Removals
4514-6xx Installation notes: Test for proper installation of the spring and the actuators. Press the cartridge actuator. The cartridge lock should move up. Release the cartridge actuator. The cartridge lock should move back to its original position. Front removals Left front mount removal Remove the left cover.
Page 207 4514-6xx Disconnect the spring (A) from the printer. Remove the three screws (B), and then remove the left front mount. Repair information...
Page 208: Right Front Mount Removal
4514-6xx Right front mount removal Remove the right cover. See “Right cover removal” on page 194. Disconnect all control panel cables from the controller board. Disconnect the cable JCVR1 from the controller board. Remove the screw (A) to disconnect the ground wire. Repair information...
Page 209 4514-6xx Remove the four screws (B), and then remove the right front mount. Repair information...
Page 210: Transfer Roll Removal
4514-6xx Transfer roll removal Warning—Potential Damage: Do not touch the transfer roll with bare hands. Oil from the skin can damage it. Squeeze the latches at each end of the transfer roll. Lift to remove the transfer roll. Warning—Potential Damage: Do not remove the spring under the left latch. Doing so will damage the printer. Repair information...
Page 211: Cartridge Plunger Removal
4514-6xx Cartridge plunger removal Open the front door. Tilt the cartridge plunger. Twist and then remove the cartridge plunger. Repair information...
Page 212 4514-6xx Installation notes: Use a spring hook to hold the spring, and then reinstall the cartridge plunger. Repair information...
Page 213 4514-6xx Set the spring over the plunger. Repair information...
Page 214: Bezel Removals
4514-6xx Bezel removals Bezel removal (MS510dn) Open the front door. Push the latches (A), and then remove the bezel. Repair information...
Page 215 4514-6xx Bezel removal (MS610dn) Open the front door. Push the latches (A), and then remove the bezel. Repair information...
Page 216: Nameplate Removals
4514-6xx Bezel removal (MS610de) Open the front door. Pull to remove the bezel. Nameplate removals Nameplate removal (MS510dn and MS610dn) Open the front door. Remove five screws (A) securing the nameplate. Repair information...
Page 217 4514-6xx Nameplate removal (MS610de) Open the front door. Press the latch (A) to release the access cover latch (B). Release the access cover latch from the mechanical keys on both sides. Remove the spring (C) from the front access cover. Repair information...
Page 218: Control Panel Assembly Removals
4514-6xx Remove the six screws (D) securing the nameplate. Control panel assembly removals Control panel assembly removal (MS510dn and MS610dn) Remove the right cover. See “Right cover removal” on page 194. Remove the nameplate. See “Nameplate removals” on page 216. Remove the bezel.
Page 219 4514-6xx Disconnect the cables JUSBF1 (for MS610dn only) and JUICC1 and from the controller board. Remove the screw (B) from the right front mount, and route the cables through the slot. Repair information...
Page 220 4514-6xx Remove the two screws (C) securing the control panel assembly. Route all cables off the printer to completely remove the control panel assembly. Control panel assembly removal (MS610de) Remove the right cover. See “Right cover removal” on page 194. Remove the nameplate.
Page 221 4514-6xx Remove the toroid. Remove the screw (A) securing the ground connector to the controller board. Disconnect the cables JUICC1 and J24 from the controller board. Repair information...
Page 222: Uicc Removals
4514-6xx Remove the screw (B) from the right front mount, and route the cables through the slot. Remove the five screws (C) securing the control panel to the front door. UICC removals UICC removal (MS510dn and MS610dn) Remove the right cover. See “Right cover removal”...
Page 223 4514-6xx Remove the bezel. See “Bezel removals” on page 214. Remove the control panel assembly. See “Control panel assembly removals” on page 218. Remove the cable from the connector (A). Remove the eight screws (B). Flip the UICC, and then remove the screw (C). Note: The control panel cover, buttons, and light pipe are not included with the UICC.
Page 224 4514-6xx UICC removal (MS610de) Remove the right cover. See “Right cover removal” on page 194. Remove the nameplate. See “Nameplate removals” on page 216. Remove the bezel. See “Bezel removals” on page 214. Remove the control panel assembly. See “Control panel assembly removals” on page 218.
Page 225: Control Panel Usb Port Removal (Ms610Dn)
4514-6xx Flip the UICC, and remove the four screws (C) securing the display bracket. Note: The control panel cover, buttons, and light pipe are not included with the UICC. Control panel USB port removal (MS610dn) Remove the right cover. See “Right cover removal”...
Page 226: Speaker And Control Panel Usb Port Removal (Ms610De)
4514-6xx Remove the two screws (A), and then remove the control panel USB port. Speaker and control panel USB port removal (MS610de) Remove the right cover. See “Right cover removal” on page 194. Remove the nameplate. See “Nameplate removals” on page 216.
Page 227: Mpf Assembly Removal
4514-6xx MPF assembly removal Remove the nameplate. See “Nameplate removals” on page 216. Remove the two springs (A). Repair information...
Page 228 4514-6xx Squeeze the latches (B) to release the left and right links. Repair information...
Page 229 4514-6xx Release the lock (C) remove the MPF link. Do the same on the other MPF link. Release the right tab (D) of the MPF. Slide the MPF assembly to remove. Repair information...
Page 230: Mpf Pick Roller Cover Removal
4514-6xx MPF pick roller cover removal Open the front door. Remove the two screws (A), and then remove the MPF pick roller cover. MPF pick roller removal Remove the MPF pick roller cover. See “MPF pick roller cover removal” on page 230.
Page 231: Bail Removal
4514-6xx Warning—Potential Damage: Do not touch the pick tire with bare hands, as this can damage the pick roller. Bail removal Remove the MPF pick roller cover. See “MPF pick roller cover removal” on page 230. Rotate the bail. Squeeze the latches, and then remove the bail. Jam access cover removal Remove the MPF pick roller cover.
Page 232: Front Door Removal
4514-6xx Remove the four screws (A), and then remove the jam access cover. Front door removal Note: This is not a FRU. Remove the right cover. See “Right cover removal” on page 194. Disconnect the following cables from the controller board: For MS510dn and MS610dn: •...
Page 233 4514-6xx Squeeze the latch, and then detach the link from the front door. Remove the screw (A) to disconnect the ground wire. Repair information...
Page 234 4514-6xx Remove the four screws (B). Remove the right front mount, and then remove front door. Below are the front door and the right front mount. Installation notes: Mount the left side of the front door to the printer. Attach the right front mount to the front door. Repair information...
Page 235: Front Access Cover Removal
4514-6xx Install the right front mount to the printer. Front access cover removal Remove the right cover. See “Right cover removal” on page 194. Remove the front door. See “Front door removal” on page 232. Remove the nameplate. See “Nameplate removals” on page 216.
Page 236: Front Input Guide Removal
4514-6xx Front input guide removal Remove the right cover. See “Right cover removal” on page 194. Remove the front door. See “Front door removal” on page 232. Remove the MPF pick roller cover. See “MPF pick roller cover removal” on page 230.
Page 237 4514-6xx Rotate the MPF shaft inward so that the cams at each end point up. Release the front guide from the guides at each end. Installation note: The cams at each end of the MPF shaft must point down. Repair information...
Page 238: Separator Pad Removal
4514-6xx Separator pad removal Remove the right cover. See “Right cover removal” on page 194. Remove the front door. See “Front door removal” on page 232. Remove the MPF pick roller cover. See “MPF pick roller cover removal” on page 230.
Page 239 4514-6xx While pressing down the MPF sensor flag and separator pad, move the restraint roller (G) to the right. Remove the E‑clip (H), and then move the shaft (I) to the right. Remove the separator pad and the spring underneath. Repair information...
Page 240: Bottom Removals
4514-6xx Bottom removals Power supply removal Remove the left cover. See “Left cover removal” on page 181. Remove the rear door and cover. See “Rear door and cover removal” on page 257. Disconnect the cable (A) from the rear, and disconnect the cable (B) from the left side. Position the printer so that it sits on its right side.
Page 241: Power Supply Shield Removal
4514-6xx Remove the five metal screws (D) and the plastic screw (E) securing the power supply. Remove the power supply, and then disconnect all cables from the power supply. Power supply shield removal Remove the left cover. See “Left cover removal” on page 181.
Page 242: Duplex Removal
4514-6xx Remove the three screws (A), and then remove the power supply shield. Duplex removal Remove the left cover. See “Left cover removal” on page 181. Remove the rear door and cover. See “Rear door and cover removal” on page 257.
Page 243: Duplex Sensor And Input Sensor Removal
4514-6xx Remove the four screws (A) securing the duplex. Note: The duplex link (B) is part of the FRU. Duplex sensor and input sensor removal Remove the left cover. See “Left cover removal” on page 181. Remove the right cover. See “Right cover removal”...
Page 244 4514-6xx Remove the rear door and cover. See “Rear door and cover removal” on page 257. Remove the power supply. See “Power supply removal” on page 240. Remove the power supply shield. See “Power supply shield removal” on page 241. Remove the duplex.
Page 245 4514-6xx Installation notes: Install the duplex sensor, followed by the input sensor. Route the cable using the new path. Secure the cable at the pick/lift motor gearbox using cable ties. Cut off any excess cable tie. Repair information...
Page 246: Index Sensor Removal
4514-6xx Index sensor removal Remove the left cover. See “Left cover removal” on page 181. Remove the right cover. See “Right cover removal” on page 194. Remove the rear door and cover. See “Rear door and cover removal” on page 257.
Page 247: Media Present Sensor Removal
4514-6xx Remove the duplex. See “Duplex removal” on page 242. Disconnect the spring (A) from the printer. Remove the two screws (B), and then remove the sensor. Disconnect the cable from the sensor. Media present sensor removal Remove the left cover. See “Left cover removal”...
Page 248 4514-6xx Disconnect the cable from the media present sensor (A). From inside the printer, release the three latches (B). Repair information...
Page 249: Trailing Edge Sensor Removal
4514-6xx Trailing edge sensor removal Remove the left cover. See “Left cover removal” on page 181. Remove the right cover. See “Right cover removal” on page 194. Remove the rear door and cover. See “Rear door and cover removal” on page 257.
Page 250 4514-6xx Remove the duplex. See “Duplex removal” on page 242. Remove the retainer spring (A). Remove the two springs (B). Remove the two screws (C). Below are the cam release and bracket. Repair information...
Page 251 4514-6xx Remove the screw (D) securing the ACM lift cam to the ACM housing. Remove the ACM lift cam by sliding it off the shaft. Remove the screw (E), and then remove the media present sensor flag. Note: Use a #1 Phillips screwdriver. Repair information...
Page 252 4514-6xx Installation note: Do the following to ensure proper installation of the sensor flag: Lift the ACM. Repair information...
Page 253: Acm Assembly Removal
4514-6xx The protrusion on the ACM must align with the notch on the sensor flag. The sensor flag must align with the media present sensor (A). ACM assembly removal Remove the left cover. See “Left cover removal” on page 181. Remove the rear door and cover.
Page 254 4514-6xx Remove the E-clip (A), and slide the washer (B) from the shaft. Release the lock by sliding the bushing and then rotating it clockwise. Remove the ACM assembly along with its shaft. Repair information...
Page 255: Pick/Lift Motor Gearbox Removal
4514-6xx Below is the ACM assembly. Pick/Lift motor gearbox removal Remove the left cover. See “Left cover removal” on page 181. Remove the rear door and cover. See “Rear door and cover removal” on page 257. Remove the power supply. See “Power supply removal”...
Page 256 4514-6xx Remove the three screws (A). Disconnect the cable from the pick/lift motor gearbox. Repair information...
Page 257: Rear Side Removals
4514-6xx Rear side removals Dust cover removal Press the latches on each side of the dust cover. Remove the dust cover. Rear door and cover removal Position the printer so that it sits on either its left or right side. Open the rear door at an angle of 45 degrees.
Page 258: Narrow Media/Bin Full Sensor Removal
4514-6xx Pull the rear door to remove. Remove the two screws (A) securing the rear cover. Press the two latches to release the rear cover. Narrow media/bin full sensor removal Remove the right cover. See “Right cover removal” on page 194.
Page 259 4514-6xx Remove the top cover. See “Top cover removal” on page 264. Disconnect the cable JNRW1 from the controller board. Remove the six screws (A) securing the sensor and upper exit guide to the redrive assembly. Remove the ground (B), sensor (C), and sensor flag (D). Repair information...
Page 260: Redrive Assembly Removal
4514-6xx Redrive assembly removal Remove the right cover. See “Right cover removal” on page 194. Remove the left cover. See “Left cover removal” on page 181. Remove the rear door and cover. See “Rear door and cover removal” on page 257.
Page 261: Redrive Shaft Removal
4514-6xx Remove the six screws (B) securing the redrive assembly. Redrive shaft removal Remove the right cover. See “Right cover removal” on page 194. Remove the left cover. See “Left cover removal” on page 181. Remove the rear door and cover. See “Rear door and cover removal”...
Page 262 4514-6xx Remove the shaft. If necessary, remove the bushing (B) from the redrive assembly. Installation note: Install the bushing (A) on the redrive assembly before installing the shaft. Repair information...
Page 263: Fuser Removal
4514-6xx Fuser removal Remove the right cover. See “Right cover removal” on page 194. Remove the rear door and cover. See “Rear door and cover removal” on page 257. Remove the redrive assembly. See “Redrive assembly removal” on page 260. Disconnect the cable JEXIT1 from the controller board.
Page 264: Top Side Removals
4514-6xx Top side removals Top cover removal Remove the right cover. See “Right cover removal” on page 194. Remove the left cover. See “Left cover removal” on page 181. Remove the rear door and cover. See “Rear door and cover removal” on page 257.
Page 265: Laser Scanning Unit (Lsu) Removal
4514-6xx Laser scanning unit (LSU) removal Remove the right cover. See “Right cover removal” on page 194. Remove the left cover. See “Left cover removal” on page 181. Remove the rear door and cover. See “Rear door and cover removal” on page 257.
Page 266 4514-6xx Remove the three screws (B) securing the LSU. Installation note: Mechanical and electronic LSU adjustments are required to complete the installation of the LSU. “Printhead assembly adjustments” on page 178. Repair information...
Page 267: 250/550-Sheet Option Tray Removals
4514-6xx 250/550-sheet option tray removals Pick roller removal Press the latches. Remove the pick roller. Repair information...
Page 268: Separator Roll Assembly Removal
4514-6xx Separator roll assembly removal Remove the screw (A) from under the tray insert. Remove the E-clip, and then remove the gear. Repair information...
Page 269 4514-6xx Remove the four screws (B). Push out the top part of the drawer cover, and then remove the separator roll assembly. Repair information...
Page 270: Acm Assembly Removal
4514-6xx ACM assembly removal Remove the seven screws (A), and release the two latches (B) from the top of the drawer. Remove the two screws (C), and then release the two latches under the screws. Repair information...
Page 271 4514-6xx Swing the right cover backward to remove. Remove the screw (D). Repair information...
Page 272 4514-6xx Disconnect the spring (E). Remove the two screws (F), and then remove the controller card cover. Disconnect the cable J11 from the controller card. Route the cable off the option, and then remove the ACM assembly. Repair information...
Page 273: Component Locations
4514-6xx Component locations Exterior locations MS510dn and MS610dn exterior locations Front view Part name Control panel Paper stop Standard bin Front door release button Controller board access door 100‑sheet multipurpose feeder Standard tray Optional 250‑ or 550‑sheet tray Component locations...
Page 274: Rear View
4514-6xx Rear view Part name USB port USB printer port Ethernet port Parallel port Note: This port is available only in select printer models. Power switch Printer power cord socket Security slot Component locations...
Page 275: Ms610De Exterior Locations
4514-6xx MS610de exterior locations Front view Part name Control panel Paper stop Standard bin Front door release button Controller board access door 100‑sheet multipurpose feeder Standard tray Optional 250‑ or 550‑sheet tray Component locations...
Page 276 4514-6xx Rear view Part name Security slot USB printer port USB port USB port Ethernet port Power switch Printer power cord socket Component locations...
Page 277: Maintenance
• Damaged, missing, or altered covers, especially in the area of the top cover and the power supply cover • Possible safety exposure from any non-Lexmark attachments Use the following table to determine when specified parts should be inspected: EVERY...
Page 278: Scheduled Maintenance
4514-6xx Scheduled maintenance The control panel displays an 80.xy error when it reaches 200K page counts. It is necessary to install the appropriate maintenance kit to maintain the print quality and reliability of the printer. Reset the maintenance counter after replacing the maintenance kit.
Page 279: Resetting The Maintenance Counter
4514-6xx Part number and kit Contents 40X8435—200K Maintenance Kit (MS610dn, 220 V) • Fuser (220V) • Redrive assembly • ACM tires/hubs • Transfer roll • Tray separator bracket • MPF pick roll and separator pad 40X8441—200K Maintenance Kit (MS610de, 100 V)* •...
Page 280: Cleaning The Printer
4514-6xx Cleaning the printer Note: You may need to perform this task after every few months. Warning—Potential Damage: Damage to the printer caused by improper handling is not covered by the printer warranty. Make sure that the printer is turned off and unplugged from the electrical outlet. CAUTION—SHOCK HAZARD: To avoid the risk of electrical shock when cleaning the exterior of the printer, unplug the power cord from the electrical outlet and disconnect all cables from the printer before proceeding.
Page 281 4514-6xx...
Page 282: Parts Catalog
4514-6xx Parts catalog Legend The following column headings are used in the parts catalog: • Asm‑index—Identifies the item in the illustration. • Part number—Identifies the unique number that correlates with the part. • Units/mach—Refers to the number of units actually used in the base machine or product. •...
Page 283: Assembly 1: Covers
4514-6xx Assembly 1: Covers Parts catalog...
Page 284 4514-6xx Assembly 1: Covers Asm-index Units/mach Units/FRU Description Removal procedure 40X8520 Dust cover (250‑sheet tray) “Dust cover removal” on page 257 40X8521 Dust cover (550‑sheet tray) “Dust cover removal” on page 257 40X8054 Rear door and cover “Rear door and cover removal” on page 257 (MS510dn and M1145) 40X8270...
Page 285 4514-6xx Asm-index Units/mach Units/FRU Description Removal procedure 40X8057 Control panel cover and buttons “Control panel assembly removals” on page 218 (MS610de and M3150) “UICC removals” on page 222 Note: Does not include the UICC. 40X8068 Bezel “Bezel removals” on page 214 (MS610de and M3150) 40X8060 Control panel cover and buttons...
Page 286 4514-6xx Parts catalog...
Page 287: Assembly 2: Electronics 1
4514-6xx Assembly 2: Electronics 1 Parts catalog...
Page 288 4514-6xx Assembly 2: Electronics 1 Asm-index Units/mach Units/FRU Description Removal procedure 40X8080 Laser scanning unit “Laser scanning unit (LSU) removal” on page 265 (MS510dn and M1145) 40X8079 Laser scanning unit “Laser scanning unit (LSU) removal” on page 265 (MS610dn, MS610de, M3150dn, and M3150) 40X8343 Fuser, 100 V...
Page 289: Assembly 3: Electronics 2
4514-6xx Assembly 3: Electronics 2 Parts catalog...
Page 290 4514-6xx Assembly 3: Electronics 2 Asm-index Units/mach Units/FRU Description Removal procedure 40X8048 Front door sensor “Front door sensor removal” on page 235 40X8266 Cartridge smart chip “Toner cartridge smart chip contact contact removal” on page 204 40X8046 Toner density sensor “Toner density sensor removal”...
Page 291 4514-6xx Parts catalog...
Page 292: Assembly 4: Frame
4514-6xx Assembly 4: Frame Parts catalog...
Page 293 4514-6xx Assembly 4: Frame Asm-index Units/mach Units/FRU Description Removal procedure 40X8393 Transfer roll “Transfer roll removal” on page 210 40X8298 Redrive assembly “Redrive assembly removal” on page 260 (MS510dn and M1145) 40X8437 Redrive assembly “Redrive assembly removal” on page 260 (MS610dn and M3150dn) 40X8438 Redrive assembly...
Page 294 4514-6xx Parts catalog...
Page 295: Assembly 5: Option Trays
4514-6xx Assembly 5: Option trays Parts catalog...
Page 296 4514-6xx Assembly 5: Option trays Asm-index Units/opt Units/FRU Description Removal procedure 40X8287 250-sheet tray 40X8286 550-sheet tray 40X9654 550-sheet tray, lockable 40X8520 Dust cover, 250‑sheet tray “Dust cover removal” on page 257 40X8521 Dust cover, 550‑sheet tray “Dust cover removal” on page 257 40X8262 ACM assembly “ACM assembly removal”...
Page 297: Assembly 6: Maintenance Kits
4514-6xx Assembly 6: Maintenance kits Asm-index Units/mach Units/FRU Description Removal procedure 40X8439 Maintenance kit, 100 V (MS510dn and M1145) • 100 V fuser (40X8343) • Paper exit guide (40X8298) • ACM pick roll (40X8297) • Transfer roll (40X8393) • Tray separator roll assembly (40X8444) •...
Page 298 4514-6xx Asm-index Units/mach Units/FRU Description Removal procedure 40X8435 Maintenance kit, 220 V (MS610dn and M3150dn) • 220 V fuser (40X8024) • Paper exit guide (40X8437) • ACM pick roll (40X8297) • Transfer roll (40X8393) • Tray separator roll assembly (40X8444) •...
Page 299: Assembly 7: Power Cords
4514-6xx Assembly 7: Power cords Asm-index Units/mach Units/FRU Description Removal procedure 40X0269 Power cord, 2.5 m (straight)—USA, Canada 40X0289 Power cord, 1.8 m (straight)—USA 40X3141 Power cord, 2.5 m (straight)—Europe and others 40X0288 Power cord, 2.5 m (straight)—Argentina 40X0271 Power cord, 2.5 m (straight)—United Kingdom 40X0275 Power cord, 2.5 m (straight)—Israel 40X1772...
Page 300 4514-6xx Parts catalog...
Page 301: Assembly 8: Miscellaneous
4514-6xx Assembly 8: Miscellaneous Asm-index Units/mach Units/FRU Description Removal procedure 40X8737 RFID card reader 40X8330 MarkNet N8352 802.11 b/g/n Wireless Print Server 40X4819 Adapter, RS232C serial 40X5315 Screw, Ship with ISP (2) 40X5316 Cable, 14 pin JST for ISP 40X5317 Standoff, Tee with thumbscrew 40X4826 Adapter, N8120 GB INA...
Page 302 Units/mach Units/FRU Description Removal procedure 40X8557 Font card, Simplified Chinese 40X8555 256MB flash card 40X7856 160GB hard disk (MS610de and M3150) 40X1368 USB cable, packaged (2 m) 40X8695 Relocation kit (MS510) 40X8696 Relocation kit (MS610dn) 40x8697 Relocation kit (MS610de) Parts catalog...
Page 303: Appendix A: Printer Specifications
The product is plugged into an electrical outlet, but the power switch is turned off. The power consumption levels listed in the previous table represent time-averaged measurements. Instantaneous power draws may be substantially higher than the average. Values are subject to change. See www.lexmark.com for current values. Electrical specifications Low-voltage models •...
Page 304: Operating Clearances
4514-6xx Operating clearances Right 30 cm (12 in.) Front 51 cm (20 in.) Left 20 cm (8 in.) Rear 20 cm (8 in.) 30 cm (12 in.) Allow additional clearance around the printer for adding the optional input trays. Acoustics All measurements are made in accordance with ISO 7779 and conform with ISO 9296.
Page 305: Operating Environment
4514-6xx Status 1 meter average sound pressure Declared sound power level (Bels) Idle (Standby) Inaudible Inaudible Quiet Mode 51 dBA 6.6 Bels Simplex Printing 54 dBA 6.9 Bels Sleep/Hibernate Mode Inaudible Inaudible Measurements apply to 300 dpi, 600 dpi and 1200 dpi printing. Status 1 meter average sound pressure Declared sound power level (Bels)
Page 306 4514-6xx...
Page 307: Appendix B: Options And Features
MarkNet N8130 10/100 fiber interface – RS‑232‑C serial interface This internal option is available only in the MS610de printer model. Media handling options • Standard output bin – 150‑sheet bin (MS510) – 250‑sheet bin (MS610) • Standard tray – 250‑sheet tray (MS510) –...
Page 308 4514-6xx...
Page 309: Appendix C: Theory Of Operation
4514-6xx Appendix C: Theory of operation POR sequence At power on, the engine code goes through a series of tests to verify hardware integrity. If a hardware failure is detected, then it is reported to the printer. If the POR sequence cannot be completed successfully, then the printer may post an error message identifying that service may be needed.
Page 310: Multipurpose Feeder (Mpf)
4514-6xx Part First input roller Secondary input roller Separator roller Pick rollers Option tray Multipurpose feeder (MPF) The driving force from the main drive motor is transmitted through the MPF gearbox. When the MPF solenoid activates, it allows the MPF sector gear linked to the MPF gearbox to rotate. The MPF pick roll shaft is connected to the MPF sector gear.
Page 311: Duplex Printing
4514-6xx The media with the embedded toner image goes through the fuser assembly to permanently bond the toner to the media. When it passes between the heat belt and pressure roll of the fuser assembly, the combination of heat and pressure fuses the toner image to the media.
Page 312: Media Handling Components
4514-6xx Part First input roller Secondary input roller Duplex front deliver roller Duplex rear deliver roller Paper exit roller Media handling components Main drive gearbox The gearbox supplies all mechanical power requirements of the printer. Its motor, through several gears, transfers power to following paths: photoconductor drum, transfer roll, fuser, paper exit, input, duplex, and MPF.
Page 313: Key Components
Duplex sensor Trailing edge sensor Pass through sensor Index sensor Media present Trailing edge sensor sensor MS510/MS610 sensors Bin full sensor Input sensor Fuser exit MPF paper present sensor sensor Duplex sensor Index sensor Media present Trailing edge sensor...
Page 314: Other Key Components
4514-6xx Trailing edge sensor Detects the media’s trailing edge as it passes the pick tires. Among other capabilities, this sensor can be used to determine the paper size sensor and the media stack height. MPF sensor Detects the presence of media in the MPF tray. Media present sensor Detects the presence of media in the tray.
Page 315 MPF pick roller Secondary input roller Duplex rear deliver roller Transfer roll Pick rollers Duplex front deliver roller Separator roll Pick rollers MS510/MS610 rollers Paper exit roller Photoconductor drum Fuser assembly First input roller Fuser exit roller Secondary input roller Duplex rear...
Page 316: Electrophotographic Process (Ep Process)
4514-6xx Electrophotographic process (EP process) Printhead The printhead scans the photo conductor drum surface with a laser beam. It consists of the following components: • Laser diode (LD) card assembly • Oscillator • Start of scan card assembly When a laser beam is scanned across the photoconductor drum surface from one end to the other while turning on and off the beam, one line of latent image is created.
Page 317 4514-6xx Step 2: Expose The laser fires a focused beam of light at the surface of the photoconductor and writes an invisible image, called a latent image. The laser beam only discharges the surface where the beam hits the photoconductor. This creates a difference in charge potential between the exposed area and the rest of the photoconductor surface.
Page 318 4514-6xx This process would be similar to using glue to write on a can and then rolling it over glitter. The glitter sticks to the glue but not to the rest of the can. HVPS Developer Metering Roll Blade Toner DRUM -VDC Drum Surface...
Page 319 4514-6xx Step 5: Clean The cleaning blade removes any toner that remains on the photoconductor after the transfer process. The toner removed is collected inside the imaging unit. Used Toner Cleaning Blade Charge roll DRUM Appendix C: Theory of operation...
Page 320 4514-6xx...
Page 321: Appendix D: Acronyms
4514-6xx Appendix D: Acronyms Acronyms ASIC Application-Specific Integrated Circuit BLDC Brushless DC Motor Black Only Retract Cyan Charge Coupled Device Carbonless Copy Paper Cyclic Redundancy Check Customer Setup CTLS Capacitance Toner Level Sensing DIMM Dual Inline Memory Module DRAM Dynamic Random Access Memory Enhanced Data Out Electrophotographic Process EPROM...
Page 322 4514-6xx Microswitch Nonvolatile Memory NVRAM Nonvolatile Random Access Memory Original Equipment Manufacturer Optical Sensor Photoconductor pel, pixel Picture element Power-On Reset POST Power-On Self Test Position Sensing Device Pulse Width Modulation Raster Imaging Processor Read Only Memory SDRAM Synchronous Dual Random Access Memory SIMM Single Inline Memory Module SRAM...
Page 323: Index
4514-6xx Index accessing 145 Symbols action for prompts 149 [x]‑page jam, clear manual feeder. [25y.xx] 72 automatically display error screens 153 [x]‑page jam, clear standard bin. [20y.xx] 55 clear supply usage history 153 [x]‑page jam, open front door. [20y.xx] 47 clearing custom status 153 [x]‑page jam, open rear door.
Page 324 4514-6xx quick disk 139 electrophotographic process, theory 316 diagnostics electrostatic‑sensitive parts 157 print tests 133 embedded solutions 163 registration 132 energy diagnostics menu conserving 148 accessing 132 envelopes automatic darkness adjustment 143 tips on using 28 base sensor test 139 environment specifications 305 button test 134 EP process, theory 316...
Page 325 4514-6xx event log in duplex area 59 print log 144 in front door 47 exterior of the printer in manual feeder 72 cleaning 280 in standard bin 55 in tray 1 62 in tray [x] 66 firmware card 307 labels, paper tips on using 29 hardware tests laser notices 13...
Page 326 4514-6xx network SE menu print quality troubleshooting accessing 155 blank pages 37 Non‑Lexmark [supply type], see User’s Guide gray background on prints 36 [33.xy] 81 repeating defects 39 Not enough free space in flash memory for resources shadow images appear on prints 39...
Page 327 ACM assembly, option tray 270 Memory full [38] 80 bail 231 Network [x] software error [54] 80 bezel 214 Non‑Lexmark [supply type], see User’s Guide cartridge gearbox 191 [33.xy] 81 cartridge plunger 211 Not enough free space in flash memory for resources...
Page 328 4514-6xx main drive gearbox 182 selecting paper 27 media present sensor 247 Serial option [x] error [54] 83 media present sensor flag 249 service checks troubleshooting MPF assembly 227 network service check 122 MPF gearbox 187 service engineer (SE) menu 155 MPF pick tire 230 accessing 155 MPF pick tire cover 230...
Page 329 4514-6xx troubleshooting, print quality blank pages 37 gray background on prints 36 repeating defects 39 shadow images appear on prints 39 skewed print 40 solid black pages 38 streaked vertical lines appear on prints 42 toner rubs off 42 toner specks appear on prints 43 troubleshooting, service checks network service check 122 unacceptable paper 26...
Page 330 4514-6xx Index...
Page 331: Part Number Index
4514-6xx Part number index Part name Page 40X0269 Power cord, 2.5 m (straight)—USA, Canada..................299 40X0270 Power cord, 2.5 m (straight)—Japan......................299 40X0271 Power cord, 2.5 m (straight)—United Kingdom..................299 40X0273 Power cord, 2.5 m (straight)—Traditional Italy..................299 40X0275 Power cord, 2.5 m (straight)—Israel......................299 40X0288 Power cord, 2.5 m (straight)—Argentina....................299 40X0289 Power cord, 1.8 m (straight)—USA......................299 40X0301 Power cord, 2.5 m (straight)—Australia....................299...
Page 332 4514-6xx Part name Page 40X8023 Fuser, 110 V............................288 40X8024 Fuser, 220 V............................288 40X8029 Controller board (MS510dn and M1145)....................288 40X8030 Controller board (MS610dn and M3150dn)...................288 40X8043 Duplex sensor and input sensor......................290 40X8044 Index sensor............................290 40X8045 Trailing edge sensor..........................290 40X8046 Toner density sensor..........................290 40X8048 Front door sensor...........................290 40X8050 Narrow media/bin full sensor........................288 40X8051 Nameplate (MS510dn and M1145)......................284...
Page 333 4514-6xx Part name Page 40X8269 Left cover (MS610dn, MS610de, M3150dn, and M3150)..............285 40X8270 Rear door and cover (MS610dn, MS610de, M3150dn, and M3150).............284 40X8271 Top cover (MS610dn, MS610de, M3150dn, and M3150)..............285 40X8272 Nameplate (MS610de and M3150)......................284 40X8273 Rubber foot............................285 40X8275 Duplex assembly............................293 40X8276 Cooling fan (MS510dn, MS610dn, M1145, and M3150dn)..............288 40X8277 Duplex gear assembly..........................293 40X8279 Jam access cover............................293...
Page 334 40X8605 Prescribe Card (MS510dn, MS610dn, M1145, and M3150dn)..............301 40X8606 Forms and Barcode Card (MS610de and M3150)..................301 40X8607 IPDS card (MS610de and M3150)......................301 40X8608 Prescribe Card (MS610de and M3150)....................301 40X8695 Relocation kit (MS510)...........................302 40X8696 Relocation kit (MS610dn)........................302 40x8697 Relocation kit (MS610de)........................302 40X8737 RFID card reader.............................301...
Page 335 4514-6xx Part name Page 40X8837 Forms and Barcode + Japanese Font (MS510dn, MS610dn, M1145, and M3150dn)......301 40X8850 Redrive shaft............................293 40X9131 MPF assembly (100 sheets)........................284 40X9148 Cartridge plunger...........................284 40X9181 Cooling fan (MS610de and M3150)......................288 40X9651 Right cover (MS610de and M3150)......................284 40X9654 550-sheet tray, lockable.........................296 41X0003 Power supply, 100 V/110 V Latin America.....................290 41X0005 Nameplate (MS610dn and M3150dn)....................284 41X0239 Rear door and cover (MS610de and M3150)..................284...
Page 336 4514-6xx Part number index...
Page 337: Part Name Index
4514-6xx Part name index Part name Page 40X8524 1284-B Parallel Interface Card........................301 40X7856 160GB hard disk (MS610de and M3150)....................302 40X7567 1GB DDR3 RAM............................301 40X8305 250-sheet tray............................284 40X8287 250-sheet tray............................296 40X8305 250-sheet tray insert..........................296 40X8555 256MB flash card...........................302 40X7445 2GB DDR3 RAM............................301 40X8086 550-sheet tray............................284 40X8286 550-sheet tray............................296 40X8086 550-sheet tray insert..........................296...
Page 338 4514-6xx Part name Page 40X8029 Controller board (MS510dn and M1145)....................288 40X8388 Controller board (MS610de and M3150)....................288 40X8030 Controller board (MS610dn and M3150dn)...................288 40X8276 Cooling fan (MS510dn, MS610dn, M1145, and M3150dn)..............288 40X9181 Cooling fan (MS610de and M3150)......................288 40X8275 Duplex assembly............................293 40X8277 Duplex gear assembly..........................293 40X8043 Duplex sensor and input sensor......................290 40X8520 Dust cover (250‑sheet tray)........................284 40X8521 Dust cover (550‑sheet tray)........................284...
Page 339 4514-6xx Part name Page 40X8279 Jam access cover............................293 40X8080 Laser scanning unit (MS510dn and M1145)...................288 40X8079 Laser scanning unit (MS610dn, MS610de, M3150dn, and M3150)............288 40X8053 Left cover (MS510dn and M1145)......................285 40X8269 Left cover (MS610dn, MS610de, M3150dn, and M3150)..............285 40X8085 Main drive gearbox..........................293 40X8439 Maintenance kit, 100 V (MS510dn and M1145)..................297 40X8441 Maintenance kit, 100 V (MS610de and M3150)..................298 40X8440 Maintenance kit, 100 V (MS610dn and M3150dn)................297...
Page 340 40X8270 Rear door and cover (MS610dn, MS610de, M3150dn, and M3150).............284 40X8298 Redrive assembly (MS510dn and M1145).....................293 40X8438 Redrive assembly (MS610de and M3150)....................293 40X8437 Redrive assembly (MS610dn and M3150dn)..................293 40X8850 Redrive shaft............................293 40X8695 Relocation kit (MS510)...........................302 40x8697 Relocation kit (MS610de)........................302 40X8696 Relocation kit (MS610dn)........................302 40X8301 Reverse solenoid............................288 40X8737 RFID card reader.............................301...
Page 341 4514-6xx Part name Page 40X5315 Screw, Ship with ISP (2)..........................301 40X8444 Separator roll assembly..........................296 40X5317 Standoff, Tee with thumbscrew......................301 40X8046 Toner density sensor..........................290 40X8055 Top cover (MS510dn and M1145)......................285 40X8271 Top cover (MS610dn, MS610de, M3150dn, and M3150)..............285 40X8045 Trailing edge sensor..........................290 40X8393 Transfer roll............................293 40X7592 Tray present sensor..........................288 40X1368 USB cable, packaged (2 m) ........................302...
Page 342 4514-6xx Part name index...
Page 344 OPERATOR PANEL WIRING DIAGRAM UICC TOUCH SCREEN OP PANEL USB SPEAKER JPLEN1 JADF1 PCN5 JCIS1 PCN1 JUICC FUSER ASSEMBLY TONER LEVEL SENSOR CARTRIDGE SMARTCHIP CONTACTS JAUD1 POWER SUPPLY JBT1 JBT2 IMAGING UNIT SMARTCHIP CONTACTS JBT3 PCN6 JFAN2 JMTR1 JEXIT1 JSWISS1 JTHM1 JFAN1 MAIN MOTOR...

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M1145,M3150 Ms610

Lexmark MS510 Service Manual

Product Information

Edition Notice

Notices and Safety Information

Preface

General Information

Diagnostic Information

Service Menus

Repair Information

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Summary of Contents for Lexmark MS510