Page 1: Service Manual
MS510, MS610, M1145, & M3150 Machine Type 4514-630, -635, -636, -638, -639, -649 Service Manual • Start diagnostics • Maintenance • Safety and notices • Trademarks • Index February 04, 2013 www.lexmark.com P/N 12G2826...
Page 2: Product Information
February 04, 2013 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
4514-630, -635, -636, -638, -639, -649 Table of contents Product information..................2 Edition notice....................2 Notices and safety information..............11 Laser notices............................11 Safety...............................14 Preface.......................19 Service manual conventions........................19 Change history............................19 General information...................21 Media guidelines.............................21 Paper guidelines ...............................21 Using recycled paper and other office papers ....................23 Using specialty media ............................24...
Page 4 Maintenance kit very low, [x] estimated pages remain [80.xy]................76 Memory full [38] ...............................76 Network [x] software error [54] ........................76 Non‑Lexmark [supply type], see User’s Guide [33.xy] ..................77 Not enough free space in flash memory for resources [52] ................77 Printer had to restart. Last job may be incomplete..................77 Reinstall missing or unresponsive cartridge [31.xy]...
Page 5 4514-630, -635, -636, -638, -639, -649 Replace imaging unit, 0 estimated pages remain [84.xy] .................79 Replace maintenance kit, 0 estimated pages remain [80.xy] ................79 Replace unsupported cartridge [32.xy] ......................79 Replace unsupported imaging unit [32.xy] .......................79 Serial option [x] error [54] ..........................79 SMTP server not set up.
Page 6 4514-630, -635, -636, -638, -639, -649 Dead machine service check...........................109 Controller board service check ........................109 Control panel button service check ........................110 Control panel service check ..........................111 Toner starvation service check ........................111 USB print service check...........................112 Network service check............................113 Service menus..................117 Understanding the control panel (MS510dn and MS610dn)..............117 Using the printer control...
Page 7 4514-630, -635, -636, -638, -639, -649 Download Emuls .............................139 Factory Defaults.............................. Energy Conserve .............................139 Paper Prompts ..............................Envelope Prompts............................140 Action for Prompts............................140 Jobs on Disk ..............................Disk Encryption ............................... Erase All Information on Disk..........................141 Wipe All Settings............................. Font Density..............................Font Sharpening.............................. Reduced Curl..............................
Page 8 4514-630, -635, -636, -638, -639, -649 Printhead assembly adjustments........................163 Removal procedures..........................166 Left side removals..........................166 Left cover removal ............................166 Main drive gearbox removal...........................167 MPF solenoid removal ............................169 MPF gearbox removal.............................172 Reverse solenoid removal..........................175 Cartridge gearbox removal ..........................176 Duplex gear assembly removal ........................177 Right side removals..........................179...
Page 9 4514-630, -635, -636, -638, -639, -649 Power supply removal (MS610) .........................226 Power supply shield removal..........................227 Duplex removal............................... Duplex sensor and input sensor removal .......................229 Index sensor removal............................232 Media present sensor removal ........................232 Toner density sensor removal ........................234 Trailing edge sensor removal..........................234 ACM assembly removal ..........................235...
Page 10 4514-630, -635, -636, -638, -639, -649 Assembly 4: Frame..........................275 Assembly 5: Option trays........................277 Assembly 6: Maintenance kits.......................279 Assembly 7: Power cords........................281 Assembly 8: Miscellaneous........................283 Appendix A: Printer specifications............285 Product power consumption.........................285 Electrical specifications.........................285 Operating clearances..........................286 Acoustics...............................286 Operating environment.........................287 Appendix B: Options and features............289 Available internal options........................289...
Page 11: Notices And Safety Information
4514-630, -635, -636, -638, -639, -649 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 12 4514-630, -635, -636, -638, -639, -649 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 13 4514-630, -635, -636, -638, -639, -649 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 14: Safety
4514-630, -635, -636, -638, -639, -649 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 15 4514-630, -635, -636, -638, -639, -649 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 16 4514-630, -635, -636, -638, -639, -649 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. •...
Page 17 4514-630, -635, -636, -638, -639, -649 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 18 4514-630, -635, -636, -638, -639, -649...
Page 19: Preface
4514-630, -635, -636, -638, -639, -649 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.
Page 20 4514-630, -635, -636, -638, -639, -649 January 23, 2013 • Changed MPF gearbox part number from 40X8278 to 40X8777. • Added Miscellaneous parts catalog assembly. November 28, 2012 • Added installation note to LSU removal. • Removed the MPF solenoid IDC from the Frame parts catalog assembly. •...
Page 21: 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 22: Moisture Content
4514-630, -635, -636, -638, -639, -649 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 23: Selecting Paper
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 24: Using Specialty Media
4514-630, -635, -636, -638, -639, -649 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 25: 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 26: Supported Paper Sizes, Types, And Weights
4514-630, -635, -636, -638, -639, -649 • 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 27: Supported Paper Types And Weights
4514-630, -635, -636, -638, -639, -649 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.)
Page 28: Data Security Notice
4514-630, -635, -636, -638, -639, -649 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 29: Tools Required For Service
4514-630, -635, -636, -638, -639, -649 Tools required for service Flat-blade screwdrivers, various sizes #1 Phillips screwdriver, magnetic #2 Phillips screwdriver, magnetic #2 Phillips screwdriver, magnetic short-blade Needle‑nose pliers Diagonal side cutters Spring hook Feeler gauges Analog or digital multimeter Flashlight (optional) General information...
Page 30 4514-630, -635, -636, -638, -639, -649...
Page 31: Diagnostic Information
4514-630, -635, -636, -638, -639, -649 Diagnostic information • “Troubleshooting overview” on page 31 • “Fixing print quality issues” on page 32 • “Paper jams” on page 41 • “Understanding the printer messages” on page 70 • “User attendance messages (0–99.99)” on page 82 •...
Page 32: Fixing Print Quality Issues
4514-630, -635, -636, -638, -639, -649 The cooling fan turns on. The fuser heater turns on. Note: The fuser takes longer to warm up from a cold start than a warm start. The main drive motor turns on. The EP drive assembly drives the developer shaft located in the imaging unit. The exit rollers turn.
Page 33: Print Quality Checks
4514-630, -635, -636, -638, -639, -649 Print quality checks • “Gray background or toner fog on prints” on page 33 • “Printer is printing blank pages” on page 34 • “Printer is printing solid black pages” on page 35 • “Repeating defects”...
Page 34: Printer Is Printing Blank Pages
4514-630, -635, -636, -638, -639, -649 Printer is printing blank pages Actions Step 1 Replace the toner Go to step 2. cartridge. Check the toner cartridge level. Is the toner level low? Step 2 Go to step 3. Replace the cartridge plunger.
Page 35: Printer Is Printing Solid Black Pages
4514-630, -635, -636, -638, -639, -649 Printer is printing solid black pages Actions Step 1 Go to step 2. Replace the imaging unit. Check the imaging unit for damage. Is it free of damage? Step 2 Go to step 3. The problem is solved.
Page 36: Shadow Images Appear On Prints
4514-630, -635, -636, -638, -639, -649 Shadow images appear on prints Leading edge A B C D A B C D A B C D A B C D Trailing edge Actions Step 1 Go to step 2. Go to step 3. Does the shadow image appear every two pages? Step 2 Go to step 3.
Page 37: Skewed Print
4514-630, -635, -636, -638, -639, -649 Skewed print Actions Step 1 Go to step 2. The problem is solved. POR into the Diagnostics menu and perform a print test: Diagnostics Menu > Print Tests > Tray 1 Adjust the margins if necessary: Diagnostics Menu >...
Page 38: Streaked Horizontal Or Vertical Lines Appear On Prints
4514-630, -635, -636, -638, -639, -649 Actions Step 8 Go to step 11. Replace the front input guide. See “Front input Make sure the front input guide rollers are free of debris. Check for wear guide removal” on or damage. page 221.
Page 39: Toner Rubs Off
4514-630, -635, -636, -638, -639, -649 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. Make sure the paper path is free of debris or toner contamination.
Page 40: Toner Specks Appear On Prints
4514-630, -635, -636, -638, -639, -649 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 41: Paper Jams
4514-630, -635, -636, -638, -639, -649 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 195. Is it free of contamination or wear? Step 4 Go to step 5.
Page 42: Understanding Jam Messages And Locations
4514-630, -635, -636, -638, -639, -649 • Do not slide the paper into the tray. Load paper as shown in the illustration. • Make sure the guides in the tray or the multipurpose feeder are properly positioned and are not pressing tightly against the paper or envelopes.
Page 43 4514-630, -635, -636, -638, -639, -649 Notes: • When Jam Assist is set to On, the printer automatically flushes blank pages or pages with partial prints to the standard bin after a jammed page has been cleared. Check your printed output stack for discarded pages. •...
Page 44: 200 Paper Jams
4514-630, -635, -636, -638, -639, -649 200 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.
Page 45 4514-630, -635, -636, -638, -639, -649 Lift the green handle, and then pull the imaging unit out of the printer. 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.
Page 46 4514-630, -635, -636, -638, -639, -649 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 47 4514-630, -635, -636, -638, -639, -649 200 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”...
Page 48 4514-630, -635, -636, -638, -639, -649 Error code Description Action 200.38 Interpage servo gap smaller than expected for galvo Go to “Sensor (input) early/late arriving service offset target evaluation. check” on page 200.42 Rogue sheet at ACM sensor while flushing the paper path prior to declaring tray 1 source empty.
Page 49 4514-630, -635, -636, -638, -639, -649 Sensor (input) early/late arriving service check Action Step 1 Go to step 2. Go to step 5. Check the paper source. Is the paper from the MPF? Step 2 Go to step 3. Replace the MPF pick roller and separator Check the MPF pick roller and separator pad for damage and pad.
Page 50 4514-630, -635, -636, -638, -639, -649 Action Step 8 Go to step 9. 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”...
Page 51: 201 Paper Jams
4514-630, -635, -636, -638, -639, -649 Main drive motor control jam service check Action Step 1 Go to step 2. Reseat the cable. Remove the main drive gearbox. Check the main drive gearbox cable for proper connection. Is it properly connected? Step 2 Go to step 3.
Page 52: 202 Paper Jams
4514-630, -635, -636, -638, -639, -649 201 paper jam messages Error code Description Action 201.01 Narrow media sensor is covered during warm up. Go to “Sensor (narrow media) jam service check” on Input sensor is not covered. page Sensor (narrow media) jam service check Action Step 1 Go to step 2.
Page 53 4514-630, -635, -636, -638, -639, -649 Gently pull down the rear door. 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. Firmly grasp the jammed paper on each side, and then gently pull it out.
Page 54 4514-630, -635, -636, -638, -639, -649 202 paper jam messages Error code Description Action 202.01 Exit sensor is covered during warm up. Go to “Sensor (fuser exit) jam service check” on page 202.03 Media did not reach the fuser exit sensor. 202.05 Fuser exit sensor covered too long by the current sheet.
Page 55: 230 Paper Jams
4514-630, -635, -636, -638, -639, -649 Sensor (fuser exit) jam service check Action Step 1 Go to step 2. Clear the paper path of any media fragments. Check the input sensor area for jammed media fragments. Is the paper path free of partially fed or jammed media? Step 2 Go to step 3.
Page 56 4514-630, -635, -636, -638, -639, -649 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.
Page 57: Duplex Service Check
4514-630, -635, -636, -638, -639, -649 23y.xx 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. 230.03 Internal duplex sensor never made by leading edge of page.
Page 58: 240 Paper Jams
4514-630, -635, -636, -638, -639, -649 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 228. damage. Are they free of wear and damage? Step 5 Go to step 6.
Page 59 4514-630, -635, -636, -638, -639, -649 Insert the tray. From the printer control panel, touch to clear the message and continue printing. For non‑touch‑screen printer models, select Next > > Clear the jam, press OK > 24y.xx paper jam messages Error code Description Action...
Page 60 4514-630, -635, -636, -638, -639, -649 Error code Description Action 241.24 Media feeder motor stalled on the last pick attempt Go to “Tray 1 jam service check” on page in tray 1. 241.29 Tray 1 lift plate failed to make the index sensor while elevating.
Page 61 4514-630, -635, -636, -638, -639, -649 Error code Description Action 242.14 Sheets flushed from paper path either due to feed Go to “Option tray jam service check” on page error or cartridge error. 242.15 One or more trays located above the source tray 2 has been pulled.
Page 62 4514-630, -635, -636, -638, -639, -649 Error code Description Action 243.02 Input sensor detected late feed during a pick retry Go to “Option tray jam service check” on page from tray 3. 243.03 tray 3 pass thru sensor never became covered when feeding a sheet from an option below.
Page 63 4514-630, -635, -636, -638, -639, -649 Error code Description Action 243.41 Motor 1 (Pick/Lift) Elevator motor stalled. Go to “Option tray jam service check” on page 243.42 Motor 1 (Pick/Lift) Elevator motor PWM overflow error (underspeed). Motor underspeed (max PWM and motor underspeed, typical accordion jam).
Page 64 4514-630, -635, -636, -638, -639, -649 Error code Description Action 244.16 The engine timed out waiting for the tray 4 to report Go to “Option tray jam service check” on page 'ready' before the 1st pick attempt. 244.17 Page was not properly picked from tray 4. Have not exhausted all pick retry attempts as there are sheets committed to the paper path from below.
Page 65 4514-630, -635, -636, -638, -639, -649 Tray 1 jam service check Action Step 1 Replace the index Go to step 2. sensor. Restart the printer. Does it fail to complete the POST sequence and display a 241.xx error? Step 2 Go to step 3.
Page 66 4514-630, -635, -636, -638, -639, -649 Action Step 10 Go to step 11. Replace the main drive gearbox. See“Main Check the main drive gearbox drive gearbox removal” on page Is it free of wear or damage? 167. Step 11 Contact the next level The problem is solved.
Page 67: 250 Paper Jams
4514-630, -635, -636, -638, -639, -649 Action Step 8 Go to step 9. Replace the option tray. POR into the Diagnostics menu and perform a feed test: Diagnostics Menu > Input Tray Tests > Feed Test > Select an option tray Does the pick/lift motor gearbox pass the test? Step 9 Contact the next level...
Page 68 4514-630, -635, -636, -638, -639, -649 Reload paper into the multipurpose feeder. Note: Make sure the paper guide lightly rests against the edge of the paper. From the printer control panel, touch to clear the message and continue printing. For non‑touch‑screen printer models, select Next >...
Page 69: Mpf Service Check
4514-630, -635, -636, -638, -639, -649 MPF service check Action Step 1 Go to step 2. Replace the MPF assembly. See “MPF Check the springs, links, and tray guides on the MPF assembly for damage. assembly removal” on page 212. Are they free of damage? Step 2 Go to step 3.
Page 70: 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 71: Change [Paper Source] To [Custom String] Load [Paper Orientation]
4514-630, -635, -636, -638, -639, -649 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 72: Defective Flash Detected [51]
4514-630, -635, -636, -638, -639, -649 • 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 73: Incorrect Paper Size, Open [Paper Source] [34]
4514-630, -635, -636, -638, -639, -649 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 74: Insufficient Memory, Some Held Jobs Will Not Be Restored [37]
4514-630, -635, -636, -638, -639, -649 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.
Page 75: Load [Paper Source] With [Paper Type] [Paper Size] [Paper Orientation]
4514-630, -635, -636, -638, -639, -649 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 76: 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 77: 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 78: 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 79: 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 80: Smtp Server Not Set Up. Contact System Administrator
4514-630, -635, -636, -638, -639, -649 • 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.
Page 81: Too Many Trays Attached [58]
4514-630, -635, -636, -638, -639, -649 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.
Page 82: User Attendance Messages (0-99.99)
4514-630, -635, -636, -638, -639, -649 User attendance messages (0–99.99) User attendance messages (0‑99.99) User attendance messages Error code Description Action 31.21 Capactive Toner Level Sensing (CTLS) reading out of Go to “CTLS service check” on page range. 31.22 Excessive CTLS noise. 31.23 Abrupt change detected in CTLS reading.
Page 83 4514-630, -635, -636, -638, -639, -649 Error code Description Action 32.01 Capacity Class/ Model compatibility mismatch. The Check if the toner cartridge is supported. Replace supplies CC/MC is not compatible with the printer's with a supported toner cartridge if necessary. CC/MC setting.
Page 84: Toner Cartridge Smart Chip Contact Service Check
If the problem does not reoccur, replace the wireless network option. If the problem remains, replace the controller board. Maintenance kit (MS510 and MS610 only) Replace the maintenance kit, and then reset the Maintenance counter. Imaging unit low Replace the imaging unit.
Page 85: Imaging Unit Smart Chip Contact Service Check
4514-630, -635, -636, -638, -639, -649 Imaging unit smart chip contact service check Action Step 1 Go to step 2. Reseat the cables. Check the cable JARW2 for proper connection to the controller board. Is it properly connected? Step 2 Replace the controller Replace the printer.
Page 86: Printer/Cartridge Mismatch Service Check
4514-630, -635, -636, -638, -639, -649 Action Step 6 Go to step 7. Replace the main drive gearbox. See “Main Remove the main drive gearbox. drive gearbox Check the gears for wear or damage. removal” on page Check the main drive motor for rotation. 167.
Page 87: Insufficient Memory Service Check
4514-630, -635, -636, -638, -639, -649 Insufficient memory service check Action Step 1 Go to step 2. Reseat the memory card. Check the memory card for proper installation. Is it properly installed? Step 2 Replace the controller Replace the memory board.
Page 88: Printer Hardware Errors
4514-630, -635, -636, -638, -639, -649 Printer hardware errors 1xx error messages Error code Description Action 111.00 Pel clock check failed. Go to “111.xx 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...
Page 89 4514-630, -635, -636, -638, -639, -649 Error code Description Action 121.07 Fuser has been on for more than allowed after a gap Restore the engine settings to their defaults: blowout, and the temperature is still too cold. Diagnostics Menu > Printer Setup > Defaults 121.08 Fuser was under temp when page was in fuser.
Page 90 4514-630, -635, -636, -638, -639, -649 Error code Description Action 132.01 TDS baseline too low. Go to “Toner density sensor service check” on page 132.02 TDS baseline too high. 132.03 TDS baseline excessive range. 132.16 TDS calibration at maximum. 132.17 TDS calibration too low.
Page 91: 111.Xx Lsu Service Check
4514-630, -635, -636, -638, -639, -649 111.xx LSU service check Action Step 1 Go to step 2. Reseat the cables. Check the LSU cables JVIDEO1 and JGLV1 for proper connection. Are they properly connected? Step 2 Replace the controller Replace the LSU. See board.
Page 92: Lvps Service Check
4514-630, -635, -636, -638, -639, -649 LVPS service check Action Step 1 Go to step 2. Reseat the cables. Check if the power supply cable is properly connected to the controller board. Is it properly connected? Step 2 Contact your next level Replace the power of support.
Page 93: Ctls Service Check
4514-630, -635, -636, -638, -639, -649 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. •...
Page 94: Acm Service Check
4514-630, -635, -636, -638, -639, -649 ACM service check Action Step 1 Go to step 2. Replace the pick/lift motor gearbox. See Check the pick/lift motor gearbox for proper operation. “Pick/Lift motor POR into the Diagnostics menu and perform a feed test: gearbox removal”...
Page 95: Tray 1 Pick/Lift Motor Gearbox Service Check
4514-630, -635, -636, -638, -639, -649 Tray 1 pick/lift motor gearbox service check Action Step 1 Go to step 2. Replace the tray insert. Remove Tray 1. Check the lift plate and gears for proper operation by moving the metal plate.
Page 96: 9Xx Error Messages
4514-630, -635, -636, -638, -639, -649 9xx error messages Error code Description Action 900.xx RIP firmware errors Go to “System software error service check” on page 912.xx Unrecoverable Engine firmware error POR the machine. If the error re‑occurs, then update the firmware.
Page 97 4514-630, -635, -636, -638, -639, -649 Error code Description Action 953.xx NVRAM chip failure with mirror part Replace the controller board. Go to “Controller board removals” on page 185. 954.xx NVRAM chip failure with system part 955.xx The Code ROM or NAND flash failed the Cyclic Redundancy Check (CRC) or the NAND experienced an uncorrectible multi-bit failure.
Page 98 4514-630, -635, -636, -638, -639, -649 Error code Description Action 959.30 Pensive library flagged an invalid argument(s) Replace the controller board. Go to “Controller board removals” on page 185. 959.31 Pensive library flagged an invalid device address 959.32 Failure to init physical interface 959.33 Unknown/unexpected Error 959.34...
Page 99: System Software Error Service Check
Note: Before troubleshooting, 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 100 4514-630, -635, -636, -638, -639, -649 Action Step 4 Go to step 5. Go to step 6. Properly connect the cables to the controller board. POR the printer into the Diagnostics menu. Does the error remain during startup? Step 5 Go to step 31.
Page 101 Send a print job to the printer. Does the error remain? 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.
Page 102 4514-630, -635, -636, -638, -639, -649 Action Step 18 Go to step 19. 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.
Page 103: Nvram Mismatch Failure Service Check
4514-630, -635, -636, -638, -639, -649 Action Step 26 Go to step 27. The problem is solved. Are there any more ISP options to install? Step 27 Go to step 29. Go to step 28. Install the next ISP option. POR the printer.
Page 104 4514-630, -635, -636, -638, -639, -649 Replace only one component at a time. Replace the required component and perform a POR before replacing a second component listed above. If this procedure is not followed, the printer will be rendered inoperable. Never replace two or more of the components listed above without a POR after installing each one or the printer will be rendered inoperable.
Page 105: Input Option Hardware Errors
4514-630, -635, -636, -638, -639, -649 Input option hardware errors 3xx error messages Error code Description Action 321.51 Motor 1 (Pick/Lift) motor no first encoder Go to “Option tray pick/lift motor service check” on page 106. 321.52 Motor 1 (Pick/Lift) motor stop error 321.53 Motor 1 (Pick/Lift) PWM underflow (motor overspeed)
Page 106: Option Tray Pick/Lift Motor Service Check
4514-630, -635, -636, -638, -639, -649 Error code Description Action 341.51 Motor 1 (Pick/Lift) motor no first encoder Go to “Option tray pick/lift motor service check” on page 106. 341.52 Motor 1 (Pick/Lift) motor stop error 341.53 Motor 1 (Pick/Lift) PWM underflow (motor overspeed) 342.54 Motor 2 (Separator/Passthru) motor no first encoder Go to...
Page 107: Option Tray Separator/Passthrough Motor Service Check
4514-630, -635, -636, -638, -639, -649 Option tray separator/passthrough motor service check Action Step 1 Go to step 2. Replace the tray. Remove the option tray insert. Check the separator roll assembly gear under the tray base for the following: •...
Page 108: Option Tray Controller Card Service Check
4514-630, -635, -636, -638, -639, -649 Option tray controller card service check Action Step 1 Go to step 2. Reseat the cables. Check all connections to the option tray controller card. Are the properly connected? Step 2 Go to step 3. Update the firmware.
Page 109: Dead Machine Service Check
4514-630, -635, -636, -638, -639, -649 Dead machine service check Action Step 1 Go to step 2. Reseat the cables. Check if the power supply cable is properly connected to the controller board. Are they properly connected? Step 2 Go to “Controller Replace the power board service check”...
Page 110: Control Panel Button Service Check
4514-630, -635, -636, -638, -639, -649 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 •...
Page 111: Control Panel Service Check
4514-630, -635, -636, -638, -639, -649 Action Step 4 The problem is solved. Contact the next level of support. Replace the controller board. Go to “Controller board removals” on page 185. 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.
Page 112: Usb Print Service Check
4514-630, -635, -636, -638, -639, -649 Action Step 4 The problem is solved. Go to step 5. Try a different toner cartridge. Did this fix the problem? Step 5 Go to step 7. Go to step 6. Check the connections between the cartridge gearbox and the controller board.
Page 113: 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 114 4514-630, -635, -636, -638, -639, -649 Actions Step 5 Go to step 10. Go to step 6. Does the IP address displayed on the network settngs page match the IP address in the port of the drivers using the printer? Step 6 Go to step 7.
Page 115 4514-630, -635, -636, -638, -639, -649 Actions Step 16 The problem is solved. Go to step 17. Assign the correct wireless network to the printer. Did this fix the problem? Step 17 Go to step 18. Contact the network administrator. Are the other devices on the wireless network communicating properly? Step 18 Go to step 20.
Page 116 4514-630, -635, -636, -638, -639, -649...
Page 117: Service Menus
4514-630, -635, -636, -638, -639, -649 Service menus Understanding the control panel (MS510dn and MS610dn) Using the printer control panel 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 118: Understanding The Colors Of The Indicator And Sleep Button Lights
4514-630, -635, -636, -638, -639, -649 Use the Down arrow button Scroll down. Home button Go to the home screen. Indicator light Check the status of the printer. Understanding the colors of the indicator and Sleep button lights The colors of the indicator and Sleep button lights on the printer control panel signify a certain printer status or condition. Indicator light color and its corresponding printer status Indicator light Printer status...
Page 119: Understanding The Colors Of The Indicator And Sleep Button Lights
4514-630, -635, -636, -638, -639, -649 Use the Display View the printer status and messages. Set up and operate the printer. Home button Go to the home screen. Keypad Enter numbers, letters, or symbols. Sleep button Enable Sleep mode or Hibernate mode. The following actions wake the printer from Sleep mode: •...
Page 120: Understanding The Home Screen
4514-630, -635, -636, -638, -639, -649 Understanding the home screen When the printer is turned on, the display shows a basic screen, referred to as the home screen. Use the home screen buttons and icons to initiate an action. Note: Your home screen may vary depending on your home screen customization settings, administrative setup, and active embedded solutions.
Page 121: Using The Touch-Screen Buttons
4514-630, -635, -636, -638, -639, -649 Touch Profiles and Solutions Access profiles and solutions. Features Feature Description Attendance message alert If an attendance message affects a function, then this icon appears and the red indicator light blinks. Warning If an error condition occurs, then this icon appears. Printer IP address The IP address of your printer is located at the top left corner of the home screen and appears as four sets of numbers separated by periods.
Page 122: Updating The Printer Firmware
Updating the printer firmware Go to http://support.lexmark.com. Enter the model name of the printer to be updated on the field provided (Example: Lexmark MS810de). Click GO to enter the product page. If several printers are shown, select the specific printer applicable.
Page 123: Diagnostics Menu
4514-630, -635, -636, -638, -639, -649 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...
Page 124: Print Tests
4514-630, -635, -636, -638, -639, -649 • Horizontal lines for skew adjustment • General printer information, including current page count, installed memory, processor speed, serial number, engine ID, and system card ID Change the value of any of the margin settings. Top Margin -16 to +16 Increasing the value moves the image down the page.
Page 125: Hardware Tests
4514-630, -635, -636, -638, -639, -649 Hardware Tests If the hardware test fails, replace the failing part. Panel Test This test verifies the control panel display function. To run the Panel test: From the Diagnostics menu, navigate to: Hardware Tests > Panel Test Press X to exit the test.
Page 126: Duplex Tests
4514-630, -635, -636, -638, -639, -649 To run the DRAM test: From the Diagnostics menu, navigate to: Hardware Tests > DRAM Test Testing… appears, followed by Resetting the Printer. After the printer resets, the results of the test appear: DRAM Test [x] P:###### F:######. •...
Page 127: Top Margin
4514-630, -635, -636, -638, -639, -649 To run the Duplex quick test: From the Diagnostics menu, navigate to: Duplex Tests > Quick Test Choose any of the following: • Single—Prints a single Quick test page. • Continuous—Continuously prints the Quick test pages until X is pressed. The printer attempts to print the Quick test page from the default paper source.
Page 128: Input Tray Tests
4514-630, -635, -636, -638, -639, -649 To adjust this setting: From the Diagnostics menu, navigate to: Duplex Tests > Left Margin Change the margin value. Each increment corresponds to 4 pels at 600 dpi (0.00666 in. or 0.1693 mm). A more positive offset moves the margin to the right, and a more negative offset moves the margin to the left.
Page 129: Output Bin Tests
4514-630, -635, -636, -638, -639, -649 To run the Feed test: From the Diagnostics menu, navigate to: Input Tray Tests > Feed Tests Choose the input source. All installed sources appear. Choose any of the following: • Single—Feeds a single page. •...
Page 130: Base Sensor Test
4514-630, -635, -636, -638, -639, -649 Sensor Test This test verifies that the output bin sensors are working correctly. To run this test: From the Diagnostics menu, navigate to: Output Bin Tests > Sensor Test > Standard Bin Testing... appears while the printer is verifying the state of the sensor. The control panel displays the current state of the sensor.
Page 131: Device Tests
4514-630, -635, -636, -638, -639, -649 Device Tests Quick Disk Test This test performs a non-destructive read/write test on one block per track on the disk. The test reads one block on each track, saves the data, and then writes and reads four test patterns to the bytes in the block. If the block is good, then the saved data is written back to the disk.
Page 132: Printer Setup
4514-630, -635, -636, -638, -639, -649 From the Diagnostics menu, navigate to: Device Tests > Flash Test Files will be lost. Go/Stop? appears. Do one of the following: • Depending on the printer model, press OK or touch to continue. •...
Page 133: Ep Setup
4514-630, -635, -636, -638, -639, -649 Printed Page Count The value of this setting gauges the amount of usage on the printer. The value of the Printed Page Count setting will equal the values of the Picked Sides meter. After all print tests have been completed, the value will reset to zero. Note: The value of the setting cannot be changed manually.
Page 134: Transfer Adjust
4514-630, -635, -636, -638, -639, -649 Fuser Temperature (Fuser Temp) This setting adjusts the fuser temperature to solve problems with paper curl on low‑grade paper and/or melting of letterheads on some papers. To adjust this setting: From the Diagnostics menu, navigate to: EP Setup >...
Page 135: Reports
4514-630, -635, -636, -638, -639, -649 To adjust this setting: From the Diagnostics menu, navigate to: EP Setup > Gap Adjust Press OK or touch to save any changes. Auto Dark Adj When activated, this setting attempts to optimize the amount of toner used when printing with a specific operating point.
Page 136: Exit Diags
4514-630, -635, -636, -638, -639, -649 To view the Event log: From the Diagnostics menu, navigate to: Event Log > Display Log Use the arrow buttons to navigate through the entries. Print Log Additional diagnostic information is available when the event log is printed. The first page of the report shows the general device information.
Page 137: Configuration Menu
4514-630, -635, -636, -638, -639, -649 In MS610de, this menu appears as a soft button at the bottom right corner of the display. This is always accessible to the user from the main Diagnostics menu. Configuration menu The Configuration menu group consists of menus, settings, and operations that are used to configure a printer for operation.
Page 138: Print Quality Pages
4514-630, -635, -636, -638, -639, -649 Print Quality Pages This option is a limited version of the Print quality pages setting that appears in the Diagnostics menu. See “Print Quality Pages” on page 124. This setting reports the values of a broad range of printer settings and tests the ability of the printer to generate acceptable printed output.
Page 139: Download Emuls
4514-630, -635, -636, -638, -639, -649 Available options: • Deactivate • Activate Download Emuls This appears only if at least one download emulator (DLE) is installed. The default setting is Disable. All download emulators (DLEs) are reenabled automatically after two PORs. Factory Defaults Warning—Potential Damage: This operation cannot be undone.
Page 140: Envelope Prompts
4514-630, -635, -636, -638, -639, -649 To change this setting: From the Configuration menu, navigate to Paper Prompts. Select from the available options: • Auto (default) • Multi‑purpose Feeder • Manual Paper Depending on the printer model, press OK or touch to save the setting, or press X to return to the Configuration menu without saving any changes.
Page 141: Jobs On Disk
4514-630, -635, -636, -638, -639, -649 Depending on the printer model, press OK or touch to save the setting, or press X to return to the Configuration menu without saving any changes. When set to Prompt user, the printer behaves like the past implementation. When a change prompt occurs, the printer stops printing, posts the change prompt to the target source, and waits for the user to select an action before continuing.
Page 142: Wipe All Settings
4514-630, -635, -636, -638, -639, -649 Available options: • Single Pass Erase—overwrites all data and the file system. This wipe is faster but less secure since it is possible to retrieve the deleted data with forensic data‑retrieval techniques. • Multi Pass Erase—overwrites all data without rewriting the file system. This wipe is DoD 5220.22-M compliant since the deleted data is irretrievable.
Page 143: A5 Loading
4514-630, -635, -636, -638, -639, -649 Depending on the printer model, press OK or touch to save the setting, or press X to return to the Configuration menu without saving any changes. If Standby mode is On, the printer begins functioning in Standby mode when it remains idle for an amount of time. The Standby mode enables the printer: •...
Page 144: Key Repeat Rate
4514-630, -635, -636, -638, -639, -649 Key Repeat Rate Note: This setting is available on the MS610de model only. This setting indicates the number of presses per second for repeating keys. The range is 0.5–100, with increments of 0.5. The default setting is 15 presses per second. To adjust this setting: From the Configuration menu, navigate to Key Repeat Rate.
Page 145: Usb Pnp
4514-630, -635, -636, -638, -639, -649 To change this setting: From the Configuration menu, navigate to Automatically Display Error Screens. Select from the available options: • On (default) • Depending on the printer model, press OK or touch to save the setting, or press X to return to the Configuration menu without saving any changes.
Page 146: Accessing The Network Se Menu
4514-630, -635, -636, -638, -639, -649 Accessing the Network SE menu This menu contains settings for fine tuning the communication settings for the network interfaces and protocols. Navigate to: Networks/Ports > Standard Network > Std Network Setup. Press and hold 6, 7, and 9 simultaneously. Service Engineer menu Accessing the service engineer (SE) menu From a Web browser on a host PC, add /se to the printer IP address.
Page 147: Repair Information
4514-630, -635, -636, -638, -639, -649 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. Disconnect any connections between the printer and the PCs/peripherals.
Page 148: Rip Board/Operator Panel Replacement
4514-630, -635, -636, -638, -639, -649 • Do not place the ESD-sensitive part on the machine cover or on a metal table; if you need to put down the ESD- sensitive part for any reason, first put it into its special bag. •...
Page 149: Ribbon Cable Connectors
4514-630, -635, -636, -638, -639, -649 Navigate to Solutions, and click the link. Navigate to Embedded Solutions, and click the link. On the Embedded Solutions page, select the apps to be exported by clicking the selection box next to the app. Choose Export.
Page 150: Horizontal Top Contact Connector
4514-630, -635, -636, -638, -639, -649 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.
Page 151 4514-630, -635, -636, -638, -639, -649 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 152 4514-630, -635, -636, -638, -639, -649 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 153: Horizontal Bottom Contact Connector
4514-630, -635, -636, -638, -639, -649 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.
Page 154 4514-630, -635, -636, -638, -639, -649 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 155 4514-630, -635, -636, -638, -639, -649 Place your finger in the middle of the actuator, and then rotate the locking actuator to the locked position. Repair information...
Page 156: Vertical Mount Contact Connector
4514-630, -635, -636, -638, -639, -649 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.
Page 157 4514-630, -635, -636, -638, -639, -649 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 158 4514-630, -635, -636, -638, -639, -649 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 159: Horizontal Sliding Contact Connector
4514-630, -635, -636, -638, -639, -649 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.
Page 160 4514-630, -635, -636, -638, -639, -649 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 161 4514-630, -635, -636, -638, -639, -649 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.
Page 162: Low Insertion Force (Lif) Connector
4514-630, -635, -636, -638, -639, -649 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.
Page 163: Printhead Assembly Adjustments
4514-630, -635, -636, -638, -639, -649 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 164 4514-630, -635, -636, -638, -639, -649 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 165 4514-630, -635, -636, -638, -639, -649 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 166: Removal Procedures
4514-630, -635, -636, -638, -639, -649 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 167: Main Drive Gearbox Removal
4514-630, -635, -636, -638, -639, -649 Main drive gearbox removal Remove the left cover. See “Left cover removal” on page 166. Squeeze the latch, and then detach the link from the front door. Repair information...
Page 168 4514-630, -635, -636, -638, -639, -649 Remove the 4 screws (A), and then remove the main drive gearbox. Disconnect the cable from the main drive gearbox. Repair information...
Page 169: Mpf Solenoid Removal
4514-630, -635, -636, -638, -639, -649 Remove the spring (B) and the fuser gear (C). MPF solenoid removal Remove the left cover. See “Left cover removal” on page 166. Remove the right cover. See “Right cover removal” on page 179. Remove the rear door and cover.
Page 170 4514-630, -635, -636, -638, -639, -649 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 171 4514-630, -635, -636, -638, -639, -649 Insert the cable into the hole (B). Route the cable using the new path. Repair information...
Page 172: Mpf Gearbox Removal
4514-630, -635, -636, -638, -639, -649 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 166. Remove the main drive gearbox. See “Main drive gearbox removal”...
Page 173 4514-630, -635, -636, -638, -639, -649 Disconnect the spring (A) from the printer. Remove the three screws (B), and then remove the left front mount. Repair information...
Page 174 4514-630, -635, -636, -638, -639, -649 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 175: Reverse Solenoid Removal
4514-630, -635, -636, -638, -639, -649 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 179. Remove the left cover. See “Left cover removal” on page 166.
Page 176: Cartridge Gearbox Removal
4514-630, -635, -636, -638, -639, -649 Remove the two screws (A) securing the reverse solenoid. Cartridge gearbox removal Remove the left cover. See “Left cover removal” on page 166. Remove the four screws (A) securing the cartridge gearbox. Disconnect the cable from the cartridge gearbox. Repair information...
Page 177: Duplex Gear Assembly Removal
4514-630, -635, -636, -638, -639, -649 Duplex gear assembly removal Remove the left cover. See “Left cover removal” on page 166. Remove the rear door and cover. See “Rear door and cover removal” on page 242. Remove the power supply. See “Power supply removal”...
Page 178 4514-630, -635, -636, -638, -639, -649 From behind the three gears, remove the duplex coupling (D). Remove the duplex link (E) from the duplex. Repair information...
Page 179: Right Side Removals
4514-630, -635, -636, -638, -639, -649 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 180: Tray Present Sensor Removal
4514-630, -635, -636, -638, -639, -649 Release the latches (C) to remove the right cover. Tray present sensor removal Remove the right cover. See “Right cover removal” on page 179. 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 181: Cooling Fan Duct Removal
4514-630, -635, -636, -638, -639, -649 Cooling fan duct removal Note: This is not a FRU. Remove the right cover. See “Right cover removal” on page 179. 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 182 4514-630, -635, -636, -638, -639, -649 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 179. Disconnect the cable JFAN1 from the controller board. Repair information...
Page 183: Cooling Fan Mount Removal (Ms610De)
4514-630, -635, -636, -638, -639, -649 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 179. Remove the cooling fan. See “Cooling fan removals”...
Page 184 4514-630, -635, -636, -638, -639, -649 Remove two screws (A), and then remove the cooling fan mount. Repair information...
Page 185: Controller Board Shield Removal (Ms610De)
4514-630, -635, -636, -638, -639, -649 Controller board shield removal (MS610de) Note: This is not a FRU. Remove the right cover. See “Right cover removal” on page 179. Remove the four screws (A) securing the controller board shield. Controller board removals Controller board removal (MS510dn and MS610dn) Remove the right cover.
Page 186 4514-630, -635, -636, -638, -639, -649 Remove the screw (A) from the rear side of the printer. Remove the five screws (B) securing the controller board. Controller board removal (MS610de) Remove the right cover. See “Right cover removal” on page 179.
Page 187 4514-630, -635, -636, -638, -639, -649 Disconnect all cables from the controller board. Release the toroid from the holder. Repair information...
Page 188 4514-630, -635, -636, -638, -639, -649 Remove the screw (A) from the rear side of the printer. Remove the seven screws (B) securing the controller board. Repair information...
Page 189: Toner Cartridge Smart Chip Contact Removal
4514-630, -635, -636, -638, -639, -649 Toner cartridge smart chip contact removal Remove the right cover. See “Right cover removal” on page 179. Note: For MS610de, also remove the following: Controller board shield. See “Controller board shield removal (MS610de)” on page 185.
Page 190 4514-630, -635, -636, -638, -639, -649 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 191: Front Removals
4514-630, -635, -636, -638, -639, -649 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 192 4514-630, -635, -636, -638, -639, -649 Disconnect the spring (A) from the printer. Remove the three screws (B), and then remove the left front mount. Repair information...
Page 193: Right Front Mount Removal
4514-630, -635, -636, -638, -639, -649 Right front mount removal Remove the right cover. See “Right cover removal” on page 179. 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 194 4514-630, -635, -636, -638, -639, -649 Remove the four screws (B), and then remove the right front mount. Repair information...
Page 195: Transfer Roll Removal
4514-630, -635, -636, -638, -639, -649 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.
Page 196: Cartridge Plunger Removal
4514-630, -635, -636, -638, -639, -649 Cartridge plunger removal Open the front door. Tilt the cartridge plunger. Twist and then remove the cartridge plunger. Repair information...
Page 197 4514-630, -635, -636, -638, -639, -649 Installation notes: Use a spring hook to hold the spring, and then reinstall the cartridge plunger. Repair information...
Page 198 4514-630, -635, -636, -638, -639, -649 Set the spring over the plunger. Repair information...
Page 199: Bezel Removals
4514-630, -635, -636, -638, -639, -649 Bezel removals Bezel removal (MS510dn) Open the front door. Push the latches (A), and then remove the bezel. Repair information...
Page 200 4514-630, -635, -636, -638, -639, -649 Bezel removal (MS610dn) Open the front door. Push the latches (A), and then remove the bezel. Repair information...
Page 201: Nameplate Removals
4514-630, -635, -636, -638, -639, -649 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 202 4514-630, -635, -636, -638, -639, -649 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 203: Control Panel Assembly Removals
4514-630, -635, -636, -638, -639, -649 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 179. Remove the nameplate. See “Nameplate removals”...
Page 204 4514-630, -635, -636, -638, -639, -649 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 205 4514-630, -635, -636, -638, -639, -649 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 179.
Page 206 4514-630, -635, -636, -638, -639, -649 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 207: Uicc Removals
4514-630, -635, -636, -638, -639, -649 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.
Page 208 4514-630, -635, -636, -638, -639, -649 Remove the bezel. See “Bezel removals” on page 199. Remove the control panel assembly. See “Control panel assembly removals” on page 203. Remove the cable from the connector (A). Remove the eight screws (B). Flip the UICC, and then remove the screw (C).
Page 209 4514-630, -635, -636, -638, -639, -649 UICC removal (MS610de) Remove the right cover. See “Right cover removal” on page 179. Remove the nameplate. See “Nameplate removals” on page 201. Remove the bezel. See “Bezel removals” on page 199. Remove the control panel assembly. See “Control panel assembly removals”...
Page 210: Control Panel Usb Port Removal (Ms610Dn)
4514-630, -635, -636, -638, -639, -649 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.
Page 211: Speaker And Control Panel Usb Port Removal (Ms610De)
4514-630, -635, -636, -638, -639, -649 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 179. Remove the nameplate. See “Nameplate removals”...
Page 212: Mpf Assembly Removal
4514-630, -635, -636, -638, -639, -649 MPF assembly removal Remove the nameplate. See “Nameplate removals” on page 201. Remove the two springs (A). Repair information...
Page 213 4514-630, -635, -636, -638, -639, -649 Squeeze the latches (B) to release the left and right links. Repair information...
Page 214 4514-630, -635, -636, -638, -639, -649 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 215: Mpf Pick Roller Cover Removal
4514-630, -635, -636, -638, -639, -649 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 215.
Page 216: Bail Removal
4514-630, -635, -636, -638, -639, -649 Pull the MPF pick roller outward to remove. 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”...
Page 217: Front Door Removal
4514-630, -635, -636, -638, -639, -649 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 179. Disconnect the following cables from the controller board: For MS510dn and MS610dn: •...
Page 218 4514-630, -635, -636, -638, -639, -649 Squeeze the latch, and then detach the link from the front door. Remove the screw (A) to disconnect the ground wire. Repair information...
Page 219 4514-630, -635, -636, -638, -639, -649 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.
Page 220: Front Access Cover Removal
4514-630, -635, -636, -638, -639, -649 Install the right front mount to the printer. Front access cover removal Remove the right cover. See “Right cover removal” on page 179. Remove the front door. See “Front door removal” on page 217. Remove the nameplate.
Page 221: Front Input Guide Removal
4514-630, -635, -636, -638, -639, -649 Front input guide removal Remove the right cover. See “Right cover removal” on page 179. Remove the front door. See “Front door removal” on page 217. Remove the MPF pick roller cover. See “MPF pick roller cover removal” on page 215.
Page 222 4514-630, -635, -636, -638, -639, -649 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 223: Separator Pad Removal
4514-630, -635, -636, -638, -639, -649 Separator pad removal Remove the right cover. See “Right cover removal” on page 179. Remove the front door. See “Front door removal” on page 217. Remove the MPF pick roller cover. See “MPF pick roller cover removal” on page 215.
Page 224 4514-630, -635, -636, -638, -639, -649 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 225: Bottom Removals
4514-630, -635, -636, -638, -639, -649 Bottom removals Power supply removals Power supply removal Remove the left cover. See “Left cover removal” on page 166. Remove the rear door and cover. See “Rear door and cover removal” on page 242. Disconnect the cable (A) from the rear, and disconnect the cable (B) from the left side.
Page 226: Power Supply Removal (Ms610)
4514-630, -635, -636, -638, -639, -649 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 removal (MS610) Remove the left cover. See “Left cover removal”...
Page 227: Power Supply Shield Removal
4514-630, -635, -636, -638, -639, -649 Remove the five metal screws (C) and the plastic screw (D) securing the power supply. Remove the power supply, and then disconnect the cable from the power supply. Power supply shield removal Remove the left cover. See “Left cover removal”...
Page 228: Duplex Removal
4514-630, -635, -636, -638, -639, -649 Remove the three screws (A), and then remove the power supply shield. Duplex removal Remove the left cover. See “Left cover removal” on page 166. Remove the rear door and cover. See “Rear door and cover removal” on page 242.
Page 229: Duplex Sensor And Input Sensor Removal
4514-630, -635, -636, -638, -639, -649 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 166.
Page 230 4514-630, -635, -636, -638, -639, -649 Remove the rear door and cover. See “Rear door and cover removal” on page 242. Remove the power supply. See “Power supply removal” on page 225. Remove the power supply shield. See “Power supply shield removal” on page 227.
Page 231 4514-630, -635, -636, -638, -639, -649 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 232: Index Sensor Removal
4514-630, -635, -636, -638, -639, -649 Index sensor removal Remove the left cover. See “Left cover removal” on page 166. Remove the right cover. See “Right cover removal” on page 179. Remove the rear door and cover. See “Rear door and cover removal” on page 242.
Page 233 4514-630, -635, -636, -638, -639, -649 Position the printer so that it sits on its left side. Disconnect the cable from the media present sensor (A). From inside the printer, release the three latches (B). Repair information...
Page 234: Toner Density Sensor Removal
4514-630, -635, -636, -638, -639, -649 Toner density sensor removal Remove the left cover. See “Left cover removal” on page 166. Remove the main drive gearbox. See “Main drive gearbox removal” on page 167. Remove the rear door and cover. See “Rear door and cover removal”...
Page 235: Acm Assembly Removal
4514-630, -635, -636, -638, -639, -649 Remove the duplex. See “Duplex removal” on page 228. Position the printer so that it sits on its left side. Disconnect the cable JACM1 from the controller board. Release the retainer spring (A) from the bracket (B). Remove the screw (C).
Page 236 4514-630, -635, -636, -638, -639, -649 Remove the two screws (C). Below are the cam release and bracket. Repair information...
Page 237 4514-630, -635, -636, -638, -639, -649 Remove the screw (D) securing the ACM lift cam to the ACM housing. Remove the ACM lift cam by sliding it off the shaft. Repair information...
Page 238 4514-630, -635, -636, -638, -639, -649 Remove the E-clip (E), and slide the washer (F) from the shaft. Release the lock by sliding the bushing and then rotating it clockwise. Repair information...
Page 239 4514-630, -635, -636, -638, -639, -649 Remove the media present sensor flag by pushing it until it clicks, and slide it off the ACM assembly. Swing the ACM assembly. Repair information...
Page 240 4514-630, -635, -636, -638, -639, -649 Remove the screw (G) securing the media present sensor bracket. Remove the ACM assembly with shaft. Below is the ACM assembly with media present sensor flag and bracket. Repair information...
Page 241: Pick/Lift Motor Gearbox Removal
4514-630, -635, -636, -638, -639, -649 Pick/Lift motor gearbox removal Remove the left cover. See “Left cover removal” on page 166. Remove the rear door and cover. See “Rear door and cover removal” on page 242. Remove the power supply. See “Power supply removal”...
Page 242: Rear Side Removals
4514-630, -635, -636, -638, -639, -649 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 243: Narrow Media/Bin Full Sensor Removal
4514-630, -635, -636, -638, -639, -649 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”...
Page 244: Redrive Assembly
4514-630, -635, -636, -638, -639, -649 Remove the top cover. See “Top cover removal” on page 247. 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).
Page 245: Redrive Assembly Removal
4514-630, -635, -636, -638, -639, -649 Redrive assembly removal Remove the right cover. See “Right cover removal” on page 179. Remove the left cover. See “Left cover removal” on page 166. Remove the rear door and cover. See “Rear door and cover removal” on page 242.
Page 246: Fuser Removal
4514-630, -635, -636, -638, -639, -649 Remove the six screws (B) securing the redrive assembly. Fuser removal Remove the right cover. See “Right cover removal” on page 179. Remove the rear door and cover. See “Rear door and cover removal” on page 242.
Page 247: Top Side Removals
4514-630, -635, -636, -638, -639, -649 Remove the two screws (B) securing the fuser. Top side removals Top cover removal Remove the right cover. See “Right cover removal” on page 179. Remove the left cover. See “Left cover removal” on page 166.
Page 248: Laser Scanning Unit (Lsu) Removal
4514-630, -635, -636, -638, -639, -649 Remove the two screws (A) in front. Remove the two screws (B) at the rear. Lift the top cover to remove. Laser scanning unit (LSU) removal Remove the right cover. See “Right cover removal” on page 179.
Page 249 4514-630, -635, -636, -638, -639, -649 Disconnect the cable (A) from the LSU. Before loosening the screws securing the LSU, use a sharp pencil or a small, flat-blade screwdriver to mark the location of the LSU on the printer frame. This will be helpful in positioning the new LSU. Remove the three screws (B) securing the LSU.
Page 250: 250/550-Sheet Option Tray Removals
4514-630, -635, -636, -638, -639, -649 250/550-sheet option tray removals Pick roller removal Press the latches, and then remove the pick roller. Separator roll assembly removal Remove the screw (A) from under the tray insert. Repair information...
Page 251 4514-630, -635, -636, -638, -639, -649 Remove the E-clip, and then remove the gear. Remove the four screws (B). Repair information...
Page 252: Acm Assembly Removal
4514-630, -635, -636, -638, -639, -649 Push out the top part of the drawer cover, and then remove the separator roll assembly. ACM assembly removal Remove the seven screws (A), and release the two latches (B) from the top of the drawer. Repair information...
Page 253 4514-630, -635, -636, -638, -639, -649 Remove the two screws (C), and then release the two latches under the screws. Swing the right cover backward to remove. Repair information...
Page 254 4514-630, -635, -636, -638, -639, -649 Remove the screw (D). Disconnect the spring (E). Repair information...
Page 255 4514-630, -635, -636, -638, -639, -649 Remove the two screws (F), and then remove the controller card cover. Disconnect the cable J11 from the controller card. Unroute the cable, and then remove the ACM assembly. Repair information...
Page 256 4514-630, -635, -636, -638, -639, -649...
Page 257: Component Locations
4514-630, -635, -636, -638, -639, -649 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 258 4514-630, -635, -636, -638, -639, -649 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 259: Ms610De Exterior Locations
4514-630, -635, -636, -638, -639, -649 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 260 4514-630, -635, -636, -638, -639, -649 Rear view Part name Security slot USB printer port USB port USB port Ethernet port Power switch Printer power cord socket Component locations...
Page 261: 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 262: Scheduled Maintenance
4514-630, -635, -636, -638, -639, -649 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 263: Resetting The Maintenance Counter
4514-630, -635, -636, -638, -639, -649 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 264: Lubrication Specification
4514-630, -635, -636, -638, -639, -649 Lubrication specification Lubricate only when parts are replaced or as needed, not on a scheduled basis. Use of lubricants other than those specified in this service manual can cause premature failure. Some unauthorized lubricants might chemically attack polycarbonate parts.
Page 265 4514-630, -635, -636, -638, -639, -649...
Page 266: Parts Catalog
4514-630, -635, -636, -638, -639, -649 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 267: Assembly 1: Covers
4514-630, -635, -636, -638, -639, -649 Assembly 1: Covers Parts catalog...
Page 268 4514-630, -635, -636, -638, -639, -649 Assembly 1: Covers Asm-index Units/mach Units/FRU Description Removal procedure 40X8520 Dust cover (250‑sheet tray) “Dust cover removal” on page 242 40X8521 Dust cover (550‑sheet tray) “Dust cover removal” on page 242 40X8054 Rear door and cover “Rear door and cover removal”...
Page 269 4514-630, -635, -636, -638, -639, -649 Asm-index Units/mach Units/FRU Description Removal procedure 40X8061 Control panel cover and buttons “Control panel assembly removals” on page 203 (MS610dn) “UICC removals” on Note: Does not include the UICC. page 207 40X8066 Bezel (MS510dn) “Bezel removals”...
Page 270 4514-630, -635, -636, -638, -639, -649 Parts catalog...
Page 271: Assembly 2: Electronics 1
4514-630, -635, -636, -638, -639, -649 Assembly 2: Electronics 1 Parts catalog...
Page 272 4514-630, -635, -636, -638, -639, -649 Assembly 2: Electronics 1 Asm-index Units/mach Units/FRU Description Removal procedure 40X8081 Laser scanning unit “Laser scanning unit (LSU) removal” on page 248 40X8343 Fuser, 100 V “Fuser removal” on page 246 40X8023 Fuser, 110 V “Fuser removal”...
Page 273: Assembly 3: Electronics 2
4514-630, -635, -636, -638, -639, -649 Assembly 3: Electronics 2 Parts catalog...
Page 274 4514-630, -635, -636, -638, -639, -649 Assembly 3: Electronics 2 Asm-index Units/mach Units/FRU Description Removal procedure 40X8048 Front door sensor “Front door sensor removal” on page 220 40X8266 Cartridge smart chip contact “Toner cartridge smart chip contact removal” on page 189 40X8046 Toner density sensor “Toner density sensor removal”...
Page 275: Assembly 4: Frame
4514-630, -635, -636, -638, -639, -649 Assembly 4: Frame Parts catalog...
Page 276 4514-630, -635, -636, -638, -639, -649 Assembly 4: Frame Asm-index Units/mach Units/FRU Description Removal procedure 40X8393 Transfer roll “Transfer roll removal” on page 195 40X8298 Redrive assembly (MS510dn) “Redrive assembly removal” on page 245 40X8437 Redrive assembly (MS610dn) “Redrive assembly removal” on page 245 40X8438 Redrive assembly (MS610de)
Page 277: Assembly 5: Option Trays
4514-630, -635, -636, -638, -639, -649 Assembly 5: Option trays Parts catalog...
Page 278 4514-630, -635, -636, -638, -639, -649 Assembly 5: Option trays Asm-index Units/opt Units/FRU Description Removal procedure 40X8287 250-sheet tray 40X8286 550-sheet tray 40X8520 Dust cover, 250‑sheet tray “Dust cover removal” on page 242 40X8521 Dust cover, 550‑sheet tray “Dust cover removal” on page 242 40X8262 ACM assembly “ACM assembly removal”...
Page 279: Assembly 6: Maintenance Kits
4514-630, -635, -636, -638, -639, -649 Assembly 6: Maintenance kits Asm-index Units/mach Units/FRU Description Removal procedure 40X8439 Maintenance kit, 100 V (MS510dn) • 100 V fuser (40X8343) • Paper exit guide (40X8298) • ACM pick roll (40X8297) • Transfer roll (40X8393) •...
Page 280 4514-630, -635, -636, -638, -639, -649 Asm-index Units/mach Units/FRU Description Removal procedure 40X8435 Maintenance kit, 220 V (MS610dn) • 220 V fuser (40X8024) • Paper exit guide (40X8437) • ACM pick roll (40X8297) • Transfer roll (40X8393) • Tray separator roll assembly (40X8444) •...
Page 281: Assembly 7: Power Cords
4514-630, -635, -636, -638, -639, -649 Assembly 7: Power cords Asm-index Units/mach Units/FRU Description Removal procedure 40X0269 Power cord, 2.5 m (straight)—USA, Canada 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 282 4514-630, -635, -636, -638, -639, -649 Parts catalog...
Page 283: Assembly 8: Miscellaneous
4514-630, -635, -636, -638, -639, -649 Assembly 8: Miscellaneous Removal Asm-index Units/mach Units/FRU Description procedure 40X8737 RFID card reader 40X8330 MarkNet N8352 802.11 b/g/n Wireless Print Server Kit N/A 40X4819 Adapter, RS232C serial 40X5315 Screw, Ship with ISP (2) 40X5316 Cable, 14 pin JST for ISP 40X5317 Standoff, Tee with thumbscrew...
Page 284 4514-630, -635, -636, -638, -639, -649...
Page 285: 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 286: Operating Clearances
4514-630, -635, -636, -638, -639, -649 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 287: Operating Environment
4514-630, -635, -636, -638, -639, -649 MS510 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.
Page 288 4514-630, -635, -636, -638, -639, -649...
Page 289: Appendix B: Options And Features
550‑sheet tray (MS610) Optional 550-sheet tray* Optional 250‑sheet tray* Multipurpose feeder Any combination of 550-sheet and 250-sheet trays may be installed up to a total of 3 optional trays on the MS510 and MS610 models. Appendix B: Options and features...
Page 290 4514-630, -635, -636, -638, -639, -649...
Page 291: Appendix C: Theory Of Operation
4514-630, -635, -636, -638, -639, -649 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, it will be reported to the printer. If the POR sequence cannot be completed successfully, the printer may post an error message identifying service may be needed.
Page 292: Multipurpose Feeder (Mpf)
4514-630, -635, -636, -638, -639, -649 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 293: Duplex Printing
4514-630, -635, -636, -638, -639, -649 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 294: Autocompensator Mechanism (Acm)
4514-630, -635, -636, -638, -639, -649 Aside from providing rotational motion to rollers and feeders, the gearbox must also ensure that the print image is not distorted during the whole process. It must also provide easy and effective means to cut or break the transfer of motion when taking the cartridge unit out of the machine, or when clearing jammed sheets through its linkage system.
Page 295: Sensors
4514-630, -635, -636, -638, -639, -649 MS510/MS610 sensors Bin full sensor Input sensor Fuser exit MPF paper present sensor sensor Duplex sensor Index sensor Media present Trailing edge sensor sensor Pass through sensor Index sensor Media present Trailing edge sensor...
Page 296: Other Key Components
4514-630, -635, -636, -638, -639, -649 Capactive Toner Level Sensor (CTLS) Detects the amount of toner in the imaging unit. If the toner level is low, the cartridge auger motor is triggered to add toner from the toner cartridge to the imaging unit. Front door sensor Is a safety switch that cuts off a 5 V DC supply from the controller board to the LSU to prevent the laser from activating when the front door is opened.
Page 297: Electrophotographic Process (Ep Process)
4514-630, -635, -636, -638, -639, -649 MS510/MS610 rollers Paper exit roller Photoconductor drum Fuser assembly First input roller Fuser exit roller Secondary input roller Duplex rear deliver roller Transfer roll Separator roll Duplex front deliver roller Separator roll Pick rollers...
Page 298 4514-630, -635, -636, -638, -639, -649 Step 1: Charge During the charge step, voltage is sent from the HVPS to the charge roll beside the photoconductor. The charge roll applies a uniform negative charge over the entire surface of the photoconductor to prepare it for the laser beam. HVPS Charge roll (-VDC)
Page 299 4514-630, -635, -636, -638, -639, -649 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 300 4514-630, -635, -636, -638, -639, -649 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...
Page 301 4514-630, -635, -636, -638, -639, -649 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 302 4514-630, -635, -636, -638, -639, -649...
Page 303: Appendix D: Acronyms
4514-630, -635, -636, -638, -639, -649 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...
Page 304 4514-630, -635, -636, -638, -639, -649 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...
Page 305: Index
4514-630, -635, -636, -638, -639, -649 Index configuration menu Symbols A5 loading [x]‑page jam, clear manual feeder. [25y.xx] accessing [x]‑page jam, clear standard bin. [20y.xx] action for prompts [x]‑page jam, open front door. [20y.xx] automatically display error screens [x]‑page jam, open rear door. [20y.xx] clear supply usage history [x]‑page jam, open tray [x].
Page 306 4514-630, -635, -636, -638, -639, -649 base sensor test envelopes button test tips on using charge roll voltage environment specifications clear event log EP process, theory defaults EP setup disk test/clean automatic darkness adjustment display event log charge roll voltage DRAM test EP defaults duplex feed 1 test...
Page 307 Network [x] software error [54] in duplex area network SE menu in front door accessing in manual feeder Non‑Lexmark [supply type], see User’s Guide in standard bin [33.xy] in tray [x] Not enough free space in flash memory for resources [52]...
Page 308 4514-630, -635, -636, -638, -639, -649 memory cards printer messages output bin tests [x]‑page jam, clear manual feeder. [25y.xx] feed tests [x]‑page jam, clear standard bin. [20y.xx] sensor test [x]‑page jam, open front door. [20y.xx] [x]‑page jam, open rear door. [20y.xx] [x]‑page jam, open tray [x].
Page 309 [80.xy] ACM assembly Memory full [38] ACM assembly, option tray Network [x] software error [54] bail Non‑Lexmark [supply type], see User’s Guide bezel [33.xy] cartridge gearbox Not enough free space in flash memory for resources cartridge plunger control panel removal [52] Printer had to restart.
Page 310 4514-630, -635, -636, -638, -639, -649 rear cover Standard parallel port disabled [56] rear door Standard USB port disabled [56] redrive assembly storing reverse solenoid paper right cover supported paper sizes right cover (MS610de) supported paper types and weights right front mount symptoms separator pad printer...
Page 311 4514-630, -635, -636, -638, -639, -649 unacceptable paper understanding the home screen understanding the home screen buttons and icons Unformatted flash detected [53] Unsupported option in slot [x] [55] Unsupported USB hub, please remove using the printer control panel 117, using the touch‑screen buttons vertical mount contact connector zero insertion force (ZIF) connectors...
Page 312 4514-630, -635, -636, -638, -639, -649 Index...
Page 313: Part Number Index
4514-630, -635, -636, -638, -639, -649 Part number index Part name Page 40X0269 Power cord, 2.5 m (straight)—USA, Canada..................281 40X0270 Power cord, 2.5 m (straight)—Japan......................281 40X0271 Power cord, 2.5 m (straight)—United Kingdom..................281 40X0273 Power cord, 2.5 m (straight)—Traditional Italy..................281 40X0275 Power cord, 2.5 m (straight)—Israel......................281 40X0288 Power cord, 2.5 m (straight)—Argentina....................281...
Page 314 4514-630, -635, -636, -638, -639, -649 Part name Page 40X8024 Fuser, 220 V............................272 40X8029 Controller board (MS510dn)........................272 40X8030 Controller board (MS610dn)........................272 40X8043 Duplex sensor and input sensor......................274 40X8044 Index sensor............................274 40X8045 Trailing edge sensor..........................274 40X8046 Toner density sensor..........................274 40X8048 Front door sensor...........................274 40X8050 Narrow media/bin full sensor........................272...
Page 315 4514-630, -635, -636, -638, -639, -649 Part name Page 40X8271 Top cover (MS610dn, MS610de)......................269 40X8272 Nameplate (MS610de)...........................268 40X8273 Rubber foot............................269 40X8274 Cooling fan (MS610de)...........................272 40X8275 Duplex assembly............................276 40X8276 Cooling fan (MS510dn, MS610dn)......................272 40X8277 Duplex gear assembly..........................276 40X8279 Jam access cover............................276 40X8280 Front input guide............................272 40X8281 Maintenance kit, 110 V...
Page 316 4514-630, -635, -636, -638, -639, -649 Part name Page 40X8438 Redrive assembly (MS610de).........................276 40X8439 Maintenance kit, 100 V (MS510dn)......................279 40X8440 Maintenance kit, 100 V (MS610dn)......................279 40X8441 Maintenance kit, 100 V (MS610de)......................280 40X8443 Pick roller assembly..........................278 40X8444 Separator roll assembly..........................278 40X8520 Dust cover (250‑sheet tray)........................268 40X8520 Dust cover, 250‑sheet tray........................278...
Page 317: Part Name Index
4514-630, -635, -636, -638, -639, -649 Part name index Part name Page 40X8524 1284-B Parallel Interface Card........................283 40X7856 160GB hard disk (MS610de)........................283 40X7567 1GB DDR3 RAM............................283 40X8305 250-sheet tray............................268 40X8287 250-sheet tray............................278 40X8305 250-sheet tray insert..........................278 40X8555 256MB flash card ..........................283 40X7445 2GB DDR3 RAM............................283...
Page 318 4514-630, -635, -636, -638, -639, -649 Part name Page 40X8061 Control panel cover and buttons (MS610dn)..................269 40X8029 Controller board (MS510dn)........................272 40X8388 Controller board (MS610de)........................272 40X8030 Controller board (MS610dn)........................272 40X8276 Cooling fan (MS510dn, MS610dn)......................272 40X8274 Cooling fan (MS610de)...........................272 40X8275 Duplex assembly............................276 40X8277 Duplex gear assembly..........................276 40X8043 Duplex sensor and input...
Page 319 4514-630, -635, -636, -638, -639, -649 Part name Page 40X8081 Laser scanning unit..........................272 40X8053 Left cover (MS510dn)..........................269 40X8269 Left cover (MS610dn, MS610de)......................269 40X8085 Main drive gearbox..........................276 40X8439 Maintenance kit, 100 V (MS510dn)......................279 40X8441 Maintenance kit, 100 V (MS610de)......................280 40X8440 Maintenance kit, 100 V (MS610dn)......................279 40X8281 Maintenance kit, 110 V (MS510dn)......................279...
Page 320 4514-630, -635, -636, -638, -639, -649 Part name Page 40X1773 Power cord, 2.5 m (straight)—South Africa...................281 40X1772 Power cord, 2.5 m (straight)—Switzerland....................281 40X1791 Power cord, 2.5 m (straight)—Taiwan....................281 40X0273 Power cord, 2.5 m (straight)—Traditional Italy..................281 40X0271 Power cord, 2.5 m (straight)—United Kingdom..................281 40X0269 Power cord, 2.5 m (straight)—USA, Canada..................281...
Page 322 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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Lexmark MS510 Service Manual

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