Lexmark MS310 Series, Machine Type 4514-220, -230 Service Manual & Parts List

Lexmark MS310 Series Machine Type 4514-220, -230 Service Manual • Start diagnostics • Maintenance • Safety and notices • Trademarks • Index NOTICE - This manual has not been reviewed for technical accuracy. In addition, this manual has not been checked for grammar or spelling. This will be performed before the final edition is released. Not all graphics have been finalized yet. September 19, 2012 www.lexmark.com Lexmark Confidential until announced

Product information Product name: Lexmark MS310 Series Machine type: 4514 Model(s): 220, 230 Edition notice September 19, 2012 The following paragraph does not apply to any country where such provisions are inconsistent with local law: LEXMARK INTERNATIONAL, INC., PROVIDES THIS PUBLICATION “AS IS” WITHOUT WARRANTY OF ANY KIND, EITHER EXPRESS OR IMPLIED, INCLUDING, BUT NOT LIMITED TO, THE IMPLIED WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. Some states do not allow disclaimer of express or implied warranties in certain transactions; therefore, this statement may not apply to you. This publication could include technical inaccuracies or typographical errors. Changes are periodically made to the information herein; these changes will be incorporated in later editions. Improvements or changes in the products or the programs described may be made at any time. References in this publication to products, programs, or services do not imply that the manufacturer intends to make these available in all countries in which it operates. Any reference to a product, program, or service is not intended to state or imply that only that product, program, or service may be used. Any functionally equivalent product, program, or service that does not infringe any existing intellectual property right may be used instead. Evaluation and verification of operation in conjunction with other products, programs, or services, except those expressly designated by the manufacturer, are the user’s responsibility. Trademarks Lexmark and Lexmark with diamond design are trademarks of Lexmark International, Inc., registered in the United States and/or other countries. Mac and the Mac logo are trademarks of Apple Inc., registered in the U.S. and other countries. PCL® is a registered trademark of the Hewlett-Packard Company. All other trademarks are the property of their respective owners. © 2012 Lexmark International, Inc. All rights reserved. P/N 12G2991 Lexmark Confidential until announced 4514-220, -230

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 General information...................................................................................21 Media guidelines..................................................................................................................................... 21 Paper guidelines ............................................................................................................................................... 21 Using recycled paper and other office papers .................................................................................................. 23 Using specialty media ....................................................................................................................................... 24 Supported paper sizes, types, and weights ...................................................................................................... 26 Data security notice................................................................................................................................. 28 Tools required for service........................................................................................................................ 28 Diagnostic information...............................................................................31 Troubleshooting overview....................................................................................................................... 31 Performing the initial troubleshooting check ................................................................................................... 31 Power‑on reset (POR) sequence ....................................................................................................................... 31 Using the printer control panel............................................................................................................... 32 Light sequences and error messages...................................................................................................... 33 Light sequences and error messages ................................................................................................................ 33 Light sequences ................................................................................................................................................ 33 Status screens ................................................................................................................................................... 33 Status messages................................................................................................................................................ 34 User attendance messages ............................................................................................................................... 35 Paper jams ........................................................................................................................................................ 40 Service errors .................................................................................................................................................... 40 Understanding the printer messages...................................................................................................... 42 Toner cartridge messages ................................................................................................................................. 42 Imaging unit messages...................................................................................................................................... 43 Paper loading messages.................................................................................................................................... 44 Printer communication error messages ........................................................................................................... 46 Lexmark Confidential until announced 4514-220, -230 Table of contents 3

Insufficient memory error messages ................................................................................................................ 47 Miscellaneous messages ................................................................................................................................... 48 Fixing print quality issues........................................................................................................................ 48 Initial print quality check .................................................................................................................................. 48 Print quality checks ........................................................................................................................................... 49 Paper jams............................................................................................................................................... 57 Avoiding jams.................................................................................................................................................... 57 Accessing jam areas .......................................................................................................................................... 58 200 paper jams ................................................................................................................................................. 59 201 paper jams ................................................................................................................................................. 66 202 paper jams ................................................................................................................................................. 68 230 paper jams ................................................................................................................................................. 71 240 paper jams ................................................................................................................................................. 74 250 paper jams ................................................................................................................................................. 82 User attendance messages (0-99.99)...................................................................................................... 84 User attendance messages (0‑99.99) ............................................................................................................... 84 Toner cartridge smart chip contact service check ............................................................................................ 87 Imaging unit smart chip contact service check ................................................................................................. 87 Media size mismatch service check .................................................................................................................. 87 Printer/cartridge mismatch service check ........................................................................................................ 88 Insufficient memory service check ................................................................................................................... 89 Printer hardware errors.......................................................................................................................... 90 1xx error messages ........................................................................................................................................... 90 111.xx LSU service check .................................................................................................................................. 93 Fuser service check ........................................................................................................................................... 93 LVPS service check ............................................................................................................................................ 94 Toner density sensor service check .................................................................................................................. 94 CTLS service check ............................................................................................................................................ 95 Main drive gearbox service check..................................................................................................................... 95 Cartridge gearbox service check ....................................................................................................................... 96 9xx error messages ........................................................................................................................................... 96 System software error service check ................................................................................................................ 99 NVRAM mismatch failure service check ......................................................................................................... 104 Input option errors................................................................................................................................ 105 3xx error messages ......................................................................................................................................... 105 Option tray pick/lift motor service check ....................................................................................................... 106 Option tray separator/passthrough motor service check .............................................................................. 107 Option tray ACM motor service check ............................................................................................................ 108 Option tray controller card service check ....................................................................................................... 108 Symptoms.............................................................................................................................................. 108 Base printer symptoms ................................................................................................................................... 108 Cooling fan service check ................................................................................................................................ 109 Dead machine service check ........................................................................................................................... 110 Lexmark Confidential until announced 4514-220, -230 Table of contents 4

Controller board service check ....................................................................................................................... 110 Control panel service check ............................................................................................................................ 112 USB print service check................................................................................................................................... 112 Network service check .................................................................................................................................... 113 Service menus..........................................................................................117 Understanding the control panel and menus....................................................................................... 117 Navigating through the Service menus ........................................................................................................... 117 Diagnostics menu.................................................................................................................................. 117 Entering the Diagnostics menu ....................................................................................................................... 117 Print Diagnostics Menu Instruction Sheet ...................................................................................................... 117 Prt Quality Pgs ................................................................................................................................................ 118 Defaults ........................................................................................................................................................... 118 Edge to Edge ................................................................................................................................................... 118 Cont Prt Simplex Tray 1................................................................................................................................... 118 Cont Prt Duplex Tray 1 .................................................................................................................................... 118 Cont Prt Simplex Tray 2................................................................................................................................... 118 Cont Prt Duplex Tray 2 .................................................................................................................................... 119 Par 1 Strobe Adj .............................................................................................................................................. 119 Print Event Log ................................................................................................................................................ 119 Auto Dark Adj .................................................................................................................................................. 119 Configuration menu.............................................................................................................................. 119 Entering the Configuration menu ................................................................................................................... 119 Print Configuration Menu Instruction Sheet .................................................................................................. 120 Restore Base ................................................................................................................................................... 120 Restore STD NET ............................................................................................................................................. 120 Hex Trace ........................................................................................................................................................ 120 Prt Quality Pgs ................................................................................................................................................ 120 A5 Loading ...................................................................................................................................................... 120 Reduced Curl ................................................................................................................................................... 121 PPDS Emulation .............................................................................................................................................. 121 Demo Mode .................................................................................................................................................... 121 Auto CR after LF .............................................................................................................................................. 121 Auto LF after CR .............................................................................................................................................. 122 Energy Conserve ............................................................................................................................................. 122 Wipe All Settings ............................................................................................................................................. 122 Font Density .................................................................................................................................................... 122 Font Sharpening .............................................................................................................................................. 122 Parallel Protocol .............................................................................................................................................. 122 Parallel Mode 2 ............................................................................................................................................... 123 MAC Binary PS ................................................................................................................................................ 123 USB Speed ....................................................................................................................................................... 123 USB PnP .......................................................................................................................................................... 123 Set Network Card Speed ................................................................................................................................. 123 Lexmark Confidential until announced 4514-220, -230 Table of contents 5

Entering Invalid engine mode................................................................................................................ 124 Entering Recovery mode....................................................................................................................... 124 Service engineer menu.......................................................................................................................... 124 Accessing the service engineer (SE) menu...................................................................................................... 124 Service engineer (SE) menu ............................................................................................................................ 124 Repair information...................................................................................127 Removal precautions............................................................................................................................. 127 Data security notice ........................................................................................................................................ 127 Handling ESD‑sensitive parts .......................................................................................................................... 127 RIP board/operator panel replacement.......................................................................................................... 128 Ribbon cable connectors ................................................................................................................................ 129 Zero Insertion Force (ZIF) connectors ........................................................................................................ 129 Horizontal top contact connector .............................................................................................................. 130 Horizontal bottom contact connector ........................................................................................................ 133 Vertical mount contact connector ............................................................................................................. 136 Horizontal sliding contact connector ......................................................................................................... 139 Low Insertion Force (LIF) connector ........................................................................................................... 142 Printhead assembly mechanical adjustment .................................................................................................. 143 Removal procedures............................................................................................................................. 144 Left side removals................................................................................................................................. 144 Left cover removal .......................................................................................................................................... 144 Main drive gearbox removal ........................................................................................................................... 145 MPF solenoid removal .................................................................................................................................... 147 MPF gearbox removal ..................................................................................................................................... 149 Reverse solenoid removal ............................................................................................................................... 152 ACM clutch removal........................................................................................................................................ 153 Cartridge gearbox removal ............................................................................................................................. 158 Duplex gear assembly removal ....................................................................................................................... 158 Right side removals............................................................................................................................... 160 Right cover removal ........................................................................................................................................ 160 Cooling fan duct removal ................................................................................................................................ 161 Cooling fan removal ........................................................................................................................................ 161 Controller board removal ............................................................................................................................... 162 Toner cartridge smart chip contact removal .................................................................................................. 164 Front removals...................................................................................................................................... 165 Left front mount removal ............................................................................................................................... 165 Right front mount removal ............................................................................................................................. 166 Transfer roll removal ...................................................................................................................................... 168 Cartridge plunger removal .............................................................................................................................. 169 Bezel removal ................................................................................................................................................. 172 Nameplate removal ........................................................................................................................................ 173 Control panel assembly removal .................................................................................................................... 173 Lexmark Confidential until announced 4514-220, -230 Table of contents 6

UICC removal .................................................................................................................................................. 175 MPF assembly removal ................................................................................................................................... 176 MPF pick roller cover removal ........................................................................................................................ 179 MPF pick roller removal .................................................................................................................................. 179 Bail removal .................................................................................................................................................... 180 Jam access cover removal ............................................................................................................................... 180 Front door removal ......................................................................................................................................... 181 Front access cover removal ............................................................................................................................ 184 Front door sensor removal ............................................................................................................................. 184 Front input guide removal .............................................................................................................................. 185 Separator pad removal ................................................................................................................................... 187 Bottom removals................................................................................................................................... 189 Power supply removal .................................................................................................................................... 189 Power supply shield removal .......................................................................................................................... 190 Duplex removal ............................................................................................................................................... 191 Duplex sensor and input sensor removal ....................................................................................................... 192 Toner density sensor removal ........................................................................................................................ 194 Trailing edge sensor removal .......................................................................................................................... 195 ACM assembly removal .................................................................................................................................. 200 Rear side removals................................................................................................................................ 205 Dust cover removal ......................................................................................................................................... 205 Rear door and cover removal ......................................................................................................................... 205 Narrow media/bin full sensor removal ........................................................................................................... 206 Redrive assembly removal .............................................................................................................................. 208 Fuser removal ................................................................................................................................................. 209 Top side removals................................................................................................................................. 210 Top cover removal .......................................................................................................................................... 210 Laser scanning unit (LSU) removal .................................................................................................................. 211 250/550-sheet tray removals................................................................................................................ 212 Pick roller removal .......................................................................................................................................... 212 Separator roll assembly removal .................................................................................................................... 213 ACM assembly removal .................................................................................................................................. 215 Component locations...............................................................................219 Exterior locations.................................................................................................................................. 219 Front view ....................................................................................................................................................... 219 Rear view ........................................................................................................................................................ 220 Connectors............................................................................................................................................ 221 Controller board ............................................................................................................................................. 221 Power supply .................................................................................................................................................. 223 Maintenance............................................................................................225 Inspection guide.................................................................................................................................... 225 Lexmark Confidential until announced 4514-220, -230 Table of contents 7

Lubrication specification....................................................................................................................... 225 Cleaning the printer.............................................................................................................................. 226 Parts catalog............................................................................................228 Legend................................................................................................................................................... 228 Assembly 1: Covers................................................................................................................................ 229 Assembly 2: Electronics 1...................................................................................................................... 231 Assembly 3: Electronics 2...................................................................................................................... 233 Assembly 4: Frame................................................................................................................................ 235 Assembly 5: Option trays...................................................................................................................... 237 Assembly 6: Power cords...................................................................................................................... 239 Appendix A: Printer specifications............................................................241 Product power consumption................................................................................................................. 241 Electrical specifications......................................................................................................................... 241 Operating clearances............................................................................................................................. 242 Acoustics............................................................................................................................................... 242 Operating environment......................................................................................................................... 243 Appendix B: Options and features............................................................245 Available internal options..................................................................................................................... 245 Media handling options......................................................................................................................... 245 Appendix C: Theory of operation..............................................................247 POR sequence....................................................................................................................................... 247 Printer control....................................................................................................................................... 247 Paper path information......................................................................................................................... 247 Input tray (MS310, MS410)............................................................................................................................. 247 Multipurpose feeder (MPF) ............................................................................................................................ 247 Simplex printing .............................................................................................................................................. 248 Duplex printing ............................................................................................................................................... 249 Media handling components................................................................................................................. 249 Main drive gearbox ......................................................................................................................................... 249 Autocompensator mechanism (ACM) ............................................................................................................ 249 Key components.................................................................................................................................... 250 Sensors............................................................................................................................................................ 250 Other key components ................................................................................................................................... 251 Electrophotographic process (EP process)............................................................................................ 253 Lexmark Confidential until announced 4514-220, -230 Table of contents 8

Appendix D: Acronyms.............................................................................257 Acronyms............................................................................................................................................... 257 Index........................................................................................................259 Part number index...................................................................................263 Part name index.......................................................................................267 Lexmark Confidential until announced 4514-220, -230 Table of contents 9

Lexmark Confidential until announced 4514-220, -230 Table of contents 10

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Lexmark MS310 Series, Machine Type 4514-220, -230 Service Manual & Parts List

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