Lexmark MX310dn, MX410de, XM1140, MX510de, MX511de, XM1145, MX511dhe, Service Manual & Parts List

MX310, MX410, MX51x & XM114x Machine Type 7015-270, -47x, -6xx Service Manual • Start diagnostics • Maintenance • Safety and notices • Trademarks • Index August 19, 2013 www.lexmark.com P/N 12G2376

Product information Product name: Lexmark MX310, MX410 and MX510 Series Machine type: 7015 Model(s): 270, 470, 630, 670, 675 Edition notice August 19, 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. 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. 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 12G2376 7015

Table of contents Product information..................................................................................... 2 Edition notice...............................................................................................2 Notices and safety information..................................................................15 Laser notices............................................................................................................................................ 15 Safety information...................................................................................................................................18 Preface.......................................................................................................23 Service manual conventions....................................................................................................................23 Change history.........................................................................................................................................23 General information...................................................................................27 Media guidelines.....................................................................................................................................27 Paper guidelines ............................................................................................................................................... 27 Using recycled paper and other office papers .................................................................................................. 30 Using specialty media ....................................................................................................................................... 30 Supported paper sizes, types, and weights ...................................................................................................... 32 Data security notice.................................................................................................................................35 Tools required for service........................................................................................................................35 Diagnostic information...............................................................................37 Troubleshooting overview.......................................................................................................................37 Performing the initial troubleshooting check ................................................................................................... 37 Power‑on Reset (POR) sequence ...................................................................................................................... 38 Using Safe Mode ............................................................................................................................................... 38 Fixing print quality issues........................................................................................................................39 Initial print quality check .................................................................................................................................. 39 Gray background or toner fog on prints ........................................................................................................... 40 Repeating defects ............................................................................................................................................. 40 Printer is printing blank pages .......................................................................................................................... 41 Printer is printing solid black pages .................................................................................................................. 42 Shadow images appear on prints ..................................................................................................................... 42 Skewed print ..................................................................................................................................................... 43 Streaked horizontal or vertical lines appear on prints ...................................................................................... 45 Toner rubs off ................................................................................................................................................... 45 Toner specks appear on prints.......................................................................................................................... 46 Paper jams............................................................................................................................................... 47 7015 Table of contents 3

Avoiding jams.................................................................................................................................................... 47 Understanding jam messages and locations..................................................................................................... 48 200 paper jams ................................................................................................................................................. 49 201 paper jams ................................................................................................................................................. 57 202 paper jams ................................................................................................................................................. 59 23y paper jams ................................................................................................................................................. 62 24y paper jams ................................................................................................................................................. 64 25y paper jams ................................................................................................................................................. 73 28y paper jams ................................................................................................................................................. 76 29y paper jams ................................................................................................................................................. 78 Understanding printer messages............................................................................................................80 Cartridge low [88.xy]......................................................................................................................................... 80 Cartridge nearly low [88.xy].............................................................................................................................. 80 Cartridge very low, [x] estimated pages remain [88.xy] ................................................................................... 80 Change [paper source] to [custom string] load [paper orientation]................................................................. 80 Change [paper source] to [custom type name] load [orientation] ................................................................... 80 Change [paper source] to [paper size] load [orientation] ................................................................................ 81 Change [paper source] to [paper type] [paper size] load [orientation] ............................................................ 81 Close flatbed cover and load originals if restarting job [2yy.xx] ....................................................................... 81 Close door ......................................................................................................................................................... 81 Configuration change, some held jobs were not restored [57] ........................................................................ 81 Complex page, some data may not have printed [39] ...................................................................................... 82 Defective flash detected [51]............................................................................................................................ 82 Disk must be formatted for use in this device .................................................................................................. 82 Error reading USB drive. Remove USB. ............................................................................................................. 82 Error reading USB hub. Remove hub. ............................................................................................................... 82 Fax partition inoperative. Contact system administrator. ................................................................................ 82 Fax server 'To Format' not set up. Contact system administrator.................................................................... 83 Fax Station Name not set up. Contact system administrator. .......................................................................... 83 Fax Station Number not set up. Contact system administrator. ...................................................................... 83 Imaging unit low [84.xy] ................................................................................................................................... 83 Imaging unit nearly low [84.xy] ........................................................................................................................ 83 Imaging unit very low, [x] estimated pages remain [84.xy] .............................................................................. 83 Incorrect paper size, open [paper source] [34] ................................................................................................ 84 Insufficient memory, some Held Jobs were deleted [37] ................................................................................. 84 Insufficient memory, some held jobs will not be restored [37] ........................................................................ 84 Insufficient memory for Flash Memory Defragment operation [37] ................................................................ 84 Insufficient memory to collate job [37] ............................................................................................................ 84 Insufficient memory to support Resource Save feature [35]............................................................................ 85 Load manual feeder with [custom string] [paper orientation] ......................................................................... 85 Load manual feeder with [custom type name] [paper orientation] ................................................................. 85 Load manual feeder with [paper size] [paper orientation]............................................................................... 85 Load manual feeder with [paper type] [paper size] [paper orientation] .......................................................... 86 Load [paper source] with [custom string] [paper orientation] ......................................................................... 86 Load [paper source] with [custom type name] [paper orientation] ................................................................. 86 7015 Table of contents 4

Load [paper source] with [paper size] [paper orientation]............................................................................... 86 Load [paper source] with [paper type] [paper size] [paper orientation] .......................................................... 87 Maintenance kit low [80.xy] ............................................................................................................................. 87 Maintenance kit nearly low [80.xy] .................................................................................................................. 87 Maintenance kit very low, [x] estimated pages remain [80.xy] ........................................................................ 87 Memory full [38] ............................................................................................................................................... 87 Memory full, cannot print faxes ....................................................................................................................... 87 Memory full, cannot send faxes ....................................................................................................................... 88 Network [x] software error [54] ....................................................................................................................... 88 No analog phone line connected to modem, fax is disabled. ........................................................................... 88 Non‑Lexmark [supply type], see User’s Guide [33.xy] ...................................................................................... 88 Not enough free space in flash memory for resources [52] ............................................................................. 89 Printer had to restart. Last job may be incomplete.......................................................................................... 89 Reinstall defective or unresponsive cartridge [31.xy]....................................................................................... 89 Reinstall missing or unresponsive cartridge [31.xy] ......................................................................................... 89 Remove paper from standard output bin ......................................................................................................... 89 Replace all originals if restarting job................................................................................................................. 89 Replace cartridge, 0 estimated pages remain [88.xy] ....................................................................................... 90 Replace cartridge, printer region mismatch [42.xy] ......................................................................................... 90 Replace defective imaging unit [31.xy] ............................................................................................................. 90 Replace jammed originals if restarting job. ...................................................................................................... 91 Replace imaging unit, 0 estimated pages remain [84.xy] ................................................................................. 91 Replace maintenance kit, 0 estimated pages remain [80.xy] ........................................................................... 91 Reinstall missing or unresponsive imaging unit [31.xy] .................................................................................... 91 Replace unsupported cartridge [32.xy] ............................................................................................................ 91 Replace unsupported imaging unit [32.xy] ....................................................................................................... 92 Restore held jobs? ............................................................................................................................................ 92 Scanner automatic feeder cover open ............................................................................................................. 92 Scanner disabled by admin [840.01]................................................................................................................. 92 Scanner disabled. Contact system administrator if problem persists. [840.02] ............................................... 92 Scanner jam, remove all originals from the scanner [2yy.xx] ........................................................................... 92 Scanner jam, remove jammed originals from the scanner [2yy.xx] ................................................................. 92 Serial option [x] error [54] ................................................................................................................................ 93 SMTP server not set up. Contact system administrator. .................................................................................. 93 Some held jobs were not restored ................................................................................................................... 93 Standard network software error [54].............................................................................................................. 93 Standard USB port disabled [56]....................................................................................................................... 93 Supply needed to complete job ........................................................................................................................ 94 Too many flash options installed [58] ............................................................................................................... 94 Too many trays attached [58] ........................................................................................................................... 94 Unformatted flash detected [53] ...................................................................................................................... 94 Weblink server not set up. Contact system administrator. .............................................................................. 94 User attendance messages......................................................................................................................95 User attendance messages (0‑99.99) ............................................................................................................... 95 Toner cartridge smart chip contact service check ............................................................................................ 96 7015 Table of contents 5

Imaging unit smart chip contact service check ................................................................................................. 96 Toner smart chip compatibility service check................................................................................................... 97 Imaging chip compatibility service check ......................................................................................................... 97 Media size mismatch service check .................................................................................................................. 98 Printer/cartridge mismatch service check ........................................................................................................ 99 Flash full service check.................................................................................................................................... 100 Maintenance kit service check........................................................................................................................ 100 Insufficient memory service check ................................................................................................................. 100 Imaging unit low service check ....................................................................................................................... 101 Toner cartridge low service check .................................................................................................................. 101 Printer hardware errors........................................................................................................................102 1yy error messages ......................................................................................................................................... 103 LSU service check ............................................................................................................................................ 106 Fuser service check ......................................................................................................................................... 106 LVPS service check .......................................................................................................................................... 107 Toner density sensor service check ................................................................................................................ 108 CTLS service check .......................................................................................................................................... 108 Main drive gearbox service check................................................................................................................... 109 ACM service check .......................................................................................................................................... 109 Cartridge gearbox service check ..................................................................................................................... 110 Tray 1 pick/lift motor gearbox service check .................................................................................................. 111 Cooling fan service check ................................................................................................................................ 111 9yy error messages ......................................................................................................................................... 112 Steps before starting the 9yy service checks .................................................................................................. 115 System software error service check .............................................................................................................. 117 NVRAM mismatch failure service check ......................................................................................................... 121 NVRAM cyclic redundancy service check........................................................................................................ 122 Invalid firmware/controller board service check ............................................................................................ 123 RAM memory error service check .................................................................................................................. 123 Download emulation cyclic redundancy service check................................................................................... 123 Base printer symptoms ................................................................................................................................... 123 Dead machine service check ........................................................................................................................... 124 Controller board service check ....................................................................................................................... 125 Control panel service check ............................................................................................................................ 126 Control panel button service check ................................................................................................................ 127 USB print service check................................................................................................................................... 128 Front door not closed service check ............................................................................................................... 129 Network service check .................................................................................................................................... 130 ADF/Scanner hardware errors...............................................................................................................132 8yy error messages ......................................................................................................................................... 132 Scanner disabled error service check ............................................................................................................. 133 ADF service check ........................................................................................................................................... 135 Scanner configuration error service check ..................................................................................................... 136 Scan/fax/copy symptoms ............................................................................................................................... 136 7015 Table of contents 6

Black or blank page copy service check .......................................................................................................... 137 CCD service check ........................................................................................................................................... 138 Flatbed motor service check ........................................................................................................................... 138 Flatbed home position service check.............................................................................................................. 139 ADF rattling noise service check ..................................................................................................................... 139 Flatbed legal scan service check ..................................................................................................................... 140 ADF streak service check ................................................................................................................................ 140 ADF feed errors service check ........................................................................................................................ 141 ADF duplex service check................................................................................................................................ 142 Modem/fax card service check ....................................................................................................................... 143 Blank spaces on incoming fax service check ................................................................................................... 144 Stretched words on incoming fax service check ............................................................................................. 144 Fax reception service check ............................................................................................................................ 144 Fax transmission service check ....................................................................................................................... 146 Fax error log codes ......................................................................................................................................... 148 Escalating a fax issue to second‑level support................................................................................................ 152 Input option hardware errors...............................................................................................................153 3yy error messages ......................................................................................................................................... 153 Option tray pick/lift motor service check ....................................................................................................... 155 Option tray separator/passthrough motor service check .............................................................................. 156 Option tray ACM motor service check ............................................................................................................ 156 Option tray controller card service check ....................................................................................................... 157 Service menus..........................................................................................159 Understanding the control panel and menus.......................................................................................159 Using the printer control panel....................................................................................................................... 159 Understanding the colors of the Sleep button and indicator lights................................................................ 160 Understanding the home screen .................................................................................................................... 161 Using the touch-screen buttons ..................................................................................................................... 162 Updating the printer firmware..............................................................................................................163 Menus list..............................................................................................................................................164 Diagnostics menu..................................................................................................................................164 Entering the Diagnostics menu ....................................................................................................................... 164 Registration..................................................................................................................................................... 165 Scanner calibration ......................................................................................................................................... 165 Print Tests ....................................................................................................................................................... 165 Print Quality Pages.......................................................................................................................................... 166 HARDWARE TESTS .......................................................................................................................................... 166 DUPLEX TESTS ................................................................................................................................................. 169 INPUT TRAY TESTS .......................................................................................................................................... 171 OUTPUT BIN TESTS ......................................................................................................................................... 172 BASE SENSOR TEST.......................................................................................................................................... 172 DEVICE TESTS .................................................................................................................................................. 173 7015 Table of contents 7

PRINTER SETUP ............................................................................................................................................... 174 EP SETUP ......................................................................................................................................................... 175 REPORTS ......................................................................................................................................................... 177 EVENT LOG ...................................................................................................................................................... 178 Scanner tests................................................................................................................................................... 179 Exit Diags......................................................................................................................................................... 183 Configuration menu..............................................................................................................................184 Entering the Configuration menu ................................................................................................................... 184 Reset ADF Maintenance Kit Counter .............................................................................................................. 184 Maintenance Counter Value ........................................................................................................................... 184 Reset Maintenance Counter ........................................................................................................................... 184 Print Quality Pages.......................................................................................................................................... 185 Reports ........................................................................................................................................................... 185 Panel Menus ................................................................................................................................................... 185 PPDS Emulation .............................................................................................................................................. 186 Download Emuls ............................................................................................................................................. 186 Safe Mode ....................................................................................................................................................... 186 Factory Defaults .............................................................................................................................................. 186 Energy Conserve ............................................................................................................................................. 187 Fax low power support ................................................................................................................................... 187 Min copy memory ........................................................................................................................................... 187 Num pad job assist.......................................................................................................................................... 187 Format fax storage.......................................................................................................................................... 188 ADF edge erase ............................................................................................................................................... 188 Flatbed edge erase.......................................................................................................................................... 188 Scanner manual registration........................................................................................................................... 188 Disable scanner ............................................................................................................................................... 190 Paper Prompts ................................................................................................................................................ 190 Envelope Prompts ........................................................................................................................................... 190 Action for Prompts.......................................................................................................................................... 191 Jobs on Disk .................................................................................................................................................... 191 Disk Encryption ............................................................................................................................................... 192 Erase All Information on Disk.......................................................................................................................... 192 Wipe All Settings ............................................................................................................................................. 192 Font Density .................................................................................................................................................... 192 Font Sharpening .............................................................................................................................................. 192 Reduced Curl ................................................................................................................................................... 193 Require Standby.............................................................................................................................................. 193 A5 Loading ...................................................................................................................................................... 193 UI Automation ................................................................................................................................................ 194 LES Applications .............................................................................................................................................. 194 Key Repeat Initial Delay .................................................................................................................................. 194 Key Repeat Rate.............................................................................................................................................. 195 Clear Supply Usage History ............................................................................................................................. 195 Clear Custom Status ........................................................................................................................................ 195 7015 Table of contents 8

USB Speed ....................................................................................................................................................... 195 Automatically Display Error Screens ............................................................................................................... 196 USB PnP .......................................................................................................................................................... 196 Entering Invalid engine mode................................................................................................................196 Entering Recovery mode.......................................................................................................................196 Accessing the Network SE menu...........................................................................................................197 Service Engineer menu..........................................................................................................................197 Accessing the service engineer (SE) menu ...................................................................................................... 197 Service engineer (SE) menu ............................................................................................................................ 197 Fax service engineer (SE) menu ...................................................................................................................... 198 Repair information...................................................................................199 Removal precautions.............................................................................................................................199 Data security notice ........................................................................................................................................ 199 Handling ESD‑sensitive parts .......................................................................................................................... 200 Controller board/control panel replacement ................................................................................................. 200 Restoring the printer configuration after replacing the controller board ...................................................... 201 eSF solutions backup ...................................................................................................................................... 203 Ribbon cable connectors ................................................................................................................................ 204 Zero Insertion Force (ZIF) connectors ........................................................................................................ 204 Horizontal top contact connector .............................................................................................................. 205 Horizontal bottom contact connector ........................................................................................................ 208 Vertical mount contact connector ............................................................................................................. 211 Horizontal sliding contact connector ......................................................................................................... 214 Low Insertion Force (LIF) connector ........................................................................................................... 217 Printhead assembly adjustments.................................................................................................................... 218 Removal procedures.............................................................................................................................221 Left side removals.................................................................................................................................221 Left cover removal .......................................................................................................................................... 221 Main drive gearbox removal ........................................................................................................................... 223 MPF solenoid removal .................................................................................................................................... 225 MPF gearbox removal ..................................................................................................................................... 227 Reverse solenoid removal............................................................................................................................... 230 ACM clutch removal (MX310, MX410) ........................................................................................................... 231 Cartridge gearbox removal ............................................................................................................................. 236 Duplex gear assembly removal ....................................................................................................................... 236 Right side removals...............................................................................................................................238 Right cover removal ........................................................................................................................................ 238 Memory access door removal ........................................................................................................................ 241 Tray present sensor removal .......................................................................................................................... 241 Cooling fan removal ........................................................................................................................................ 242 Controller board removal ............................................................................................................................... 243 Controller board shield removal ..................................................................................................................... 245 7015 Table of contents 9

Upper shield removal ..................................................................................................................................... 247 Toner cartridge smart chip contact removal .................................................................................................. 247 Modem removal ............................................................................................................................................. 249 Front removals......................................................................................................................................251 Left front mount removal ............................................................................................................................... 251 Right front mount removal ............................................................................................................................. 252 Transfer roll removal ...................................................................................................................................... 254 Cartridge plunger removal .............................................................................................................................. 255 Name plate cover removal ............................................................................................................................. 257 Front bin cover removal ................................................................................................................................. 259 Control panel assembly removal .................................................................................................................... 260 UICC removal .................................................................................................................................................. 263 UICC (MX310) removal ................................................................................................................................... 263 UICC shield removal ........................................................................................................................................ 264 USB cable bracket removal ............................................................................................................................. 265 Speaker removal ............................................................................................................................................. 265 Control panel cover removal .......................................................................................................................... 266 Display removal (MX410, MX51x)................................................................................................................... 267 Display (MX310) removal ............................................................................................................................... 269 Light tube removal .......................................................................................................................................... 269 Keypad assembly removal .............................................................................................................................. 271 MPF tray removal ........................................................................................................................................... 271 MPF pick roller cover removal ........................................................................................................................ 274 MPF pick roller removal .................................................................................................................................. 274 Bail removal .................................................................................................................................................... 275 Jam access cover removal............................................................................................................................... 275 Front access cover removal ............................................................................................................................ 276 Front door sensor removal ............................................................................................................................. 278 Front input guide removal .............................................................................................................................. 278 Separator pad removal ................................................................................................................................... 280 Bottom removals...................................................................................................................................283 Power supply removal .................................................................................................................................... 283 Power supply shield removal .......................................................................................................................... 284 Duplex removal ............................................................................................................................................... 285 Duplex sensor and input sensor removal ....................................................................................................... 286 Duplex sensor and input sensor (MX310, MX410) removal ........................................................................... 289 Index sensor removal...................................................................................................................................... 290 Media present sensor removal ....................................................................................................................... 291 Toner density sensor removal ........................................................................................................................ 293 Trailing edge sensor removal .......................................................................................................................... 293 Trailing edge sensor (MX310, MX410) removal .............................................................................................. 294 Media present sensor flag removal ................................................................................................................ 299 ACM assembly removal .................................................................................................................................. 303 ACM assembly (MX310, MX410) removal ...................................................................................................... 305 7015 Table of contents 10

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Lexmark MX310dn, MX410de, XM1140, MX510de, MX511de, XM1145, MX511dhe, Service Manual & Parts List

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