Lexmark X543 Service Manual
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Lexmark X543 Service Manual

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Revision: July 31, 2013
™
Lexmark
X543, X544, X546
7525-xxx
• Table of contents
• Start diagnostics
• Safety and notices
• Trademarks
• Index
Lexmark and Lexmark with diamond design are
trademarks of Lexmark International, Inc., registered
in the United States and/or other countries.

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  • Page 1 Lexmark X543, X544, X546 7525-xxx • Table of contents • Start diagnostics • Safety and notices • Trademarks • Index Lexmark and Lexmark with diamond design are trademarks of Lexmark International, Inc., registered in the United States and/or other countries.
  • Page 2 Lexmark, Lexmark with diamond design, and MarkNet are trademarks of Lexmark International, Inc., registered in the United States and/or other countries. Optra Forms is a trademark of Lexmark International, Inc.

  • Page 3: Table Of Contents

    7525-xxx Table of contents Previous Table of contents ............iii Notices and safety information .
  • Page 4 7525-xxx Supported scan destinations ........... 1-17 Previous Multiple copies .
  • Page 5 7525-xxx Print quality—residual image ..........2-58 Previous Print quality—solid color page .
  • Page 6 7525-xxx Device Tests ..............3-18 Previous Flash Test .
  • Page 7 7525-xxx History ..............3-38 Previous MAC .
  • Page 8 7525-xxx Removal procedures ..............4-2 Previous Print engine removal procedures .
  • Page 9 7525-xxx AIO release lever ............. . 4-100 Previous AIO link .
  • Page 10 7525-xxx Previous Next Go Back Service Manual...

  • Page 11: Notices And Safety Information

    7525-xxx Notices and safety information Previous The laser notice label may be affixed to this printer. Next Laser notice Go Back This product is certified in the U.S. to conform to the requirements of DHHS 21 CFR Subchapter J for Class I (1) laser products, and elsewhere is certified as a Class I laser product conforming to the requirements of IEC 60825-1.

  • Page 12: Aviso Sobre O Laser

    7525-xxx Previous Avvertenze sui prodotti laser Questo prodotto è certificato negli Stati Uniti come prodotto conforme ai requisiti DHHS 21 CFR Sottocapitolo J per i prodotti laser di Classe I (1), mentre in altri paesi è certificato come prodotto laser di Classe I conforme ai requisiti IEC 60825-1.
  • Page 13 7525-xxx Previous Laserinformatie Dit product is in de Verenigde Staten gecertificeerd als een product dat voldoet aan de vereisten van DHHS 21 CFR paragraaf J voor laserproducten van klasse I (1). Elders is het product gecertificeerd als een laserproduct van klasse I dat voldoet aan de vereisten van IEC 60825-1. Next Laserproducten van klasse I worden geacht geen gevaar op te leveren.
  • Page 14 7525-xxx Previous Laser-notis Denna produkt är certifierad i USA i enlighet med kraven i DHHS 21 CFR underkapitel J för klass I (1)- laserprodukter, och på andra platser certifierad som en klass I-laserprodukt i enlighet med kraven i IEC 60825-1. Next Klass I-laserprodukter betraktas inte som skadliga.
  • Page 15 7525-xxx Previous Next Go Back Notices and safety information...
  • Page 16 7525-xxx Previous Next Go Back Service Manual...

  • Page 17: Lithium Warning

    7525-xxx Previous Lithium warning CAUTION This product contains a lithium battery. THERE IS A RISK OF EXPLOSION IF THE BATTERY Next IS REPLACED BY AN INCORRECT TYPE. Discard used batteries according to the battery manufacturer’s instructions and local regulations. Go Back Safety information The safety of this product is based on testing and approvals of the original design and specific •...
  • Page 18 7525-xxx Previous Sicherheitshinweise • Die Sicherheit dieses Produkts basiert auf Tests und Zulassungen des ursprünglichen Modells und bestimmter Bauteile. Bei Verwendung nicht genehmigter Ersatzteile wird vom Hersteller keine Verantwortung oder Haftung für die Sicherheit übernommen. Next Die Wartungsinformationen für dieses Produkt sind ausschließlich für die Verwendung durch einen •...
  • Page 19 7525-xxx Previous Informació de Seguretat • La seguretat d'aquest producte es basa en l'avaluació i aprovació del disseny original i els components específics. El fabricant no es fa responsable de les qüestions de Next seguretat si s'utilitzen peces de recanvi no autoritzades. •...

  • Page 20: Preface

    7525-xxx Preface Previous This manual contains maintenance procedures for service personnel. It is divided into the following chapters: General information contains a general description of the printer and the maintenance approach used to Next repair it. Special tools and test equipment, as well as general environmental and safety instructions, are discussed.

  • Page 21: Conventions

    7525-xxx Previous Conventions Note: A note provides additional information. Warning: A warning identifies something that might damage the product hardware or software. Next There are several types of caution statements: CAUTION Go Back A caution identifies something that might cause a servicer harm. CAUTION This type of caution indicates there is a danger from hazardous voltage in the area of the product where you are working.
  • Page 22 7525-xxx Previous Next Go Back Service Manual xxii...

  • Page 23: General Information

    1. General information Previous The Lexmark™ X54x series are color laser MFPs that combine print, scan, copy, and fax functions. The X54x series are the ideal MFPs for presentations, business graphics, line art, and text. They use laser diode electrophotographic technology to deliver remarkable quality print images and text. The Next scan and copy functions work with A4, letter, and legal (ADF only) size paper.

  • Page 24: Options And Features

    • Flash memory card—One 64MB may be added. Font cards—One language card can be added. • Memory ✔ —Supported Lexmark X544n, Lexmark Lexmark Lexmark X543 ✘ —Not supported X544dn, X544dtn X544dw X546dtn Memory Optional slots One slot Standard DIMM sizes...

  • Page 25: Print Quality

    1200 dpi (reduced printer speed) is supported in PS and PCL only • Connectivity (network support) ✔ —Supported Lexmark ✘ —Not supported X544n, Lexmark X544dn, Lexmark Lexmark Network protocol X543 X544dtn X544dw X546dtn ✔ ✔ ✔ ✔ Standard Ethernet 10/100 Base T ✔ ✔ ✔ ✔ Standard USB-B (Full speed) device port ✘...

  • Page 26: Operating Modes

    • Energy + Paper All of the above. Data streams ✔ —Supported Lexmark ✘ —Not supported X544n, X544dn, Lexmark Lexmark Data streams Lexmark X543 X544dtn X544dw X546dtn ✔ ✔ ✔ ✔ PCL 6 emulation ✔ ✔ ✔ ✔ PostScript Level III emulation...

  • Page 27: Dimensions

    76.2 mm (3.0 in.) 360 mm (14 in.)* * Add 133 mm (5.2 in.) to the top if you want to add an optional 650-sheet Duo Drawer (Lexmark X544-6 models only). - This does not include the 550 sheet tray height. General information...

  • Page 28: Power And Electrical Specifications

    Power and electrical specifications Previous The following table specified nominal average power requirements for the base printer configurations. All power levels are shown in Watts (W). Maximum current is given in Amperes (A). Next Lexmark Lexmark X544dw, Lexmark Lexmark Printing states...

  • Page 29: Acoustics

    All acoustic measurements are made in accordance with ISO 7779-1999 and reported in conformance with ISO9296:1988-04-15. Next Operating mode 1-Meter average sound pressure at 4800 CQ Lexmark Lexmark Lexmark X543 X544 X546 dtn Go Back Printing (simplex mono) 46 dBA 46 dBA 47 dBA...

  • Page 30: Media Handling

    7525-xxx Previous Media handling Input and output sources Next Lexmark Sheet numbers are assuming X544dw, Lexmark Lexmark X543 Lexmark X544n 20 lb. xerographic paper X544dn, X546dtn Go Back X544dtn Standard input sources Standard input tray (250- 250 sheets 250 sheets...

  • Page 31: Duplex Capability

    7525-xxx Duplex capability Previous Duplex Type ✔ —Supported Automatic duplex Models Next ✔ Lexmark X543dn Lexmark X544n Go Back ✔ Lexmark X544dn ✔ Lexmark X544dw ✔ Lexmark X544dtn ✔ Lexmark X546dtn Media input size specifications ✔ —Supported without size sensing ✘...
  • Page 32 7525-xxx Previous ✔ —Supported without size sensing ✘ —Not supported Next Input source Go Back 210mm x 279.4mm to 216mm x 356mm ✔ ✔ ✔ ✔ ✔ ✔ (8.27 in. x 11 in. to 8.5 in. to 14 in.) ✘ ✘...

  • Page 33: Media Input Type Specifications

    7525-xxx Media input type specifications Previous ✔ —Supported ✘ —Not supported Next Input type Go Back ✔ ✔ ✔ ✔ ✔ ✔ Plain paper ✘ ✔ ✔ ✔ ✔ ✔ Card stock ✘ ✔ ✔ ✔ ✔ ✔ Transparency ✔ ✔...

  • Page 34: Index

    (16–28 pound) grain long bond. The duplex unit does not support card stock, transparencies, envelopes, and labels. Lexmark transparency part numbers 12A8240, and 12A8241 are supported from the standard tray, manual slot and the multipurpose feeder. Paper 90 to 104.9 g/m (23.9 to 27.8 lb) must be printed with Paper Type set to Heavy Paper.

  • Page 35: Media Guidelines

    7525-xxx Media guidelines Previous Paper characteristics The following paper characteristics affect print quality and reliability. Consider these characteristics when evaluating new paper stock. Next Weight—The printer can automatically feed paper weights from 60 to 176 g/m (16 to 47 lb bond) grain •...

  • Page 36: Selecting Paper

    US fed as well as non-recycled paper. However, no blanket statement can be made that all recycled paper will feed well. Lexmark consistently tests its printers with recycled paper (20–100% post-consumer waste) and a variety of test paper from around the world, using chamber tests for different temperature and humidity conditions.
  • Page 37 7525-xxx Recycled paper, paper of lower weight (<60 g/m [16 lb bond]) and/or lower caliper (<3.8 mils [0.1 mm]), and Previous paper that is cut grain-short for portrait (or short-edge) fed printers may have lower bending resistance than is required for reliable paper feeding. Before using these types of paper for laser (electrophotographic) printing, consult your paper supplier.

  • Page 38: Digital Imaging Specifications

    7525-xxx Previous Digital imaging specifications General specifications Next ADF Scan speed Simplex ADF - Up to 5 ppm Go Back Duplex ADF - Up to 5 ppm (page sides) ADF Document handling ADF input capacity - 50 sheets. ADF output capacity - 50 sheets. ADF document width - 4.9”...

  • Page 39: Scan And Copy Specific Specifications

    Previous Scan Resolutions Optical - 600 dpi (Local Twain only) • Enhanced (vial Lexmark Scan Center) - 1200 X 1200 dpi, 2400 X 2400 dpi, 4800 X 4800 dpi, 9600 X 9600 • Next dpi, 19200 X 19200 dpi Output resolutions...

  • Page 40: Fax Specifications

    7525-xxx Previous Fax specifications Phone network connectivity Phone networks types supported PSTN or analog PABX (RJ-11) Next ITU COMPATIBILITY Group 3/ECM Standard Resolution 8 x 3.85 pels/mm (200X100dpi) (204x98) Fine 8 x 7.7 pels/mm (200X200dpi) (204x196) Go Back Superfine 11.8 x 11.8 pels/mm(300x300 dpi) (204x391) Ultrafine 15.7 x 15.7 pels/mm (400x400 dpi) (408x391) Coding...

  • Page 41: Tools Required For Service

    7525-xxx Previous Tools required for service Flat-blade screwdrivers, various sizes #1 Phillips screwdriver, magnetic #2 Phillips screwdriver, magnetic Next #2 Phillips screwdriver, magnetic short-blade 7/32 inch (5.5 mm) open-end wrench 7.0 mm nut driver Go Back Needlenose pliers Diagonal side cutters Spring hook Feeler gauges Analog or digital multimeter...

  • Page 42: Acronyms

    7525-xxx Previous Acronyms. Alternating Current Autocompensator Mechanism (or paper feed) Automatic document feeder Next Analog front end All-In-One Automatic Paper Size Go Back ASIC Application Specific Integrated Circuit BLDC Brushless DC Motor Black Only Retract Belt up down Cyan Charge-Couple Device CCFL Cold Cathode Fluorescent Lamp Counter clockwise...
  • Page 43 Light amplification by stimulated emission of radiation Liquid crystal display Go Back Liquid Crystal Module Laser Diode Light emitting diode Long edge feed Lexmark Embedded Solution (applications) Laser Scanning Unit Low Voltage LVPS Low voltage power supply Magenta Megabyte Motor Driver Control...
  • Page 44 7525-xxx Pulse Width Modulation Previous Random access memory RFID Radio frequency identification Relative humidity Raster image processor Read-only memory Next Read-only storage Revolutions Per Minute Scanner Control Card Go Back SDRAM Synchronous Dynamic Random Access Memory Short edge feed SIMM Single Inline Memory Module Solenoid Start of scan...

  • Page 45: Diagnostic Information

    7525-xxx 2. Diagnostic information Previous Start Next CAUTION Unplug the power cord from the electrical outlet before you connect or disconnect any cable Go Back or electronic board or assembly for personal safety and to prevent damage to the printer. Disconnect any connections between the printer and PCs/peripherals.

  • Page 46: Por (Power-On Reset) Sequence

    7525-xxx Previous POR (Power-On Reset) sequence The following is an example of the events that occur during the POR sequence for the base machine with no paper-handling options installed. Next When you turn the printer on, it performs a Power-On Self Test. Check for correct POST functioning of the base printer by observing the following: The LED turns on.

  • Page 47: Symptom Tables

    7525-xxx Previous Symptom tables Printer symptom table Next Symptom Action Dead printer Go to “Dead printer service check” on page 2-38. Operator panel—one or more buttons do Go to “One or more operator panel buttons fail” on Go Back not work. page 2-45.

  • Page 48: Scan / Fax / Copy Symptom Table

    7525-xxx Previous Symptom Action Unexpected page breaks occur • Increase the Print Timeout value on the operator panel (Settings–>General Settings–>Timeouts–>Print Timeout.) Scan / fax / copy symptom table Next Symptom Action Go Back 840.xx scanner error Go to “840.xx service check” on page 2-66.

  • Page 49: Print Quality Symptom Table

    7525-xxx Print quality symptom table Previous Symptom Action Background Go to “Print quality—background” on page 2-52. Blank page Go to “Print quality—blank page” on page 2-53. Next Blurred or fuzzy print Go to “Print quality—blurred or fuzzy print” on page 2-55.

  • Page 50: Error Codes And Messages

    7525-xxx Previous Error codes and messages User status and attendance messages User status and attendance messages Next User primary message Explanation Busy Wait for the message to clear. Go Back Calibrating The printer is performing a color adjustment. Close Door Message clears when upper and lower doors are closed.
  • Page 51 7525-xxx User status and attendance messages (continued) Previous User primary message Explanation Load <source> Printer does not detect media meeting the description <custom type> in <source>, <custom type> where <source> is Tray 1 or Tray 2, Tray 3. • Load the input source with the correct type and size media. Next •...
  • Page 52 7525-xxx User status and attendance messages (continued) Previous User primary message Explanation Remove Paper ADF This posts when there is paper detected in the ADF upon POR or when the cover is closed (or any other situation that re-inits the scanner). Message clears when paper is removed.
  • Page 53 7525-xxx User status and attendance messages (continued) Previous User primary message Explanation 31.xx Defective <color> The specified cartridge is defective. Try one of the following: cartridge • Open and close the top cover. • Remove and re-install the cartridge(s). Listen for the click to ensure the cartridge Next is installed properly.
  • Page 54 7525-xxx User status and attendance messages (continued) Previous User primary message Explanation 37 Insufficient memory This message is displayed when insufficient printer memory is available to perform for flash defragment Flash Memory Defragment operation. operation This message appears prior to the actual start of the defragment operation. Next press Select ( ) to stop the defragment operation.
  • Page 55 7525-xxx User status and attendance messages (continued) Previous User primary message Explanation 52 Flash Full • press Select ( to clear the message and continue printing. • Delete fonts, macros, and other data stored on the flash memory. • Install a larger capacity flash memory card. Next 53 Unformatted Flash press Select (...
  • Page 56 7525-xxx User status and attendance messages (continued) Previous User primary message Explanation 82.xx Waste toner The following actions can be taken: nearly full • Replace the waste toner bottle, and then press Select ( ) to clear the message and continue printing. See Go to “Waste toner bottle”...

  • Page 57: Paper Jam Messages

    7525-xxx Paper Jam messages Previous Paper jam messages (2xx) Error code Description Action Next 2xx paper jams 200.xx Paper Jam A single page of media jam at the input Remove the tray1 unit, open the front door, Go Back Check <area> sensor.
  • Page 58 7525-xxx Paper jam messages (2xx) (continued) Previous Error code Description Action 250.xx Paper Jam A single page of media is jammed in Open tray 2 to access the jam area. Check Manual the multipurpose feeder. Remove the jammed page. See “250 Feeder Next...

  • Page 59: Service Error Messages

    7525-xxx Service error messages Previous Service error messages (1XX, 8XX and 9xx) Error code Description Action Next 106.xx Service Yellow printhead error. Perform a POR. If the problem persists, go Yellow Printhead “Printhead service check” on page 2-60. Go Back 106.01 Service The yellow printhead lost HSYNC.
  • Page 60 7525-xxx Service error messages (1XX, 8XX and 9xx) (continued) Previous Error code Description Action 107.08 Service The cyan laser showed bad in EMS Perform a POR. If the problem persists, go Cyan Printhead testing. “Printhead service check” on Next page 2-60.
  • Page 61 7525-xxx Service error messages (1XX, 8XX and 9xx) (continued) Previous Error code Description Action 109.02 Service The black printhead failed to complete Perform a POR. If the problem persists, go Black Printhead servo. “Printhead service check” on Next page 2-60 109.03 Service The black printhead mirror motors Perform a POR.
  • Page 62 7525-xxx Service error messages (1XX, 8XX and 9xx) (continued) Previous Error code Description Action 122.13 Service Fuser open thermistor check failed for Go to “Fuser service check” on Fuser Error second thermistor. page 2-42. Next 122.14 Service Fuser shorted thermistor check failed Go to “Fuser service check”...
  • Page 63 7525-xxx Service error messages (1XX, 8XX and 9xx) (continued) Previous Error code Description Action 152.xx Service Go to “Main drive gear assembly (EP CMY Cartridge Motor drive) service check” on page 2-44. Next 152.01 Service Failed to achieve lock for motor within Go to “Main drive gear assembly (EP CMY Cartridge Motor...
  • Page 64 7525-xxx Service error messages (1XX, 8XX and 9xx) (continued) Previous Error code Description Action Rear scan module lamp level too low Rear Mono channel, Rear Color channels, Rear Red channel, Rear Green channel, 844.03 and/or Rear Blue channel is detected to Next have low lamp level.
  • Page 65 7525-xxx Service error messages (1XX, 8XX and 9xx) (continued) Previous Error code Description Action Front calibration strip has excessive Front excessive variability for Mono, Red, 846.06 dark area Green, or Blue. Go to “CCD service Next check” on page 2-68 Front magnification exceeds limits Rear excessive variability for Mono, Red, 846.07...
  • Page 66 7525-xxx Service error messages (1XX, 8XX and 9xx) (continued) Previous Error code Description Action 907.xx Service A general engine software error. Go to “90x.xx error (902.xx–907.xx)” on Engine Software page 2-33 Next 908.01 Service Board level was not obtained. Engine Software? Go Back 908.02 Service Timeout waiting for bullet serial data to...
  • Page 67 7525-xxx Service error messages (1XX, 8XX and 9xx) (continued) Previous Error code Description Action 950.xx Service There is a mismatch between controller Go to “950.xx NVRAM failure service NVRAM Failure EEPROM and mirror. check” on page 2-36. Next • 950.00 through 950.29 codes: mismatch between controller and mirror •...
  • Page 68 7525-xxx Service error messages (1XX, 8XX and 9xx) (continued) Previous Error code Description Action 958.xx Service Printer has performed more than 100 NAND Failure “shift and reflash” operations as a result of ECC bit corrections. Next 959.01 Service Controller verification failure of pensive Update firmware or replace controller Invalid Firmware boot code...
  • Page 69 7525-xxx Service error messages (1XX, 8XX and 9xx) (continued) Previous Error code Description Action 964.xx Service Download emulation cyclic redundancy The following actions may be taken: Emulation Error check (CRC) failure has occurred. A 1. Disable the Download Emulation. checksum failure detected in the Next 2.
  • Page 70 7525-xxx Service error messages (1XX, 8XX and 9xx) (continued) Previous Error code Description Action 990.xx Service This error message indicates that an <device> equipment check condition has occurred in the specified device, but Next the device is unable to identify the exact component failure.

  • Page 71: Fax Error Log Codes

    7525-xxx Fax error log codes Previous Fax error log codes Error code Description Action Next No error occurred during fax No action needed transmission Go Back Error occurred when transmitting • Check line quality. • Select a lower ‘Max Speed’. training.
  • Page 72 7525-xxx Fax error log codes (continued) Previous Error code Description Action T5 Timeout occurred when transmitting • Check line quality. image data to remote fax device. • Adjust ‘Transmit Level’. Next • Select a lower ‘Max Speed’value under Fax Send settings. Too many errors when transmitting in •...
  • Page 73 7525-xxx Fax error log codes (continued) Previous Error code Description Action Failure to transmit training successfully • Select a lower “Max Speed” under Fax in V17, V29 terminal modulation Send settings. schemes. Next • Adjust the “Transmit Level”. • Check line quality. Failure to transmit training successfully •...
  • Page 74 7525-xxx Fax error log codes (continued) Previous Error code Description Action Modem detected a digital line Verify the MFP is connected to an analog connection. line. See“Fax transmission service Next check” on page 2-75. Phone line was disconnected Restore phone line connection. Go Back Received request for unsupported No action needed.

  • Page 75: Service Checks

    Note: Before troubleshooting, determine the operating system used when the error occured. If possible determine whether a PostScript or PCL file was sent to the device when the error occured. Ask the customer which Lexmark Solutions applications are installed on the device. Step Action and questions POR the device.
  • Page 76 Reinstall the memory, and send a print job to the Go to step 15. Go to step 16. device. Does the 900.xx error reoccur? Install a Lexmark recommended memory option. Send Go to step 31. Problem a print job to the device. resolved.

  • Page 77: 90X.xx Error (902.Xx-907.Xx)

    7525-xxx Previous Step Action and questions Reinstall the first ISP option. Restart the device. Go to step 24. Go to step 23. Does the 900.xx error reoccur? Run a job to test the option. Go to step 24. Go to step 26. Next Does the 900.xx error reoccur? Upgrade the firmware.

  • Page 78: 925.01-Fan Error Service Check

    7525-xxx 925.01—Fan error service check Previous Step Questions / actions Turn off the printer, and remove the rear Replace the top cover Replace the controller shield. See (which includes the fan). board. See “Rear shield removal” on “Controller Next 4-7. Unplug the fan cable at JFAN1 and page “Top cover assembly board removal”...

  • Page 79: Printhead Service Check

    7525-xxx Printhead service check Previous Error code Color 106.xx Yellow 107.xx Cyan Next 108.xx Magenta 109.xx Black Go Back Step Questions / actions Turn the printer off, and remove the rear Replace the printhead. See Go to step 2. shield. See “Rear shield removal”...

  • Page 80: 950.Xx Nvram Failure Service Check

    7525-xxx 950.xx NVRAM failure service check Previous Replace one of the following components, and perform a POR before replacing a second Warning: component. Never replace both of the components without performing a POR after installing each one, or the printer will be rendered inoperable: Operator panel assembly •...

  • Page 81: Bin Full Sensor Service Check

    7525-xxx Previous Step Questions / actions Turn the printer on, and then verify the Replace the Replace the controller following approximate values at JSP1: autocompensator board. See “Controller mechanism. See board removal” on JSP1 “Autocompensator page 4-18. Next mechanism (ACM)— Value standard tray removal”...

  • Page 82: Dead Printer Service Check

    7525-xxx Dead printer service check Previous A dead printer is a condition where the display is blank, the LED on the operator panel is off, the fan does not turn, no motors turn, and the fuser does not heat. If a 650-sheet Duo Drawer is installed, remove the option and check the base printer for correct operation. If the Next base printer operates correctly, replace the 650-sheet Duo Drawer.

  • Page 83: Duplex/Manual Feed Sensor (S1) Service Check

    7525-xxx Duplex/manual feed sensor (S1) service check Previous Note: Before performing this service check, ensure that the printer is on a hard level surface. Step Questions / actions Next Enter Diagnostics Menu (turn the printer off, Go to step 2. Go to step 4.

  • Page 84: Front Door Sensor Or Switches Service Check

    7525-xxx Front door sensor or switches service check Previous Step Questions / actions Enter Diagnostics Menu (turn the printer off, press Sensor, toner door, and Go to step 2. and hold , turn the printer on, and then right doors are OK. Next release the buttons when the installed memory and processor speed displays).

  • Page 85: Fuser Exit Sensor Service Check

    7525-xxx Fuser exit sensor service check Previous Step Questions / actions Enter Diagnostics Menu (turn the printer off, Correct the sensor or Go to step 2. press and hold , turn the printer on, replace it. See “” on Next and then release the buttons when the page 4-31.

  • Page 86: Fuser Service Check

    7525-xxx Fuser service check Previous Step Questions / actions Some low-voltage power supply FRUs have a Check the switch on the Go to step 2. voltage selector switch. If it does, the switch side of the LVPS to verify Next needs to be set to the correct voltage for your the correct voltage is set.

  • Page 87: Input Sensor (S2) Service Check

    7525-xxx Previous Step Questions / actions Replace the fuser. See Problem resolved. Replace the controller “Fuser assembly board. See removal” on page 4-28. “Controller board removal” on Does the error clear? page 4-18. Next Input sensor (S2) service check Go Back The Input sensor (S2) is part of the autocompensator FRU and is not available otherwise.

  • Page 88: Main Drive Gear Assembly (Ep Drive) Service Check

    7525-xxx Main drive gear assembly (EP drive) service check Previous Step Questions / actions Turn the printer off, and remove the rear Replace the JCARTB1 Go to step 2. shield. See cable. “Rear shield removal” on Next 4-7. Check the cable at JCARTB1 for page proper connection to the controller board, the cable for pinch points, and the cable or...

  • Page 89: Operator Panel Service Check

    7525-xxx Operator panel service check Previous Replace one of the following components, and perform a POR before replacing a second Warning: component. Never replace both of the components without performing a POR after installing each one, or the printer will be rendered inoperable: Operator panel assembly •...

  • Page 90: Operator Panel Display Blank, Printer Beeps Five Times And Pauses

    7525-xxx Previous Step Questions / actions Turn the printer off, and remove the rear Go to step 3. Replace the controller shield. See board. See “Rear shield removal” on “Controller 4-7. Disconnect the operator panel page board removal” on assembly cable at JOPP1 on the controller page 4-18.

  • Page 91: Operator Panel Displays All Diamonds, No Beeps

    7525-xxx Operator panel displays all diamonds, no beeps Previous Step Questions / actions Turn off the printer, and remove the rear Go to step 2. Replace the controller shield. See board. See “Rear shield removal” on “Controller Next 4-7. Disconnect the cable at JOPP1 on page board removal”...

  • Page 92: Operator Panel Display Is Dim And Unchanging

    7525-xxx Operator panel display is dim and unchanging Previous Step Questions / actions Turn off the printer, and remove the rear Go to step 2. Replace the controller shield. See board. See “Rear shield removal” on “Controller Next 4-7. Disconnect the cable at JOPP1 on page board removal”...

  • Page 93: Networking Service Check

    Next interference. Have the network administrator verify that the device is using the correct SSID, and wireless security protocols. For more network troubleshooting information, consult the Lexmark Network Setup Guide. Go Back Step...
  • Page 94 7525-xxx Previous Step Questions / actions Try using a different ethernet cable. Problem resolved Go to step 14. Did this remedy the situation? Have the network administrator check the Replace the controller Contact the network Next network drop for activity. board.

  • Page 95: Print Quality Service Check

    7525-xxx Print quality service check Previous Note: This symptom may require replacement of one or more CRUs (Customer Replaceable Units) designated as supplies or maintenance items, which are the responsibility of the customer. With the customer's permission, you may need to install a developer (toner) cartridge or photo conductor unit. Next Service tip Before troubleshooting any print quality problems, do the following:...

  • Page 96: Print Quality-Background

    Print quality—background Previous Service tip: Some background problems can be caused by rough papers, non-Lexmark toner cartridges or if the media texture is set to the rough setting. Some slick or coated papers may also cause background problems. Some problems occur with printers that run a large amount of graphics in a humid environment.

  • Page 97: Print Quality-Blank Page

    7525-xxx Previous Step Questions / actions Clean the printhead. Problem resolved. Replace the printhead. See “Printhead removal” on Does this fix the problem? page 4-61. Next Print quality—blank page Go Back Step Questions / actions Is all the packing material for the imaging unit Go to step 2.
  • Page 98 7525-xxx Previous Step Questions / actions 1. Remove the image unit and waste toner Go to step 5. Replace the Main drive gear bottle. assembly. See “Main drive 2. Replace the right cover and close the front gear assembly with motor door.

  • Page 99: Print Quality-Blurred Or Fuzzy Print

    7525-xxx Print quality—blurred or fuzzy print Previous Run the automatic alignment. The TPS sensor may be damaged. To run Reset Color Cal: Enter the Diagnostics Menu. (Turn the printer off, press and hold , turn Next the printer on, and release the buttons when installed memory and processor speed displays.

  • Page 100: Print Quality-Horizontal Line

    7525-xxx Print quality—horizontal line Previous Either the photoconductor unit or one of the developer units that make up the imaging unit is defective. Remove and inspect the imaging unit. Replace the damaged part of the imaging unit. See “Imaging unit (IU) removal” on page 4-45.

  • Page 101: Print Quality-Narrow Vertical Line

    7525-xxx Print quality—narrow vertical line Previous ABCDE ABCDE Next ABCDE Go Back Step Questions / actions Replace the photoconductor unit. See Problem solved. Replace the developer unit. “Developer unit “Imaging unit (IU) removal” on page 4-45. removal” on page 4-47 Print quality—random marks Service tip: The primary cause of random marks is due to loose material moving around inside the printer and attaching to the photoconductor unit, developer roll, or transfer belt.

  • Page 102: Print Quality-Residual Image

    7525-xxx Print quality—residual image Previous Service tip: Install a new print cartridge, if available, before doing this service check. Residual image can be caused by the photoconductor, cleaning blade, and other parts ABCDE inside the print cartridge. ABCDE Next ABCDE Go Back Step Questions / actions...

  • Page 103: Print Quality-Solid Color Page

    7525-xxx Print quality—solid color page Previous Service tip: A solid color page is generally caused by a problem in the high-voltage controller or an incorrect high voltage in the printing process resulting in toner development on the entire photoconductor drum. Next Go Back Step...

  • Page 104: Printhead Service Check

    7525-xxx Printhead service check Previous This service check includes the following errors: Error codes Color Next 106.xx Yellow 107.xx Cyan 108.xx Magenta Go Back 109.xx Black Step Questions / actions Turn the printer off, and remove the rear Replace the printhead. See Go to step 2.

  • Page 105: Toner Meter Cycle (Tmc) Card

    7525-xxx Toner meter cycle (TMC) card Previous Step Questions / actions Perform the Base Sensor Test: Replace the toner cartridge. Replace the toner meter cycle (TMC) card. See Next 1. Enter Diagnostics menu (turn off the “Toner meter cycle (TMC) printer, press and hold and Select ( card removal”...

  • Page 106: Transfer Roll Service Check

    7525-xxx Transfer roll service check Previous Step Questions / actions Remove the ITU. See Replace the ITU. See Problem resolved. “Image transfer unit 4-40. Check the contacts (ITU)” on page “Image transfer unit (ITU)” Next between the HVPS and the ITU. Clean the on page 4-40.

  • Page 107: Tray (X) Sensor Service Check

    7525-xxx Tray (x) sensor service check Previous Step Questions / actions When the printer is in Ready state, pull the Go to step 2. Go to step 4. standard tray out. The display should indicate Next Tray (x) Missing. Insert the tray. Does the message remain on the display? Go Back Check the vertical well at the right rear of the...

  • Page 108: Option Trays 2 And 3 Service Check

    7525-xxx Option trays 2 and 3 service check Previous Step Questions / actions Are two option trays being used? Go to step 2. Go to step 4. Next If two option trays are being used, is the 550 Go to step 4. Go to step 3.
  • Page 109 7525-xxx Previous Step Questions / actions Turn off the printer, and remove the rear Consult your second level Replace the controller shield. support. board. See “Rear shield removal” on page 4-7. Disconnect the cable at JOPT1 on the controller board. Turn the printer on, and Next measure the voltages below.

  • Page 110: 840.Xx Service Check

    7525-xxx Previous Scanner / Copy / Fax service checks 840.xx service check Next Step Questions / actions POR the machine into configuration mode. Go to step 2. Stop. Problem resolved. Go to the disable scanner menu item. See Go Back 3-36.
  • Page 111 7525-xxx Previous Step Questions / actions Replace the ADF unit. See Go to step 8. Stop. Problem solved. “Duplex ADF removal” on page 4-88or “Simplex ADF 4-89. POR the machine removal” on page into configuration mode. Go to the disable Next scanner menu item.

  • Page 112: Black Or Blank Page Copy Service Check

    7525-xxx Black or blank page copy service check Previous Step Questions / actions Print a menu page, or a page from the host. Go to step 2. “Print quality—solid Is the page black? color page” on page 2-59 Next Is the copy an ADF scan? Go to step 3.

  • Page 113: Flatbed Home Position Service Check

    7525-xxx Flatbed home position service check Previous Step Questions / actions POR the MFP. Does the CCD move and Problem solved. Go to step 2. return to the home position? Next Perform the home position sensor test. Go Go to step 3. Go to step 5.

  • Page 114: Adf Cover Open Service Check

    7525-xxx ADF cover open service check Previous Step Questions / actions Is the ADF cover properly closed Go to step 3. Go to step 2. Next Close the ADF cover. Issue resolved Go to step 3. Does the problem go away? Go Back Perform the ADF cover open sensor test.

  • Page 115: Adf Paper Jam Service Check

    7525-xxx ADF paper jam service check Previous Note: This service check should be used if the paper feeds and jams in the ADF. If the paper is not feeding into the ADF see “ADF feed errors service check” on page 2-72.

  • Page 116: Adf Feed Errors Service Check

    7525-xxx ADF feed errors service check Previous Step Questions / actions If the ADF is multi-feeding, check for Clean them with a lint free Replace the separator pad and dirt on the ADF separator pad and cloth and isopropyl alcohol. ADF pick roll.

  • Page 117: Adf Duplex Service Check

    7525-xxx ADF Duplex service check Previous Step Questions / actions Perform sensor 1, and sensor 2 Go to step 2. Go to step 3. sensor tests. Go to Next “Scanner Tests” on page 3-25. Are the sensors working properly? Go Back Check the ADF sensor actuators to Go to step 3.

  • Page 118: Modem / Fax Card Service Check

    7525-xxx Modem / fax card service check Previous Step Questions / actions Is the phone line properly connected to the Go to step 2. Go to step 3. modem card and the wall jack? Next Properly connect the phone line to the Problem resolved.

  • Page 119: Fax Transmission Service Check

    7525-xxx Fax transmission service check Previous Note: Before performing this service check, verify that the correct country code for the MFP is selected. This setting must match the country in which the MFP is used to transmit and receive faxes. If the setting is wrong, the modem settings can be changed in the Fax/SE menu.
  • Page 120 7525-xxx Previous Step Questions / actions Adjust the “Transmit Level” setting in the SE Stop. Problem resolved. Go to your second-level of menu. press **411 to enter the SE menu, support. See “Escalating a enter Modem settings, and select “Transmit fax issue to second-level Level”.

  • Page 121: Fax Reception Service Check

    7525-xxx Fax reception service check Previous Step Questions / actions Is the phone line properly connected to the Go to step 2. Go to step 3. modem card and the wall jack? Next Properly connect the phone line to the Problem resolved.
  • Page 122 7525-xxx Previous Step Questions / actions Go to the Administrator menu. Enter the Fax Go to step18 Go to step 19. settings - Analog Fax Settings submenu. Verify the remote device number is not in the Banned Fax List user setting. Next Is the remote device number in the banned fax list?

  • Page 123: Escalating A Fax Issue To Second-Level Support

    7525-xxx Escalating a fax issue to second-level support Previous Before contacting the second-level support, go to the SE menu on the MFP.and generate a Fax error file. This file contains machine settings information and debug information that will help second-level support determine the cause of a failure.

  • Page 124: User Operator Panel, Menus And Messages

    7525-xxx Previous User operator panel, menus and messages Understanding the operator panel The printer operator panel has a four-line, back lit, grayscale display that can show both graphics and text. The Next Mode selection, job setup, Back, and Menu buttons are located to the left of the display, the navigation buttons are located below the display, and the start buttons, stop button, and numeric pad are located to the right of the display.
  • Page 125 7525-xxx Previous Button or indicator Function Start / Black and White press to start a job in black and white. Stop/Cancel Stops all printer activity. Next A list of options is offered once Stopped appears on the display. Operating modes Go Back Copy Selecting this option enables copy mode.

  • Page 126: Menu Map

    7525-xxx Menu map Previous This menu map identifies menus available to customers. The diagram shows the menus on the operator panel and items available under each menu. Some menu items or values are displayed only if a specific option or feature is installed on your printer. Other Next menu items may be effective only for a particular printer language.

  • Page 127: Diagnostic Aids

    7525-xxx 3. Diagnostic aids Previous This chapter explains the tests and procedures to identify printer failures and verify repairs have corrected the problem. Next Menu key combinations. There are different test menus that can be accessed during POR to identify problems with the printer. Go Back Configuration Menu 1.

  • Page 128: Diagnostics Menu (Diag Menu)

    7525-xxx Previous Diagnostics Menu (Diag Menu) Note: Tray 2 refers to the 650-sheet tray located in the 650-sheet Duo Drawer assembly. Diagnostics menu structure Next When the Diagnostics mode is entered, each Diagnostics main menu item displays on the operator panel. When a diagnostic test is selected from the main menu, a sub menu displays, and each individual test displays in the Go Back order shown.
  • Page 129 7525-xxx Diagnostics mode tests (continued) Previous INPUT TRAY TESTS (if Tray 2 is installed) Feed Tests “Feed Tests” on page 3-17. Sensor Tests “Sensor Test” on page 3-17. Next BASE SENSOR TEST “Base Sensor Test” on page 3-18. Front Door Input S1 Go Back Input S2...

  • Page 130: Registration

    7525-xxx Diagnostics mode tests (continued) Previous Print Log “Print Log” on page 3-23. Clear Log “Clear Log” on page 3-24. Do not use. For development use only. Development Menu Next Scanner Tests ASIC Test “ASIC Test” on page 3-25. Feed test “Feed Test”...

  • Page 131: Skew

    7525-xxx Previous Description Value Direction of change Right margin -50 to +50 A positive change moves the image to the left, and a negative change moves the image to the Each increment corresponds to an right. approximate shift of 4 pixels at 600 dpi.

  • Page 132: Quick Test

    • General printer information, including current page count, installed memory, serial number, and code level. Go Back Lexmark x54x To print the Quick Test page: Note: Print the Quick Test Page on letter or A4 paper. Select REGISTRATION from DIAGNOSTICS.

  • Page 133: Alignment

    7525-xxx Alignment Previous Aligns each of the color planes to the black plane. Print the Quick Test under each color, Cyan, Yellow, and Magenta, and adjust the Top Margin, Left Margin, Right Margin, Skew, and Bow. Prints the Print Alignment Pages and requires that the best line in each set of lines must be selected. Next To get started: Select Alignment Menu from the Diag Menu, and press Select (...
  • Page 134 7525-xxx Select Top Margin, and press Select ( Previous Select the best choice for fine or coarse adjustment in Step 1 (first page), and add it to the current value for the Top Margin. Next Go Back to enter the sum of the numbers, and press Select ( Submitting changes…...
  • Page 135 7525-xxx Select the Skew value in the same way, enter the value, press Select ( ), and print the Quick Test to see Previous if the observed values and the current values are the same. Next Go Back On the second page of the latest Quick Test you printed, proceed to Step 2; adjust the left, right,and bow settings.

  • Page 136: Factory Scanner

    7525-xxx Factory Scanner Previous Note: This setting is not used by field service. Factory Manual Next Note: This setting is not used by field service. Miscellaneous Tests Go Back Motor Detect This test initiates an automatic motor detection process that should be performed whenever the controller board is replaced.

  • Page 137: Print Tests

    The print quality test consists of five pages. Pages one and two contain a mixture of graphics and text. The remainder of the pages contain only graphics. The test prints on the media in tray 1. Lexmark x54x Diagnostic aids...
  • Page 138 7525-xxx This test may be printed from either Configuration Menu or the Diagnostics Menu. Previous To run the print quality pages from the Diagnostics Menu: Select PRINT TESTS, and press Select ( Select Print Quality Pgs, and press Select ( Next The message Printing Quality Test Pages is displayed.

  • Page 139: Hardware Tests

    7525-xxx Hardware Tests Previous Panel Test This test verifies the operator panel LCD function. Next To run the Panel Test: Select Hardware Tests from Diag Menu, and press Select ( Go Back Select Panel Test, and press Select ( The Panel Test continually executes. press Stop ( ) to cancel the test.

  • Page 140: Cache Test

    7525-xxx To stop the test early, turn off the printer. Previous CACHE Test The CACHE Test is used to verify the processor cache is functioning properly. Next Select Hardware Test in Diag Menu, and press Select ( Select CACHE Test, and press Select ( The printer displays: Go Back CACHE Test Testing…...

  • Page 141: Duplex Tests

    This test prints a duplex version of the Quick Test that can be used to verify the correct placement of the top margin on the back side of a duplex page. Next Go Back Lexmark x54x Note: Before you set the duplex top margin, be sure to set the registration. See “Registration” on page 3-4.

  • Page 142: Top Margin (Duplex)

    7525-xxx Hold the page to the light to see whether the left margin of the back aligns with the left margin of the front. Previous Select Left Margin from DUPLEX TESTS. to select the margin setting you need to change. •...

  • Page 143: Input Tray Tests

    7525-xxx Input Tray tests Previous Feed Tests This test allows you to observe the paper path of media as it passes through the printer. Any installed input tray can be tested. The pages fed through the printer are blank. Next To run the Feed Test: Go Back Select INPUT TRAY TESTS from Diag Menu, and press Select (...

  • Page 144: Base Sensor Test

    7525-xxx Base Sensor Test Previous These tests allow you to verify the correct functioning of the front door, input, and output sensors. Select Base Sensor Test from Diag Menu, and press Select ( Select the sensor you want to test, and press Select ( Next The following test are available: Go Back...

  • Page 145: Printer Setup

    7525-xxx Printer Setup Previous Defaults US/Non-US defaults changes whether the printer uses the US factory defaults or the non-US factory defaults. The settings affected include paper size, envelope size, PCL symbol set, code pages, and units of measure. Next Warning: Changing this setting resets the printer to factory defaults, and data may be lost. It cannot be undone. Go Back Page Counts You can view, but not change any of the three counts displayed under PAGE COUNTS.

  • Page 146: Itu Barcode

    7525-xxx Unless the menu is in DIAGNOSTICS, Check Config ID displays. • Previous To set the configuration ID: Select PRINTER SETUP from DIAGNOSTICS, and press Select ( Select Configuration ID, and press Select ( Next The current value for Configuration ID 1 appears with the left character or digit underlined. Enter the Configuration ID 1.

  • Page 147: Reset Fuser Count

    7525-xxx Reset Fuser Count Previous Resets the fuser count value to zero. The Event Log records each time that a user executes the Reset Fuser Count operation. See for more information. This setting appears only if the “Event Log” on page 3-32 Maintenance Warning and Intervention function is enabled in the printer Configuration ID.

  • Page 148: Tps Setup

    7525-xxx TPS Setup Previous Right or Left TPS The value of the TPS sensor is set at manufacturing. If a sensor is replaced, enter the 32-digit hexadecimal TPS value from the barcode next to the sensor. Next To enter the value: Go Back Select TPS SETUP from Diag Menu, and press Select ( Select Right or Left, and press Select (...

  • Page 149: Event Log

    Time and date stamps • • Page counts for most errors Additional debug information in some cases • Model and Lexmark x54x (s/n: 98P104V) Serial number Printer information Panel display when error occurred Page count Earliest error code Diagnostic aids...

  • Page 150: Clear Log

    7525-xxx The printed event log can be faxed to your next level of support for verification or diagnosis. Previous To print the event log: Select EVENT LOG from DIAGNOSTICS, and press Select ( Select Print Log, and press Select ( Next press Back ( ) to return to EVENT LOG.

  • Page 151: Scanner Tests

    7525-xxx Scanner Tests Previous ASIC Test This test initiates a scan of the scanner ASIC’s memory. Next While this test is executing ASIC Test Running is displayed. When the test is complete, ASIC Test Passed is displayed if the ASIC memory is ok. ASIC Test Failed is displayed if the test fails. press the Back or Stop buttons to clear the display message Go Back Feed Test...
  • Page 152 7525-xxx ADF paper present sensor test Previous This test should be used if the ADF fails to feed paper when a scan is performed. To test this sensor perform the following steps: In the sensor test menu, press to scroll to the ADF paper present test. ).Starting Test displays.
  • Page 153 7525-xxx FB Cover closing sensor test Previous This test verifies the functionality of the FB cover closed sensor. To test this sensor. perform the following steps: In the sensor test menu, press to scroll to the FB Cover closing sensor test. ).
  • Page 154 7525-xxx Sensor 1 test Previous This test verifies the functionality of scan sensor 1. To test this sensor. perform the following steps: In the sensor test menu, press to scroll to the Sensor1 test. ). Starting Test displays. Sensor 1: Closed displays. press Select ( Lift the ADF top cover, and close the ADF cover sensor by pressing down on the ADF sensor actuator (A) Next...
  • Page 155 7525-xxx Sensor2 test Previous This test verifies the functionality of scan sensor 2. To test this sensor. perform the following steps: In the sensor test menu, press to scroll to the Sensor 2 test. ). Starting Test displays. Sensor 2: Closed displays. press Select ( Lift the ADF top cover, and close the ADF cover sensor (A) by pressing down on the ADF sensor actuator Next...

  • Page 156: Exit Diags

    7525-xxx EXIT Diags Previous press Select ( ) to exit Diag Menu. The printer performs a power-on reset and returns to normal mode. Next Go Back Service Manual 3-30...

  • Page 157: Configuration Menu

    7525-xxx Previous Configuration Menu Available tests The tests display on the operator panel in the order shown for all models. Next Configuration menu Go Back USB Scan to Local “USB Scan to Local” on page 3-31. Prt Quality Pgs “Prt Quality Pages” on page 3-31.

  • Page 158: Reports

    7525-xxx Uses an algorithm to compensate for mechanical incorrect registration in the printer. When small black text or Previous fine black lines are being printed, the printer checks to see if they are being printed on top of a colored background.

  • Page 159: Demo Mode

    7525-xxx Demo Mode Previous Lets marketing personnel or merchandisers demonstrate the printer to potential customers by printing the demo page. Selections include Deactivate (default) and Activate. Select Deactivate to turn Demo Mode off; or select Next Activate to turn Demo Mode on. Factory defaults Go Back Sets the majority of printer values back to their factory default settings.

  • Page 160: Min Copy Memory

    7525-xxx Min Copy Memory Previous This setting allocates the amount of DRAM memory to be used for storing copy jobs in the queue. 25, 35,50,80 and 100 MB are the available settings. To adjust the minimum copy memory, perform the following steps: In the configuration menu, scroll to the MinCopy Memory item, and press Next Use the...

  • Page 161: Fb Edge Erase

    7525-xxx FB Edge Erase Previous This menu item sets the size, in millimeters, of the no print are around a flatbed scan job. Copy jobs will use the setting or two millimeters, whichever is larger. To adjust the flatbed edge erase setting, perform the following steps: Next In the Configuration menu, select the FB Edge Erase menu item.

  • Page 162: To Manually Register The Flatbed, Perform The Following Steps

    7525-xxx Use the to increase or decrease the settings value. Previous Note: Each button press moves the margin values one pixel in the respective direction. Press to accept the value. Scroll to Top Edge, and press Use the to increase or decrease the settings value. Next Note: Pressing moves the margin up, and pressing...

  • Page 163: Font Sharpening

    7525-xxx Font Sharpening Previous This setting is used to set a text point size value below which the high frequency screens will be used when printing data. This setting affects only PCL, PostScript and PDF emulators. Settings are in the range of 0–150 (24 is the default). For example, if the value is set to 24, then all fonts sized 24 Next points or less use the high frequency screens.

  • Page 164: Se Menu

    7525-xxx Previous SE Menu Note: This is not the Fax SE menu. To enter the Fax SE menu, press **411 from the Ready screen. Note: This menu should be used as directed by second-level support. Next Print SE Menus Go Back General Copyright - Displays copyright information.

  • Page 165: Paper Jams

    Next Use only recommended paper or specialty media. • For more information, see the Card Stock & Label Guide available on the Lexmark Web site at Go Back www.lexmark.com/publications. Do not load too much paper. Make sure the stack height does not exceed the indicated maximum height.

  • Page 166: Understanding Jam Numbers And Locations

    7525-xxx Understanding jam numbers and locations Previous Next Go Back When a jam occurs, a message indicating the jam location appears. The following illustration and table list the paper jams that can occur and the location of each jam. Open doors and covers, and remove trays to access jam locations.

  • Page 167: 200 Paper Jams

    7525-xxx 200 paper jams Previous Remove the standard 250-sheet tray (tray 1). Remove the jam. Note: Make sure all paper fragments are removed. Next Go Back Insert the tray. press Select ( 201 paper jam Grasp the front door at the side handholds, and then pull it toward you to open it. Remove the jammed paper.

  • Page 168: 202 Paper Jam

    7525-xxx 202 paper jam Previous Raise the scanner assembly to the up position. Grasp the front door at the side handholds, and then pull it toward you to open it. Grasp the green lever, and pull the fuser cover toward you. Next Go Back Hold the fuser cover down, and then remove the jammed paper.

  • Page 169: 230 Paper Jam

    7525-xxx 230 paper jam Previous Grasp the front door at the side handholds, and pull it toward you to open it. Remove the jam. press Select ( ) to continue printing. Next 235 paper jam Load the tray with the correct paper size. Go Back Insert the tray.

  • Page 170: 29X Adf Paper Jam

    7525-xxx 29x ADF paper jam Previous Remove all original documents from the ADF input tray. Open the ADF top cover. Remove the jammed paper. Next Go Back Close the ADF cover. Open the flatbed cover. Remove any jammed pages. Close the scanner lid. Press Service Manual 3-44...

  • Page 171: 291.Xx Adf Paper Jams

    7525-xxx 291.xx ADF paper jams Previous Remove all original documents from the ADF input tray. Remove the ADF input tray. See “ADF input tray” on page 4-89. Remove the original from the ADF by pulling the lower of the two sheets (A) from the ADF exit. Next Go Back Replace the ADF input tray.

  • Page 172: Updating Printer Firmware

    7525-xxx Previous Updating printer firmware The latest firmware can be found by going to http://support.lexmark.com/printerfirmware and inputting keycode x54x (all lowercase). Next Warning: Before performing a firmware update on the printer, contact the technical service center or second level of support to verify the correct firmware and keycode. The wrong firmware or wrong level of firmware could lead to a malfunction or render the printer inoperable.
  • Page 173 7525-xxx Open the USBFlash utility. This window will display. Previous Next Go Back Click the Browse Files button. The file browse dialog displays. In the file browse dialog, browse to the fullnet.fls (also called 1.fls) file. The fullnet.fls file is the RIP firmware file.
  • Page 174 7525-xxx Select the printer needing the firmware update from the “Select Printer From List” dropdown menu. Previous Next Go Back Click Start. The printer will start the update process. Various status and progress messages will appear on the printer’s operator panel. Warning: Do not turn the machine off until the update is complete.
  • Page 175 7525-xxx 0pen the USBFlash utility. This window will display. Previous Next Go Back Click the Browse Files button. The file browse dialog displays. In the file browse dialog, browse to the updeng.fls (also known as 2.fls) file. The fullnet.fls file is the engine firmware file.
  • Page 176 7525-xxx Select the printer needing the firmware update from the “Select Printer From List” dropdown menu. Previous Next Go Back Click Start. The printer will start the update process. Various status and progress messages will appear on the printer’s operator panel. Warning: Warning: Do not turn the machine off until the update is complete.
  • Page 177 7525-xxx Open the USBFlash utility. This window will display. Previous Next Go Back Click the Browse Files button. The file browse dialog displays. In the file browse dialog, browse to the scanner.fls (also known as 3.fls) file. The scanner.fls file is the scanner firmware file.
  • Page 178 7525-xxx Select the printer needing the firmware update from the “Select Printer From List” dropdown menu. Previous Next Go Back Click Start. The printer will start the update process. Various status and progress messages will appear on the printer’s operator panel. Warning: Warning: Do not turn the machine off until the update is complete.

  • Page 179: Updating The Firmware Using A Usb Thumb Drive

    Updating the firmware using a USB thumb drive Previous If a USB thumbdrive is available, it can be used to update the printer firmware. Before updating the firmware, download the zip file containing the firmware files from http://support.lexmark.com/printerfirmware and inputting keycode x54x (all lowercase). Next Warning: Before performing a firmware update on the printer, contact the technical service center or second level of support to verify the correct firmware and keycode.

  • Page 180: Updating The Firmware Using A Networked Computer

    Updating the firmware using a networked computer Using FTP Next Before updating the firmware, download the zip file containing the firmware files from http:support.lexmark.com/ printerfirmware and inputting keycode x54x (all lowercase). Go Back Note: To update the printer using FTP, you should have an understanding of how to use an FTP client.

  • Page 181: Using The Printer's Internal Web Server

    Using the printer’s internal Web server Previous Before updating the firmware, download the zip file containing the firmware files from http:support.lexmark.com/ printerfirmware and inputting keycode x54x (all lowercase). Note: You will need the IP address of the printer on the network. This can be obtained from the Network Next Settings page found under Network Setup menu under Reports, in the Administrative menu.
  • Page 182 7525-xxx Scanner firmware update Previous On a computer attached to the network, open a Web browser. Enter the printers IP address in the Web browsers address bar. Press Enter. The printers homepage opens. Click Settings. The settings page opens. Next Click the Update Firmware link.

  • Page 183: Theory Of Operation

    7525-xxx Previous Theory of operation Print engine theory Next Electrophotographic Process (EP Process) The method that all laser and LED printers use to print is called the electrophotographic process. These machines use differences in charge to manipulate and move toner from the toner cartridge to the printed page. Go Back Even though the basic EP process is the same for every laser and LED printer, the specifics for each printer are different.

  • Page 184: Step 1: Charge

    7525-xxx Step 1: Charge Previous During the charge step, voltage is sent from the high-voltage power supply to the charge roller (A) beside each of the four photoconductors. The charge roller is part of the photoconductor unit. The charge roller (A) puts a uniform negative charge over the entire surface of the photoconductor to prepare it Next for the laser beam.

  • Page 185: Step 2: Expose

    7525-xxx Step 2: Expose Previous During the expose step, the laser fires a focused beam of light at the surface of each photoconductor (B) and writes an invisible image called a latent image or electrostatic image for each color. The laser beam actually discharges the surface only where the beam hits the photoconductor. This creates a Next difference in charge potential between the exposed area and the rest of the photoconductor surface.

  • Page 186: Step 3: Develop

    7525-xxx Step 3: Develop Previous Once the laser exposes the photoconductor, the high-voltage power supply sends charge to the developer roll (C). For each color, the toner cartridge engages the photoconductor so it is in contact with the surface. Because of the charge difference between the toner on the developer roller and the electrostatic image created by the laser, the toner will attract to the photoconductor only where the laser exposed the surface.

  • Page 187: Step 4A: First Transfer

    7525-xxx Step 4a: First transfer Previous When the latent images are developed on each Photoconductor, the high-voltage power supply sends voltage to the 1st Transfer Rollers inside the ITU (D). The charge difference between the developed toner image on the Photoconductor surface and the 1st Transfer Next Roller causes the images to transfer to the surface of the ITU belt for each color.

  • Page 188: Step 4B: Second Transfer

    7525-xxx Step 4b: Second transfer Previous Once the four planes of color are transferred to the transfer belt from the photoconductors, the image is carried towards the transfer roll (E). This transfer roll is also part of the ITU. Based on the speed of the transfer belt, the proper time to send the signal to pick the media from an input source is determined.

  • Page 189: Step 5: Fuse

    7525-xxx Step 5: Fuse Previous Once the image has been fully transferred to the media, the transfer roll helps move the paper into the fuser area. The fuser (F) applies heat and pressure to the page to melt the tiny toner particles and bond them permanently Next to the media.

  • Page 190: Step 6: Clean/Erase

    7525-xxx Step 6: Clean/Erase Previous There are two main cleaning processes that take place during the EP Process. One process cleans the transfer belt, and the other cleans the photoconductors. Transfer Unit Clean Next Once the toner image on the transfer belt has been transferred to the page, the transfer belt rotates around and is cleaned by the cleaning blade (G).
  • Page 191 7525-xxx Photoconductor Clean/Erase Previous After each plane of color has been transferred to the transfer belt from the photoconductors, a cleaning blade (H) scrapes the remaining toner from the surface of each photoconductor. This is the clean/erase process. Now the photoconductor surface is prepared to begin the EP cycle once again. This cleaning/erasing cycle happens after each plane of color is transferred to the transfer belt.

  • Page 192: Paper Path, Transport Components

    7525-xxx Paper path, transport components Previous In order for an image to be printed, the media has to be moved from an input source (such as a tray) into the printer and eventually exit into an output source. The most important component in this process is this media itself. Old, damaged, or out-of-specification media Next can and will cause feed and transport problems.

  • Page 193: Transport Components

    7525-xxx Transport components Previous In summary, the media is fed from the tray into the printer by a feed roll and carried to the transfer roll (ITU). The pick rollers time the media to enter the EP process at just the right moment. The pick rollers push the media to the ITU where the image is transferred to the page.
  • Page 194 7525-xxx When the trailing edge of the media clears the fuser, the fuser engine rotates forward to prepare the fuser for the Previous page travelling through the duplexer. As the media reaches the gate aligner, a sensor (S1) is triggered indicating the presence of the leading edge. When the S1 sensor is triggered, the paper continues to the S2 sensor.

  • Page 195: Scanner Theory

    7525-xxx Scanner theory Previous Duplex ADF The following illustration shows the paperpath, rollers and sensors used in the X544 duplex ADF. Next Go Back The X544 and X546 duplex ADF enables the user to create duplex scans automatically, eliminating the need to stop the scanning process to flip the media being duplicated over.
  • Page 196 7525-xxx with the ADF scan sensor ensure that the media is travelling at the correct speed through the scan area. The Previous speed the document travels through the ADF scan area is dependent on the image DPI specified by the user. 7.

  • Page 197: Color Theory

    7525-xxx Color theory Previous What is RGB color? Red, green, and blue light can be added together in various amounts to produce a large range of colors observed in nature. For example, red and green can be combined to create yellow. Televisions and computer Next monitors create colors in this manner.

  • Page 198: My Color Transparencies Seem Dark When They Are Projected. Is There Anything I Can Do To Improve The Color

    7525-xxx My color transparencies seem dark when they are projected. Is there anything I can Previous do to improve the color? This problem most commonly occurs when projecting transparencies with reflective overhead projectors. To obtain the highest projected color quality, transmissive overhead projectors are recommended. If a reflective projector must be used, then adjusting the Toner Darkness setting to 1, 2, or 3 will lighten the transparency.

  • Page 199: How Can I Match A Particular Color (Such As A Corporate Logo)

    7525-xxx How can I match a particular color (such as a corporate logo)? Previous From the printer Quality menu, nine types of Color Samples sets are available. These are also available from the Color Samples page of the Embedded Web Server. Selecting any sample set generates a multiple-page printout consisting of hundreds of colored boxes.
  • Page 200 7525-xxx Previous Next Go Back Service Manual 3-74...

  • Page 201: Repair Information

    7525-xxx 4. Repair information Previous Warning: Read the following before handling electronic parts. Next Handling ESD-sensitive parts Go Back Many electronic products use parts that are known to be sensitive to electrostatic discharge (ESD). To prevent damage to ESD-sensitive parts, use the following instructions in addition to all the usual precautions, such as turning off power before removing logic boards: Keep the ESD-sensitive part in its original shipping container (a special “ESD bag”) until you are ready to •...

  • Page 202: Removal Procedures

    7525-xxx Previous Removal procedures CAUTION Remove the power cord from the electrical outlet before you connect or disconnect any cable Next or electronic board or assembly for personal safety and to prevent damage to the printer. Disconnect any connections between the printer and PCs/peripherals. Go Back Notes: Some removal procedures require removing cable ties.
  • Page 203 7525-xxx Remove the five screws (A) from the cable cover. Previous Next Go Back Remove the cable cover. Remove the screw (B) securing the right restraining strap to the front cover. Note: Support the door with one hand after removing the screw holding the restraining strap. This is the longest screw of the eight.

  • Page 204: Front Middle Cover Removal

    7525-xxx Front middle cover removal Previous Open the front cover. Remove the five screws (A) attaching the front middle cover to the lower front cover. Next Go Back Pull the front middle cover away from the front cover. Left cover removal Remove the media tray.
  • Page 205 7525-xxx Remove the three screws (A) on the rear side of the left cover. Previous Next Go Back Repair information...
  • Page 206 7525-xxx Remove the screw (B) on the bottom of the cover. Previous Next Go Back With a hand on the bottom of the cover, ease the cover over the off/on switch, and rotate the cover away from the printer. Warning: Be careful not to damage the rear tab at the upper rear side of cover. Installation note: When replacing the left cover, flex the cover slightly to engage the tab near the power switch.

  • Page 207: Right Cover Removal

    7525-xxx Right cover removal Previous Remove the media tray. Lift and lock the flatbed assembly to the raised position. Open the front cover. Release the green latches securing the door. Next Go Back Lower the right cover and remove it from the hinges. Rear shield removal The rear shield is not a field replaceable unit (FRU).

  • Page 208: Aio Back Cable Cover Removal

    7525-xxx AIO back cable cover removal Previous Remove the two screws (A) which secure the AIO back cable cover to the MFP. Next Go Back Place a small flat-blade screwdriver under the bottom of the cover, and gently pry the cover upward. Service Manual...

  • Page 209: Top Cover Assembly Removal

    7525-xxx Top cover assembly removal Previous Remove the flatbed assembly. Go to “Flatbed removal” on page 4-77. Remove the AIO toner cover. Go to “AIO toner cover” on page 4-102. Remove the five screws (A) from the left front side. Next Go Back Remove one screw (B) from the top right side of the cover.
  • Page 210 7525-xxx Remove the four screws (C) on the right side of the top cover. Previous Next Go Back Remove the toroid holder (D) and two screws (E) from the rear. The toroid holder will be used on the new top cover. Service Manual 4-10...

  • Page 211: Installation

    7525-xxx Detach the re-drive belt (F) from the pulley on the fuser exit roll shaft. Previous Next Go Back Disconnect the fan power cable from JFAN1 on the controller board. Disconnect the bin full sensor cable from JPJ1 on the controller board. Remove the top cover, being careful to route the bin full sensor cable through the top of the controller board cage.

  • Page 212: Autocompensator Mechanism (Acm)-Standard Tray Removal

    7525-xxx Autocompensator mechanism (ACM)—standard tray removal Previous Remove the toner bottles, the waste toner container, and the imaging unit (IU). See “Imaging unit (IU) and see removal” on page 4-45 “Waste toner bottle” on page 4-72. Remove the rear shield. See “Rear shield removal”...
  • Page 213 7525-xxx Remove the two springs (D). Previous Next Go Back Remove the two screws (E) on the bottom. Repair information 4-13...
  • Page 214 7525-xxx On the right side, loosen the screw (F) with a screwdriver, and hold the ACM in place as you use your Previous fingers to remove the screw. Next Go Back Move the right side of the ACM out to free the shaft from the hole in the frame. Note: Observe the location of the shaft and hole for reinstallation.

  • Page 215: Bin Full Sensor

    7525-xxx Bin full sensor Previous Remove the flatbed unit. See “Flatbed removal” on page 4-77. Using a small flatblade screwdriver, gently depress the tabs (A) which secure the sensor to the top cover assembly. Next Go Back Pull the sensor away from the top cover assembly. Disconnect the sensor from the cable.

  • Page 216: Narrow Media Sensor Flag Removal

    7525-xxx Narrow media sensor flag removal Previous Open the front cover. Remove the narrow media sensor flag. Remove the cable from the retainer. Note: Be sure to note the routing for re-installation. Next Disconnect the cable (A) from the narrow media sensor. Go Back Service Manual 4-16...
  • Page 217 7525-xxx If there is a sensor retaining plate (B), remove the plate. Previous Next Go Back Pinch the retainers on the rear of the sensor, and gently remove the sensor from the bracket by hand. Installation note: Clean the contact surface where you removed the sensor retaining plate, or where you need to install the new one.

  • Page 218: Controller Board Removal

    7525-xxx Controller board removal Previous Warning: Observe all ESD precautions while handling electrostatic-discharge sensitive parts. See “Handling ESD-sensitive parts” on page 4-1. Warning: When replacing any one of the following components: Next • Operator panel assembly Controller board • Replace only one component at a time. Replace the required component, and perform a POR before replacing a Go Back second component listed above.
  • Page 219 7525-xxx A blank page that should have toner on it could be an indication that toner is applied to the ITU belt Previous but not transferred. Therefore the toner goes into the ITU cleaner which cannot process massive amounts of toner. It is important to prevent extensive blank pages from being processed if they should have toner on them.

  • Page 220: Duplex Reference Edge Removal

    7525-xxx Duplex reference edge removal Previous Note: If the duplex reference edge is made out of plastic, then replace it. If the duplex reference edge is made out of metal, then do not replace it. Next Go Back Plastic Metal Open the front door.
  • Page 221 7525-xxx Lift the duplex aligner on the right side, and disengage the gears (C) on the left. Previous Next Go Back Remove the four screws (D) from the duplex reference guide, and remove the guide. Repair information 4-21...
  • Page 222 7525-xxx Previous Installation notes: Depending on the kind of front cover, follow the procedure below that applies: If the front cover has the slot below, then place the tab in the slot as shown. Slot Next Go Back Service Manual 4-22...
  • Page 223 7525-xxx Rotate the tab into position, and replace the three screws (A). Previous Next Go Back If the front cover has no slot, then place the tab against the cover as shown. Repair information 4-23...
  • Page 224 7525-xxx Replace the two screws (B). Previous Next Go Back Be sure the shaft and bearing have not shifted out of the guide, and that the bearing on the left is aligned with the slot (C) facing down (towards the front door). Note: Improperly aligned bearings or shafts incorrectly seated may cause vibration and noise in the front door.
  • Page 225 7525-xxx Align the duplex aligner guide so the gears (D) mesh on the left. Previous Next Go Back Replace the eight screws in the duplex aligner. Close the front door. Repair information 4-25...

  • Page 226: Duplex Sensor Removal

    7525-xxx Duplex sensor removal Previous Remove the waste toner container. See “Waste toner bottle” on page 4-72. Remove the two screws (A) from the cable channel cover. Next Go Back Pull the corner of the cable channel cover (B) away from the right side to access the sensor posts (C). Service Manual 4-26...
  • Page 227 7525-xxx If there is a plate on the side the latches of the sensor connected, remove the old adhesive plate (D). Previous Next Go Back Unlatch the sensor by pushing on the latches. Remove the sensor, and disconnect the cable (E) from the duplex sensor. Note: Close the front cover, and slightly lift the front of the printer to get better access.

  • Page 228: Fuser Assembly Removal

    7525-xxx Fuser assembly removal Previous Remove the right cover. See “Right cover removal” on page 4-7. Next Remove the left cover. See “Left cover removal” on page 4-4. Disconnect the two-wire fuser cable (A) from the LVPS. Position the fuser cable so that it can be pulled through from the front of the printer, and guide the cable to Go Back the front.
  • Page 229 7525-xxx Unhook the springs (D) from either side of the fuser. Previous Next Go Back Detach the geared belt (E) from the drive pulley on the fuser exit roll shaft. Note: Do not remove the pulley or spacer from the shaft. Rotate the top of the fuser toward the front, slide it to the left to align the fuser side frame with the flat areas of the shaft (F) and lift to remove the fuser.
  • Page 230 7525-xxx Previous Installation notes: • Install the narrow media sensor flag to the fuser before putting the fuser into the printer. Make sure the springs are resting on the top so they can be reached once the fuser is in place. •...

  • Page 231: Fuser Drive Motor Assembly Removal

    7525-xxx Fuser drive motor assembly removal Previous Open the front cover. Remove the right cover. See “Right cover removal” on page 4-7. Disconnect the cable (A) from the fuser drive motor assembly. Note: If you remove the toroid (B) from the cable, be sure to return the toroid to the cable when you re- Next install.

  • Page 232: Fuser Exit Sensor Removal

    7525-xxx Fuser exit sensor removal Previous Open the front cover. Remove the right cover assembly. See “Right cover removal” on page 4-7. Remove the left cover. See “Left cover removal” on page 4-4. Disconnect the two-wire fuser cable (A) from the LVPS. Next Note: You do not have to extract the cable.
  • Page 233 7525-xxx Unhook the springs (D) from both sides of the fuser. Previous Next Go Back Rotate the fuser toward the front of the printer until the screw (E) can be accessed, and removed. Disconnect the cable (G) from the fuser exit sensor. Remove the screw (F) securing the fuser exit sensor.

  • Page 234: High-Voltage Power Supply (Hvps) Assembly Removal

    7525-xxx High-voltage power supply (HVPS) assembly removal Previous Before you begin, unplug the printer and remove the imaging unit. See “Imaging unit (IU) removal” on page 4-45. Remove the rear shield. See “Rear shield removal” on page 4-7. Next Remove the cable cover (A). Go Back Disconnect the high-voltage power supply (HVPS) cable at the HVPS and at the controller board.

  • Page 235: High-Voltage Power Supply (Hvps) With Or Without Spring

    7525-xxx High-voltage power supply (HVPS) with or without spring Previous Remove the left cover. See “Left cover removal” on page 4-4. Is there a leaf spring (A) biasing the HVPS upward? If yes, then go to • “High-voltage power supply (HVPS) with spring” on page 4-37.

  • Page 236: High-Voltage Power Supply (Hvps) Without Spring

    7525-xxx High-voltage power supply (HVPS) without spring Previous Note: This removal requires a magnetized, long-shank Phillips screwdriver at least 8 in. or 200 mm long. Remove the top cover assembly. See “Top cover assembly removal” on page 4-9. Remove the screw (A). The screw is accessible from the top of the printer, and requires a long-shank, magnetized Phillips screwdriver.

  • Page 237: High-Voltage Power Supply (Hvps) With Spring

    7525-xxx High-voltage power supply (HVPS) with spring Previous Remove the screw (A) securing the HVPS. Next Go Back Press down on the spring as shown on the right below while pushing the HVPS toward the right or opposite side of the printer. After about 25mm, pull the HVPS out from the right side. Repair information 4-37...
  • Page 238 7525-xxx Installation notes: Previous CAUTION After disconnecting the high-voltage power cable from the controller board, always check that the HVPS connection was not loosened. Make this check anytime you are working near the HVPS cable. Next The following procedures apply to installing the new HVPS board. Go Back Note: It is recommended that the cable be attached to the HVPS before inserting the HVPS.
  • Page 239 7525-xxx Check the position of the card at the left side of the printer. The small vertical post (A) in the endcap Previous has to be positioned in the hole above it as shown. Next Go Back Install the new cable making sure the connector to the board is locked into position. Reinstall the screw to hold the HVPS on the right side of the printer.

  • Page 240: Image Transfer Unit (Itu)

    7525-xxx Image transfer unit (ITU) Previous Write down the number on the new ITU before installing it. You will need the 16-digit numeric value from the barcode after the installation, and it is easier to see at this point. Remove the right cover. See “Right cover removal”...
  • Page 241 7525-xxx Snap the new gear onto the shaft (D). The installation is the same as the old gear. Previous Next Go Back Repair information 4-41...
  • Page 242 7525-xxx Continuing the removal (with or without the spring clamp kit) Previous Disconnect the one spring (A) from the side frames, leaving them attached to the ITU or spring clamp. Next Go Back Rotate the left spring (B) and pivot the cam away from the ITU so the spring is held out of the ITU path. Service Manual 4-42...
  • Page 243 7525-xxx Rotate the release lever (C) in a counter clockwise direction with a spring hook or needlenose pliers to Previous decouple the ITU while pulling the ITU toward the front. Next Go Back Hold the release lever while removing the ITU. Repair information 4-43...
  • Page 244 7525-xxx Installation note: Previous • Write down the 16-digit numeric value of the new FRU before you begin to install it. You may have to rotate the release lever again to install the new ITU. • Rotate the spring clamp so it hooks over the new ITU (E). •...

  • Page 245: Imaging Unit (Iu) Removal

    7525-xxx Imaging unit (IU) removal Previous The Imaging unit is customer-replaceable unit and is not a FRU. Open the front cover. Lift the toner cover by sliding the latch to the left. Next Remove the waste toner bottle. See “Waste toner bottle” on page 4-72.
  • Page 246 7525-xxx Press and hold the release lever (B), and pull the imaging unit straight out. Previous Next Go Back Warning: When pulling the imaging unit out, Only grab the release levers (B) of the imaging unit.Do not touch the photoconductors in the bottom of the imaging unit. Service Manual 4-46...

  • Page 247: Developer Unit Removal

    7525-xxx Developer unit removal Previous The developer units are not FRUs. Raise the scanner unit, and remove the toner cartridges. Next Go Back Remove the imaging unit. See “Imaging unit (IU) removal”. Warning: Do not touch the underside of the imaging unit. This could damage the developer units. Remove the developer unit you need.

  • Page 248: Low-Voltage Power Supply (Lvps) Assembly

    7525-xxx Low-voltage power supply (LVPS) assembly Previous Next Remove the left cover. See “Left cover removal” on page 4-4. Disconnect the three cables (A) from the LVPS. Go Back Remove the six screws (B) and the ground cable connected to the LVPS cage. Remove the LVPS.
  • Page 249 7525-xxx If you receive a new low-voltage power supply with a voltage selector switch (C), be sure to set the Warning: Previous switch to the correct setting for your voltage requirements before installing the low-voltage power supply. The switch can be set for either 115 V or 230 V. Failure to do so will result in damage to the power supply.

  • Page 250: Lower Frame Removal, Right And Left

    7525-xxx Lower frame removal, right and left Previous The right and left lower frames are in the same FRU. Left lower frame Next Remove the media tray, and remove the screw (A) in front. Go Back Remove the waste toner bottle. See “Waste toner bottle”...
  • Page 251 7525-xxx At the rear of the printer, remove the two screws (C) from the AC receptacle, and the ground screw (D). Previous Next Go Back Remove the three screws (E) securing the left lower frame. Remove the LVPS. See Repair information 4-51...
  • Page 252 7525-xxx Remove the screw (F) on top of the frame. Previous Next Go Back Swing the left lower frame away from the printer, and remove. Service Manual 4-52...

  • Page 253: Right Lower Frame

    7525-xxx Right lower frame Previous Note: Remove the duplex sensor, the tray present sensor, the spring, spring holder, and the wireless antenna plate which are not part of the right and left lower frames. The cable cover is part of the right lower frame FRU. Note: To properly reinstall the duplex sensor and the tray present sensor, also order two sensor retaining plates.
  • Page 254 7525-xxx Remove the screw (C) securing the wireless antenna (Wireless models only) to access the right frame. Do Previous not remove the antenna. Next Go Back Remove the duplex sensor. See “Duplex sensor removal” on page 4-26. Remove the three screws (D) securing the lower right frame to the printer. Remove the screw (E) close to the front of the printer.
  • Page 255 7525-xxx Swing the rear part away from the printer to access the spring, and remove the spring (F) from the right Previous lower frame. Next Go Back Next to screw (E), lift the right lower frame pin (F) out of the hole in the printer frame. Repair information 4-55...
  • Page 256 7525-xxx Swing the rear part away from the printer to access the spring (G), and remove the spring (G) from the right Previous lower frame. Next Go Back Disconnect the cable (H) from the tray present sensor. Swing the rear of the lower frame away from the printer, and remove the right lower frame. Note: There are parts in the right lower frame that are not included in the frame.
  • Page 257 7525-xxx Remove the screw (L) and remove the spring bracket. Previous Note: For non-wireless models—Remove the screw (M), and remove plate from your printer if it does not have a wireless antenna. Next Go Back Installation notes: Reinstall the spring bracket, and the wireless antenna plate (or the blank plate, if this is not a wireless model).

  • Page 258: Main Drive Gear Assembly With Motor Removal

    7525-xxx Main drive gear assembly with motor removal Previous Next Remove the left cover. See “Left cover removal” on page 4-4. Remove the LVPS. See “Low-voltage power supply (LVPS) assembly” on page 4-48 Go Back Remove the screws (A) on the top cover. Remove the two screws (B) from the inside left side.
  • Page 259 7525-xxx Remove the screws securing the LVPS shield. Previous Unplug the cables (C) from the motors, and remove all cables from the retainer (D). Note: Observe the cable routing for reinstallation. Remove the two screws (E) from the rear. Next Go Back Remove the two screws (F) from below the main drive gear assembly.

  • Page 260: Pick Tires Removal-Integrated 250-Sheet Media Tray

    7525-xxx Pick tires removal—integrated 250-sheet media tray Previous Note: You will need to have a soft, padded work surface. Warning: Remove only the rubber tires and not the paper pick tire assembly to avoid losing small parts. The paper pick tires are located in the base printer. There are also tires in the optional 550-page media tray. If Next you have this additional option, and you are having problems with media picking, replace these tires also.

  • Page 261: Printhead Removal

    7525-xxx Printhead removal Previous Remove the scanner assembly. See“Flatbed removal” on page 4-77. Remove the top cover. See “Top cover assembly removal” on page 4-9. Disconnect the cables. Remove the toroid (A) from the ribbon cable. Next Go Back Remove the three screws (B). Remove the printhead.

  • Page 262: Imaging Unit (Iu) Removal

    7525-xxx Imaging unit (IU) removal Previous The imaging unit is customer replaceable unit and is not a FRU. Note: The imaging unit contains: Photoconductor unit • Next Developer units • To remove only the photoconductor, remove the entire imaging unit, remove the developer units, place the Go Back original developer units in the new photoconductor, and re-install the imaging unit.
  • Page 263 7525-xxx Pull the two latches until the imaging unit meets resistance. Previous Next Go Back Press and hold the handles (B), and pull the imaging unit straight out. Note: Do not wrap your fingers around the imaging unit. Avoid touching the bottom. Note: Store the imaging unit in a dark place or cover it with a blanket.

  • Page 264: Toner Cartridge Contacts

    7525-xxx Toner cartridge contacts Previous Remove the right cover assembly. See “Right cover removal” on page 4-7. Remove the waste toner bottle. See “Waste toner bottle” on page 4-72. Remove the imaging unit. See “Imaging unit (IU) removal” on page 4-45.
  • Page 265 7525-xxx Disconnect the cable (E) from the controller board at JSC1. Previous Next Go Back Remove the cable from the retainer on the bottom of the printer. Extract the cable through the frame, and remove the cable with the spring contacts. Repair information 4-65...

  • Page 266: Toner Meter Cycle (Tmc) Card Removal

    7525-xxx Toner meter cycle (TMC) card removal Previous Remove the right cover. See “Right cover removal” on page 4-7. Remove the waste toner container. See “Waste toner bottle” on page 4-72. Remove the imaging unit (IU). See “Imaging unit (IU) removal” on page 4-45.
  • Page 267 7525-xxx Installation note: Previous • Be sure the cable runs through the retainer. The toner meter cycle card is a tight fit. Insert the bottom edge inside the frame, and then push down on • the top edge to clear the top cover. In some cases the top cover will have to be loosened so the right edge of the top cover can be lifted to get •...

  • Page 268: Toner Density Sensor (Tps)-Left And Right Removal

    7525-xxx Toner density sensor (TPS)—left and right removal Previous The toner patch sensors are similar, but the left sensor includes an extra cable and sensing device. Remove them the same way. Remove the ITU. See “Image transfer unit (ITU)” on page 4-40.

  • Page 269: Tray Present Sensor Removal

    7525-xxx Continue entering and pausing. Previous After the 32nd number is entered and becomes solid, the number is automatically entered. If the number is incorrect, Checksum does not match appears, and the original screen appears to re- • enter the value. If the number is correct, Saving changes to NVRAM appears.
  • Page 270 7525-xxx Next to screw (D), lift the right lower frame pin (E) out of the hole in the printer frame. Previous Next Go Back Swing the rear of the lower frame away from the printer to access the tray present sensor latches. Remove and secure the spring (F) from the right lower frame.
  • Page 271 7525-xxx Remove the sensor retaining plate (G), and then pinch the latches together to remove the tray present Previous sensor. Next Go Back Installation notes: Clean the contact surface where you removed the sensor retaining plate, or where you need to install the new one.

  • Page 272: Usb Connector Removal

    7525-xxx USB connector removal Previous Remove the rear shield. See “Rear shield removal” on page 4-7. Disconnect the USB connector from the controller board. Remove the flatbed assembly. See “Flatbed removal” on page 4-77. Note: Do not remove the flatbed covers, or any of the hinges. The flatbed only needs to be removed from Next the print engine.

  • Page 273: Waste Toner Bottle Contact Block Removal

    7525-xxx Waste toner bottle contact block removal Previous Open the front cover. Remove the right cover assembly. See “Right cover removal” on page 4-7. Remove the waste toner bottle. See “Waste toner bottle” on page 4-72. Remove the screw (A) from the back of the waste toner bottle contact block Next Go Back Remove the rear shield.

  • Page 274: Wireless Network Antenna

    7525-xxx Wireless network antenna Previous Remove the rear shield. See “Rear shield removal” on page 4-7. Lift to disconnect the wireless card (A) from the controller board. Carefully disconnect the antenna cable (B) from the wireless card at the card. Next Go Back Remove the screw (C) that secures the antenna cover (D) to the frame, and remove the antenna cover and...
  • Page 275 7525-xxx Straighten the antenna perpendicular to the cover, push against the cover with your fingers, and gently Previous squeeze the fastener (E) with needlenose pliers. Slide the antenna cable and cable through the hole in the bracket. Next Go Back If the fastener is damaged, remove the fastener by pressing the tabs on each side.

  • Page 276: Wireless Network Card

    7525-xxx Wireless network card Previous Remove the rear shield. See “Rear shield removal” on page 4-7. Lift to remove the wireless card (A) from the controller board. Carefully disconnect the antenna cable (B) from the wireless card at the card. Next Go Back Service Manual...

  • Page 277: Scanner Component Removal Procedures

    7525-xxx Previous Scanner component removal procedures Flatbed removal Remove the AIO rear cable cover. See Next “AIO back cable cover removal” on page 4-8. Remove the rear shield. See “Rear shield removal” on page 4-7. Remove the left cover. See “Left cover removal”...
  • Page 278 7525-xxx Disconnect the USB cable from JUSB1, op panel cable from JOPP1, flatbed home sensor cable from Previous JHS1, and flatbed motor cable from JFBM1. Route the cables through the right side of the card cage. Disconnect the operator panel ground wire (C) from the LVPS. Next Go Back Thread the ground wire under the top cover.
  • Page 279 7525-xxx Disconnect the screw (D) connecting the flatbed to the AIO link on the rear of the MFP. Previous Next Go Back Carefully disconnect the AIO link from the flatbed. Remove the two screws (E) securing the flatbed hinge to the top cover. Remove the two springs (F) between the flatbed and top cover.
  • Page 280 7525-xxx Gently push the front flatbed hinge (G) towards the front of the top cover to disengage it from the top cover Previous guide Pin. Next Go Back Carefully pull the flatbed unit towards the front of the MFP while using your other hand to route the cables through the top cover.
  • Page 281 7525-xxx Remove the steel hinge stud (H). Save this for use on the replacement flatbed. Previous Next Go Back Remove the redrive (I) See“Redrive unit” on page 4-96., Remove the cable cover plates and scanner homing plates (J). These will be used on the replacement flatbed unit.
  • Page 282 7525-xxx Remove the screws (K) securing the flatbed link to the flatbed. Previous Next Go Back Remove the flatbed link; it will be used on the replacement flatbed unit. Note: The redrive, cable covers, operator panel assembly, scanner flatbed guides, op panel cable, and USB cable need to be transferred to the replacement flatbed unit.

  • Page 283: Preparing And Installing The New Flatbed

    7525-xxx Preparing and installing the new flatbed Previous Unbox the scanner, and place it top down on a non-marring surface. Next Go Back Unfold the ribbon cable, and replace the toroid (A) from the old flatbed. Repair information 4-83...
  • Page 284 7525-xxx Locate the folding guide line (B), and remove the paper from the adhesive strip located next to the folding Previous guide line on the scanner. Next Go Back Fold the ribbon cable at a 90 degree angle, align the fold of the cable with the fold line on the flatbed, and press the cable down on the adhesive so it adheres to the flatbed.
  • Page 285 7525-xxx Locate the second folding guide line (C), and remove the paper from the adhesive strip. Previous Next Go Back Fold the ribbon cable a second time at a 90 degree angle, align the fold of the cable with the fold line on the flatbed, and press the cable down on the adhesive so it adheres to the flatbed.

  • Page 286: Flatbed Pivot Link Removal

    7525-xxx Flatbed pivot link removal Previous Remove the AIO link. See “AIO link” on page 4-101. Remove the right scanner cover. See “Cover scanner right” on page 4-98. Remove the AIO release lever. See “AIO release lever” on page 4-100. Remove the screws (A) securing the flatbed link to the flatbed.

  • Page 287: Duplex Adf Rear Cover

    7525-xxx Duplex ADF rear cover Previous While lifting the ADF, use a flatblade screwdriver to pry open the three tabs (A) on the bottom of the ADF cover. Next Go Back Lift and remove the rear cover from the ADF assembly. Repair information 4-87...

  • Page 288: Duplex Adf Removal

    7525-xxx Duplex ADF removal Previous Remove the duplex ADF rear cover from the ADF assembly. See “Duplex ADF rear cover” on 4-87. Save the cover for use on the new ADF unit. page Disconnect the ground cable (A) from the ADF assembly. Next Go Back Disconnect the ADF cable (B) from the ADF card located on the ADF assembly.

  • Page 289: Simplex Adf Rear Cover

    7525-xxx Simplex ADF rear cover Previous While lifting the ADF, use a flatblade screwdriver to pry open the two tabs on the bottom of the ADF cover. Lift and remove the rear cover from the ADF assembly. Simplex ADF removal Next Tilt the flatbed cover to the upright position.

  • Page 290: Adf Cable Removal

    7525-xxx ADF cable removal Previous Remove the simplex, or duplex ADF rear cover. See Remove the left cover.See “Left cover removal” on page 4-4 Remove the AIO back cable cover.See “AIO back cable cover removal” on page 4-8 Remove the rear shield. See “Rear shield removal”...
  • Page 291 7525-xxx With your right hand, pull the relay card end of the ADF cable up and away from the ADF while using your Previous left hand to guide the ADF cable up through the card cage opening. Next Go Back Note: Be careful to avoid contact with the CCD ribbon cable.

  • Page 292: Adf Separator Pad

    7525-xxx ADF separator pad Previous Remove the ADF separator roll. See “ADF separator roll assembly” on page 4-93. Pinch the two tabs on each side of the pad inward. Next Go Back Tilt the pad up, and lift it out of the ADF assembly. Service Manual 4-92...

  • Page 293: Adf Separator Roll Assembly

    7525-xxx ADF separator roll assembly Previous Lift the locking lever (A). Next Go Back Slightly lift the separator roll assembly, and pull it out of the mount (B) on the opposite side. Repair information 4-93...

  • Page 294: Bezel Cover

    7525-xxx Bezel cover Previous Remove the op panel bezel. See “Op panel bezel removal” on page 4-105. Remove the two screws (A) securing the bezel cover to the top of the op panel mounting frame. Next Go Back Remove the AIO link. See “AIO link”...
  • Page 295 7525-xxx While holding the op panel mounting assembly, remove the op panel bezel cover. Previous Next Go Back Repair information 4-95...

  • Page 296: Redrive Unit

    7525-xxx Redrive unit Previous Remove the flatbed assembly from the MFP. See “Flatbed removal” on page 4-77. Place the flatbed facedown on a soft surface to avoid scratching the glass or marring the covers. Remove the cable cover plate (A). Next Go Back Remove the four screws (B) securing the redrive to the flatbed unit.

  • Page 297: Cover Scanner Left

    7525-xxx Cover scanner left Previous Remove the flatbed assembly. See “Flatbed removal” on page 4-77. Release the tabs (A) securing the left flatbed cover to the flatbed unit using a small flatblade screwdriver. Next Go Back Repair information 4-97...

  • Page 298: Cover Scanner Right

    7525-xxx Cover scanner right Previous Remove the imaging unit in the print engine. Raise the scanner assembly to the up position, and lock in place. Remove the four screws (A) securing the right scanner cover to the flatbed unit. Next Go Back Service Manual 4-98...
  • Page 299 7525-xxx While holding the ADF away from the flatbed, use the other hand to lift and disengage the right scanner Previous cover from the flatbed unit. Next Go Back Repair information 4-99...

  • Page 300: Aio Release Lever

    7525-xxx AIO release lever Previous Remove the right scanner cover. See “Cover scanner right” on page 4-98. Remove the screw (A) securing the AIO link to the flatbed unit. Next Go Back Disengage the AIO link from the flatbed unit. Remove the screw (B) securing the AIO release lever to the flatbed.

  • Page 301: Aio Link

    7525-xxx AIO link Previous Lift the scanner to the up position. Use a phillips screwdriver to remove the screw (A) securing the AIO link to the AIO toner cover. Next Go Back Return the flatbed to the down position. Remove the screw (B) securing the AIO link to the flatbed unit. Repair information 4-101...

  • Page 302: Aio Toner Cover

    7525-xxx AIO toner cover Previous Lift the scanner unit to the up position. Remove the screw (A) fastening the AIO toner cover to the scanner unit. Next Go Back Remove the screws (B) securing the AIO hinge to the MFP. Remove the hinge (C).

  • Page 303: Operator Panel Removal

    7525-xxx Operator panel removal Previous When replacing any one of the following components: Warning: • Operator panel assembly Controller board • Next Replace only one component at a time. Replace the required component, and perform a POR before replacing a second component listed above.
  • Page 304 7525-xxx Disconnect the operator panel cable (B). Previous Next Go Back Remove the two screws (C) attaching the USB connector to the operator panel. Set the USB connector aside to attach to the new operator panel. Note: The USB is only used on certain X544 and X546 models. Remove the ground wire from the op panel.

  • Page 305: Op Panel Bezel Removal

    7525-xxx Op panel bezel removal Previous Place a flatbed screwdriver under the front of the bezel. Next Go Back Pry the bezel up and away from the op panel. Be careful to avoid marring the bezel cover. Repair information 4-105...

  • Page 306: Op Panel Cable

    7525-xxx Op panel cable Previous Remove the operator panel bezel cover. Remove the operator panel. See “Operator panel removal” on page 4-103. Remove the flatbed assembly. See “Flatbed removal” on page 4-77. Remove the CCD cable cover. Next Go Back Unroute the operator panel cable through the tabs (B).

  • Page 307: Fax Card Removal

    7525-xxx Pull the logo cover away from the op panel bezel cover. Previous Next Go Back Fax card removal Remove the rear shield. See “Rear shield removal” on page 4-7. Disconnect the fax interface cable from the fax card. See “Fax interface cable”...

  • Page 308: Output Bin Tray

    7525-xxx Output bin tray Previous Grasp and lift the rear output bin tray away from the MFP. Next Go Back Bin full flag removal Lift the scanner assembly and lock it into the up position. Gently disconnect the three snaps (A) from the rear shaft of redrive unit. Remove the bin full flag.

  • Page 309: Locations

    7525-xxx 5. Locations Previous Exterior views Next Front Go Back Front view Callout Part name Operator panel ADF input tray Output bin AIO release Right imaging unit cover (right cover) Primary paper tray Manual feeder Multipurpose feeder Locations...

  • Page 310: Rear

    7525-xxx Rear Previous Next Go Back Rear view Callout Part name Power Line Extension Ethernet Wireless antenna Service Manual...

  • Page 311: Interior View

    7525-xxx Interior view Previous Next Go Back Locations...

  • Page 312: Printer Boards

    7525-xxx Printer boards Previous Controller Board Next Go Back Service Manual...

  • Page 313: Connectors

    7525-xxx Connectors Previous Controller board Connector Pin no. Signal JUSB1 Port Ground Next USB_5V_Sense USB D- Go Back USB D+ Ground Ground JUSBW1 Ground USB_HST_VP USB_HST_VM Ground +3.3 V +3.3V JFAN1 FAN_FG, 3.3V Ground V_FAN_P3 JMIRR1 MM_REFR MM_LOCK, +3.3 V dc MM_START +24V_VC JCTM1...
  • Page 314 7525-xxx Controller board Previous Connector Pin no. Signal JMOD2 NC_30V_CUHD NC_JMOD2_2 Next POR_CHUD_R- +3.3V Go Back +3.3V NC_TONE_CUHD IRQ_CUHD Ground SDA_CUHD Ground SCL_CUHD Ground CLK_CUHD Ground SDO_CUHD Ground SDI_CUHD Ground CS_CUHD Service Manual...
  • Page 315 7525-xxx Controller board Previous Connector Pin no. Signal JPH1 VDO_HSYNC1_C, + 5 V dc VDO_PH_OK, +3.3 V dc Next VDO_HSYNC0, + 5 V dc VDO_LEN0, +3.3 V dc Go Back VDO_BOOST3 +3.3V VDO_BOOST1 +5V_PH, + 5 V dc VDO_BOOST2 (Shade B) +5V_PH, + 5 V dc VDO_BOOST0 Ground...
  • Page 316 7525-xxx Controller board Previous Connector Pin no. Signal JPH1 (continued) Ground D_VDO_2+ Next D_VDO_2- Ground Go Back D_VDO_5+ D_VDO_5- Ground D_VDO_1+ D_VDO_1- Ground D_VDO_4+ D_VDO_4- Ground D_VDO_0+ D_VDO_0- Ground I2CCLK_PH VDO_LADJ1, + 3.3 V dc I2CDATA_PH VDO_LADJ, + 3.3 V dc Service Manual...
  • Page 317 7525-xxx Controller board Previous Connector Pin no. Signal JCCD1 - CCD ribbon cable FBR_AFE_SDI FBR_AFE_SCK Next FBR_AFE_SEN Go Back FBR_AFE_D(0) FBR_AFE_D(1) FBR_AFE_D(2) FBR_AFE_D(3) FBR_AFE_D(4) FBR_AFE_D(5) FBR_AFE_D(6) FBR_AFE_D(7) FB_AFE_VSMP_R FB_AFE_RSMP_R FB_CCD_CLK_R FB_CCD_CLAMP_R FB_CCD_RESET_R FB_CCD_PHASE1_R FB_CCD_PHASE2_R FBR_CCD_TRANSFER +14V +14V FB_POWER_SAVER FB_LAMP_ON Locations...
  • Page 318 7525-xxx Controller board Previous Connector Pin no. Signal JHS - Home Sensor GNDS Next HOME_C JFBM1 - Flatbed Motor FBA- Go Back FBB- JADF - ADF connector I0A_ADF_C I1A_ADF_C DIRA_ADF_C I0B_ADF_C I1B_ADF_C DIRB_ADF_C +24V +24V PAP_PRES2_2 PAP_PRES3_C VREF2_ADF_C PAP_PRES_C ADF_CVR_C FIRST_SCAN_C FB_CVR_C SOL_EN_2...
  • Page 319 7525-xxx Controller board Previous Connector Pin no. Signal JOPP1 I2C_DATA, +5V dc V_PANEL+5V Next I2C_CLK Ground Go Back OP_IRQ_N, +4.5V dc +3.3 Ground JWT1 SENSE VREF JCVR1 V_24V_CVR, +24V dc COVER_OPEN (cover open +0V dc; closed: +24V JINT1 +5V Fused Ground VS_INT, +5 V dc (door closed), 0V dc (door open) JTRAY1...
  • Page 320 7525-xxx Controller board Previous Connector Pin no. Signal JPJP1 +5V_SW PAPER_JAM_DET Next Ground JBIN1 V_BF Go Back S_BIN_FB, +3.3V dc Ground V_BIN_4 FUSER_EXIT_SNSR, +3.3V dc Ground JHVPS1 M_DEV_PWM_OUT K_DEV_PWM_OUT C_DEV_PWM_OUT CMY_CHG_PWM_OUT Y_DEV_PWM_OUT K_CHG_PWM_OUT CMY_SRVO_OUT, +3.3 V dc ITM_TX_PWM_OUT CMY_TX_PWM_OUT ITM_SRVO_OUT, +3.3 V dc K_SRVO_OUT, +3.3 V dc K_TX_PWM_OUT +24V...
  • Page 321 7525-xxx Controller board Previous Connector Pin no. Signal JCARTB1 CART1_HALL_U NC_CARTB1_2 Next CART1_HALL_V V_CART2_WIND_W Go Back CART1_HALL_W V_CART2_WIND_V CART1_PG V_CART2_WIND_U Ground Ground V_CART1_WIND_U CART2_PG V_CART1_WIND_V V_CART1_WIND_W V_CART1_WIND_W V_CART1_WIND_V NC_JCARTR1_19 V_CART1_WIND_U JSP1 ANODE (no wire) M1_OUT1, +24 V dc (0V dc with door open) CATHODE M1_OUT2, +24 V dc (0V dc with door open) (+5V SW) VCC...
  • Page 322 7525-xxx Controller board Previous Connector Pin no. Signal JLVPS1 Ground Next Ground Go Back Ground +24VC Ground +24VC Ground +24VC Ground RELAY_DRIVE ZERO_XING_IN HEAT1_ON JOPT1 TXD_PP Ground Ground RXD_PP +24V Ground +5V_OPTIONS, +5 V dc Ground Ground Service Manual 5-14...

  • Page 323: Hvps

    7525-xxx HVPS Previous Next Go Back Locations 5-15...

  • Page 324: Connectors

    7525-xxx Connectors Previous HVPS board Connector Pin no. Signal Connection from controller board M-Drpwm Next K-Drpwm C-Drpwm Go Back CMY-Chrgpwm Y-Drpwm K-Chrgpwm CMY-Srvo_Out I-Txpwm CMY-Txpwm I-Srvo_Out K-Srvo_Out K-Txpwm +24V +24VRtn VREF Buffered +24VRtn Contacts to machine I-Transfer CMY-Transfer K-Transfer K-Charge CMY-Charge K-DR Blade M-DR Blade...

  • Page 325: Lvps

    7525-xxx LVPS Previous Next Go Back Locations 5-17...

  • Page 326: Connectors

    7525-xxx Connectors Previous LVPS board Connector Pin no. Signal Next Ground Go Back Ground Ground +25V Ground +25V Ground +25V Ground Relay Drive ZC Out Heat On AC phase input AC neutral input AC Out AC load phase Service Manual 5-18...

  • Page 327: Toner Meter Card

    7525-xxx Toner meter card Previous Next Go Back Toner meter card connectors Toner meter card Connector Pin no. Signal From JCTM1 connector on the +5 V_SW controller board Cart_Meter_C_IN Cart_Meter_M_IN Cart_Meter_Y_IN Cart_Meter_K_IN Ground Locations 5-19...

  • Page 328: Wireless Card

    7525-xxx Wireless card Previous Next Go Back Connectors Wireless card Connector Pin no. Signal From JUSBW1 on controller Ground USB_HST_VP USB_HST_VM Ground Wireless_POR Service Manual 5-20...

  • Page 329: Preventive Maintenance

    Damaged, missing, or altered parts, especially in the area of the On/Off switch and the power supply • Damaged, missing, or altered covers, especially in the area of the top cover and the power supply cover • Possible safety exposure from any non-Lexmark attachments • Scheduled maintenance Maintenance kit After 60,000 printed pages (sides) a maintenance kit may be required.
  • Page 330 7525-xxx Previous Next Go Back Service Manual...

  • Page 331: Parts Catalog

    PP: (Parts Packet) in the parts description column indicates the part is contained in a parts packet. • Model information used in the parts catalog: • Machine type/model Term used in parts Product name Description 7525-131 Lexmark X543dn Network, duplex print 7525-133 Lexmark X543dn Network, duplex print, DBCS op panel 7525-138 Lexmark X543dn Network, duplex print,...
  • Page 332 7525-xxx Previous Machine type/model Term used in parts Product name Description 7525-393 Lexmark X546dtn Duplex scan/print, DBCS op panel 7525-396 Lexmark X546dtn Duplex scan/print, Fax Next 7525-397 Lexmark X546dtn Duplex scan/print, DBCS op panel, Fax Go Back A dtn version of this model is available. This version includes the 650-sheet tray.
  • Page 333 7525-xxx Previous Next Go Back Parts catalog...

  • Page 334: Assembly 1: Covers

    7525-xxx Assembly 1: Covers Previous Next Go Back Service Manual...
  • Page 335 7525-xxx Assembly 1: Covers Previous Asm- Part Units/ Units/ Description index number mach 40X5484 Tray, Output Bin Next 40X5489 Cover, AIO Back Cable 40X5482 Assembly, Top Cover 40X5537 Link, AIO Go Back 40X5534 Cover, AIO Toner 40X5486 Cover, Right AIO 40X5419 Tray Asm, 250 sheet 40X5168...

  • Page 336: Assembly 2: Scanner

    7525-xxx Assembly 2: Scanner Previous Next Go Back Service Manual...
  • Page 337 7525-xxx Assembly 2: Scanner Previous Asm- Part Units/ Units/ Description index number mach 40X5470 Tray, ADF input Next 40X5477 Cover, ADF rear simplex 40X5478 Cover, ADF rear duplex 40X5479 Cable, ADF Go Back 40X5872 Bin full flag 40X5467 Asm, Flatbed 40X8342 Asm, redrive 40X5536...
  • Page 338 7525-xxx Assembly 2 (continued): Scanner Previous Next Go Back Service Manual...
  • Page 339 7525-xxx Assembly 2 (continued): Scanner Previous Asm- Part Units/ Units/ Description index number mach 40X5514 Bezel, op panel 3-1 (Finnish Next 40X2602 X546 Finnish operator panel bezel 40X5509 Bezel, op panel 4-1 (Italian) 40X5510 Bezel, op panel 3-1 (Italian) Go Back 40X2517 X546 Italian operator panel bezel 40X5523...

  • Page 340: Assembly 3: Paperpath

    7525-xxx Assembly 3: Paperpath Previous Next Go Back Service Manual 7-10...
  • Page 341 7525-xxx Assembly 3: Paperpath Previous Asm- Part Units/ Units/ Description index number mach 40X5411 Printhead Next 40X5415 Fuser drive motor assembly 40X5422 Bottom left and right frame and cable cover 40X5424 Screw packet, miscellaneous screws Go Back • TAPTITE M3 L6 PANHD(4) •...

  • Page 342: Assembly 4: Electronics 1

    7525-xxx Assembly 4: Electronics 1 Previous Next Go Back Service Manual 7-12...
  • Page 343 Previous Asm- Part Units/ Units/ Description index number option 40X1524 Controller board,X544/X546 40X1523 Controller board, X543 Next 40X5319 Wireless antenna 40X5036 Wireless card assembly Go Back 40X5404 Toner meter cycle card assembly 40X8395 High-voltage power supply 40X5426 Photo sensor (one per package) used for...

  • Page 344: Assembly 5: Electronics 2

    7525-xxx Assembly 5: Electronics 2 Previous Next Go Back Service Manual 7-14...
  • Page 345 7525-xxx Assembly 5 (continued): Electronics 2 Previous Asm- Part Units/ Units/ Description index number option 40X5429 ITU paper path thermistor Next 40X5414 Toner density sensors, left or right (one in package) 40X7046 Waste toner bottle contact block 40X5421 Imaging unit contact (Pogo pin) Go Back 40X5423 Cable packet, used for:...

  • Page 346: Assembly 6: Media Drawers And Trays

    7525-xxx Assembly 6: Media drawers and trays Previous Next Go Back Service Manual 7-16...
  • Page 347 7525-xxx Assembly 6: Media drawers and trays Previous Asm- Part Units/ Units/ Description Index number opt. Asm- Part Units/ Units/ Description Index number opt. Next 5—1 40X6997 Optional 650-sheet Duo Drawer (complete)— (includes 100-sheet MPF) 40X5168 Pick tires Go Back 40X2285 650-sheet Duo Drawer tray assembly (includes 100-sheet MPF) 40X8341...

  • Page 348: Assembly 7: Options

    7525-xxx Assembly 7: Options Previous Asm- Part Units/ Units/ Description Index number opt. 6—NS 40X2254 115 V Maintenance kit (fuser, ITU, duplex reference edge) Next 40X2255 230 V Maintenance kit (fuser, ITU, duplex reference edge) 40X2261 100 V Maintenance kit (fuser, ITU, duplex reference edge) Go Back 40X5937 128MB DDR DRAM DIMM card assembly...

  • Page 349: Index

    7525-xxx Index Previous removal Numerics 4-74 Next attendance messages 1xx service errors –?? 2-15 Auto Color Adj 3-34 1xx, 8xx, 9xx error codes 2-15 autocompensator mechanism (ACM) 2xx paper jam service checks 2-36 Go Back messages ??– 2-14 2xx paper jam messages locations 3-40 bezel cover...
  • Page 350 7525-xxx removals defaults 3-19 Previous engine setting 1 through 4 3-19 model name 3-19 data streams page counts 3-19 dead printer service check 2-38 serial number 3-19 defaults printer setup 3-19 factory defaults Next 3-33 REGISTRATION Demo Mode 3-33 Bottom Margin developer unit Left Margin removal...
  • Page 351 Lexmark confidential until announce 7525-xxx factory defaults 3-33 Previous fax card parts catalog 7-10 removal 4-107 fax interface cable jam locations 3-40 removal 4-107 fax reception service check 2-77 Next fax specifications 1-18 LCD operator panel 4-103 miscellaneous 1-18 left scanner cover...
  • Page 352 7525-xxx print quality Previous background 2-52 Op panel bezel blank page 2-53 removal 4-105 blurred or fuzzy print 2-55 Op panel cable half-color page 2-55 removal 4-106 horizontal banding 2-55 operating modes Next horizontal line 2-56 Operator panel insufficient fusing 2-56 removal 4-103...
  • Page 353 Lexmark confidential until announce 7525-xxx left cover scan fax and copy symptoms Previous rear shield Scanner ASIC test 3-25 right cover scanner covers scanner left parts catalog 4-97 scanner right Scanner manual registration 4-98 3-35 top cover SE Menu 3-38...
  • Page 354 7525-xxx ADF cover open tray (x) 2-70 Previous ADF duplex service check parts catalog 2-73 7-16 ADF feed errors 2-72 ADF paper am 2-71 USB connector black page or blank page 2-68 removal 4-72 CCD service check 2-68 USB scan to local Next 3-31 escalating a fax issue to second-level support...
  • Page 355 7525-xxx Part number index Previous Description Page Next 100V fuser assembly(40X7564) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-11 128MB DDR DRAM DIMM card assembly (40X5937) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-18...
  • Page 356 7525-xxx AIO release lever (40X5536) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Previous AIO toner cover (40X5534) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Bezel cover (40X5533) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -...
  • Page 357 7525-xxx Op panel bezel 3-1 Korean(40X5532) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Previous Op panel bezel 3-1 Norwegian(40X5516) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Op panel bezel 3-1 Polish(40X5522) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -...
  • Page 358 7525-xxx Previous X546 Braz Por operator panel bezel(40X2515) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - X546 Czech operator panel bezel(40X2689) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - X546 Danish operator panel bezel(40X2519) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - X546 Dutch operator panel bezel(40X2518) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -...

  • Page 359: Part Number Index

    7525-xxx Previous Next Go Back Part number index I-11...

This manual is also suitable for:

X546X544

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