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Lexmark X543 Service Manual

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Page 201

Repair information4-17
Lexmark confidential until announce7525xxx
Duplex sensor removal 
1.Open the toner supply cover.
2.Open the front cover.
3.Remove the right cover. See “Right cover removal” on page 4-7. 
4.Remove the waste toner container. See “Waste toner bottle” on page 4-49. 
5.Remove the two screws (A) from the cable channel cover. 

Page 202

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6.Pull the corner of the cable channel cover (B) away from the right side to access the sensor posts (C). 
Unclip the sensor.
7.Remove the sensor, and disconnect the cable (D) from the duplex sensor.
Note:  Close the front cover, and slightly lift the front of the printer to get better access. 

Page 203

Repair information4-19
Lexmark confidential until announce7525xxx
Fuser assembly removal
1.Remove the right cover. See “Right cover removal” on page 4-7.
2.Remove the left cover. See “Left cover removal” on page 4-4.
3.Disconnect the two-wire fuser cable (A) from the LVPS.
4.Position the fuser cable so that it can be pulled through from the front of the printer, and guide the cable to 
the front.
Warning:  Be careful not to damage the cable by pulling too hard or cutting the cable insulation
5.Remove the...

Page 204

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7.Unhook the springs (D) from either side of the fuser.
8.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.
9.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.
Warning:  Be careful to not interfere with or damage the fuser exit sensor to the...

Page 205

Repair information4-21
Lexmark confidential until announce7525xxx
Installation notes:
Make sure the springs are resting on the top so they can be reached once the fuser is in place.
When reinstalling on the right, make sure the gears mesh.
Be careful not to interfere with the exit sensor on the left side.
Reroute the cables back through their retainers. 

Page 206

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Fuser drive motor assembly removal
1.Open the front cover. 
2.Remove the right cover. See “Right cover removal” on page 4-7.
3.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-
install.
4.Remove the two screws (C).
5.Remove the fuser drive motor assembly. 

Page 207

Repair information4-23
Lexmark confidential until announce7525xxx
Fuser exit sensor removal
1.Open the front cover. 
2.Remove the fuser assembly. See “Fuser assembly removal” on page 4-19.
3.Remove the screw (A) securing the fuser exit sensor.
4.Disconnect the cable (B) from the fuser exit sensor.
5.Remove the lower end of the sensor with a flat blade screwdriver, and gently pull the sensor from the 
bracket.
6.Remove the sensor. 

Page 208

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High-voltage power supply (HVPS) assembly removal
Note:  This removal requires a magnetized, short-handled Phillips head screwdriver.
1.Remove the top cover assembly. See “Top cover assembly removal” on page 4-9.
2.Remove the rear shield. See “Rear shield removal” on page 4-7.
3.Remove controller board. See “Controller board removal” on page 4-16.
4.Remove the cable cover (A).
5.Disconnect the high-voltage power supply (HVPS) cable at the...

Page 209

Repair information4-25
Lexmark confidential until announce7525xxx
8.Carefully slide the HVPS out.
Installation notes: 
When replacing the HVPS, loosely replace screw (C), replace (tighten) screw (B), and tighten screw (C). Also 
make sure that the HVPS cable is securely connected to the controller board and the HVPS unit.
Image transfer unit (ITU)
1.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...

Page 210

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6.Disconnect the two springs (A) from the side frames, leaving them attached to the ITU at the moment.
7.Rotate the left spring (B) and pivot the cam away from the ITU so the spring is held out of the ITU path. 
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