Lexmark X543 Service Manual

							Diagnostic information2-47
Lexmark confidential until announce7525xxx
Operator panel display is dim and unchanging
Op panel USB cable service check
USB service check
Step Questions / actions Yes No
1Turn off the printer, and remove the rear shield. 
See “Rear shield removal” on page 4-7. 
Disconnect the cable at JOPP1 on the 
controller board. Verify the following values:
Are all these values approximately correct?Go to step 2. Replace the controller 
board. See “Controller 
board removal” on 
page 4-16.
2Check for continuity in the operator panel cable 
connector.
Do all the conductors indicate continuity?Replace the operator panel. 
See “Operator panel 
removal” on page 4-76. Replace the operator panel 
cable. See “Op panel 
cable” on page 4-79. 
Step Questions / actions Yes No
1 Check the op panel USB cable for continuity.
Is there continuity?Replace the controller 
board. See “Controller 
board removal” on 
page 4-16Replace the Op panel USB 
cable.
Step Questions / actions Yes No
1 Is the USB cable properly connected to the 
MFP and host PC? Go to step 2. Properly connect the cable 
at both ends.
2 Try a different USB cable. Does this fix the 
issue?Issue fixed. Go to step 3.
3 Connect a different device to the USB cable. 
Did the host PC see the device?Replace the RIP/system 
board.See “Controller 
board removal” on 
page 4-16.There is an issue with the 
host machine.
JOPP1
Pin Voltage
10 V dc
2 +5 V dc
30 V dc
4 Ground
5 +5 V dc
6 +3.3 V dc
7 Ground 
						

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Networking service check
Note:  Before starting this service check, print out the network setup page. This page is found under Menu - 
Reports - Network Settings. Consult the network administrator to verify that the physical and wireless network 
settings displayed on the network settings page for the device are properly configured. If a wireless network is 
used, verify that the printer is in range of the host computer or wireless access point, and there is no electronic 
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.
Step Questions / actions Yes No
1If the device is physically connected to the 
network, verify that the ethernet cable is 
properly connected on both ends. 
Is the cable properly connected?Go to step 3.
If the network is wireless, 
got to step 3.Go to step 2.
2Connect the ethernet cable.
Did this fix the problem?Problem resolved Go to step 3.
3Check the printer’s online status under Printers 
and Faxes on the host computer. Delete all 
print jobs in the print queue.
Is the printer online and in a Ready state.Go to step 5. Go to step 4.
4Change the printer status to online.
Did this fix the issue?Problem resolved. Go to step 5.
5Does the IP address displayed on the network 
settings page match the IP address in the port 
of the drivers using the printer?Go to step 10. Go to step 6.
6Does the LAN use DHCP?
Note: A printer should use a static IP 
address on a network.Go to step 7. Go to step 9.
7Are the first two segments if the IP address 
169.254?Go to step 8. Go to step 9
8POR the printer. 
Is the problem resolvedProblem resolved Go to step 10.
9Reset the address on the printer to match the 
IP address on the driver.
Did this resolve the issue?Problem fixed. Go to step 10.
10Have the network admin verify that the printer 
and PC’s IP address have identical subnet 
addresses. 
Are the subnet addresses the same?Go to step 12. Go to step 11.
11Using the subnet address supplied by the 
network admin, assign a unique IP address to 
the printer. 
Note: The printer IP address should match 
the IP address on the printer driver.
Did this fix the problem?Problem resolved. Go to step 12.
12Is the device physically connected (ethernet 
cable) to the network?Go to step 13. Go to step15. 
						

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13Try using a different ethernet cable.
Did this remedy the situation?Problem resolved Go to step 14.
14Have the network administrator check the 
network drop for activity.
Is the drop functioning properly?Replace the controller 
board. Go to “Controller 
board removal” on 
page 4-16Contact the network 
administrator.
15Is the printer on the same wireless network as 
the other devices?Go to step 17. Go to step 16.
16Assign the correct wireless network to the 
printer.
Did this fix the problem?Problem resolved Go to step 17.
17Are the other devices on the wireless network 
communicating properly?Go to step 18. Contact the network 
administrator.
18Verify that the wireless card is properly seated 
on the controller board. 
Is the wireless card seated correctly?Go to step 20. Go to step 19.
19Properly reseat the wireless card.
Did this fix the problem?Problem resolved. Go to step 20.
20Is the antenna damaged? Go to step 22. Go to step 21.
21Replace the antenna.
Did this fix the problem?Problem resolved Go to step 22.
22Verify that the antenna is properly connected 
to the wireless card. 
Is it connected correctly?Go to step 24. Go to step 23.
23Properly connect the antenna. 
Did this fix the problem?Problem resolved Go to step 24.
24Check pin 6 for +3.3V, and Pin 5 for +5V. on 
connector JUSBW1 of the controller board. Pin 
1 and 4 are GND. 
Are the voltages and GNDs correct?Replace the wireless card. 
Go to “Wireless network 
card” on page 4-52Replace the controller 
board. Go to “Controller 
board removal” on 
page 4-16 Step Questions / actions Yes No 
						

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Print quality service check
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 customers permission, 
you may need to install a developer (toner) cartridge or photo conductor unit.
Service tip
Before troubleshooting any print quality problems, do the following:
1.Print a menu settings page, and check the life status of all supplies. Any supplies that are low should be 
replaced.
To print a menu settings page:
a.press Menu ( ) on the operator panel.
b.Select Reports from the Admin Menu, and press Select ().
c.Select Menu Settings, and press Select ().
Note:  Be sure and keep the original menu page to restore the customers custom settings if needed.
2.On the menu page, make sure the following is set to the default level:
–Color Correction: Set to Auto.
–Print Resolution: Set to 1200 dpi (print quality problems should be checked at different resolution 
settings).
–Toner Darkness: Set to 4 (default).
–Color Saver: Set to OFF.
–RGB Brightness, RGB Contrast, RGB Saturation: Set to 0.
–Color Balance: Select Reset Defaults to zero out all colors.
–Check the paper type, texture and weight settings against what is loaded in the printer.
Once the printer has been restored to its default levels, do the following:
1.Inspect the imaging unit for damage, including the developers and toner cartridges. Replace if damaged.
2.If paper other than 20lb plain letter/A4 paper is being used, load 20lb plain letter/A4.
3.Print the Print Quality pages to see if the problem remains. Look for variations in the print from what is 
expected.
To print the print Quality pages
a.Enter Diagnostics (turn off the printer, press and hold Left ( ) and Select ( ), turn on the printer 
and release when the installed memory and processor speed displays).
b.Select PRINT TESTS, and press Select (). 
c.Select Print Quality Pgs, and press Select ().
The message Printing Quality Test Pages is displayed. 
An incorrect printer driver for the installed software can cause problems. Incorrect characters could print, and the 
copy may not fit the page correctly.
Measure all voltages from the connector to the printer ground.  
						

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Print quality—background
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.
Step Questions / actions Yes No
1Read the current status of the imaging unit 
from the customer menus. 
To view the status of the photoconductor units:
1. In Ready mode, press Menus ().
2. Select Reports, and press Select ( ). 
3. Select Device Statistics, and press 
Select().
It is possible a new imaging unit was installed, 
but the counter was not reset. 
Has the imaging unit been recently replaced?Reset the value. To reset 
this value:
1. In Ready mode, press 
Menus ().
2. Select Supplies Menu, 
and press Select ().
3. Select Replace Supply, 
and press Select ().
4. Select the imaging unit 
you want to change, and 
press Select ().
5. Select Ye s, and press 
Select ().
If this does not fix the 
problem, go to step 2.Go to step 2.
2Is the background only one of the primary 
colors; yellow, cyan, magenta, or black?Replace the developer unit 
for the background color and 
retest. See “Developer unit 
removal” on page 4-30. 
Go to step 3.Go to step 4.
3Did replacing the developer unit correct the 
problem?Problem resolved. Go to step 4.
4Replace the photoconductor unit. 
Does this fix the problem?Problem resolved. Go to step 5.
5Check the high-voltage contact from the HVPS 
to the image transfer unit (ITU).
Is a problem found?Replace the failing part:
 Image transfer unit 
(ITU). See “Image 
transfer unit (ITU)” on 
page 4-25.
 High-voltage power 
supply (HVPS). See 
“High-voltag e power 
supply (HVPS) 
assembly removal” on 
page 4-24. Go to step 6.
6Reseat the cable in the JHVPS1 connector.
Does this fix the problem?Problem resolved. Go to step 7.
7Replace the HVPS. See “High-voltage power 
supply (HVPS) assembly removal” on 
page 4-24.
Does this fix the problem?Problem resolved. Go to step 8. 
						

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Print quality—blank page
8Clean the printhead.
Does this fix the problem?Problem resolved. Replace the printhead. See 
“Printhead removal” on 
page 4-42.
Step Questions / actions Yes No
1Is all the packing material for the imaging unit 
in question removed?Go to step 2. Remove the packing 
material.
2Print a document that requires all four colors 
with just a few characters to verify if one 
specific color is a problem. For example, print 
the Print Quality Test Pages:
1. Enter Diagnostic mode. (Turn the printer 
off, press and hold Left ( ) and 
Select( ), turn the printer on, and then 
release the buttons when the installed 
memory and processor speed displays.)
2. Select PRINT TESTS, and press 
Select().
3. Select Prt Qual Pgs, and press 
Select().
Is only one color missing?Replace the developer unit 
for the missing color.Go to step 3.
3Replace the imaging unit. See “Imaging unit 
(IU) removal” on page 4-28.
Does this fix the problem?Problem resolved. Go to step 4. Step Questions / actions Yes No 
						

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4Enter the Diagnostics Menu (turn the printer 
off, press and hold   and  , turn the printer 
on, and release the buttons when installed 
memory and processor speed displays), and 
run the appropriate cartridge drive motor test 
for the missing color:
1. Select MISC TESTS in the Diag Menu, and 
press Select ().
2. Select Motor Detect. 
Remove Cartridge. press Select appears.
Note: Do not press Select yet.
3. Remove all toner cartridges and the 
imaging unit.
4. Close the front cover. 
If you press Select before closing the front 
cover, a message appears: Close Cover. 
press Select. 
5. press Select ().
Motor Detection In Progress… appears. The 
motor detection process takes about 10 
seconds, and stops automatically.
Detect Complete. Rebooting… appears, and 
the printer performs a POR (Power On 
Reset).
Did the motor run?Go to step 5. Replace the Main drive gear 
assembly. See “Main drive 
gear assembly with motor 
removal” on page 4-39. 
5Remove the developer unit. See “Developer 
unit removal” on page 4-30. Check the 
developer cartridge contacts from the HVPS to 
the IU. 
Are all the toner cartridge contacts clean on 
both the Pin and IU?Go to step 6. Clean the developer 
cartridge contacts. See 
“Developer unit removal” 
on page 4-30. 
6Are all the spring-loaded Pin in the HVPS free 
to move in and out with an equal amount of 
spring force?Go to step 7. Replace the HVPS. See 
“High-voltage power 
supply (HVPS) assembly 
removal” on page 4-24.
7Turn the printer off, and remove the rear shield. 
See “Rear shield removal” on page 4-7. 
Check the continuity between the spring-
loaded Pin and the JSC1 connector on the 
controller board.
Are all conductors continuous?Go to step 8. Replace the cable.
8Replace the printhead. See “Printhead 
removal” on page 4-42.
Did this fix the problem?Problem resolved. Replace the controller 
board. See “Controller 
board removal” on 
page 4-16. Step Questions / actions Yes No 
						

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Print quality—blurred or fuzzy print
Run the automatic alignment. The TPS sensor may be damaged. To run Reset Color 
Cal:
1.Enter the Diagnostics Menu. (Turn the printer off, press and hold   and  , turn 
the printer on, and release the buttons when installed memory and processor 
speed displays.
2.Select TPS Setup from Diag Menu, and press Select ().
3.Select Reset Color Cal, and press Select ().
Resetting appears. When the reset is complete, the screen is automatically returned 
to TPS Setup.
Blurred or fuzzy print is usually caused by a problem in the main drive gear assembly or in the image transfer 
unit (ITU). Check the main drive gear assembly and ITU for correct operation.
Blurred print can also be caused by incorrect feeding from one of the input paper sources, media trays, or duplex 
paper path.
Check the high-voltage spring contacts to ensure they are not bent, corroded, or damaged. Replace the high-
voltage power supply as necessary. See “High-voltage power supply (HVPS) assembly removal” on 
page 4-24. 
Print quality—half-color page
A photoconductor unit is not properly seated. Reset the specific photoconductor unit.
Print quality—horizontal banding
Print the Print Defect Page:
1.At the Ready prompt, press Menu ().
2.Select Reports, and press Select ().
3.Select Print Defects, and press Select ().
Step Questions / actions Yes No
1Measure the distance between repeating 
bands.
Is the distance between bands either 34.6 or 
94.2 mm?Replace the photoconductor 
unit. Remove the imaging 
unit and remove the original 
developer units, and then 
put them back into the new 
photoconductor unit, and 
reinstall the imaging unit. 
See “Imaging unit (IU) 
removal” on page 4-28. Go to step 2.
2Does the distance measure 95 mm or 
108 mm?Replace the fuser. See 
“Fuser assembly removal” 
on page 4-19. Go to step 3.
3Does the distance measure 37.7, 55, or 
78.5 mm?Replace the ITU. See 
“Image transfer unit (ITU)” 
on page 4-25. Go to step 4.
4Does the distance measure 43.9 mm or 45.5? Replace the developers that 
match the missing color 
(black, cyan, magenta, or 
yellow). See “Developer 
unit removal” on 
page 4-30. Check the various rollers in 
the printer for debris. 
						

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Print quality—horizontal line
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 4-28. 
Print quality—insufficient fusing
Print quality—missing image at edge
Remove and reseat the following:
Toner cartridge
Imaging unit
Developer units.
Print quality—mottle (2–5mm speckles)
Keep running prints through, and the problem normally clears up. If the problem persists, 
replace the developer cartridge. Step Questions / actions Yes No
1Is the printer setup to use the correct media? Go to step 2. Change the settings to 
indicate the correct media.
2Check the fuser connections on the left and 
right side of the printer.
Are the cables and connection correct?Go to step 3. Properly reconnect or 
replace the cables.
3Is the fuser properly installed? Go to step 4. Install the fuser properly.
4Replace the fuser. See “Fuser assembly 
removal” on page 4-19.
Does this fix the problem?Problem resolved. Replace the LVPS. see 
“Low-voltage power 
supply (LVPS) assembly” 
on page 4-31.  
						

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Print quality—narrow vertical line
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. Step Questions / actions Yes No
1Replace the photoconductor unit. See 
“Imaging unit (IU) removal” on page 4-28. Problem solved. Replace the developer unit. 
See “Developer unit 
removal” on page 4-30
Step Questions / actions Yes No
1Is there any loose or foreign material on the 
imaging unit?Inspect the imaging unit by 
looking at the individual 
developers and 
photoconductors. Clean or 
replace the faulty unit. See 
“Imaging unit (IU) 
removal” on page 4-28.Go to step 2.
2Is there any loose or foreign material on the 
developer roll?Replace the developer unit. Go to step 3.
3Is there any loose or foreign material on the 
transfer belt?Replace the image transfer 
unit. See “Image transfer 
unit (ITU)” on page 4-25.Contact your next level of 
support.
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