Lexmark X543 Service Manual

							Diagnostic information2-57
Lexmark confidential until announce7525xxx
Print quality—residual image
Ser vice tip: Install a new print car tridge, if available, before doing this ser vice check. 
Residual image can be caused by the photoconductor, cleaning blade, and other parts 
inside the print cartridge. 
Step Questions / actions Yes No
1Check the condition of the imaging unit using 
the customer menus (administrative menus):
1. At the Ready prompt, press Menu ().
2. Select Supplies Menu, and press Select 
().
3. Select Imaging Kit, and press Select().
Does the display indicate OK?Go to step 2. Replace the imaging unit or 
the photoconductor unit. 
See “Imaging unit (IU) 
removal” on page 4-28. 
2Measure the distance from the original image 
to the same point on the residual image.
Is the distance 43.9 mm?Replace the developer 
corresponding to the color of 
the image. See “Developer 
unit removal” on 
page 4-30. Replace the imaging unit or 
the photoconductor unit. 
See “Imaging unit (IU) 
removal” on page 4-28.
3Is the distance between the original image and 
the residual image 94.2 mm?Replace the 
photoconductor. See 
“Developer unit removal” 
on page 4-30.
4Run the Menu Setting Page twice to clear any 
debris.
To print a menu settings page:
1. press Menu ( ) on the operator panel.
2. Select Reports from the Admin Menu, and 
press Select ().
3. Select Menu Settings, and press 
Select().
Is there still any toner contamination on the 
fuser assembly?Replace the fuser. See 
“Fuser assembly removal” 
on page 4-19.Contact your next level of 
support.
ABCDE
ABCDE ABCDE 
						

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Print quality—solid color page
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.
Print quality—vertical banding
Replace the developer cartridge. Step Questions / actions Yes No
1Replace the photoconductor unit (part of the 
imaging unit). Remove the imaging unit and 
remove the developers. Place the original 
developers in the new photoconductor, and 
then replace the imaging unit. See “Imaging 
unit (IU) removal” on page 4-28. 
Does this fix the problem?Problem resolved. Go to step 2.
2A faulty printhead can cause the problem. To 
test the printhead for solid colors, place a 
narrow strip of paper over the gap between the 
developers. Make sure the paper stays in place 
when you replace the imaging unit. This will 
block the laser from discharging the 
photoconductors. Print a Quality Test Page. 
Does the page have a white vertical band?Replace the printhead. See 
“Printhead removal” on 
page 4-42. Go to step 3.
3Check the high-voltage contact from the HVPS 
to the photoconductor charge roll. Ensure the 
contact springs are properly mounted and that 
the charge roll contact spring is making good 
contact with the HPVS spring that runs through 
the left printer frame. See “Imaging unit 
contacts” on page 4-43 to view the proper 
mounting and for removal procedures.
Are the spring(s) defective?Replace the transfer contact 
assembly. See “Imaging 
unit contacts” on 
page 4-43.Go to step 4.
4Turn the printer off, and check the continuity of 
the HVPS cable.
Is there continuity?Go to step 5. Replace the cable assembly.
5Replace the HVPS. See “High-voltage power 
supply (HVPS) assembly removal” on 
page 4-24. 
Did this solve the problem?Problem resolved. Replace the controller 
board. See “Controller 
board removal” on 
page 4-16.  
						

							Diagnostic information2-59
Lexmark confidential until announce7525xxx
Printhead service check
This service check includes the following errors:
Error codes Color
106.xx Yellow
107.xx Cyan 
108.xx Magenta
109.xx Black
Step Questions / actions Yes No
1Turn the printer off, and remove the rear shield. 
See “Rear shield removal” on page 4-7. 
Check the cable at JMIRR1 for proper 
connection to the controller board, the 
printhead cable for pinch points, and the cable 
or connector for any other damage.
Is the cable damaged?Replace the printhead. See 
“Printhead removal” on 
page 4-42. Go to step 2.
2Turn the printer on, and then wait until the 
printer posts an error. Using a voltmeter, check 
the following values at JMIRR1:
Are the values approximately correct?Replace the controller board 
See “Controller board 
removal” on page 4-16.Replace the printhead. See 
“Printhead removal” on 
page 4-42.
JMIRR1
Pin Volt. 
(V dc)
15
23.3
35
4GND
524 
						

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Toner meter cycle (TMC) card
Toner sensors (Y, C, M, K) on TMC card
Step Questions / actions Yes No
1Perform the Base Sensor Test:
1. Enter Diagnostics menu (turn off the 
printer, press and hold   and Select (), 
turn on the printer, and release the buttons 
when the installed memory and processor 
speed displays).
2. Select Base Sensor Test, and press 
Select ().
3. Select the sensor you want to test, open 
the toner door, remove the corresponding 
toner cartridge, and press Select ().
4. Note whether the operator panel shows a 
change in state.
Note: If the reflective disk is not showing on 
the cartridge, rotate the gear clockwise to 
expose the reflective surface.
For additional information about the Base 
Sensor Test, see “Base Sensor Test” on 
page 3-18.
Does the operator panel display a change of 
state?Replace the toner cartridge. Replace the toner meter 
cycle (TMC) card. See 
“Toner meter cycle (TMC) 
card removal” on 
page 4-45.
Step Questions / actions Yes No
1Remove the toner cartridge, and inspect the 
lenses on the toner meter cycle (TMC) card.
Are the lenses blocked, damaged, or dirty?Repair or replace the TMC 
card. See “Toner meter 
cycle (TMC) card removal” 
on page 4-45. Go to step 2.
2Turn off the printer, and remove the rear shield. 
See “Rear shield removal” on page 4-7. 
Disconnect the cable at the JSP1 connector on 
the controller board. Turn the printer on, and 
measure the voltages below:
Are any of the voltage values incorrect?Replace the controller 
board. See “Controller 
board removal” on 
page 4-16. Replace the TMC card. See 
“Toner meter cycle (TMC) 
card removal” on 
page 4-45.
JSP1
Pin Voltage
1 Ground
2 +3.3 V dc
3 +3.3 V dc
4 +3.3 V dc
5 +3.3 V dc
6 +0.0 V dc 
						

							Diagnostic information2-61
Lexmark confidential until announce7525xxx
Transfer roll service check
Step Questions / actions Yes No
1Remove the ITU. See “Image transfer unit 
(ITU)” on page 4-25. Check the contacts 
between the HVPS and the ITU. Clean the 
contacts and recheck.
Does the error reoccur?. Replace the ITU. See 
“Image transfer unit (ITU)” 
on page 4-25.
Go to step 2.Problem resolved.
2Does the new ITU fix the problem Problem resolved. Go to step 3.
3Turn the printer off, and remove the rear shield. 
See“Rear shield removal” on page 4-7. 
. Turn the printer on, and check the cable at 
JHVPS1 connector on the controller board 
without disconnecting it. Verify the following 
voltage values:
Are the values approximately correct?Replace the HVPS“High-
voltage power supply 
(HVPS) assembly 
removal” on page 4-24. Replace the controller 
board. See “Controller 
board removal” on 
page 4-16.
JHVPS1
Pin Voltage
7 +3.3 V dc
11 +3.3 V dc
13 +24 V dc
14 Ground
16 Ground 
						

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Tray 1 sensor service check
Step Questions / actions Yes No
1When the printer is in Ready state, pull the 
standard tray out. The display should indicate 
Tray 1 Missing. Insert the tray.
Does the message remain on the display?Go to step 2. Go to step 4.
2Check the vertical well at the right rear of the 
tray for damage.
Is the tray damaged?Replace the tray. Go to step 3.
3Check for a dislodged sensor. 
Is the sensor dislodged?Replace the tray 1 sensor. Contact the next level of 
support.
4Does the message Tr ay  1  M iss in g fail to appear 
when the tray is pulled out?Go to step 5. Problem resolved.
5Turn off the printer, and remove the rear shield. 
“Rear shield removal” on page 4-7. 
Disconnect the cable at JTRAY1 connector on 
the controller board. Turn the printer on, and 
measure the voltages below:
Are the voltage values approximately correct?Problem resolved. Replace the controller 
board. See “Controller 
board removal” on 
page 4-16. 
JTRAY1
Pin Voltage
1 +5 V dc
2 +5 V dc
3 Ground 
						

							Diagnostic information2-63
Lexmark confidential until announce7525xxx
Scanner / Copy / Fax service checks
840.xx service check
Step Questions / actions Yes No
1 POR the machine into configuration mode. 
Go to the disable scanner menu item. See 
“Disable Scanner” on page 3-36. Select 
“Enable ADF/FB -Enabled and press   to 
save the change. POR the MFP to operating 
mode. Try running a copy from the ADF and 
flatbed. 
Did the 840.xx error recur?Go to step 2. Stop. Problem resolved.
2 Re-enter Configuration mode, scroll to and 
select the Disable Scanner menu item.
Does the screen display ADF Disabled or 
Auto Disabled?Go to step 3. Go to step 8.
3 Check the ADF cable connections on the 
ADF relay card and the controller board. 
Also inspect JFBM1, JHS1 and JCCD1 on 
the controller board.
Are the connections properly connected?Go to step 5. Go to step 4.
4 Properly connect the connections on the 
ADF relay card and controller board. POR 
the machine into configuration mode. Go to 
the disable scanner menu item. See 
“Disable Scanner” on page 3-36. Select 
“Enable ADF/FB -Enabled and press   to 
save the change. POR the MFP to operating 
mode. Try running a copy from the ADF and 
flatbed.
Did the 840.xx error recur?Go to step 5. Stop. Problem solved.
5 Check the continuity on the ADF cable. 
Is there continuity?Go to step 7 Go to step 6.
6 Replace the ADF cable. POR the machine 
into configuration mode. Go to the disable 
scanner menu item. See “Disable 
Scanner” on page 3-36. Select “Enable 
ADF/FB -Enabled and press   to save the 
change. POR the MFP to operating mode. 
Try running a copy from the ADF and 
flatbed.
Did the 840.xx error recur?Go to step 7. Stop. Problem solved. 
						

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7 Replace the ADF unit. See “Duplex ADF 
removal” on page 4-63or “Simplex ADF 
removal” on page 4-64. POR the machine 
into configuration mode. Go to the disable 
scanner menu item. See “Disable 
Scanner” on page 3-36. Select “Enable 
ADF/FB -Enabled and press   to save the 
change. POR the MFP to operating mode. 
Run a copy from the ADF.
Did the 840.xx error recur?Go to step 8. Stop. Problem solved.
8 Inspect JFBM1, JHS1 and JCCD1 on the 
controller board.
Are the connections properly connected?Go to step 10. Go to step 9.
9 Properly connect all the connections.
Did the 840.xx error recur?Stop Problem solved. Go to step 10.
10 Replace the flatbed unit. See “Flatbed 
removal” on page 4-53. POR the machine 
into configuration mode. Go to the disable 
scanner menu item. See “Disable 
Scanner” on page 3-36. Select “Enable 
ADF/FB -Enabled and press   to save the 
change. POR the MFP to operating mode. 
Run a copy from the flatbed.
Did the 840.xx error recur?Go to step 11 Stop. Problem solved.
11 Replace the controller board. See 
“Controller board removal” on page 4-16.
Did this fix the problem?Problem solved. Contact second-level 
support. Step Questions / actions Yes No 
						

							Diagnostic information2-65
Lexmark confidential until announce7525xxx
Black or blank page copy service check
CCD service check
Flatbed motor service check
Step Questions / actions Yes No
1 Print a menu page, or a page from the host. 
Is the page black?See “Print quality—solid 
color page” on page 2-58Go to step 2.
2 Is the copy an ADF scan? Go to step 3. Go to step 4.
3 Run a flat bed copy.
Is it blank or black?Go to step 5 Go to step 4
4 Did the sheet feed into the ADF? Go to step 5.
5 Is the CCD ribbon cable properly connected 
to JCCD1 on the controller board?Go to step 6. Properly connect the ribbon 
cable to JCCD1.
6 Check for +14VDC on Pin 33 and 34 on 
connector JCCD1. Pin 31 and 32 are 
+5VDC. Are the voltages present?Replace the flatbed unit. 
See “Flatbed assembly 
removal” on page 4-50.Replace the system board. 
See “Controller board 
removal” on page 4-16.
Step Questions / actions Yes No
1 Restart the device, and retry the scan / copy 
job. Repeat this step with a few copy jobs.
Does the error return?Go to step 2. No issue.
2 Is the CCD ribbon cable properly connected 
to JCCD1 on the controller board?Go to step 3. Properly connect the ribbon 
cable to JCCD1.
3 Replace the flatbed unit. See “Flatbed 
removal” on page 4-53.
Did this resolve the issue?Problem resolved. Replace the system board. 
See “Controller board 
removal” on page 4-16.
Step Questions / actions Yes No
1 Ensure that the flatbed motor cable (JFB1) 
is connected. Is the cable connected?Go to step 2. Properly connect the cable.
2 Check pin 1 in JFBM1 for voltage. The 
voltage is only present when a flatbed copy 
job is running. The voltage should measure 
+24V AC. Is voltage present?Replace the flatbed unit. 
See “Flatbed removal” on 
page 4-53.Replace the controller 
board. Go to “Controller 
board removal” on 
page 4-16. 
						

							2-66Service Manual 7525xxxLexmark confidential until announce
Flatbed home position service check
Step Questions / actions Yes No
1 POR the MFP. Does the CCD move and 
return to the home position?Problem solved. Go to step 2.
2 Perform the home position sensor test. Go 
to “Scanner Tests” on page 3-25.
Is the sensor working properly?Go to step 3. Go to step 5.
3 Check JFBM1 on the controller for proper 
connection.
Is it connected properly?Go to step 4. Properly connect the cable.
4 Check pin 1 in JFBM1 for voltage. The 
voltage is only present when a flatbed copy 
job is running. The voltage should measure 
+24V AC. Is voltage present?Go to step 5. Replace the controller 
board. Go to “Controller 
board removal” on 
page 4-16
5 Ensure that the home position cable (JHS1) 
is connected. Is the cable connected?Go to step 6. Properly connect the cable.
6 Check pin 1 in JHS1 for voltage. The voltage 
should measure +5V DC. Pin 2 should be 
GND. Is voltage present and is it correct?Replace the flatbed unit. 
See “Flatbed assembly 
removal” on page 4-50.Replace the controller 
board. Go to “Controller 
board removal” on 
page 4-16.