Lexmark X543 Service Manual

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Paper jams
Avoiding jams
The following hints can help you avoid jams:
Use only recommended paper or specialty media.
For more information, see the Card Stock & Label Guide available on the Lexmark Web site at 
www.lexmark.com/publications.
Do not load too much paper. Make sure the stack height does not exceed the indicated maximum height.
Do not load wrinkled, creased, damp, or curled paper.
Flex, fan, and straighten paper before loading it.
Do not use paper that has been cut or trimmed by hand.
Do not mix paper sizes, weights, or types in the same stack.
Store the paper in an appropriate environment.
Do not remove trays while the printer is printing. Wait for Load tray  or Ready to appear before removing 
a tray.
Do not load the manual feeder while the printer is printing. Wait for Load Manual feeder with  to appear.
Push all trays in firmly after loading paper.
Make sure the guides in the trays are properly positioned, and are not pressing too tightly against the 
paper.
Make sure all paper sizes and paper types are set correctly in the operator panel menu.
Make sure all printer cables are attached correctly.  
						

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Understanding jam numbers and locations
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.
# Error message Jam message Instructions Go to page
1 200 Standard 250-sheet tray and 
manual feeder (tray 1)Pull tray 1 out, and remove the jam.3-41
2 201 Jam under the fuser Open the front door, and remove the jam.3-41
3 202 Jam in the fuser Open the front door, and pull the fuser 
cover toward you. 
Remove the jam.3-42
4 230 Jam in the duplex Open the front door, and remove the jam.3-43
5 235 Media not supported in the 
duplexLoad the tray with the correct paper size.3-43
6 24x 650-sheet Duo Drawer (tray 
2) /MP feederPull tray 2 out, and remove the jam.3-43
7 250 Jam in the multipurpose 
feederPull tray 2 out, and remove the jam.3-43
8 29x Jams in the ADF unit Remove the jam from the top or bottom of 
the ADF unit.3-44
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200 paper jams
1.
Remove the standard 250-sheet tray (tray 1).
2.Remove the jam.
Note:  Make sure all paper fragments are removed.
3.Inser t the tray.
4.press Select ().
201 paper jam
1.
Grasp the front door at the side handholds, and then pull it toward you to open it.
2.Remove the jammed paper.
Note:  Make sure all paper fragments are removed.
3.Close the top door.
4.press Select ().
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202 paper jam
1.
Raise the scanner assembly to the up position.
2.Grasp the front door at the side handholds, and then pull it toward you to open it.
3.Grasp the green lever, and pull the fuser cover toward you.
4.Hold the fuser cover down, and then remove the jammed paper.
The fuser cover closes when released.
5.Close the fuser cover.
6.Close the front door.
7.press Select ( ) to continue. 
						

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230 paper jam
1.
Grasp the front door at the side handholds, and pull it toward you to open it.
2.Remove the jam.
3.press Select ( ) to continue printing.
235 paper jam
1.
Load the tray with the correct paper size.
2.Inser t the tray.
3.Close the front door.
4.press Select ( ) to continue printing.
24x paper jam
1.
Remove the 650-sheet Duo Drawer (tray 2) out.
2.Remove the jam.
Note:  Make sure all paper fragments are removed.
3.Align the tray, and insert it.
4.press Select ( ) to continue.
250 paper jam
1.
Push the lever to remove the media jam in the multipurpose feeder.
Note:  Make sure all paper fragments are removed.
2.press Select (). 
						

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29x ADF paper jam
1.
Remove all original documents from the ADF input tray.
2.Open the ADF top cover. Remove the jammed paper.
3.Close the ADF cover.
4.Open the flatbed cover. Remove any jammed pages.
5.Close the scanner lid.
6.Press .
291.xx ADF paper jams
1.
Remove all original documents from the ADF input tray.
2.Remove the ADF input tray. See “ADF input tray” on page 4-64. 
						

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3.Remove the original from the ADF by pulling the lower of the two sheets (A) from the ADF exit.
4.Replace the ADF input tray. 
						

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Theory of operation
Print engine theory
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.   
Even though the basic EP process is the same for every laser and LED printer, the specifics for each printer are 
different. We will discuss the X54x series print engine and its particular method of printing.
MFP electrophotographic process basics
These MFPs are single-laser MFPs that use four toner cartridges (cyan, yellow, magenta, and black) to create 
text and images on media. 
The MFP has four photoconductors (called a photodeveloper cartridge or PC unit) and an image transfer unit 
(ITU). Each color toner is painted to it’s respective photoconductor at the same time. The transfer belt passes 
under the four photoconductors and the four-color image is produced and transferred to the media in one pass.
During the printing process, the MFP follows the six basic EP Process steps to create its output to the page. 
These six steps are:
1.Charge the photoconductor (PC unit). 
2.Expose the photoconductor (PC unit) with the laser.
3.Develop toner on the photoconductor (PC unit).
4.First transfer to the ITU, and second transfer to the media. 
5.Fuse the toner to the media.
6.Clean/erase the photoconductor and the ITU.
In summary, the printer’s controller board receives print data and the command to print. The controller board 
then initiates the print process. The controller board is the command center for the EP process and coordinates 
the various motors and signals.
The high-voltage power supply sends charge to various components in the EP process. The laser fires on the 
photoconductors and alters the surface charge relative to the planed image for each photoconductor. Each 
photoconductor rotates past its respective developer roll, and toner is developed on the surface of each 
photoconductor. The four separate color images are then transferred to the transfer belt on the ITU as it passes 
under the photoconductors. After the image is transferred to the transfer belt, the photoconductors are cleaned 
and recharged. 
The transfer belt carries the four-colored image towards the transfer roll. Media is picked up from the tray and 
carried to the transfer roll where the image is transferred from the transfer belt to the media. The timing of the 
paper pick is determined by the speed of the transfer belt.
The media is carried to the fuser rollers where heat and pressure are applied to the page to permanently bond 
the toner to the page. The fuser rollers push the media into the output bin. The transfer unit is cleaned and the 
process begins again for the next page.  
						

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Step 1: Charge
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 
for the laser beam. 
Service tips
If the surface of the charge roller is damaged (such as a nick or pit), it will cause the charge to be 
uneven on the photoconductor. This will cause a repeating mark on the printed page. Check the 
service manual for the repeating marks table.
If the charge roller is severely damaged, the surface of the photoconductor will not be charged 
properly, and heavy amounts of toner will be deposited on the photoconductor. This will cause the 
printed page to be saturated with 100% of each color. The imaging basket will need to be replaced 
sooner. 
						

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Step 2: Expose
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 
difference in charge potential between the exposed area and the rest of the photoconductor surface. 
Service tips
The laser beam passes through a glass lens as it exits the laser unit. If this lens gets contaminated 
with toner or other debris, it will cause vertical streaking of white/lightness on the page. Cleaning the 
lens will solve the problem.
Never touch the surface of the photoconductor with your bare hand. The oil from your skin may cause 
a charge differential on the surface, and toner will not stick properly. The result would be repeating 
blotches of voids/light print on a page. Then the photoconductor will have to be replaced.
The surface of the photoconductor is coated with an organic substance that makes it sensitive to light. 
Be sure and cover the photoconductor when you are working on the printer so you don’t “burn” it. If 
exposed to light for too long, it will cause light/dark print quality problems and have to be replaced.