Lexmark X543 Service Manual

							Repair information4-37
Lexmark confidential until announce7525xxx
12.Swing the rear part away from the printer to access the spring and sensor.
13.Release the tabs to remove the tray present sensor (F) from the side frame.
Note:  The sensor is not part of the left lower frame FRU. 
						

							4-38Service Manual 7525xxxLexmark confidential until announce
14.Remove the spring (G) from the left lower frame FRU.
15.Swing the rear of the lower frame away from the printer, and remove. 
						

							Repair information4-39
Lexmark confidential until announce7525xxx
Main drive gear assembly with motor removal
1.Remove the left cover. See “Left cover removal” on page 4-4. 
2.Remove the LVPS. See “Low-voltage power supply (LVPS) assembly” on page 4-31
3.Remove the screws (A) on the top cover.
4.Remove the two screws (B) from the inside left side.
A 
						

							4-40Service Manual 7525xxxLexmark confidential until announce
5.Unplug the cables (C) from the motors, and remove all cables from the retainer (D).
Note:  Observe the cable routing for reinstallation.
6.Remove the two screws (E) from the rear.
7.Remove the two screws (F) from below the main drive gear assembly.
8.Remove the two screws (G) from the right of the main drive gear assembly.
9.Lift the main drive gear assembly with motor, and remove. 
						

							Repair information4-41
Lexmark confidential until announce7525xxx
Pick tires removal—integrated 250-sheet media tray
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 
you have this additional option, and you are having problems with media picking, replace these tires also. Always 
replace the paper pick tires in pairs. The tires come in a package of two.
1.Remove the media tray.
2.Place the printer so the front edge extends over the edge of the table or desk.
3.Lower the autocompensator mechanism.
4.Remove the rubber tires (A) from the pick roll assembly (B). Repeat for the other tire. 
Warning:  Be ver y careful not to unlatch the right side hub, or the clutch may be damaged. If the ball 
bearings come out of the clutch, it will have to be reassembled on a flat surface.
Installation notes:
Install the new rubber tires with the surface texture turning in the direction as shown.
Note:  Feel each rubber surface to verify it turns properly in the direction shown. 
						

							4-42Service Manual 7525xxxLexmark confidential until announce
Printhead removal
1.Remove the scanner assembly. See“Flatbed removal” on page 4-53.
2.Remove the top cover. See “Top cover assembly removal” on page 4-9. 
3.Disconnect the cables.
4.Remove the three screws (A). 
5.Remove the printhead.
Installation note:
When the printhead is replaced, perform the registration (black planes) and alignment (color planes). See 
“Registration” on page 3-4 and “Alignment” on page 3-7.  
						

							Repair information4-43
Lexmark confidential until announce7525xxx
Imaging unit contacts
1.Remove the right cover assembly. See “Right cover removal” on page 4-7.
2.Remove the waste toner bottle. See “Waste toner bottle” on page 4-49.
3.Remove the imaging unit. See “Imaging unit (IU) removal” on page 4-28.
4.Remove the rear cover. See “Right cover removal” on page 4-7.
5.Remove the rear screw (A) in the waste toner bottle sensor contact to allow access to the cable cover. 
Note:  The waste toner bottle sensor contact does not need to be unplugged or removed. 
6.Remove the four screws (B) securing the cable cover.
7.Turn the printer on the left side.
8.Remove the screw (C) securing the spring contacts.
9.Release the tabs (D) on the spring contact to release the spring contacts. 
						

							4-44Service Manual 7525xxxLexmark confidential until announce
10.Disconnect the cable (E) from the controller board at JSC1.
11.Remove the cable from the retainer on the bottom of the printer.
12.Extract the cable through the frame, and remove the cable with the spring contacts. 
						

							Repair information4-45
Lexmark confidential until announce7525xxx
Toner meter cycle (TMC) card removal
1.Remove the right cover. See “Right cover removal” on page 4-7.
2.Remove the waste toner container. See “Waste toner bottle” on page 4-49. 
3.Remove the imaging unit (IU). See “Imaging unit (IU) removal” on page 4-28. 
4.Remove the rear shield. See “Rear shield removal” on page 4-7. 
5.Disconnect and remove the toner meter cycle card cable (A).
Note:  Observe the routing for reinstallation. 
6.Remove the two plastic screws (B) and the two metal screws (C), and remove the card. 
						

							4-46Service Manual 7525xxxLexmark confidential until announce
Installation note: 
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 
the toner meter cycle card back into position. 
1.Remove the two machine screws (A).
2.Remove the two screws (B).
3.Push in on the cover above the locating Pin (C) while lifting to disengage the cover. Carefully lift the cover 
just enough for clearance for the toner meter cycle card.
4.Position the toner meter cycle card.
5.Replace the screws (D), and replace the top cover.