Lexmark X543 Service Manual
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General information1-19 Lexmark confidential until announce7525xxx Tools required for service Flat-blade screwdrivers, various sizes #1 Phillips screwdriver, magnetic #2 Phillips screwdriver, magnetic #2 Phillips screwdriver, magnetic short-blade 7/32 inch (5.5 mm) open-end wrench 7.0 mm nut driver Needlenose pliers Diagonal side cutters Spring hook Feeler gauges Analog or digital multimeter Parallel wrap plug 1319128 Flash light (optional)
1-20Service Manual 7525xxxLexmark confidential until announce Acronyms. ac Alternating Current ACM Autocompensator Mechanism (or paper feed) ADF Automatic document feeder AFE Analog front end AIO All-In-One APS Automatic Paper Size ASIC Application Specific Integrated Circuit BLDC Brushless DC Motor BOR Black Only Retract BUD Belt up down CCyan CCD Charge-Couple Device CCFL Cold Cathode Fluorescent Lamp CCW Counter clockwise CDB Command Descriptor Blocks CMYK Cyan yellow magenta black CPU Central processing unit CRC Cyclic redundancy check CRU Customer Replaceable Unit CSU Customer Setup CW Clockwise DBCS Double byte character set dc Direct Current DIMM Dual Inline Memory Module DLE Downloadable emulator DRAM Dynamic random access memory DVM Digital multimeter ECC Error correcting code ECM Error correction mode EDO Enhanced Data Out EEPROM Electrical Erasable Programmable Read-Only Memory ENA External Network Adapter EOL End of line EP Electrophotographic process EPROM Erasable programmable read-only memory ESD Electrostatic Discharge FB Flatbed FD Facedown FRU Field replaceable unit FU Face up GB Gigabyte GFI Ground Fault Interrupter GHz Gigahertz HBP Host Based Printing HCF High-capacity feeder HCIT High-capacity Input Tray HCOF High-Capacity Output Finisher HCPF High-capacity feeder HTML Hypertext markup language HV High Voltage HVPS High voltage power supply
General information1-21 Lexmark confidential until announce7525xxx HVU High voltage unit Hz Hertz INTL International ITC Internal Tray Card ITU Image Transfer Unit KBlack (Key) LAN Local area network LASER Light amplification by stimulated emission of radiation LCD Liquid cr ystal display LCM Liquid Crystal Module LD Laser Diode LED Light emitting diode LEF Long edge feed LES Lexmark Embedded Solution (applications) LSU Laser Scanning Unit LV Low Voltage LVPS Low voltage power supply M Magenta MB Megabyte MDC Motor Driver Control MFD Multifunction Device MFP Multifunction Printer MH Message handling MIF Motor interface mm Millimetre MMR Modified modified read MPF Multipurpose feeder MR Modem ready MROM Masked Read Only Memory MS Microswitch NAND NAND (usage: NAND gate) NVM Nonvolatile Memor y NVRAM Nonvolatile Random Access Memory OCF Operator correctable failure OCR Oil coating roll OEM Original Equipment Manufacturer OHP Overhead projector OPC Optical photo conductor OPT Optical Sensor PC Photoconductor PDF Por table Document Format PICS Problem isolation charts PIN Personal identification number PIXEL Picture element PJL Printer Job Language POR Power-on reset POST Power-on self test PPDS Personal Printer Data Stream ppm Pages per minute PQET Print Quality Enhancement Technology PRC Peoples Republic of China PSC Parallel Synchronous Communications PSD Position Sensing Device PSO Participating Standards Organization
1-22Service Manual 7525xxxLexmark confidential until announce PWM Pulse Width Modulation RAM Random access memory RFID Radio frequency identification RH Relative humidity RIP Raster image processor ROM Read-only memory ROS Read-only storage RPM Revolutions Per Minute SCC Scanner Control Card SDRAM Synchronous Dynamic Random Access Memory SEF Short edge feed SIMM Single Inline Memory Module SOL Solenoid SOS Start of scan SRAM Static random access memory TAR Toner Add Roll TPS Toner Patch Sensing TTM Tandem Tray Module TVOC Total Volatile Organic Compound UAT Universally Adjustable Tray UPR Used Parts Return USB Universal Serial Bus VVolts V ac Volts alternating current V dc Volts direct current VOIP Voice over internet protocol VOM Volt Ohmmeter VTB Vacuum Transport Belt XPS XML Paper Specification YYellow
Diagnostic information2-1 Lexmark confidential until announce7525xxx 2. Diagnostic information Start Begin here to locate the service error code, user status message, user error message, symptom table, service checks, and diagnostic aids in this chapter to determine the corrective action necessary to repair a malfunctioning printer. They will lead you to solutions or service checks, including use of various tests. Does the POR stop? Check the “POR (Power-On Reset) sequence” on page 2-2 Do you have a symptom, rather than an error message? Locate your symptom, and take the appropriate action: –“Printer symptom table” on page 2-3 –“Scan / fax / copy symptom table” on page 2-4 If you have an error message or user message, check the following: –“Service error messages” on page 2-14 –“User status and attendance messages” on page 2-6 –“Paper Jam messages” on page 2-12 –“Service checks” on page 2-32 for individual error messages Additional information can be found at the following locations: –“Operator panel and menus” on page 2-2 –“POR (Power-On Reset) sequence” on page 2-2 –“Print engine theory” on page 3-46 CAUTION Unplug the power cord from the electrical outlet before you connect or disconnect any cable or electronic board or assembly for personal safety and to prevent damage to the printer. Disconnect any connections between the printer and PCs/peripherals.
2-2Ser vice Manual 7525xxxLexmark confidential until announce POR (Power-On Reset) sequence The following is an example of the events that occur during the POR sequence for the base machine with no paper-handling options installed. When you turn the printer on, it performs a Power-On Self Test. Check for correct POST functioning of the base printer by observing the following: 1.The LED turns on. 2.The main fan turns on. 3.The operator panel turns on. 4.A partial row of pixels appears. 5.The operator panel display clears. 6.Another row of pixels appears. 7.The operator panel display clears again. 8.The operator panel displays system information. For example: 9.The fuser lamp turns on. The fuser takes longer to warm up from a cold start than a warm start. 10.The operator panel LED starts blinking. The following errors or messages may appear: Close Door or Insert Cartridge display if the upper front cover is open or the print cartridge is missing. Any cartridge errors, such as Defective Cartridge or Missing Cartridge. 11.Ready appears on the display. 12.The main drive motor turns on. 13.The EP drive assembly drives the developer shaft located in the toner cartridge. 14.The exit rollers turn. 15.The printer calibrates. *256MB 500Mhz
Diagnostic information2-3 Lexmark confidential until announce7525xxx Symptom tables Printer symptom table Symptom Action Dead printer Go to “Dead printer service check” on page 2-37. Operator panel—one or more buttons do not work.Go to “One or more operator panel buttons fail” on page 2-44. Operator panel—display is blank. Printer sounds five beeps.Go to “Operator panel display blank, five beeps” on page 2-44. Operator panel—display is blank. Go to “Operator panel display blank, five beeps” on page 2-44. Operator panel continuously displays all diamonds and does not complete POST.Go to “Operator panel display blank, five beeps” on page 2-44. Pages print blank after replacing the controller board.When replacing the controller board, verify the cable from the high-voltage power supply is seated properly. The cable may have come loose from the HVPS. Tray linking does not work. Check that the same size and type of paper are in each tray. Check the location of the paper guides. The multipurpose feeder does not automatically sense the paper size. You must set the size from the Paper Size/Type menu. Print a menu settings page, compare the settings for each tray, and adjust on the operator panel, if necessary. Unexpected page breaks occur Increase the Print Timeout value on the operator panel (Settings–>General Settings–>Timeouts–>Print Timeout). Multipurpose feeder has constant misfeeds or jams. Remove and flex the paper in the tray. Reload the paper, and try printing. Turn the paper over inside the tray. Make sure the feeder is properly installed. Make sure the paper is loaded correctly in the tray. Make sure the paper is not damaged. Make sure the paper meets specifications. See “Media input type specifications” on page 1-10. Make sure the paper guides are positioned correctly for the paper size loaded in the tray. Page that jammed does not reprint after you clear the jam.Jam Recovery may be set to Off. Change the setting to Auto or On on the operator panel (Settings–>General settings–>Print Recover y–>Jam Recovery.) Pages print blank after replacing the controller board.When replacing the controller board, verify the cable from the high-voltage power supply is seated properly. The cable may have come loose from the HVPS. Warning: A blank page that should have toner on it could be an indication that toner is applied to the ITU belt but not transferred. Therefore the toner goes into the ITU cleaner which cannot process massive amounts of toner. It is important to prevent extensive blank pages from being processed if they should have toner on them. Unexpected page breaks occur Increase the Print Timeout value on the operator panel (Settings–>General Settings–>Timeouts–>Print Timeout.)
2-4Ser vice Manual 7525xxxLexmark confidential until announce Scan / fax / copy symptom table Symptom Action 840.xx scanner error Go to “840.xx service check” on page 2-63. ADF won’t duplex (Duplex ADF only) Go to “ADF Duplex service check” on page 2-69. ADF skew Go to “ADF feed errors service check” on page 2-69. Multiple pages feed into ADF Documents wont feed into ADF Scanner makes buzzing noise on startup or during a scan.Go to “Flatbed home position service check” on page 2-66. Document feeds, but jams in ADF. Go to “ADF paper jam service check” on page 2-68. Black streaks on scans Go to “ADF streak service check” on page 2-67. Blank page Go to “Black or blank page copy service check” on page 2-65. Black page No dial tone Go to “Modem / fax card service check” on page 2-70. Machine dials a number but fails to make a connection with another fax machine.The other fax machine may be turned off. Ask the fax recipient to check their machine. Incoming fax has blank spaces or poor quality.1. The sending fax machine may be faulty. 2. The sending fax machine may have a dirty document glass. 3. A noisy phone line can cause errors. 4. Check the MFP print quality by making a copy. 5. The print cartridge may be empty. Replace as necessary. Invalid fax partition, or fax partition too small.See “Format Fax Storage” on page 3-34. Some words on an incoming fax are stretched.The sending fax machine had a temporary jam. Faxes fail to transmit. Go to “Fax transmission service check” on page 2-71. Fax reception fails. Go to “Fax reception service check” on page 2-73.
Diagnostic information2-5 Lexmark confidential until announce7525xxx Print quality symptom table Symptom Action Background Go to “Print quality—background” on page 2-51. Blank page Go to “Print quality—blank page” on page 2-52. Blurred or fuzzy print Go to “Print quality—blurred or fuzzy print” on page 2-54. Half-color page Go to “Print quality—half-color page” on page 2-54. Horizontal banding Go to “Print quality—horizontal banding” on page 2-54. Horizontal line Go to “Print quality—horizontal line” on page 2-55. Insufficient fusing Go to “Print quality—insufficient fusing” on page 2-55. Missing image at edge Go to “Print quality—missing image at edge” on page 2-55. Mottle (2–5mm speckles) Go to “Print quality—mottle (2–5mm speckles)” on page 2-55. Narrow ver tical line Go to “Print quality—narrow vertical line” on page 2-56. Random marks Go to “Print quality—random marks” on page 2-56. Residual image Go to “Print quality—residual image” on page 2-57. Solid color page Go to “Print quality—solid color page” on page 2-58. Vertical banding Go to “Print quality—vertical banding” on page 2-58. Color problems Go to “Color theory” on page 3-60.
2-6Ser vice Manual 7525xxxLexmark confidential until announce Error codes and messages User status and attendance messages User status and attendance messages User primary message Explanation Calibrating The printer is performing a color adjustment. Close Door Message clears when upper and lower doors are closed. Insert Tray This message is displayed when the printer requests the user to insert tray x before it can continue printing the job. The printer needs to pick media from the missing tray or the trays below it. Tr a y x=Tray 1, Tray 2 Note: This message displays when refilling the trays during a job. Before filling tray a tray, take the printer offline by pressing Stop , and wait for pages to stop feeding into the output bin. The following actions can be taken: Insert the requested tray. Cancel the current job No Analog Phone Line An analog line is not detected as being plugged into the modem. If the device is in Analog mode, this has a source of Fax. If the device is in Fax Server mode, and the Enable analog receive Fax Server setting is set to On, this has a source of Fax Receive. If the device is in Fax Server mode and the Enable analog receive Fax Server setting is set to Off, then this IR is not generated. Memory Full, cannot send faxesAfter a start, there is no memory to do the fax job. Attempted fax is cancelled. Insert Duplex Page in Tr a y Reload printed page in tray . Cancel Job appears if the job can be cancelled. Install Tray or Cancel jobPrinter detects that tray is missing, where x is 1 or 2. This message appears if the job was begun, but the paper has not yet been retrieved. The tray is no longer detected. Replace the indicated tray. Load Printer does not detect media meeting the description in , where is Tray 1, Tray 2, Multi-Page Feeder (MP feeder), or Envelope Feeder. Load the input source with the correct type and size media. Cancel the current job. Load Printer does not detect media meeting the description in , where is Tray 1 or Tray 2. Load the input source with the correct type and size media. Cancel the current job. Load Printer does not detect media meeting the size requested in the source indicated. Load the input source with the correct type and size media. Cancel the current job. Load Printer does not detect media meeting the size or type requested in the source indicated. Load the input source with the correct type and size media. Cancel the current job. Load Manual Printer does not detect media meeting the description in the single sheet feeder (manual feeder). The following actions can be taken: Load paper, and the job continues. Select ( ), and choose an alternate source for media. Cancel the current job.