Lexmark X543 Service Manual
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Diagnostic information2-37 Lexmark confidential until announce7525xxx Dead printer service check A dead printer is a condition where the display is blank, the LED on the operator panel is off, the fan does not turn, no motors turn, and the fuser does not heat. If a 650-sheet Duo Drawer is installed, remove the option and check the base printer for correct operation. If the base printer operates correctly, replace the 650-sheet Duo Drawer. Warning:Observe all necessary ESD precautions when removing and handling the controller board or any installed option cards or assemblies. See “Handling ESD-sensitive parts” on page 4-1. Remove any input paper handling options from the printer. Step Questions / actions Yes No 1Check the AC line voltage. Is the line voltage correct?Go to step 2. Inform the customer. 2Is the AC line cord damaged? Replace the line cord. Go to step 3. 3Is the JLVPS1 cable correctly connected at JLVPS1 on the controller board?Go to step 5. Reconnect the JLVPS1 cable, and go to step 4. 4Turn the printer off, and then on. Does the problem persist?Go to step 5. Problem resolved. 5Warning: Damage to the printer is possible. Be careful to touch only one conductor at a time. Rest the probe against the connector to steady it. With the printer on.verify the following values at JLVPS1: Are the values approximately correct?Replace the controller board. See “Controller board removal” on page 4-16.Replace the LVPS. See“Low-voltage power supply (LVPS) assembly” on page 4-31. CAUTION When you see this symbol, there is a danger from hazardous voltage in the area of the product where you are working. Unplug the product before you begin, or use caution if the product must receive power in order to perform the task. JLVPS1 (exposed conductors) Pin Value Pin Value 1 +5 V dc 7 +24 V dc 3 +5 V dc 9 +24 V dc 5 +5 V dc 11 +24 V dc
2-38Service Manual 7525xxxLexmark confidential until announce Duplex/manual feed sensor (S1) service check Note: Before performing this service check, ensure that the printer is on a hard level surface. Step Questions / actions Yes No 1Enter Diagnostics Menu (turn the printer off, press and hold and , turn the printer on, and then release the buttons when the installed memory and processor speed displays). Perform the Base Sensor Test. See “Base Sensor Test” on page 3-18. 1. Select Base Sensor Test, and press Select (). 2. Select S1, and press Select (). 3. Install tray 1. Does the display indicate InputS1—Media Clear…?Go to step 2. Go to step 4. 2Pull tray 1 out. Does the display indicate InputS1—Media Present…? The sensor is functioning correctly.Go to step 3. 3Remove the tray, and inspect sensor. Is there something obstructing the sensor?Remove the obstruction and restart the test.Go to step 4. 4Inspect the spring-loaded shaft/flag in the tray. The flag portion of the shaft intercepts the sensor, except when a sheet is being staged for duplexing. Does the shaft rotate freely and return to home position (flag at top of rotation)?Go to step 5. Replace the tray with a new one. 5Is the flag on the shaft broken? Replace the tray. Go to step 6. 6Is the cable correctly connected to JFUSES1 on the controller board and to the sensor. Is the sensor cable properly connected?Go to step 7. Reconnect the cable. If the problem persists, go to step 7. 7Turn the printer off, and remove the rear shield. See “Rear shield removal” on page 4-7. Turn the printer on, and check the values at JFUSES1: Are the values approximately correct?Replace the duplex sensor. See “Duplex sensor removal” on page 4-17. Replace the controller board. See “Controller board removal” on page 4-16. JFUSES1 Pin Value 8 Ground 9 +3.3 V dc
Diagnostic information2-39 Lexmark confidential until announce7525xxx Front door sensor or switches service check Step Questions / actions Yes No 1Enter Diagnostics Menu (turn the printer off, press and hold and , turn the printer on, and then release the buttons when the installed memory and processor speed displays). Perform the Base Sensor Test. See “Base Sensor Test” on page 3-18. 1. Select Base Sensor Test, and press Select (). 2. Select Front Door, and press Select (). 3. Open and close the front door, and observe the display. Does the display indicate Va l u e C l o s e d with the door closed and Value Opened with the door opened?Sensor, toner door, and right doors are OK.Go to step 2. 2Open the front door and check the thin, tall, plastic web (pivot plate) at the top right of the printer. With the other covers in place and closed, this web interacts with switches in the door. Open the toner cover and check the motion of the web. Is the web loose, damaged, or missing?Replace the right cover assembly. See“Right cover removal” on page 4-7.Go to step 3. 3Open the toner door and inspect the vertical web that pushes and rotates the pivot plate. Is it damaged?Replace the top cover assembly. See “Top cover assembly removal” on page 4-9.Go to step 4. 4With the front cover open, inspect the two switches. Using a tool, such as a spring hook, push the metal arms to check the movement. Is there any damage to the switches or the surrounding area?Replace the right cover assembly. See“Right cover removal” on page 4-7.Go to step 5. 5Turn the printer off, and remove the rear shield. See “Rear shield removal” on page 4-7. Turn the printer on, and verify the following values at JINT1 and JCVR1: Are the values approximately correct?Go to step 6. Replace the controller board. See “Controller board removal” on page 4-16. 6Close the front cover and the toner door. Be sure the right cover is in place. Turn the printer off, and then disconnect the cables at JINT1 and JCVR1. Test continuity at the connector under the following conditions: With front cover and toner door closed: Test pin 1 and pin 3 at JINT1 cable end and pin 1 and pin 2 at JCVR1 cable end. With one or both doors open: Pin 2 and 3 at JINT1 cable end should indicate continuity, but Pin 1 and 2 at JCVR1 should have no continuity. Are the tests verified?Contact your next level of support.Replace the front cover assembly. See “Front cover assembly removal” on page 4-2. JINT1 JCVR1 Pin Value Pin Value 1 +5 V dc 1 +24 V dc 2 Ground
2-40Service Manual 7525xxxLexmark confidential until announce Fuser exit sensor service check Step Questions / actions Yes No 1Enter Diagnostics Menu (turn the printer off, press and hold and , turn the printer on, and then release the buttons when the installed memory and processor speed displays). Perform the Base Sensor Test. See “Base Sensor Test” on page 3-18. 1. Select Base Sensor Test, and press Select (). 2. Select Fuser Exit Sensor, and press Select (). 3. Open and close the front door, and inspect the fuser exit sensor located on the LVPS shield. Is the sensor dislodged or damaged?Correct the sensor or replace it. See “” on page 4-22.Go to step 2. 2Rotate the flag (paper diverter) in and out of the sensor. Does the display indicate Media Clear and Media Present with the cycle?Sensor is good. Go to step 3. 3Does the flag rotate freely, but returns to block the sensor?Go to step 4. Replace the fuser. See“Fuser assembly removal” on page 4-19. 4Is the cable correctly connected to JBIN1 on the controller board and to the sensor. is the sensor properly connected?Go to step 5. Reconnect the cable. 5Make sure the printer is turned off. Disconnect the cable at the sensor and at JBIN1 on the controller board. Turn the printer on and check the voltage values: Does the voltage values correct?Replace the fuser exit sensor. See “” on page 4-22. Replace the controller board. See “Controller board removal” on page 4-16. JBIN1 Pin Value 4 +5 V dc 5 +0 V dc (no media), +3.3 V dc (media) 6 Ground
Diagnostic information2-41 Lexmark confidential until announce7525xxx Fuser service check Step Questions / actions Yes No 1Some low-voltage power supply FRUs have a voltage selector switch. If it does, the switch needs to be set to the correct voltage for your area Has the LVPS been changed?Check the switch on the side of the LVPS to verify the correct voltage is set.Go to step 2. 2Turn the printer off, and remove the rear shield. See “Rear shield removal” on page 4-7. Check the cable at JFUSES1 for proper connection to the controller board, the cable for pinch points, and the cable or connector for any other damage. Is the cable damaged?Replace the fuser cable. Go to step 3. 3Check the connector JLVPS1 for proper connection to the controller board, the cable for pinch points, and the cable or connector for any other damage. Is the cable damaged?Repair or replace the LVPS cable. See “Low-voltage power supply (LVPS) assembly” on page 4-31.Go to step 4. 4Check the power cable on the left side of the fuser and the thermistor cables and connections on the right side of the fuser. Are the cables or connectors damaged?Repair the cables. If the cables cannot be repaired, replaced the fuser. See “Fuser assembly removal” on page 4-19.Go to step 5. 5Disconnect the cable at JFUSES1 on the controller board, and check the following voltages: Are the voltages correct?Go to step 6. Replace the controller board. See “Controller board removal” on page 4-16. 6Replace the fuser. See “Fuser assembly removal” on page 4-19. Does the error clear?Problem resolved. Replace the controller board. See “Controller board removal” on page 4-16. JFUSES1 Pin Voltage 5 +3.3 V dc 6 Ground 8 Ground 10 +2.7 V dc 11 Ground
2-42Service Manual 7525xxxLexmark confidential until announce Input sensor (S2) service check The Input sensor (S2) is part of the ACM FRU. Step Questions / actions Yes No 1Enter Diagnostics Menu (turn the printer off, press and hold and , turn the printer on, and then release the buttons when the installed memory and processor speed displays). Perform the Base Sensor Test. See “Base Sensor Test” on page 3-18. 1. Select Base Sensor Test, and press Select (). 2. Select S2, and press Select (). 3. Pull tray 1 out, and rotate the S2 sensor flag (S2 is located in front of the center autocompensator mechanism housing.) It should rotate freely and return to its original position. Is the input (S2) sensor flag damaged?Replace the autocompensator mechanism. See “Autocompensator mechanism (ACM)— standard tray removal” on page 4-12. Go to step 2. 2Watch the display while rotating the flag. Does the display indicate Media Clear and Media Present?Problem resolved. Go to step 3. 3Turn the printer off, and remove the rear shield. See “Rear shield removal” on page 4-7. Is the JSP1 cable connector properly connected to the controller board?Go to step 4. Reseat the connector. 4Turn the printer on, and check the voltage at JSP1 pin 15. Is the voltage approximately +5 V dc?Replace the autocompensator mechanism. See “Autocompensator mechanism (ACM)— standard tray removal” on page 4-12. Replace the controller board. See “Controller board removal” on page 4-16.
Diagnostic information2-43 Lexmark confidential until announce7525xxx Main drive gear assembly (EP drive) service check 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 JCARTB1 for proper connection to the controller board, the cable for pinch points, and the cable or connector for any other damage. Is the cable damaged?Replace the JCARTB1 cable.Go to step 2. 2Disconnect the cable at JCARTB1 on the controller board, and verify the following values. Are the voltages correct? Go to step 3. Replace the controller board. See “Controller board removal” on page 4-16. 3Replace the main drive assembly. See “Main drive gear assembly with motor removal” on page 4-39. Does the error clear?Problem resolved. Replace the controller board. See “Controller board removal” on page 4-16. JCARTB1 Pin Voltage 4 +24 V dc 6 +24 V dc 8 +24 V dc 9 Ground 12 Ground 13 +24 V dc 15 +24 V dc 17 +24 V dc
2-44Service Manual 7525xxxLexmark confidential until announce Operator panel service check Warning:Replace one of the following components, and perform a POR before replacing a second component. Never replace both of the components without performing a POR after installing each one, or the printer will be rendered inoperable: Operator panel assembly Controller board Warning:Never install and remove components listed above as a method of troubleshooting components. Once a component has been installed in a printer, and the printer is powered on, it cannot be used in another printer. It must be returned to the manufacturer. One or more operator panel buttons fail Operator panel display blank, five beeps Service tip: The printer has detected a problem with the controller board, the operator panel assembly cable (part of the front cover assembly), or the operator panel assembly if POST does not complete. The printer emits five beeps, and sticks in a continuous pattern until the printer is turned off. Step Questions / actions Yes No 1Run the Button Test. See “Button Test” on page 3-13 in Diagnostics Menu. Did any of the buttons fail the test?Replace the operator panel assembly. See “Operator panel removal” on page 4-76. Go to step 2. 2Turn the printer off, and remove the rear shield. “Rear shield removal” on page 4-7. Disconnect the operator panel assembly cable at JOPP1 on the controller board. Turn on the printer, and verify the following voltages: Are the voltage values approximately correct?Replace the operator panel. See “Operator panel removal” on page 4-76. If the problem is not resolved, replace the operator panel cable. See “Op panel cable” on page 4-79Replace the controller board. See “Controller board removal” on page 4-16. Step Questions / actions Yes No 1Is the operator panel assembly cable properly installed at controller board JOPP1 and at the operator panel assembly?Go to step 2. Reinstall the cable. JOPP1 Pin Voltage 2 +5 V dc 4 Ground 5 +5 V dc 6 +3.3 V dc 7 Ground
Diagnostic information2-45 Lexmark confidential until announce7525xxx Operator panel display blank, printer beeps five times and pauses 2Turn the printer off, and remove the rear shield. See “Rear shield removal” on page 4-7. Disconnect the operator panel assembly cable at JOPP1 on the controller board. Turn on the printer, and verify the following voltages: Are the voltage values approximately correct?Go to step 3. Replace the controller board. See “Controller board removal” on page 4-16. 3Check continuity of the operator panel assembly cable. Is there continuity?Replace the operator panel assembly. 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 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 JOPP1 Pin Voltage 2 +5 V dc 4 Ground 5 +5 V dc 6 +3.3 V dc 7 Ground 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
2-46Service Manual 7525xxxLexmark confidential until announce Operator panel displays all diamonds, no beeps Operator panel displays all diamonds, five beeps 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 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 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 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