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X543 - X544 series 7525-xxx • Table of contents • Start diagnostics • Safety and notices • Trademarks • Index Lexmark and Lexmark with diamond design are trademarks of Lexmark International, Inc., registered in the United States and/or other countries.
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Lexmark, Lexmark with diamond design, and MarkNet are trademarks of Lexmark International, Inc., registered in the United States and/or other countries. Optra Forms is a trademark of Lexmark International, Inc.
7525-xxx Notices and safety information The following laser notice labels may be affixed to this printer. Laser notice The printer is certified in the U.S. to conform to the requirements of DHHS 21 CFR Subchapter J for Class I (1) laser products, and elsewhere is certified as a Class I laser product conforming to the requirements of IEC 60825-1.
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7525-xxx Avisos sobre el láser Se certifica que, en los EE.UU., esta impresora cumple los requisitos para los productos láser de Clase I (1) establecidos en el subcapítulo J de la norma CFR 21 del DHHS (Departamento de Sanidad y Servicios) y, en los demás países, reúne todas las condiciones expuestas en la norma IEC 60825-1 para productos láser de Clase I (1).
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7525-xxx Laserilmoitus Tämä tulostin on sertifioitu Yhdysvalloissa DHHS 21 CFR Subchapter J -standardin mukaiseksi luokan I (1) - lasertuotteeksi ja muualla IEC 60825-1 -standardin mukaiseksi luokan I lasertuotteeksi. Luokan I lasertuotteita ei pidetä haitallisina. Tulostimen sisällä on luokan IIIb (3b) laser, joka on nimellisteholtaan 5 mW:n galliumarsenidilaser ja toimii 770 - 795 nanometrin aallonpituuksilla.
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7525-xxx Avís sobre el Làser Segons ha estat certificat als Estats Units, aquesta impressora compleix els requisits de DHHS 21 CFR, apartat J, pels productes làser de classe I (1), i segons ha estat certificat en altres llocs, és un producte làser de classe I que compleix els requisits d’IEC 60825-1.
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7525-xxx Notices and safety information...
7525-xxx Lithium warning CAUTION This product contains a lithium battery. THERE IS A RISK OF EXPLOSION IF THE BATTERY IS REPLACED BY AN INCORRECT TYPE. Discard used batteries according to the battery manufacturer’s instructions and local regulations. Safety information • The safety of this product is based on testing and approvals of the original design and specific components.
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7525-xxx Sicherheitshinweise • Die Sicherheit dieses Produkts basiert auf Tests und Zulassungen des ursprünglichen Modells und bestimmter Bauteile. Bei Verwendung nicht genehmigter Ersatzteile wird vom Hersteller keine Verantwortung oder Haftung für die Sicherheit übernommen. • Die Wartungsinformationen für dieses Produkt sind ausschließlich für die Verwendung durch einen Wartungsfachmann bestimmt.
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7525-xxx Informació de Seguretat • La seguretat d'aquest producte es basa en l'avaluació i aprovació del disseny original i els components específics. El fabricant no es fa responsable de les qüestions de seguretat si s'utilitzen peces de recanvi no autoritzades. •...
7525-xxx Preface This manual contains maintenance procedures for service personnel. It is divided into the following chapters: General information contains a general description of the printer and the maintenance approach used to repair it. Special tools and test equipment, as well as general environmental and safety instructions, are discussed.
7525-xxx 1. General information The Lexmark™ X54x series are color laser MFPs that combine print, scan, copy, and fax functions. The X54x series are the ideal MFPs for presentations, business graphics, line art, and text. They use laser diode electrophotographic technology to deliver remarkable quality print images and text. The scan and copy functions work with A4, letter, and legal (ADF only) size paper.
• Power supply energy consumption is reduced. • Duplex is on if Energy + Paper is selected (duplex models only) (can be overwritten by the driver.) Data streams ✔ —Supported ✘ —Not supported Lexmark X544n, Data streams Lexmark X543 X544dn, X544dtn Lexmark X544dw ✔ ✔ ✔...
100 mm (3.9 in.) Left side 100 mm (3.9 in.) Above 360 mm (14 in.)* * Add 133 mm (5.2 in.) to the top if you want to add an optional 650-sheet Duo Drawer (Lexmark X54x models only). General information...
The following table specified nominal average power requirements for the base printer configurations. All power levels are shown in Watts (W). Maximum current is given in Amperes (A). Lexmark Printing states Lexmark 543dn X544dw, X544dn, Lexmark X544n and X544dtn Average power while printing...
7525-xxx Acoustics All acoustic measurements are made in accordance with ISO 7779-1999 and reported in conformance with ISO9296:1988-04-15. 1-Meter average sound Operating mode pressure at 4800 CQ Lexmark Lexmark X543 X544 Printing (simplex mono) 46 dBA 46 dBA Printing (simplex color)
(16–28 pound) grain long bond. The duplex unit does not support card stock, transparencies, envelopes, and labels. Lexmark transparency part numbers 12A8240, and 12A8241 are supported from the standard tray, manual slot and the multipurpose feeder. Paper 90 to 104.9 g/m (23.9 to 27.8 lb) must be printed with Paper Type set to Heavy Paper.
7525-xxx Media guidelines Paper characteristics The following paper characteristics affect print quality and reliability. Consider these characteristics when evaluating new paper stock. • Weight—The printer can automatically feed paper weights from 60 to 176 g/m (16 to 47 lb bond) grain long.
US fed as well as non-recycled paper. However, no blanket statement can be made that all recycled paper will feed well. Lexmark consistently tests its printers with recycled paper (20–100% post-consumer waste) and a variety of test paper from around the world, using chamber tests for different temperature and humidity conditions.
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7525-xxx Recycled paper, paper of lower weight (<60 g/m [16 lb bond]) and/or lower caliper (<3.8 mils [0.1 mm]), and paper that is cut grain-short for portrait (or short-edge) fed printers may have lower bending resistance than is required for reliable paper feeding. Before using these types of paper for laser (electrophotographic) printing, consult your paper supplier.
7525-xxx Fax specifications Phone network connectivity Phone networks types supported PSTN or analog PABX (RJ-11) ITU COMPATIBILITY Group 3/ECM 8 x 3.85 pels/mm (200X100dpi) (204x98) Standard Resolution Fine 8 x 7.7 pels/mm (200X200dpi) (204x196) Superfine 11.8 x 11.8 pels/mm(300x300 dpi) (204x391) Ultrafine 15.7 x 15.7 pels/mm (400x400 dpi) (408x391) Coding...
7525-xxx 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)
7525-xxx Acronyms. Alternating Current Autocompensator Mechanism (or paper feed) Automatic document feeder Analog front end All-In-One Automatic Paper Size ASIC Application Specific Integrated Circuit BLDC Brushless DC Motor Black Only Retract Belt up down Cyan Charge-Couple Device CCFL Cold Cathode Fluorescent Lamp Counter clockwise Command Descriptor Blocks CMYK...
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LASER Light amplification by stimulated emission of radiation Liquid crystal display Liquid Crystal Module Laser Diode Light emitting diode Long edge feed Lexmark Embedded Solution (applications) Laser Scanning Unit Low Voltage LVPS Low voltage power supply Magenta Megabyte Motor Driver Control...
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7525-xxx Pulse Width Modulation Random access memory RFID Radio frequency identification Relative humidity Raster image processor Read-only memory Read-only storage Revolutions Per Minute Scanner Control Card SDRAM Synchronous Dynamic Random Access Memory Short edge feed SIMM Single Inline Memory Module Solenoid Start of scan SRAM...
7525-xxx 2. Diagnostic information Start 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. 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.
7525-xxx 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: The LED turns on.
7525-xxx 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 Go to “One or more operator panel buttons fail” on not work. page 2-44. Operator panel—display is blank. Printer Go to “Operator panel display blank, five beeps”...
7525-xxx 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”...
7525-xxx 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”...
7525-xxx 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 <x> This message is displayed when the printer requests the user to insert tray x before it can continue printing the job.
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7525-xxx User status and attendance messages (continued) User primary message Explanation Load Manual Printer does not detect media meeting the description <custom string> in the single <custom string> sheet feeder (manual feeder). The following actions can be taken: • Load paper and the job continues. •...
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7525-xxx User status and attendance messages (continued) User primary message Explanation 31.xx Defective <color> The specified cartridge is defective. Try one of the following: cartridge • Open and close the top cover. • Remove and re-install the cartridge(s). Listen for the click to ensure the cartridge is installed properly.
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7525-xxx User status and attendance messages (continued) User primary message Explanation 37 Insufficient memory This message is displayed when insufficient printer memory is available to perform for flash defragment Flash Memory Defragment operation. operation This message appears prior to the actual start of the defragment operation. press Select ( ) to stop the defragment operation.
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7525-xxx User status and attendance messages (continued) User primary message Explanation 53 Unformatted Flash press Select ( to clear the message and continue printing. You must format the flash memory before you can store any resources on it. If the error message remains, the flash memory may be defective and require replacing.
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7525-xxx User status and attendance messages (continued) User primary message Explanation 88 <color> Cartridge The term <color> includes black, cyan, magenta, and yellow. Early Warning • Replace the toner cartridge and press Select ( to clear the message and continue printing. 88 Replace <color>...
7525-xxx Paper Jam messages Paper jam messages (2xx) Error code Description Action 2xx paper jams 200.xx Paper Jam A single page of media jam at the input Remove the tray1 unit, open the front door, Check <area> sensor. and remove the print cartridge to access the jam area.
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7525-xxx Paper jam messages (2xx) (continued) Error code Description Action 290.20 Scanner This message occurs when paper is Remove original documents from the ADF. Static Jam-Paper detected in the ADF during a POR, or Present when the MFP is starting up. 290.30-Scanner This message displays when paper is Remove original documents from the ADF.
7525-xxx Service error messages Service error messages (1XX, 8XX and 9xx) Error code Description Action 106.xx Service Yellow printhead error. Perform a POR. If the problem persists, go Yellow Printhead “Printhead service check” on page 2-59. 106.01 Service The yellow printhead lost HSYNC. Perform a POR.
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7525-xxx Service error messages (1XX, 8XX and 9xx) (continued) Error code Description Action 107.07 Service The cyan printhead thermistor is Perform a POR. If the problem persists, go Cyan Printhead shorted to ground. “Printhead service check” on page 2-59. 107.08 Service The cyan laser showed bad in EMS Perform a POR.
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7525-xxx Service error messages (1XX, 8XX and 9xx) (continued) Error code Description Action 109.05 Service Failure reading NVRAM from Perform a POR. If the problem persists, go Black Printhead printhead. “Printhead service check” on page 2-59. 109.06 Service The black printhead thermistor is open. Perform a POR.
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7525-xxx Service error messages (1XX, 8XX and 9xx) (continued) Error code Description Action 122.16 Service EWC Error—Estimated power is at or Go to “Fuser service check” on Fuser Error above maximum power. page 2-41. 141.xx Service Staging motor error. Go to “Autocompensator mechanism Staging Motor service check”...
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7525-xxx Service error messages (1XX, 8XX and 9xx) (continued) Error code Description Action 152.04 Service Timeout waiting for SAP BLDC motor Go to “Main drive gear assembly (EP Cyan Cartridge Motor drive) service check” on page 2-43. 152.05 Service Lost lock for motor. Go to “Main drive gear assembly (EP Cyan Cartridge Motor...
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7525-xxx Service error messages (1XX, 8XX and 9xx) (continued) Error code Description Action 154.05 Service Lost lock for motor. Go to “Main drive gear assembly (EP Yellow Cartridge drive) service check” on page 2-43. Motor 154.06 Service Excessive SAP BLDC PWM. Go to “Main drive gear assembly (EP Yellow Cartridge...
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7525-xxx Service error messages (1XX, 8XX and 9xx) (continued) Error code Description Action Front scan module cable failure or SCC CCD channel failure. Check each card failure channel(mono, R, G, B) for identical values indicating bad cable and/or SCC card. Excessive noise test for the dark data indicating some sort of CCD or analog electronics issue on that channel or...
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7525-xxx Service error messages (1XX, 8XX and 9xx) (continued) Error code Description Action Fax Storage The amount of flash storage available on the device is too small. Note: The NAND Flash partition can shrink as bit failures cause blocks to be invalidated. Go to 847.01 “Format Fax Storage”...
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7525-xxx Service error messages (1XX, 8XX and 9xx) (continued) Error code Description Action 914.xx Service The DC pick has no encoder feedback. Go to “Autocompensator mechanism PC Pick Motor service check” on page 2-35 917.xx Service There is a problem with the transfer Go to Go to “Transfer roll service check”...
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7525-xxx Service error messages (1XX, 8XX and 9xx) (continued) Error code Description Action 930.xx Service A RIP to engine communication failure. LV Power Supply The zero crossing signal used for fuser control in the low-voltage (LV) power supply has failed, or the wrong low- voltage power supply has been installed.
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7525-xxx Service error messages (1XX, 8XX and 9xx) (continued) Error code Description Action 955.xx Service The Code ROM or NAND flash failed Code CRC <loc> the Cyclic Redundancy Check (CRC) check or the NAND experienced an uncorrectible multi-bit failure. "<loc>" indicates the source of the failure and has one of the following values: •...
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7525-xxx Service error messages (1XX, 8XX and 9xx) (continued) Error code Description Action 959.22 Service Challenge Secret Failure. ASIC/SP mismatch System Board Replace controller board. See“Controller board removal” on page 4-16. 959.23 Service Hardware control self test failure during Replace controller board. See“Controller System Board initialization.
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7525-xxx Service error messages (1XX, 8XX and 9xx) (continued) Error code Description Action 978.xx Service Bad checksum while programming Check the following: Standard Network network port. • Make sure you have downloaded the code in binary mode, not ASCII. • Reprogram the Network card. 978.xx Service •...
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7525-xxx Service error messages (1XX, 8XX and 9xx) (continued) Error code Description Action 990.xx Service This error message indicates that an <device> equipment check condition has occurred in the specified device, but the device is unable to identify the exact component failure. Note: <device>...
7525-xxx Fax error log codes Fax error log codes Error code Description Action No error occurred during fax No action needed transmission Error occurred when transmitting • Check line quality. • Select a lower ‘Max Speed’. training. • value under Fax Send settings •...
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7525-xxx Fax error log codes (continued) Error code Description Action T5 Timeout occurred when transmitting • Check line quality. image data to remote fax device. • Adjust ‘Transmit Level’. • Select a lower ‘Max Speed’value under Fax Send settings. Too many errors when transmitting in •...
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7525-xxx Fax error log codes (continued) Error code Description Action Failure to transmit training successfully • Select a lower “Max Speed” under Fax in V17, V29 terminal modulation Send settings. schemes. • Adjust the “Transmit Level”. • Check line quality. Failure to transmit training successfully •...
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7525-xxx Fax error log codes (continued) Error code Description Action Modem detected a digital line Verify the MFP is connected to an analog connection. line. See“Fax transmission service check” on page 2-71. Phone line was disconnected Restore phone line connection. Received request for unsupported No action needed.
7525-xxx Service checks Autocompensator mechanism service check Step Questions / actions Turn the printer off, and then remove the rear Go to step 3. Properly connect the cables, shield. See “Rear shield removal” on and POR the printer. page 4-7. Check the cable at JSP1 on the Go to step 2.
7525-xxx Step Questions / actions Turn the printer on and check following values Replace the fuser assembly. Replace the controller on JFUSES1. “Fuser assembly board. See “Controller removal” on page 4-19. board removal” on JFUSES1 page 4-16. Value +3.3 V dc Ground Ground +3.3 V dc...
7525-xxx 930.xx–935.xx—Printhead errors service check Step Questions / actions Turn the printer off, and remove the rear shield. Replace the printhead. See Go to step 2. “Rear shield removal” on page 4-7. “Printhead removal” on Check the cables connected at JMIRR1 and page 4-42.
7525-xxx 950.xx EPROM mismatch failure 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: •...
7525-xxx Bin full sensor service check Step Questions / actions Inspect the bin full sensor located towards the Repair or replace the bin full Go to step 2. rear of the top cover assembly. sensor. See“Bin full sensor” on page 4-15 Is the bin full sensor dislodged or damaged? With the scanner assembly in the down Go to step 3.
7525-xxx 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.
7525-xxx 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 Enter Diagnostics Menu (turn the printer off, Go to step 2. Go to step 4. press and hold , turn the printer on, and then release the buttons when the...
7525-xxx Front door sensor or switches service check Step Questions / actions Enter Diagnostics Menu (turn the printer off, press Sensor, toner door, and Go to step 2. and hold , turn the printer on, and then right doors are OK. release the buttons when the installed memory and processor speed displays).
7525-xxx Fuser exit sensor service check Step Questions / actions Enter Diagnostics Menu (turn the printer off, Correct the sensor or Go to step 2. press and hold , turn the printer on, replace it. See “” on and then release the buttons when the page 4-22.
7525-xxx Fuser service check Step Questions / actions Some low-voltage power supply FRUs have a Check the switch on the side Go to step 2. voltage selector switch. If it does, the switch of the LVPS to verify the needs to be set to the correct voltage for your correct voltage is set.
7525-xxx Input sensor (S2) service check The Input sensor (S2) is part of the ACM FRU. Step Questions / actions Enter Diagnostics Menu (turn the printer off, Replace the Go to step 2. press and hold , turn the printer on, autocompensator and then release the buttons when the mechanism.
7525-xxx Main drive gear assembly (EP drive) service check Step Questions / actions Turn the printer off, and remove the rear shield. Replace the JCARTB1 Go to step 2. “Rear shield removal” on page 4-7. cable. 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.
7525-xxx 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: •...
7525-xxx Step Questions / actions Turn the printer off, and remove the rear shield. Go to step 3. Replace the controller “Rear shield removal” on page 4-7. board. See “Controller Disconnect the operator panel assembly cable board removal” on at JOPP1 on the controller board. Turn on the page 4-16.
7525-xxx Operator panel displays all diamonds, no beeps Step Questions / actions Turn off the printer, and remove the rear shield. Go to step 2. Replace the controller “Rear shield removal” on page 4-7. board. See “Controller Disconnect the cable at JOPP1 on the board removal”...
7525-xxx Operator panel display is dim and unchanging Step Questions / actions Turn off the printer, and remove the rear shield. Go to step 2. Replace the controller “Rear shield removal” on page 4-7. board. See “Controller Disconnect the cable at JOPP1 on the board removal”...
Have the network administrator verify that the device is using the correct SSID, and wireless security protocols. For more network troubleshooting information, consult the Lexmark Network Setup Guide. Step...
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7525-xxx Step Questions / actions Try using a different ethernet cable. Problem resolved Go to step 14. Did this remedy the situation? Have the network administrator check the Replace the controller Contact the network network drop for activity. board. Go to “Controller administrator.
7525-xxx Print quality service check Note: This symptom may require replacement of one or more CRUs (Customer Replaceable Units) designated as supplies or maintenance items, which are the responsibility of the customer. With the customer's permission, you may need to install a developer (toner) cartridge or photo conductor unit. Service tip Before troubleshooting any print quality problems, do the following: Print a menu settings page, and check the life status of all supplies.
7525-xxx Print quality—background Service tip: Some background problems can be caused by rough papers, non-Lexmark toner cartridges or if the media texture is set to the rough setting. Some slick or coated papers may also cause background problems. Some problems occur with printers that run a large amount of graphics in a humid environment.
7525-xxx Step Questions / actions Clean the printhead. Problem resolved. Replace the printhead. See “Printhead removal” on Does this fix the problem? page 4-42. Print quality—blank page Step Questions / actions Is all the packing material for the imaging unit Go to step 2.
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7525-xxx Step Questions / actions Enter the Diagnostics Menu (turn the printer Go to step 5. Replace the Main drive gear off, press and hold , turn the printer assembly. See “Main drive on, and release the buttons when installed gear assembly with motor memory and processor speed displays), and removal”...
7525-xxx Print quality—blurred or fuzzy print Run the automatic alignment. The TPS sensor may be damaged. To run Reset Color Cal: Enter the Diagnostics Menu. (Turn the printer off, press and hold , turn the printer on, and release the buttons when installed memory and processor speed displays.
7525-xxx Print quality—horizontal line Either the photoconductor unit or one of the developer units that make up the imaging unit is defective. Remove and inspect the imaging unit. Replace the damaged part of the imaging unit. See “Imaging unit (IU) removal” on page 4-28.
7525-xxx Print quality—narrow vertical line ABCDE ABCDE ABCDE Step Questions / actions Replace the photoconductor unit. See Problem solved. Replace the developer unit. “Developer unit “Imaging unit (IU) removal” on page 4-28. removal” on page 4-30 Print quality—random marks Service tip: The primary cause of random marks is due to loose material moving around inside the printer and attaching to the photoconductor unit, developer roll, or transfer belt.
7525-xxx Print quality—residual image Service tip: Install a new print cartridge, if available, before doing this service check. Residual image can be caused by the photoconductor, cleaning blade, and other parts ABCDE inside the print cartridge. ABCDE ABCDE Step Questions / actions Check the condition of the imaging unit using Go to step 2.
7525-xxx 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. Step Questions / actions Replace the photoconductor unit (part of the Problem resolved.
7525-xxx 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 Turn the printer off, and remove the rear shield. Replace the printhead. See Go to step 2. “Rear shield removal”...
7525-xxx Toner meter cycle (TMC) card Step Questions / actions Perform the Base Sensor Test: Replace the toner cartridge. Replace the toner meter cycle (TMC) card. See 1. Enter Diagnostics menu (turn off the “Toner meter cycle (TMC) printer, press and hold and Select ( card removal”...
7525-xxx Transfer roll service check Step Questions / actions Remove the ITU. See “Image transfer unit Replace the ITU. See Problem resolved. (ITU)” on page 4-26. Check the contacts “Image transfer unit (ITU)” between the HVPS and the ITU. Clean the on page 4-26.
7525-xxx Tray 1 sensor service check Step Questions / actions When the printer is in Ready state, pull the Go to step 2. Go to step 4. standard tray out. The display should indicate Tray 1 Missing. Insert the tray. Does the message remain on the display? Check the vertical well at the right rear of the Replace the tray.
7525-xxx Scanner / Copy / Fax service checks 840.xx service check Step Questions / actions POR the machine into configuration mode. Go to step 2. Stop. Problem resolved. Go to the disable scanner menu item. See “Disable Scanner” on page 3-36.
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7525-xxx Step Questions / actions Replace the ADF unit. See “Duplex ADF Go to step 8. Stop. Problem solved. 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”...
7525-xxx Black or blank page copy service check Step Questions / actions Print a menu page, or a page from the host. “Print quality—solid Go to step 2. Is the page black? color page” on page 2-58 Is the copy an ADF scan? Go to step 3.
7525-xxx Flatbed home position service check Step Questions / actions POR the MFP. Does the CCD move and Problem solved. Go to step 2. return to the home position? Perform the home position sensor test. Go Go to step 3. Go to step 5.
7525-xxx ADF cover open service check Step Questions / actions Is the ADF cover properly closed Go to step 3. Go to step 2. Close the ADF cover. Issue resolved Go to step 3. Does the problem go away? Perform the ADF cover open sensor test. Go Go to step 4 Go to step 8.
7525-xxx ADF paper jam service check Note: This service check should be used if the paper feeds and jams in the ADF. If the paper is not feeding into the ADF see “ADF feed errors service check” on page 2-69. Step Questions / actions If the ADF is multi-feeding, check for dirt on...
7525-xxx ADF feed errors service check Step Questions / actions If the ADF is multi-feeding, check for Clean them with a lint free Replace the separator pad and dirt on the ADF separator pad and cloth and isopropyl alcohol. ADF pick roll. ADF separator rollers.
7525-xxx Check all the connections on the ADF Go to step 4 Properly connect all the relay card. Are they properly connections. connected? Check the ADF cable to ensure it is Go to step 5. Properly connect the ADF cable properly connected to CN 15 on the to its connections.
7525-xxx Fax transmission service check Note: Before performing this service check, verify that the correct country code for the MFP is selected. This setting must match the country in which the MFP is used to transmit and receive faxes. If the setting is wrong, the modem settings can be changed in the Fax/SE menu.
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7525-xxx Step Questions / actions Adjust the “Transmit Level” setting in the SE Stop. Problem resolved. Go to your second-level of menu. press **411 to enter the SE menu, support. See “Escalating a enter Modem settings, and select “Transmit fax issue to second-level Level”.
7525-xxx Fax reception service check Step Questions / actions Is the phone line properly connected to the Go to step 2. Go to step 3. modem card and the wall jack? Properly connect the phone line to the Problem resolved. Go to step 3.
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7525-xxx Step Questions / actions Go to the Administrator menu. Enter the Fax Go to step18 Go to step 19. settings - Analog Fax Settings submenu. Verify the remote device number is not in the Banned Fax List user setting. Is the remote device number in the banned fax list? Remove the remote number from the...
7525-xxx Escalating a fax issue to second-level support Before contacting the second-level support, go to the SE menu on the MFP.and generate a Fax error file. This file contains machine settings information and debug information that will help second-level support determine the cause of a failure.
7525-xxx User operator panel, menus and messages Understanding the operator panel The printer operator panel has a four-line, back lit, grayscale display that can show both graphics and text. The Mode selection, job setup, Back, and Menu buttons are located to the left of the display, the navigation buttons are located below the display, and the start buttons, stop button, and numeric pad are located to the right of the display.
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7525-xxx Button or indicator Function Start / Black and White press to start a job in black and white. Stop/Cancel Stops all printer activity. A list of options is offered once Stopped appears on the display. Operating modes Copy Selecting this option enables copy mode. Scan / E-mail Selecting this enables scan and scan to E-mail mode.
7525-xxx Menu map This menu map identifies menus available to customers. The diagram shows the menus on the operator panel and items available under each menu. Some menu items or values are displayed only if a specific option or feature is installed on your printer. Other menu items may be effective only for a particular printer language.
7525-xxx 3. Diagnostic aids This chapter explains the tests and procedures to identify printer failures and verify repairs have corrected the problem. Menu key combinations. There are different test menus that can be accessed during POR to identify problems with the printer. Configuration Menu 1.
7525-xxx Diagnostics Menu (Diag Menu) Note: Tray 2 refers to the 650-sheet tray located in the 650-sheet Duo Drawer assembly. Diagnostics menu structure When the Diagnostics mode is entered, each Diagnostics main menu item displays on the operator panel. When a diagnostic test is selected from the main menu, a sub menu displays, and each individual test displays in the order shown.
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7525-xxx Diagnostics mode tests (continued) INPUT TRAY TESTS (if Tray 2 is installed) Feed Tests “Feed Tests” on page 3-17. Sensor Tests “Sensor Test” on page 3-17. BASE SENSOR TEST “Base Sensor Test” on page 3-18. Front Door Input S1 Input S2 Fuser Exit Standard Bin...
7525-xxx Diagnostics mode tests (continued) Print Log “Print Log” on page 3-23. Clear Log “Clear Log” on page 3-24. Development Menu Do not use. For development use only. Scanner Tests ASIC Test “ASIC Test” on page 3-25. Feed test “Feed Test” on page 3-25.
7525-xxx Description Value Direction of change Right margin -50 to +50 A positive change moves the image to the left, and a negative change moves the image to the Each increment corresponds to an right. approximate shift of 4 pixels at 600 dpi.
Horizontal lines to check for skew • General printer information, including current page count, installed memory, serial number, and code level. Lexmark x54x To print the Quick Test page: Note: Print the Quick Test Page on letter or A4 paper.
7525-xxx Alignment Aligns each of the color planes to the black plane. Print the Quick Test under each color, Cyan, Yellow, and Magenta, and adjust the Top Margin, Left Margin, Right Margin, Skew, and Bow. Prints the Print Alignment Pages and requires that the best line in each set of lines must be selected. To get started: Select Alignment Menu from the Diag Menu, and press Select ( Select a color (Cyan, Yellow, or Magenta), and press Select (...
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7525-xxx Select Top Margin, and press Select ( Select the best choice for fine or coarse adjustment in Step 1 (first page), and add it to the current value for the Top Margin. to enter the sum of the numbers, and press Select ( Submitting changes…...
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7525-xxx Select the Skew value in the same way, enter the value, press Select ( ), and print the Quick Test to see if the observed values and the current values are the same. On the second page of the latest Quick Test you printed, proceed to Step 2; adjust the left, right ,and bow settings.
7525-xxx Factory Scanner Note: This setting is not used by field service. Factory Manual Note: This setting is not used by field service. Miscellaneous Tests Motor Detect This test initiates an automatic motor detection process that should be performed whenever the controller board is replaced.
The print quality test consists of five pages. Pages one and two contain a mixture of graphics and text. The remainder of the pages contain only graphics. The test prints on the media in tray 1. Lexmark x54x 3-11 Diagnostic aids...
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7525-xxx This test may be printed from either Configuration Menu or the Diagnostics Menu. To run the print quality pages from the Diagnostics Menu: Select PRINT TESTS, and press Select ( Select Print Quality Pgs, and press Select ( The message Printing Quality Test Pages is displayed. Note: Once the test is started, it cannot be cancelled.
7525-xxx Hardware Tests Panel Test This test verifies the operator panel LCD function. To run the Panel Test: Select Hardware Tests from Diag Menu, and press Select ( Select Panel Test, and press Select ( The Panel Test continually executes. press Stop ( ) to cancel the test.
7525-xxx To stop the test early, turn off the printer. CACHE Test The CACHE Test is used to verify the processor cache is functioning properly. Select Hardware Test in Diag Menu, and press Select ( Select CACHE Test, and press Select ( The printer displays: CACHE Test Testing…...
This test prints a duplex version of the Quick Test that can be used to verify the correct placement of the top margin on the back side of a duplex page. Lexmark x54x Note: Before you set the duplex top margin, be sure to set the registration. See “Registration”...
7525-xxx Hold the page to the light to see whether the left margin of the back aligns with the left margin of the front. Select Left Margin from DUPLEX TESTS. to select the margin setting you need to change. • Each increment shifts the duplex left margin by 4 pixels at 500 dpi (0.0067 inches or 0.1693 mm).
7525-xxx Input Tray tests Feed Tests This test allows you to observe the paper path of media as it passes through the printer. Any installed input tray can be tested. The pages fed through the printer are blank. To run the Feed Test: Select INPUT TRAY TESTS from Diag Menu, and press Select ( Select Feed Tests, and press Select ( Select the tray to be tested.
7525-xxx Base Sensor Test These tests allow you to verify the correct functioning of the front door, input, and output sensors. Select Base Sensor Test from Diag Menu, and press Select ( Select the sensor you want to test, and press Select ( The following test are available: Sensor Value...
7525-xxx Printer Setup Defaults US/Non-US defaults changes whether the printer uses the US factory defaults or the non-US factory defaults. The settings affected include paper size, envelope size, PCL symbol set, code pages, and units of measure. Warning: Changing this setting resets the printer to factory defaults, and data may be lost. It cannot be undone. Page Counts You can view, but not change any of the three counts displayed under PAGE COUNTS.
7525-xxx Unless the menu is in DIAGNOSTICS, Check Config ID displays. • To set the configuration ID: Select PRINTER SETUP from DIAGNOSTICS, and press Select ( Select Configuration ID, and press Select ( The current value for Configuration ID 1 appears with the left character or digit underlined. Enter the Configuration ID 1.
7525-xxx Reset Fuser Count Resets the fuser count value to zero. The Event Log records each time that a user executes the Reset Fuser Count operation. See “Event Log” on page 3-32 for more information. This setting appears only if the Maintenance Warning and Intervention function is enabled in the printer Configuration ID.
7525-xxx TPS Setup Right or Left TPS The value of the TPS sensor is set at manufacturing. If a sensor is replaced, enter the 32-digit hexadecimal TPS value from the barcode next to the sensor. To enter the value: Select TPS SETUP from Diag Menu, and press Select ( Select Right or Left, and press Select ( TPS Right 1-16 or TPS Left 1-16 appears above a blinking 0 in the left position.
Detailed printer information, including code versions • Time and date stamps • Page counts for most errors • Additional debug information in some cases Model and Lexmark x54x (s/n: 98P104V) Serial number Printer information Panel display when error occurred Page count Earliest error code 3-23...
7525-xxx The printed event log can be faxed to your next level of support for verification or diagnosis. To print the event log: Select EVENT LOG from DIAGNOSTICS, and press Select ( Select Print Log, and press Select ( press Back ( ) to return to EVENT LOG.
7525-xxx Scanner Tests ASIC Test This test initiates a scan of the scanner ASIC’s memory. While this test is executing ASIC Test Running is displayed. When the test is complete, ASIC Test Passed is displayed if the ASIC memory is ok. ASIC Test Failed is displayed if the test fails. press the Back or Stop buttons to clear the display message Feed Test This test executes a continuous feed test from ADF or flatbed.
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7525-xxx ADF paper present sensor test This test should be used if the ADF fails to feed paper when a scan is performed. To test this sensor perform the following steps: In the sensor test menu, press to scroll to the ADF paper present test. ).Starting Test displays.
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7525-xxx FB Cover closing sensor test This test verifies the functionality of the FB cover closed sensor. To test this sensor. perform the following steps: In the sensor test menu, press to scroll to the FB Cover closing sensor test. ).
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7525-xxx Sensor 1 test This test verifies the functionality of scan sensor 1. To test this sensor. perform the following steps: In the sensor test menu, press to scroll to the Sensor1 test. ). Starting Test displays. Sensor 1: Closed displays. press Select ( Lift the ADF top cover, and close the ADF cover sensor by pressing down on the ADF sensor actuator (A) with a small flat blade screwdriver.
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7525-xxx Sensor2 test This test verifies the functionality of scan sensor 2. To test this sensor. perform the following steps: In the sensor test menu, press to scroll to the Sensor 2 test. ). Starting Test displays. Sensor 2: Closed displays. press Select ( Lift the ADF top cover, and close the ADF cover sensor (A) by pressing down on the ADF sensor actuator with a small flat blade screwdriver.
7525-xxx Configuration Menu Available tests The tests display on the operator panel in the order shown for all models. Configuration menu USB Scan to Local “USB Scan to Local” on page 3-31. Prt Quality Pgs “Prt Quality Pages” on page 3-31.
7525-xxx Uses an algorithm to compensate for mechanical incorrect registration in the printer. When small black text or fine black lines are being printed, the printer checks to see if they are being printed on top of a colored background. If so, rather than remove the color from beneath the black content, the printer leaves the color around the edge of the text or line.
7525-xxx Demo Mode Lets marketing personnel or merchandisers demonstrate the printer to potential customers by printing the demo page. Selections include Deactivate (default) and Activate. Select Deactivate to turn Demo Mode off; or select Activate to turn Demo Mode on. Factory defaults Sets the majority of printer values back to their factory default settings.
7525-xxx Min Copy Memory This setting allocates the amount of DRAM memory to be used for storing copy jobs in the queue. 25, 35,50,80 and 100 MB are the available settings. To adjust the minimum copy memory, perform the following steps: In the configuration menu, scroll to the MinCopy Memory item, and press Use the to increase or decrease the setting’s value.
7525-xxx FB Edge Erase This menu item sets the size, in millimetres, of the no print are around a flatbed scan job. Copy jobs will use the setting or two millimetres, whichever is larger. To adjust the flatbed edge erase setting, perform the following steps: In the Configuration menu, select the FB Edge Erase menu item.
7525-xxx Use the to increase or decrease the settings value. Note: Each button press moves the margin values one pixel in the respective direction. Press to accept the value. Scroll to Top Edge, and press Use the to increase or decrease the settings value. Note: Pressing moves the margin up, and pressing moves the margin down.
7525-xxx Font Sharpening This setting is used to set a text point size value below which the high frequency screens will be used when printing data. This setting affects only PCL, PostScript and PDF emulators. Settings are in the range of 0–150 (24 is the default). For example, if the value is set to 24, then all fonts sized 24 points or less use the high frequency screens.
7525-xxx SE Menu Note: This is not the Fax SE menu. To enter the Fax SE menu, press **411 from the Ready screen. Note: This menu should be used as directed by second-level support. Print SE Menus General Copyright - Displays copyright information. Optra Forms mode - On or off Code Revision Info Network Code Level - Displays network code level...
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.
7525-xxx 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.
7525-xxx 200 paper jams Remove the standard 250-sheet tray (tray 1). Remove the jam. Note: Make sure all paper fragments are removed. Insert the tray. press Select ( 201 paper jam Grasp the front door at the side handholds, and then pull it toward you to open it. Remove the jammed paper.
7525-xxx 202 paper jam Raise the scanner assembly to the up position. Grasp the front door at the side handholds, and then pull it toward you to open it. Grasp the green lever, and pull the fuser cover toward you. Hold the fuser cover down, and then remove the jammed paper.
7525-xxx 230 paper jam Grasp the front door at the side handholds, and pull it toward you to open it. Remove the jam. press Select ( ) to continue printing. 235 paper jam Load the tray with the correct paper size. Insert the tray.
7525-xxx 29x ADF paper jam Remove all original documents from the ADF input tray. Open the ADF top cover. Remove the jammed paper. Close the ADF cover. Open the flatbed cover. Remove any jammed pages. Close the scanner lid. Press 3-44 Service Manual...
7525-xxx 291.xx ADF paper jams Remove all original documents from the ADF input tray. Remove the ADF input tray. See “ADF input tray” on page 4-64. Remove the original from the ADF by pulling the lower of the two sheets (A) from the ADF exit. Replace the ADF input tray.
7525-xxx 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.
7525-xxx 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.
7525-xxx 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.
7525-xxx Step 3: Develop Once the laser exposes the photoconductor, the high-voltage power supply sends charge to the developer roll (C). For each color, the toner cartridge engages the photoconductor so it is in contact with the surface. Because of the charge difference between the toner on the developer roller and the electrostatic image created by the laser, the toner will attract to the photoconductor only where the laser exposed the surface.
7525-xxx Step 4a: First transfer When the latent images are developed on each Photoconductor, the high-voltage power supply sends voltage to the 1st Transfer Rollers inside the ITU (D). The charge difference between the developed toner image on the Photoconductor surface and the 1st Transfer Roller causes the images to transfer to the surface of the ITU belt for each color.
7525-xxx Step 4b: Second transfer Once the four planes of color are transferred to the transfer belt from the photoconductors, the image is carried towards the transfer roll (E). This transfer roll is also part of the ITU. Based on the speed of the transfer belt, the proper time to send the signal to pick the media from an input source is determined.
7525-xxx Step 5: Fuse Once the image has been fully transferred to the media, the transfer roll helps move the paper into the fuser area. The fuser (F) applies heat and pressure to the page to melt the tiny toner particles and bond them permanently to the media.
7525-xxx Step 6: Clean/Erase There are two main cleaning processes that take place during the EP Process. One process cleans the transfer belt, and the other cleans the photoconductors. Transfer Unit Clean Once the toner image on the transfer belt has been transferred to the page, the transfer belt rotates around and is cleaned by the cleaning blade (G).
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7525-xxx Photoconductor Clean/Erase After each plane of color has been transferred to the transfer belt from the photoconductors, a cleaning blade (H) scrapes the remaining toner from the surface of each photoconductor. This is the clean/erase process. Now the photoconductor surface is prepared to begin the EP cycle once again. This cleaning/erasing cycle happens after each plane of color is transferred to the transfer belt.
7525-xxx Paper path, transport components In order for an image to be printed, the media has to be moved from an input source (such as a tray) into the printer and eventually exit into an output source. The most important component in this process is this media itself. Old, damaged, or out-of-specification media can and will cause feed and transport problems.
7525-xxx Transport components In summary, the media is fed from the tray into the printer by a feed roll and carried to the transfer roll (ITU). The pick rollers time the media to enter the EP process at just the right moment. The pick rollers push the media to the ITU where the image is transferred to the page.
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7525-xxx When the trailing edge of the media clears the fuser, the fuser engine rotates forward to prepare the fuser for the page travelling through the duplexer. As the media reaches the gate aligner, a sensor (S1) is triggered indicating the presence of the leading edge. When the S1 sensor is triggered, the paper continues to the S2 sensor.
7525-xxx Scanner theory Duplex ADF The following illustration shows the paperpath, rollers and sensors used in the X544 duplex ADF. The X544 duplex ADF enables the user to create duplex scans automatically, eliminating the need to stop the scanning process to flip the media being duplicated over. The ADF uses a step motor, and a series of sensors to determine the media’s position in the paper path during the scan process.
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7525-xxx with the ADF scan sensor ensure that the media is travelling at the correct speed through the scan area. The speed the document travels through the ADF scan area is dependent on the image DPI specified by the user. 7.
7525-xxx Color theory What is RGB color? Red, green, and blue light can be added together in various amounts to produce a large range of colors observed in nature. For example, red and green can be combined to create yellow. Televisions and computer monitors create colors in this manner.
7525-xxx My color transparencies seem dark when they are projected. Is there anything I can do to improve the color? This problem most commonly occurs when projecting transparencies with reflective overhead projectors. To obtain the highest projected color quality, transmissive overhead projectors are recommended. If a reflective projector must be used, then adjusting the Toner Darkness setting to 1, 2, or 3 will lighten the transparency.
7525-xxx How can I match a particular color (such as a corporate logo)? From the printer Quality menu, nine types of Color Samples sets are available. These are also available from the Color Samples page of the Embedded Web Server. Selecting any sample set generates a multiple-page printout consisting of hundreds of colored boxes.
7525-xxx 4. Repair information Warning: Read the following before handling electronic parts. Handling ESD-sensitive parts Many electronic products use parts that are known to be sensitive to electrostatic discharge (ESD). To prevent damage to ESD-sensitive parts, use the following instructions in addition to all the usual precautions, such as turning off power before removing logic boards: •...
7525-xxx Removal procedures CAUTION Remove 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. Notes: •...
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7525-xxx Remove the five screws (A) from the cable cover. Remove the cable cover. Remove the screw (B) securing the right restraining strap to the front cover. Note: Support the door with one hand after removing the screw holding the restraining strap. This is the longest screw of the eight.
7525-xxx Front middle cover removal Open the front cover. Remove the five screws (A) attaching the front middle cover to the lower front cover. Pull the front middle cover away from the front cover. Left cover removal Remove the media tray. Open the front cover.
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7525-xxx Remove the three screws (A) on the rear side of the left cover. Repair information...
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7525-xxx Remove the screw (B) on the bottom of the cover. With a hand on the bottom of the cover, ease the cover over the off/on switch, and rotate the cover away from the printer. Warning: Be careful not to damage the rear tab at the upper rear side of cover. Installation note: When replacing the left cover, flex the cover slightly to engage the tab near the power switch.
7525-xxx Right cover removal Remove the media tray. Lift and lock the flatbed assembly to the raised position. Open the front cover. Release the green latches securing the door. Lower the right cover and remove it from the hinges. Rear shield removal The rear shield is not a field replaceable unit (FRU).
7525-xxx AIO back cable cover removal Remove the two screws (A) which secure the AIO back cable cover to the MFP. Place a small flat-blade screwdriver under the bottom of the cover, and gently pry the cover upward. Service Manual...
7525-xxx Top cover assembly removal Remove the flatbed assembly. Go to “Flatbed removal” on page 4-53. Remove the AIO toner cover. Go to “AIO toner cover” on page 4-76. Remove the five screws (A) from the left front side. Remove one screw (B) from the top right side of the cover. Repair information...
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7525-xxx Remove the four screws (C) on the right side of the top cover. Remove one screw (D) from the rear. 4-10 Service Manual...
7525-xxx Detach the re-drive belt (E) from the pulley on the fuser exit roll shaft. Disconnect the fan power cable from JFAN1 on the controller board. Disconnect the bin full sensor cable from JPJ1 on the controller board. Remove the top cover, being careful to route the fuser exit sensor cable through the top of the controller board cage.
7525-xxx Autocompensator mechanism (ACM)—standard tray removal Remove the toner bottles, the waste toner container, and the imaging unit (IU). See “Imaging unit (IU) removal” on page 4-28 and see “Waste toner bottle” on page 4-49. Remove the rear shield. See “Rear shield removal”...
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7525-xxx Remove the two springs (D). Remove the two screws (E) on the bottom. 4-13 Repair information...
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7525-xxx On the right side, loosen the screw (F) with a screwdriver, and hold the ACM in place as you use your fingers to remove the screw. Move the right side of the ACM out to free the shaft from the hole in the frame. Note: Observe the location of the shaft and hole for reinstallation.
7525-xxx Bin full sensor Remove the flatbed unit. See “Flatbed removal” on page 4-53. Using a small flatblade screwdriver, gently depress the tabs (A) which secure the sensor to the top cover assembly. Pull the sensor away from the top cover assembly. Disconnect the sensor from the cable.
7525-xxx Controller board removal Warning: Observe all ESD precautions while handling electrostatic-discharge sensitive parts. See “Handling ESD-sensitive parts” on page 4-1. Warning: When replacing any one of the following components: • Operator panel assembly • Controller board Replace only one component at a time. Replace the required component, and perform a POR before replacing a second component listed above.
7525-xxx Print a few pages to verify the installation. If the pages are blank, confirm that the high-voltage power supply cable is properly seated. The connector may have been loosened at the HVPS. A blank page that should have toner on it could be an indication that toner is applied to the ITU belt but not transferred.
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7525-xxx Pull the corner of the cable channel cover (B) away from the right side to access the sensor posts (C). Unclip the sensor. Remove the sensor, and disconnect the cable (D) from the duplex sensor. Note: Close the front cover, and slightly lift the front of the printer to get better access. 4-18 Service Manual...
7525-xxx Fuser assembly removal Remove the right cover. See “Right cover removal” on page 4-7. Remove the left cover. See “Left cover removal” on page 4-4. Disconnect the two-wire fuser cable (A) from the LVPS. Position the fuser cable so that it can be pulled through from the front of the printer, and guide the cable to the front.
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7525-xxx Unhook the springs (D) from either side of the fuser. Detach the geared belt (E) from the drive pulley on the fuser exit roll shaft. Note: Do not remove the pulley or spacer from the shaft. Rotate the top of the fuser toward the front, slide it to the left to align the fuser side frame with the flat areas of the shaft (F) and lift to remove the fuser.
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7525-xxx Installation notes: • Make sure the springs are resting on the top so they can be reached once the fuser is in place. • When reinstalling on the right, make sure the gears mesh. • Be careful not to interfere with the exit sensor on the left side. •...
7525-xxx Fuser drive motor assembly removal Open the front cover. Remove the right cover. See “Right cover removal” on page 4-7. Disconnect the cable (A) from the fuser drive motor assembly. Note: If you remove the toroid (B) from the cable, be sure to return the toroid to the cable when you re- install.
7525-xxx Fuser exit sensor removal Open the front cover. Remove the fuser assembly. See “Fuser assembly removal” on page 4-19. Remove the screw (A) securing the fuser exit sensor. Disconnect the cable (B) from the fuser exit sensor. Remove the lower end of the sensor with a flat blade screwdriver, and gently pull the sensor from the bracket.
7525-xxx High-voltage power supply (HVPS) assembly removal Note: This removal requires a magnetized, long-shank Phillips screwdriver at least 8 in. or 200 mm long. Remove the top cover assembly. See “Top cover assembly removal” on page 4-9. Remove the rear shield. See “Rear shield removal”...
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7525-xxx Remove the screw (B). The screw is accessible from the top of the printer, and requires a long-shank magnetized Phillips screwdriver. It is the only screw without a flanged head. Remove the screw (C) securing the HVPS. Carefully slide the HVPS out. Installation notes: Warning: Connect the high-voltage power supply (HVPS) cable to the high-voltage power supply before...
7525-xxx Image transfer unit (ITU) Write down the number on the new ITU before installing it. You will need the 16-digit numeric value from the barcode after the installation, and it is easier to see at this point. Remove the right cover. See “Right cover removal”...
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7525-xxx Rotate the release lever (C) in a counter clockwise direction with a spring hook to decouple the ITU while pulling the ITU toward the front. Hold the release lever while removing the ITU. Installation note: • Write down the 16-digit numeric value of the new FRU before you begin to install it. •...
7525-xxx Imaging unit (IU) removal The Imaging unit is customer-replaceable unit and is not a FRU. Open the front cover. Lift the toner cover by sliding the latch to the left. Remove the waste toner bottle. See “Waste toner bottle” on page 4-49.
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7525-xxx Press and hold the release lever (B), and pull the imaging unit straight out. Warning: When pulling the imaging unit out, Only grab the release levers (B) of the imaging unit.Do not touch the photoconductors in the bottom of the imaging unit. 4-29 Repair information...
7525-xxx Developer unit removal The developer units are not FRUs. Raise the scanner unit, and remove the toner cartridges. Remove the imaging unit. See “Imaging unit (IU) removal”. Warning: Do not touch the underside of the imaging unit. This could damage the developer units. Remove the developer unit you need.
7525-xxx Low-voltage power supply (LVPS) assembly Remove the left cover. See “Left cover removal” on page 4-4. Disconnect the three cables (A) from the LVPS. Remove the six screws (B). Remove the LVPS. 4-31 Repair information...
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7525-xxx Warning: If you receive a new low-voltage power supply with a voltage selector switch (C), be sure to set the switch to the correct setting for your voltage requirements before installing the low-voltage power supply. The switch can be set for either 115 V or 230 V. Failure to do so will result in damage to the power supply.
7525-xxx Lower frame removal, right and left The right and left lower frames are in the same FRU. Left lower frame Open the front cover. Remove the waste toner bottle. See “Waste toner bottle” on page 4-49. Remove the imaging unit. See “Imaging unit (IU) removal”...
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7525-xxx Remove the AC receptacle from the left lower frame. Remove the three screws (D) securing the left lower frame. Remove the LVPS. See Remove the screw (E) on top of the frame. 4-34 Service Manual...
7525-xxx Swing the left lower frame away from the printer, and remove. Right lower frame Open the front cover. Remove the right cover assembly. See “Right cover removal” on page 4-7. Remove the waste toner bottle. See “Waste toner bottle” on page 4-49.
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7525-xxx Carefully place the printer on its left side. Remove the screw (C) securing the wireless antenna (Wireless models only) to access the right frame. Do not remove the antenna. Remove the three screws (D) securing the lower right frame to the printer. Remove the screw from the rear of the printer (E).
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7525-xxx Swing the rear part away from the printer to access the spring and sensor. 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. 4-37 Repair information...
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7525-xxx Remove the spring (G) from the left lower frame FRU. Swing the rear of the lower frame away from the printer, and remove. 4-38 Service Manual...
7525-xxx Main drive gear assembly with motor removal Remove the left cover. See “Left cover removal” on page 4-4. Remove the LVPS. See “Low-voltage power supply (LVPS) assembly” on page 4-31 Remove the screws (A) on the top cover. Remove the two screws (B) from the inside left side. 4-39 Repair information...
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7525-xxx Unplug the cables (C) from the motors, and remove all cables from the retainer (D). Note: Observe the cable routing for reinstallation. Remove the two screws (E) from the rear. Remove the two screws (F) from below the main drive gear assembly. Remove the two screws (G) from the right of the main drive gear assembly.
7525-xxx 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.
7525-xxx Printhead removal Remove the scanner assembly. See“Flatbed removal” on page 4-53. Remove the top cover. See “Top cover assembly removal” on page 4-9. Disconnect the cables. Remove the toroid (A) from the ribbon cable. Remove the three screws (B). Remove the printhead.
7525-xxx Imaging unit contacts Remove the right cover assembly. See “Right cover removal” on page 4-7. Remove the waste toner bottle. See “Waste toner bottle” on page 4-49. Remove the imaging unit. See “Imaging unit (IU) removal” on page 4-28. Remove the rear cover.
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7525-xxx Disconnect the cable (E) from the controller board at JSC1. Remove the cable from the retainer on the bottom of the printer. Extract the cable through the frame, and remove the cable with the spring contacts. 4-44 Service Manual...
7525-xxx Toner meter cycle (TMC) card removal Remove the right cover. See “Right cover removal” on page 4-7. Remove the waste toner container. See “Waste toner bottle” on page 4-49. Remove the imaging unit (IU). See “Imaging unit (IU) removal” on page 4-28.
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7525-xxx 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. •...
7525-xxx Toner patch sensor (TPS)—left and right removal The toner patch sensors are similar, but the left sensor includes an extra cable and sensing device. Remove them the same way. Remove the ITU. See “Image transfer unit (ITU)” on page 4-26.
7525-xxx Continue entering and pausing. After the 32nd number is entered and becomes solid, the number is automatically entered. If the number is incorrect, Checksum does not match appears, and the original screen appears to re- • enter the value. If the number is correct, Saving changes to NVRAM appears.
7525-xxx USB connector removal Remove the rear shield. See “Rear shield removal” on page 4-7. Disconnect the USB connector from the controller board. Remove the flatbed assembly. See “Flatbed removal” on page 4-53. Note: Do not remove the flatbed covers, or any of the hinges. The flatbed only needs to be removed from the print engine.
7525-xxx Wireless network antenna Remove the rear shield. See “Rear shield removal” on page 4-7. Lift to disconnect the wireless card (A) from the controller board. Carefully disconnect the antenna cable (B) from the wireless card at the card. Remove the screw (C) that secures the antenna cover (D) to the frame, and remove the antenna cover and antenna.
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7525-xxx Straighten the antenna perpendicular to the cover, push against the cover with your fingers, and gently squeeze the fastener (E) with needlenose pliers. Slide the antenna cable and cable through the hole in the bracket. If the fastener is damaged, remove the fastener by pressing the tabs on each side. Note: Take note of the orientation of the fastener.
7525-xxx Wireless network card Remove the rear shield. See “Rear shield removal” on page 4-7. Lift to remove the wireless card (A) from the controller board. Carefully disconnect the antenna cable (B) from the wireless card at the card. 4-52 Service Manual...
7525-xxx Scanner component removal procedures Flatbed removal Remove the AIO rear cable cover. See “AIO back cable cover removal” on page 4-8. Remove the rear shield. See “Rear shield removal” on page 4-7. Remove the left cover. See “Left cover removal” on page 4-4.
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7525-xxx Disconnect the ADF cable ground wire (B) from the frame. Disconnect JADF1, and route the cable through the top of the card cage. Disconnect the USB cable from JUSB1, op panel cable from JOPP1, flatbed home sensor cable from JHS1, and flatbed motor cable from JFBM1.
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7525-xxx Disconnect the screw (D) connecting the flatbed to the AIO link on the rear of the MFP. Carefully disconnect the AIO link from the flatbed. Remove the two screws (E) securing the flatbed hinge to the top cover. Remove the two springs (F) between the flatbed and top cover. 4-55 Repair information...
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7525-xxx Gently push the front flatbed hinge (G) towards the front of the top cover to disengage it from the top cover guide Pin. Carefully pull the flatbed unit towards the front of the MFP while using your other hand to route the cables through the top cover.
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7525-xxx Remove the steel hinge stud (H). Save this for use on the replacement flatbed. Remove the redrive (I) See“Redrive unit” on page 4-70., Remove the cable cover plates and scanner homing plates (J). These will be used on the replacement flatbed unit.
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7525-xxx Remove the screws (K) securing the front hinge to the flatbed. Remove the hinge; it will be used on the replacement flatbed unit. Note: The redrive, cable covers, operator panel assembly, scanner flatbed guides, op panel cable, and USB cable need to be transferred to the replacement flatbed unit. Note: After replacing the flatbed unit, you will need to perform the flatbed registration procedure.
7525-xxx Preparing and installing re new flatbed Unbox the scanner, and place it top down on a non-marring surface. Unfold the ribbon cable, and replace the toroid (A) from the old flatbed. 4-59 Repair information...
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7525-xxx Locate the folding guide line (B), and remove the paper from the adhesive strip located next to the folding guide line on the scanner. Fold the ribbon cable at a 90 degree angle, align the fold of the cable with the fold line on the flatbed, and press the cable down on the adhesive so it adheres to the flatbed.
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7525-xxx Locate the second folding guide line (C), and remove the paper from the adhesive strip. Fold the ribbon cable a second time at a 90 degree angle, align the fold of the cable with the fold line on the flatbed, and press the cable down on the adhesive so it adheres to the flatbed.
7525-xxx Duplex ADF rear cover While lifting the ADF, use a flatblade screwdriver to pry open the three tabs (A) on the bottom of the ADF cover. Lift and remove the rear cover from the ADF assembly. 4-62 Service Manual...
7525-xxx Duplex ADF removal Remove the duplex ADF rear cover from the ADF assembly. See “Duplex ADF rear cover” on page 4-62. Save the cover for use on the new ADF unit. Disconnect the ground cable (A) from the ADF assembly. Disconnect the ADF cable (B) from the ADF card located on the ADF assembly.
7525-xxx Simplex ADF rear cover While lifting the ADF, use a flatblade screwdriver to pry open the two tabs on the bottom of the ADF cover. Lift and remove the rear cover from the ADF assembly. Simplex ADF removal Tilt the flatbed cover to the upright position. Lift the ADF up and away from the flatbed.
7525-xxx ADF cable Remove the flatbed assembly. See “Flatbed removal” on page 4-53. Remove the left scanner cover. See “Cover scanner left” on page 4-71. Remove the cable from the channel in the flatbed. 4-65 Repair information...
7525-xxx ADF separator pad Remove the ADF separator roll. See “ADF separator roll assembly” on page 4-67. Pinch the two tabs on each side of the pad inward. Tilt the pad up, and lift it out of the ADF assembly. 4-66 Service Manual...
7525-xxx ADF separator roll assembly Lift the locking lever (A). Slightly lift the separator roll assembly, and pull it out of the mount (B) on the opposite side. 4-67 Repair information...
7525-xxx Bezel cover Remove the op panel bezel. See “Op panel bezel removal” on page 4-79. Remove the two screws (A) securing the bezel cover to the top of the op panel mounting frame. Remove the AIO link. See “AIO link” on page 4-75.
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7525-xxx While holding the op panel mounting assembly, remove the op panel bezel cover. 4-69 Repair information...
7525-xxx Redrive unit Remove the flatbed assembly from the MFP. See “Flatbed removal” on page 4-53. Place the flatbed facedown on a soft surface to avoid scratching the glass or marring the covers. Remove the cable cover plate (A). Remove the four screws (B) securing the redrive to the flatbed unit. Remove the bin full sensor flag located on the rear shaft.
7525-xxx Cover scanner left Remove the flatbed assembly. See “Flatbed removal” on page 4-53. Release the tabs (A) securing the left flatbed cover to the flatbed unit using a small flatblade screwdriver. 4-71 Repair information...
7525-xxx Cover scanner right Remove the imaging unit in the print engine. Raise the scanner assembly to the up position, and lock in place. Remove the four screws (A) securing the right scanner cover to the flatbed unit. 4-72 Service Manual...
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7525-xxx While holding the ADF away from the flatbed, use the other hand to lift and disengage the right scanner cover from the flatbed unit. 4-73 Repair information...
7525-xxx AIO release lever Remove the right scanner cover. See “Cover scanner right” on page 4-72. Remove the screw (A) securing the AIO link to the flatbed unit. Disengage the AIO link from the flatbed unit. Remove the screw (B) securing the AIO release lever to the flatbed. Slide the AIO release lever towards the back of the flatbed.
7525-xxx AIO link Lift the scanner to the up position. Use a phillips screwdriver to remove the screw (A) securing the AIO link to the AIO toner cover. Return the flatbed to the down position. Remove the screw (B) securing the AIO link to the flatbed unit. 4-75 Repair information...
7525-xxx AIO toner cover Lift the scanner unit to the up position. Remove the screw (A) fastening the AIO toner cover to the scanner unit. Remove the screws (B) securing the AIO hinge to the MFP. Remove the hinge. Save this for the new AIO toner cover. Rotate the AIO toner cover so the tab (C) on the cover lines up with the hole on the AIO toner cover.
7525-xxx Operator panel removal Warning: When replacing any one of the following components: • Operator panel assembly • Controller board Replace only one component at a time. Replace the required component, and perform a POR before replacing a second component listed above. If this procedure is not followed, the printer will be rendered inoperable. Never replace both of the components listed above without a POR after installing each one, or the printer will be rendered inoperable.
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7525-xxx Disconnect the operator panel cable (B). Remove the two screws (C) attaching the USB connector to the operator panel. Set the USB connector aside to attach to the new operator panel. Remove the ground wire from the op panel. 4-78 Service Manual...
7525-xxx Op panel bezel removal Place a flatbed screwdriver under the front of the bezel. Pry the bezel up and away from the op panel. Be careful to avoid marring the bezel cover. 4-79 Repair information...
7525-xxx Op panel cable Remove the operator panel bezel cover. Remove the operator panel. See “Operator panel removal” on page 4-77. Remove the flatbed assembly. See “Flatbed removal” on page 4-53. Remove the CCD cable cover. Unroute the operator panel cable through the tabs (B). Warning: When replacing the op panel and USB cables, the cables must be routed in the exact same route with no overlapping of the cables.
7525-xxx Pull the logo cover away from the op panel bezel cover. Fax card removal Remove the rear shield. See “Rear shield removal” on page 4-7. Disconnect the fax interface cable from the fax card. See “Fax interface cable” on page 4-81.
7525-xxx Output bin tray Grasp and lift the rear output bin tray away from the MFP. Bin full flag removal Lift the scanner assembly and lock it into the up position. Gently disconnect the three snaps (A) from the rear shaft of redrive unit. Remove the bin full flag.
7525-xxx 5. Locations Exterior views Front Front view Callout Part name Operator panel ADF input tray Output bin AIO release Right imaging unit cover (right cover) Primary paper tray Manual feeder Multipurpose feeder Locations...
7525-xxx Connectors LVPS board Connector Pin no. Signal Ground Ground Ground +25V Ground +25V Ground +25V Ground Relay Drive ZC Out Heat On AC phase input AC neutral input AC Out AC load phase 5-18 Service Manual...
7525-xxx Toner meter card Toner meter card connectors Toner meter card Connector Pin no. Signal From JCTM1 connector on the +5 V_SW controller board Cart_Meter_C_IN Cart_Meter_M_IN Cart_Meter_Y_IN Cart_Meter_K_IN Ground 5-19 Locations...
Damaged, missing, or altered covers, especially in the area of the top cover and the power supply cover • Possible safety exposure from any non-Lexmark attachments Lubrication specifications Lubricate only when parts are replaced or as needed, not on a scheduled basis. Use of lubricants other than those specified can cause premature failure.
PP: (Parts Packet) in the parts description column indicates the part is contained in a parts packet. • Model information used in the parts catalog: Machine type/model Term used in parts Product name Description 7525-131 Lexmark X543dn Network, duplex print 7525-133 Lexmark X543dn Network, duplex print, DBCS op panel 7525-138 Lexmark X543dn...
7525-xxx Assembly 5: Electronics 2 Asm- Part Units/ Units/ Description index number option 40X5429 ITU paper path thermistor 40X5414 Toner density sensors, left or right (one in package) 40X5421 Imaging unit contact (Pogo pin) 40X5423 Cable packet, used for: A AC power in B Low-voltage power supply C High-voltage power supply D Fuser / S1...
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7525-xxx Index 2-32 2-35 Numerics service checks 2-14 2-19 1xx service errors – 2-14 1xx, 8xx, 9xx error codes bezel cover 2xx paper jam 4-68 removal 2-12 messages ??– 4-82 bin full flag removal 2xx paper jam messages bin full sensor 3-40 locations 2-36...
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7525-xxx 2-37 3-19 dead printer service check serial number 3-19 defaults printer setup 3-33 factory defaults REGISTRATION 3-33 Demo Mode Bottom Margin developer unit Left Margin 4-30 removal Right Margin diagnostics Top Margin 2-12 2xx paper jam message table registration 2-12 paper jam messages Scaner Tests...
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Lexmark confidential until announce 7525-xxx 4-81 removal 2-73 fax reception service check 4-77 LCD operator panel 1-18 fax specifications left scanner cover 1-18 miscellaneous 4-71 removal 1-18 phone network connectivity ii-xvii lithium battery 1-18 scan resolutions logo cover 2-71 fax transmission service check...
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7525-xxx 2-47 display is dim print quality symptoms 2-44 3-11 service check print tests 2-45 blank, printer beeps 5 times and pauses printer registration 2-46 diamonds, 5 beeps printhead 2-46 diamonds, no beeps parts catalog 2-44 4-42 display blank, 5 beeps removal 2-44 2-34...
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Lexmark confidential until announce 7525-xxx 4-22 fuser drive motor assembly input 4-23 3-18 fuser exit sensor Base Sensor Test 4-24 2-42 High voltage power supply service check 4-26 7-10 image transfer unit parts catalog 4-28 imaging unit (IU) 4-43 3-18...
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7525-xxx 4-64 removal simplex ADFunit 4-64 removal specifications acoustics clearances connectivity (network) data streams 1-16 digital imaging dimensions duplex capability environmental 1-18 media input size memory operating modes print quality 1-17 scan and copy specifications power and electrical symptom tables symptoms print quality printer...