Page 1: Service Manual
Lexmark CXx10 MFP Machine Type 7527-2xx, -4xx, -63x Service Manual • Start diagnostics • Maintenance • Safety and notices • Trademarks • Index January 17, 2013 www.lexmark.com P/N 12G3313...
Page 2: Product Information
January 17, 2013 The following paragraph does not apply to any country where such provisions are inconsistent with local law: LEXMARK INTERNATIONAL, INC., PROVIDES THIS PUBLICATION “AS IS” WITHOUT WARRANTY OF ANY KIND, EITHER EXPRESS OR IMPLIED, INCLUDING, BUT NOT LIMITED TO, THE IMPLIED WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE.
Page 3: Table Of Contents
7527 Table of contents Product information..................2 Edition notice....................2 Notices and safety information..............11 Laser notices............................11 Safety...............................14 Preface.......................17 Service manual conventions........................17 Change history............................17 General information...................19 Media guidelines.............................19 Characteristics that affect print quality ......................19 Unacceptable paper............................20 Selecting paper ..............................Selecting preprinted forms and letterhead ......................21 Using recycled paper and other office papers ....................21...
Page 4 7527 Print quality missing image at edge service check....................34 Print quality mottle (2‑5 mm speckles) service check ..................Print quality narrow vertical line service check ....................34 Print quality random marks service check ......................34 Print quality residual image service check......................35 Print quality solid color page service check ......................36 Print quality vertical banding service check......................36...
Page 5 7527 91x.xx (910.xx‑919.xx) Engine software service check ................... 950.xx NVRAM failure service check.......................108 Network service check............................109 Symptoms..............................111 Base printer symptoms...........................112 Narrow media sensor service check .......................113 Toner meter cycle (TMC) card service check ....................115 Dead printer service check ..........................115 Front door sensor or switches service check ....................117 Operator panel (display is dim and unchanging) service check..............121...
Page 6 7527 Understanding the basic functions of the scanner ..................160 Diagnostics menu..........................161 Entering diagnostics mode ..........................162 Available tests..............................REGISTRATION ..............................164 Skew................................Quick Test ............................... Alignment Menu .............................168 Scanner calibration ............................168 MISC TESTS ..............................PRINT TESTS ..............................Print quality test pages ...........................171 HARDWARE TESTS ............................171 DUPLEX TESTS ..............................
Page 7 7527 Num pad job assist............................194 Format fax storage............................194 Flatbed edge erase............................195 Scanner manual registration...........................195 Disable scanner............................... Auto Color Adjustment ...........................196 Font Sharpening.............................. Exit Config ............................... Entering invalid engine mode........................197 Entering recovery mode........................197 Accessing the Network SE menu......................197 Accessing the service engineer (SE) menu....................198 Accessing the fax SE menu........................198...
Page 8 7527 AIO toner cover removal ..........................235 AIO link removal ............................. AIO release lever removal..........................237 Bin‑full flag removal............................238 Controller board removal ..........................239 Developer unit removal ..........................240 Duplex reference edge removal ........................241 Duplex sensor removal ...........................244 EP drive assembly removal ..........................245 Flatbed pivot link removal ..........................251 Flatbed scanner assembly removal.........................252...
Page 9 7527 Component locations................311 Controller boards..........................311 Maintenance....................319 Inspection guide............................319 Scheduled maintenance........................321 Maintenance kits ............................321 Preventive maintenance........................321 Device‑specific preventive maintenance ......................321 Lubrication specification........................322 Cleaning the printer..........................322 Cleaning the exterior of the printer........................322 Cleaning the scanner glass..........................323 Cleaning the printhead lenses ........................324 Parts catalog....................326 Legend..............................326 Assembly 1:...
Page 10 7527 Media handling options.........................355 Option configurations...........................356 Appendix C: Theory of operation..............359 Paper path and transport components....................359 Paper path information ..........................359 Transport components ...........................360 Bubble sensors..............................Duplexing ................................ Print engine theory..........................362 Electrophotographic process (EP process)......................362 Electrophotographic process basics .......................362 theory.............................366 ADF theory of operation ..........................366 Color theory............................368...
Page 11: Notices And Safety Information
7527 Notices and safety information Laser notices Laser notice The printer is certified in the U.S. to conform to the requirements of DHHS 21 CFR, Chapter I, 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. Class I laser products are not considered to be hazardous.
Page 12 7527 Aviso de láser Esta impresora se ha certificado en EE. UU. de conformidad con los requisitos de DHHS 21 CFR, capítulo I, subcapítulo J, para los productos láser de Clase I (1), y en otros países está certificada como un producto láser de Clase I de acuerdo con los requisitos de IEC 60825-1.
Page 13 7527 Luokan I lasertuotteita ei pidetä haitallisina. Tulostimen sisällä on luokan IIIb (3b) laser, joka on nimellisteholtaan 7 mW:n galliumarsenidilaser ja toimii 655–675 nanometrin aallonpituuksilla. Laserjärjestelmä ja tulostin ovat rakenteeltaan sellaisia, että käyttäjä ei joudu alttiiksi luokkaa 1 suuremmalle säteilylle normaalin käytön, ylläpidon tai huollon aikana.
Page 14: Safety
7527 Class I 레이저 제품은 위험한 제품으로 간주되지 않습니다. 프린터에는 655-675 나노미터의 파장 영역에서 작동 하는 공칭 7 밀리와트 갈륨 비소 레이저인 클래스 IIIb(3b) 레이저가 내부에 포함되어 있습니다. 레이저 시스템 과 프린터는 정상적인 작동, 사용자 유지 관리 또는 사전 설명된 서비스 조건에는 사람에게 클래스 I 수준 이상 의...
Page 15 7527 ATTENTION : Ce symbole indique la présence d'une tension dangereuse dans la partie du produit sur laquelle vous travaillez. Débranchez le produit avant de commencer ou faites preuve de vigilance si l'exécution de la tâche exige que le produit reste sous tension. Norme di sicurezza •...
Page 16 7527 CUIDADO: Quando vir este símbolo, existe a possível presença de uma potencial tensão perigosa na zona do produto em que está a trabalhar. Antes de começar, desligue o produto da tomada eléctrica ou seja cuidadoso caso o produto tenha de estar ligado à corrente eléctrica para realizar a tarefa necessária. Informació...
Page 17: Preface
7527 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. •...
Page 18 7527 January 08, 2013 • Added the list of items under the screw parts packet (PN 40X7832) in Assembly 3 of the parts catalog chapter. • Updated the description for PN 40X7652 to “Spring parts packet” from “Screw parts packet” in Assembly 3 of the parts catalog chapter.
Page 19: General Information
Characteristics that affect print quality Selecting the appropriate media for the printer can help avoid printing problems. For detailed information about media characteristics, see the Card Stock & Label Guide available on the Lexmark Support Web site at http://support.lexmark.com. General information...
Page 20: Unacceptable Paper
7527 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 220 g/m (16 to 58 lb bond) grain long. Paper lighter than 60 g/m might not be stiff enough to feed properly, causing jams.
Page 21: Selecting Paper
LED (electrophotographic) printers. While no blanket statement can be made that all recycled paper will feed well, Lexmark consistently tests papers that represent recycled cut size copier papers available on the global market. This scientific testing is conducted with rigor and discipline.
Page 22: Storing Paper
Lexmark concerns itself with the responsible use of paper in general based on life cycle assessments of its products. To gain a better understanding of the impact of printers on the environment, the company commissioned a number of life cycle assessments and found that paper was identified as the primary contributor (up to 80%) of carbon emissions caused throughout the entire life of a device (from design to end-of-life).
Page 23: Tools Required For Service
7527 • Hard disk memory—Some devices have a hard disk drive installed. The printer hard disk is designed for device- specific functionality and cannot be used for long term storage for data that is not print-related. The hard disk does not provide the capability for users to extract information, create folders, create disk or network file shares, or transfer FTP information directly from a client device.
Page 24 7527...
Page 25: Diagnostic Information
7527 Diagnostic information • “Troubleshooting overview” on page 25 • “Power‑on Reset (POR) sequence” on page 26 • “Using Safe Mode” on page 27 • “Fixing print quality issues” on page 27 • “Paper jams” on page 37 • “User messages” on page 67 •...
Page 26: Error Code Number Key
7527 Error code number key The following chart identifies the error code numbers that should be consistent across product lines. Range Description Go to page Text prompts User prompts without code numbers “Understanding the printer messages” on page 67 100–199 Printer hardware errors “1xx service error messages”...
Page 27: Using Safe Mode
7527 Using Safe Mode Safe Mode lets the printer continue to operate in a special limited mode in which it attempts to continue offering as much functionality as possible despite known issues. See “Safe Mode print behavior” on page Warning—Potential Damage: Safe Mode is intended as a short‑term workaround and should be used only in the case of a non‑critical error when a print job must be completed before service can be arranged to repair the printer.
Page 28: Initial Print Quality Check
7527 • “Print quality horizontal line service check” on page 33 • “Print quality missing image at edge service check” on page 34 • “Print quality mottle (2‑5 mm speckles) service check” on page 34 • “Print quality narrow vertical line service check” on page 34 •...
Page 29: Print Quality Toner Rubs Off Service Check
7527 Print quality toner rubs off service check Leading edge Trailing edge Actions Step 1 Go to step 2. Change the paper type and weight settings to From the Paper Menu on the printer control panel, check the paper type match the paper in the and paper weight settings.
Page 30: Print Quality Background Service Check
7527 Print quality background service check Check Step 1 Reset the value. To Go to step 2. reset this value: Read the current status of the imaging unit from the customer menus. In Ready mode, To view the status of the photoconductor units: press Menus In Ready mode, press Menus Select Supplies...
Page 31: Print Quality Blank Page Service Check
7527 Check Step 7 Problem resolved. Go to step 8. Replace the HVPS. See High‑voltage power supply (HVPS) removal. Does this fix the problem? Step 8 Problem resolved. Replace the orinthead. See printhead removal. Clean the printhead. Does this fix the problem? Print quality blank page service check Check Step 1...
Page 32: Print Quality Blurred Or Fuzzy Print Service Check
7527 Check Step 4 Go to step 5. Replace the main drive gear assembly. See Remove the image unit and waste toner bottle. Main drive gear Replace the right cover and close the front door. assembly with motor Enter the Diagnostics Menu, and run the appropriate cartridge drive removal.
Page 33: Print Quality Half-Color Page Service Check
7527 Select TPS Setup. Select Reset Color Cal, and press Select. Resetting appears. When the reset is complete, the screen is automatically returned to TPS Setup. Blurred or fuzzy print is usually caused by a problem in the main gear drive assembly or in the image transfer unit (ITU). Check the main drive gear assembly and ITU for correct operation.
Page 34: Print Quality Missing Image At Edge Service Check
7527 Print quality missing image at edge service check Remove and reset the following: • Toner cartridge • Imaging unit • Developer units Print quality mottle (2‑5 mm speckles) service check Keep running prints through, and the problem normally clears up. If the problem persists, then replace the developer cartridge.
Page 35: Print Quality Residual Image Service Check
7527 Print quality residual image service check 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. Check Step 1 Go to step 2. Replace the imaging unit or the Check the condition of the imaging unit using the customer menus...
Page 36: Print Quality Solid Color Page Service Check
7527 Print quality solid color page service check Service tip: A solid color page is generally caused by a problem in the high‑voltage power supply or an incorrect high voltage in the printing process resulting in toner development on the entire photoconductor. Check Step 1 Problem resolved.
Page 37: Print Quality Color Problems Service Check
7527 Print quality color problems service check For more information on non‑mechanical color issues, see “Color theory” on page 368. Paper jams • “Understanding jam numbers and locations” on page 37 • “Clearing jams” on page 38 • “200 paper jams” on page 40 •...
Page 38: Clearing Jams
7527 Jam numbers and locations Area # Area name Error code Go to page Automatic document feeder (ADF) 28y.xx “28x.xx paper jams” on page 63 Standard bin 203.xx “200 paper jams” on page 40 Fuser 202.xx “202 paper jams” on page 44 Front door 20y.xx “200 paper jams”...
Page 39 7527 • Do not slide the paper into the tray. Load paper as shown in the illustration below. • Make sure the guides in the tray or the multipurpose feeder are properly positioned and are not pressing tightly against the paper or envelopes. Use recommended paper •...
Page 40: 200 Paper Jams
7527 200 paper jams Pull tray 1 out. Firmly grasp the jammed paper, and then gently pull it out. Note: Make sure all paper fragments are removed. Push tray 1 back in. From the operator panel, touch Continue, jam cleared. Diagnostic information...
Page 41 7527 200.xx paper jams Error code Description Action 200.xx A single page of media jam at the input (S2) • Pull out tray 1. sensor. Paper jam • Remove the jammed page(s). Multiple pages of media are jammed at the •...
Page 42: 200.Xx Input (S2) Sensor Service Check
7527 200.xx Input (S2) sensor service check The input (S2) sensor is part of the paper pick motor drive assembly FRU, and is not available otherwise. Actions Step 1 Replace the paper pick Go to step 2. motor drive assembly. Remove tray 1.
Page 43 7527 Actions Step 3 Problem resolved. Go to step 4. Watch the display while pushing up on the flag. Does the display indicate Media Clean and Media Present? Step 4 Go to step 5. Reset the connector. Turn the printer off, and remove the rear cover. See “Rear cover removal”...
Page 44: 202 Paper Jams
7527 202 paper jams Fuser paper jam Open the front door. CAUTION—HOT SURFACE: The inside of the printer might be hot. To reduce the risk of injury from a hot component, allow the surface to cool before touching. Open the top door. Diagnostic information...
Page 45 7527 Pull the green lever to open the fuser cover. Hold down the fuser cover, and then remove the jammed paper. Note: Make sure all paper fragments are removed. Diagnostic information...
Page 46 7527 Slide and hold the release latch on the right side of the printer, and then slowly close the top door. Close the front door. From the printer control panel, touch the check mark to clear the message and continue printing. For non‑touch printer models, select Next>Clear the jam, press OK, and then press OK to confirm.
Page 47 7527 Additional checks—202 paper jams Error code Description Action 202.xx A single page of media is jammed at the exit sensor. • Open the front door to access the jam area. Paper jam Multiple pages of media are jammed at the exit sensor. •...
Page 48: 202.Xx Fuser Exit Sensor Service Check
7527 202.xx fuser exit sensor service check Actions Step 1 Replace the fuser exit Go to step 2. sensor. See “Fuser exit Open the front cover. sensor removal” on page 260. Is the sensor dislodged or damaged? Step 2 Problem solved. Go to step 4.
Page 49 7527 Actions Step 3 Go to step 5. Reconnect the cable. Turn the printer off, and then remove the rear shield. See “Rear cover removal” on page 221. Is the cable correctly connected to JBIN1 on the controller board and to the sensor? Step 4 Replace the fuser exit...
Page 50: 203 Paper Jams
7527 203 paper jams Paper jam in the standard bin Open the top door. Firmly grasp the jammed paper on each side, and then gently pull out. Note: Make sure all paper fragments are removed. Open the front door. CAUTION—HOT SURFACE: The inside of the printer might be hot. To reduce the risk of injury from a hot component, allow the surface to cool before touching.
Page 51 7527 If there is a jammed paper under the fuser, then firmly grasp the paper on each side, and then gently pull it out. Note: Make sure all paper fragments are removed. Pull the green lever to open the fuser cover. If there is a jammed paper in the fuser, then hold down the fuser cover, and then remove the paper.
Page 52 7527 Slide and hold the release latch on the right side of the printer, and then slowly close the top door. Close the front door. From the printer control panel, touch the check mark to clear the message and continue printing. For non‑touch‑screen printer models, select Next>Clear the jam, press OK, and then press OK to confirm.
Page 53: 230 Paper Jams
7527 230 paper jams Pull tray 1 out. Firmly grasp the jammed paper, and then gently pull it out. Note: Make sure all paper fragments are removed. Push tray 1 back in. From the printer control panel, touch the check mark to clear the message and continue printing. For non‑touch‑screen printer models, select Next>Clear the jam, press OK, and then press OK to confirm.
Page 54: Additional Checks—230 Paper Jams
7527 Additional checks—230 paper jams Error code Description Action 230.xx A single page of media is jammed at the inner door. • Open the front door to access the jam area. Paper jam Multiple pages of media are jammed at the inner door.
Page 55 7527 Actions Step 3 The sensor is Go to step 4. functioning correctly. Pull tray 1 out. Does the display indicate InputS1‑Media Present...? Step 4 Remove the Go to step 5. obstruction, and Remove the tray, and inspect the sensor (A). restart the test.
Page 56 7527 Actions Step 7 Go to step 8. Reconnect the cable. If the problem persists, Turn the printer off, and remove the rear shield. See “Rear cover removal” then go to step 8. on page 221. Verify the cable is correctly connected to JFUSES1 on the controller board and to the sensor.
Page 57: 232 Paper Jams
7527 232 paper jams Pull tray 1 out. Firmly grasp the jammed paper, and then gently pull it out. Note: Make sure all paper fragments are removed. Push tray 1 back in. From the printer control panel, touch the check mark to clear the message and continue printing. For non‑touch‑screen printer models, select Next>Clear the jam, press OK, and then press OK to confirm.
Page 58: 242 Paper Jams
7527 Additional checks—232 paper jams Error code Description Action 232.xx Paper jam at input sensor. • Open the front door to access the jam area. Paper jam 232.02 The input (S2) sensor was made early while duplexing. Paper jam 232.03 The input (S2) sensor did not make while duplexing.
Page 59: 243 Paper Jams
7527 Firmly grasp the jammed paper, and then gently pull it out. Note: Make sure all paper fragments are removed. Push tray 1 back in. From the printer control panel, touch the check mark to clear the message and continue printing. For non‑touch‑screen printer models, select Next>Clear the jam, press OK, and then press OK to confirm.
Page 60: 244 Paper Jams
7527 Additional checks—243 paper jams Error code Description Action 243.xx Paper jam A single or multiple page media jam in the 650-sheet • Clear paper path. Duo Drawer (tray 2). Multiple pages of media are <x> Pages • Fan the media. jammed in the 650-sheet Duo Drawer (tray 2).
Page 61: 250 Paper Jams
7527 Additional checks—244 paper jams Error code Description Action 244.xx Paper jam A single or multiple page media jam in the 650-sheet • Clear paper path. Duo Drawer (tray 2). Multiple pages of media are Check <area> • Fan the media. jammed in the 650-sheet Duo Drawer (tray 2).
Page 62 7527 Reload the paper into the multipurpose feeder. Slide the paper guide until it rests lightly against the edge of the paper stack. From the control panel, touch the check mark to clear the message and continue printing. For non‑touch‑screen printer models, select Next>OK>Clear the jam, press OK>OK.
Page 63: 28X.xx Paper Jams
7527 Additional checks—250 paper jams Error code Description Action 250.xx Paper Jam A single page of media is jammed in the • Open tray 2 to access the jam area, and remove multipurpose feeder. the jammed page. Check Manual Feeder •...
Page 64 7527 Close the ADF cover. Straighten the edges of the original documents, then load the documents into the ADF, and then adjust the paper guide. From the printer control panel, touch the check mark to clear the message and continue printing. For non‑touch‑screen printer models, select Next>OK>Clear the jam, press OK>OK 28x.xx paper jams Error code Description...
Page 65: 29X.xx Paper Jams
7527 Error code Description Action 286.02 ADF Backfeed Too many sheets of paper in the ADF exit bin. Remove the sheets from the ADF exit bin. Page(s) in the exit area accidentally gets pulled into the reverse path. 286.03 ADF Backside Feed Jam Remove the sheet of paper from the ADF.
Page 66: Xxx.xx Paper Jams
7527 29x.xx paper jams Error code Description Action 290.11 ADF Cover Open Jam Close the cover. If the error recurs, then perform the ADF cover open service check Posted when ADF top cover is opened during ADF job. xxx.xx paper jams Pull tray 1 out.
Page 67: User Messages
7527 User messages Understanding the printer messages Message Action Wait for the process to complete. Adjusting color Try one or more of the following: Change [paper source] to [custom type name] • Load the correct size and type of paper in the tray, and then select Finished changing paper on the printer control Change [paper source] to [custom string] panel to clear the message and continue printing.
Page 68 7527 Message Action Held jobs are invalidated because of any of the following Configuration change, some held jobs were possible changes in the printer: not restored [57] • The printer firmware has been updated. • The tray for the print job is removed. •...
Page 69 You may need to order a maintenance kit. For more Maintenance kit low [80.xy] information, contact customer support at http://support.lexmark.com or your service representative. If necessary, select Continue to clear the message and continue printing. For non‑touch‑screen printer models, press OK to confirm.
Page 70 7527 Message Action For more information, contact customer support at Maintenance kit nearly low [80.xy] http://support.lexmark.com or your service representative. If necessary, select Continue to clear the message and continue printing. For non‑touch‑screen printer models, press OK to confirm. You may need to replace the maintenance kit very soon. For Maintenance kit very low [80.xy]...
Page 71 The printer has detected a non‑Lexmark supply or part installed in the printer. Your Lexmark printer is designed to function best with genuine Lexmark supplies and parts. Use of third-party supplies or parts may affect the performance, reliability, or life of the printer and its imaging components.
Page 72 Note: If you do not have a replacement cartridge, then see the “Ordering supplies” section of the User’s Guide or visit http://support.lexmark.com. Install a toner cartridge that matches the region number of Replace [color] cartridge, printer the printer.
Page 73 Note: If you do not have a replacement toner cartridge, then see the "Ordering supplies" section of the User’s Guide or visit http://support.lexmark.com. Replace the defective imaging kit to clear the message and Replace defective black and color imaging continue printing.
Page 74 7527 Message Action Try one or more of the following: Restore held jobs? • Select Restore on the printer control panel to restore all held jobs stored in the printer hard disk. For non‑touch‑screen printer models, press OK to confirm. •...
Page 75: Service Errors
7527 Message Action Turn off the printer. Too many flash options installed [58] Unplug the power cord from the electrical outlet. Remove the extra trays. Connect the power cord to properly grounded electrical outlet. Turn the printer back on. Try one or more of the following: Unformatted flash detected [53] •...
Page 76: 1Xx Service Error Messages
7527 • “Network service check” on page 109 1xx service error messages Error code Description Action 110.xx The printhead <color> error • Perform a POR. Service <color> Printhead • If the problem persists, then see “110.xx Printhead service check” on page 82 110.01 he printhead <color>...
Page 77 7527 Error code Description Action 121.02 Fuser is over temperature. Note: Some of these errors are caused by a faulty component on the LVPS. Check the Service Fuser Error history file in the printer to verify other occurrences. If there are others, then replace the LVPS.
Page 78 7527 Error code Description Action 121.27 Fuser over temperature. Note: Some of these errors are caused by a faulty component on the LVPS. Check the Service Fuser Error history file in the printer to verify other occurrences. If there are others, then replace the LVPS.
Page 79 7527 Error code Description Action 126.xx Low voltage power supply did not detect zero Replace the LVPS. See “Low‑voltage power crossing. supply (LVPS) assembly removal” on Service LVPS page 268 126.01 Low voltage power supply did not detect zero crossing. Service LVPS 133.1x The black cartridge toner meter cycle (TMC)
Page 80 7527 Error code Description Action 141.0x Cartridge motor error “141.xx—Cartridge motor error service check” on page 89 Service Cartridge Motor 141.01 Failed to achieve lock for motor within allotted time. Service Cartridge Motor 141.02 Time out waiting for SAP BLDC motor to reach valid FG speed.
Page 81 7527 Error code Description Action 147.xx Staging motor error “147.xx Paper pick motor drive assembly service check” on page Service Staging Motor 147.01 Staging motor has exceeded the ramp up table. Service Staging Motor 147.02 Staging motor has exceeded number of encoders at minimum PWM.
Page 82: 110.Xx Printhead Service Check
7527 110.xx Printhead service check Actions Step 1 Replace the printhead. Go to step 2. “Printhead Turn the printer off, and then remove the rear cover. See “Rear cover removal” on page removal” on page 221. 292. Check the cables at JMIRR1 and JPH1 on the controller board for proper connection, the printhead cable for pinch points, and the cable or connector for any other damage.
Page 83: 121.Xx Fuser Service Check
7527 121.xx Fuser service check Actions Step 1 Replace the fuser Go to step 3. cable. Turn the printer off, and remove the rear cover. See “Rear cover removal” on page 221. 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.
Page 84 7527 Actions Step 2 Repair or replace the Go to step 4. LVPS cable. Check 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? Diagnostic information...
Page 85 7527 Actions Step 3 Repair the cables. If the Go to step 5. cables cannot be Open the front cover, and check the power cable (A) on the left side of repaired, then replace the fuser. the fuser. See “Fuser Remove the right cover assembly.
Page 86 7527 Actions Step 4 Go to step 6. Replace the controller board. See “Controller Check the following values at JFUSES1: board removal” on Pin 1: +24 V dc (door closed) page 239. Pin 2: +24 V dc (doors closed) Pin 3: +24 V dc (doors closed) Pin 4: +24 V dc (doors closed) Pin 5: Between 0.6 and 3.28 V dc Pin 6: Ground...
Page 87: 133.Xx Toner Meter Sensors (Y, C, M, K) On Tmc Card Service Check
7527 133.xx Toner meter sensors (Y, C, M, K) on TMC card service check Actions Step 1 Repair or replace the Go to step 2. TMC card. See “Toner Remove the toner cartridge, and inspect the lenses on the toner meter meter cycle (TMC) card cycle (TMC) card.
Page 88 7527 Actions Step 2 Replace the controller Replace the TMC card. board. “Controller “Toner meter cycle Turn the printer off, and remove the rear cover. See “Rear cover removal” board removal” on (TMC) card removal” on page 221. page 239. on page 298.
Page 89: 141.Xx-Cartridge Motor Error Service Check
7527 141.xx—Cartridge motor error service check Check Step 1 Reseat the cable. Turn the printer off, and remove the rear cover. See “Rear cover removal” on page 221. Check the cable JCARTB1 for proper connection to the system board. Is the cable properly connected? Step 2 Replace the BLDC K transfer module cable.
Page 90 7527 Check Step 3 Go to step 4. Reseat the cable. Remove the left cover assembly. See “Left cover assembly removal” on page 219 Check the cables connected to the cartridge motor assembly. Is the cable connected properly? Step 4 Replace the controller Problem solved.
Page 91: 147.Xx Paper Pick Motor Drive Assembly Service Check
7527 147.xx Paper pick motor drive assembly service check The input (S2) sensor is part of the paper pick motor drive assembly, and is not available separately. Actions Step 1 Go to step 3. Properly connect the cables, and POR the Turn the printer off, and then remove the rear cover.
Page 92 7527 Actions Step 3 Replace the paper pick Replace the controller motor drive assembly. board. See “Controller Turn the printer on, and then verify the following approximate values at “Paper pick motor board removal” on JSP1: drive assembly page 239. Pin 2: +24 V dc (standard tray) Pin 4: +24 V dc...
Page 93: 171.Xx Fan Error Service Check
7527 171.xx Fan error service check Actions Turn the printer off, and remove the rear cover. See “Rear cover removal” Replace the fan. Replace the controller on page 221. board. See “Controller board removal” on Turn the printer on, and check the fan cable at JFAN1 for the following page 239.
Page 94: 84X.xx Service Error Messages
7527 84x.xx service error messages Error code Description Action 840.xx Scanner error Scanner error 840.01 The scanner is disabled and can’t be used. Enter the configuration menu, and reenable the scanner module. See “840.xx service Scanner disabled check” on page 840.02 This message is posted when the MFP PORs.
Page 95: 840.Xx Service Check
7527 Error code Description Action 849.xx Scanner configuration error 840.xx service check Actions Step 1 Go to step 2. Stop. Problem solved. POR the machine into configuration mode. Go to disable scanner menu item. See “Disable scanner” on page 196. Touch Enable ADF/FB‑Enabled, and press Submit to save the change.
Page 96: Service Check
7527 Actions Step 6 Go to step 8. Stop. Problem solved. Replace the ADF unit. See “ADF assembly removal” on page 231. POR the machine into configuration mode. Go to the disable scanner menu item. See“Disable scanner” on page 196. Select Enable ADF/FB -Enabled and press Select to save the change.
Page 97: Adf Service Check
7527 Actions Step 3 Go to step 4. Go to step 8. Perform the scanner sensor and motor tests. Did any test fail? Step 4 Go to step 5. Go to step 6. Did the Flatbed Home Sensor test or flatbed motor test fail? Step 5 Problem solved.
Page 98: Flatbed Legal Scan Service Check
7527 Action Step 4 Go step 5. Go to step 6. Did the Flatbed Home Sensor test, or Flatbed motor test fail? Step 5 The problem is solved. Go to step 6. Replace the flatbed. See “Flatbed scanner assembly removal” on page 252.
Page 99: 9Xx Service Error Messages
7527 Action Step 5 The problem is solved. Contact the next level of support. Replace the controller. See “Controller board removal” on page 239. Did this fix the problem? 9xx service error messages Error code Description Action 900.xx Unrecoverable RIP software error/illegal trap. See “900.xx System software error service check”...
Page 100 7527 Error code Description Action 950.xx There is a mismatch between controller “950.xx NVRAM failure service check” EEPROM and mirror. on page 108. NVRAM failure 950.00 through 950.29 codes: mismatch between controller and mirror 950.30 through 950.60 codes: mismatch between secure and controller 951.xx Error NV part on system board.
Page 101 7527 Error code Description Action 954.xx The NVRAM chip failure with controller part. • POR the printer. Service NVRAM Failure • If the problem persists, then replace the controller board. See “Controller board 955.xx The Code ROM or NAND flash failed the Cyclic removal”...
Page 102 7527 Error code Description Action 964.xx Download emulation cyclic redundancy check The following actions may be taken: (CRC) failure has occurred. A checksum failure Service Emulation Error Disable the Download Emulation. detected in the emulation header or emulation Program the download emulation into file.
Page 103: 900.Xx System Software Error Service Check
Note: Before troubleshooting, determine the operating system used when the error occurred. If possible, determine whether or PostScript or PCL files was sent to the device when the error occurred. Ask the customer which Lexmark Solutions applications are installed on the device.
Page 104 7527 Actions Step 4 Go to step 5. Go to step 6. Properly connect the cables to the RIP board. Restart the device into diagnostic mode. Does the 900.xx error reoccur during startup? Step 5 Problem resolved. Go to step 31. Replace the RIP board, and restart the device.
Page 105 Reinstall the memory, and send the print job to the device. Does the 900.xx error reoccur? Step 15 Go to step 31. Problem resolved. Install a Lexmark recommended memory option, and send a print job to the device. Does the 900.xx error reoccur? Step 16 Go to step 17.
Page 106 7527 Actions Step 18 Go to step 19. Problem resolved. Upgrade the firmware if it has not been upgraded in any previous step. Contact your next level of support for the correct firmware level to use. Restart the printer to operating mode. Send the printer a print job. Does the 900.00 error reoccur? Step 19 Go to step 31.
Page 107: 91X.xx (910.Xx-919.Xx) Engine Software Service Check
7527 Actions Step 28 Go to step 29. Go to step 26. Run a job to test the option. Does the 900.xx error reoccur? Step 29 Go to step 30. Go to step 26. Upgrade the firmware. Contact your next level of support for the correct firmware level to use.
Page 108: 950.Xx Nvram Failure Service Check
7527 950.xx NVRAM failure service check Warning—Potential Damage: When replacing any of the following components, replace only one component at a time or the printer will be rendered inoperable: For CX310 models: • Controller board • Operator panel with UICC card For CX410 and CX510 models: •...
Page 109: Network Service Check
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. Actions Step 1 Go to step 3.
Page 110 7527 Actions Step 8 Problem resolved. Go to step 10. POR the printer. Did this resolve the issue? Step 9 Problem fixed. Go to step 10. Reset the address on the printer to match the IP address on the driver. Did this resolve the issue? Step 10 Go to step 12.
Page 111: Symptoms
7527 Actions Step 19 Go to step 22. Go to step 21. If there is an attached antenna, is the antenna damaged? Note: The optional wireless unit does not have an external antenna. Step 20 Problem resolved. Go to step 22. Replace the antenna.
Page 112: Base Printer Symptoms
7527 • “Tray (x) sensor service check” on page 132 • “550 and 650 input option service check” on page 134 • “Scan/fax/copy symptoms” on page 135 • “Black or blank page copy service check” on page 136 • “CCD service check” on page 137 •...
Page 113: Narrow Media Sensor Service Check
7527 Narrow media sensor service check Actions Step 1 Repair or replace the Go to step 2. narrow media sensor. Open the front cover, and inspect the narrow media sensor (A) located “Narrow media towards the front of the top cover assembly. sensor removal”...
Page 114 7527 Actions Step 3 Problem resolved. Replace the controller board. See “Controller Enter Diagnostics Menu. board removal” on Turn the printer on, press and hold 3 and 6, and release the buttons with page 239. the installed memory and processor speed displays. Perform the Base Sensor Test.
Page 115: Toner Meter Cycle (Tmc) Card Service Check
7527 Toner meter cycle (TMC) card service check Actions Perform the Base Sensor Test: Replace the toner Replace the toner cartridge. meter cycle (TMC) Enter Diagnostics menu. card. See “Toner meter Turn the printer on, press and hold 3 and 6, and release the buttons cycle (TMC) card with the installed memory and processor speed displays.
Page 116 7527 Actions Step 3 Go to step 5. Reconnect the cable at JLVPS1, and then go to Turn the printer off, and remove the rear cover. See “Rear cover removal” step 4. on page 221. Is the LVPS cable correctly connected at JLVPS1 on the controller board? Step 4 Go to step 5.
Page 117: Front Door Sensor Or Switches Service Check
7527 Actions Step 5 Replace the controller Replace the LVPS. See board. See “Controller “Low‑voltage power Damage to the printer is possible. Be careful to touch only one conductor board removal” on supply (LVPS) at a time. Rest the probe against the connector to steady it. page 239.
Page 118 7527 Actions Step 2 Replace the right cover Go to step 3. assembly. See “Right Open the front door, and check the thin, tall, plastic web (pivot plate) (A) cover assembly at the top right of the printer. With the other covers in place and closed, removal”...
Page 119 7527 Actions Step 4 Replace the right cover Go to step 5. assembly. See “Right With the front cover open, inspect the two switches. Using a tool, such as cover assembly a spring hook, push the metal arms (C) to check the movement. removal”...
Page 120 7527 Actions Step 5 Go to step 6. Replace the controller board. See “Controller Turn the printer off, and remove the rear cover. See “Rear cover removal” board removal” on on page 221. Turn the printer on, and verify the following values at JINT1 page 239.
Page 121: Operator Panel (Display Is Dim And Unchanging) Service Check
7527 Operator panel (display is dim and unchanging) service check 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. For CX310 models: •...
Page 122 7527 Actions Step 1 Go to step 2. Replace the operator panel. See “Operator Enter the Diagnostics Menu (turn the printer off, press and hold 3 and 6, panel removal (for turn the printer on, and then release the buttons when the installed CX310 and CX410 memory and processor speed displays).
Page 123 7527 Actions Step 1 Go to step 2. Go to step 4. Enter the Diagnostics Menu (turn the printer off, press and hold 3 and 6, turn the printer on, and then release the buttons when the installed memory and processor speed displays). Perform the Panel Test.
Page 124: Operator Panel (Displays All Diamonds, No Beeps, Or Five Beeps) Service Check
7527 Operator panel (displays all diamonds, no beeps, or five beeps) service check 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. For CX310 models: •...
Page 125 7527 Actions Step 1 Go to step 2. Reinstall the cable. Turn the printer off. Remove the rear shield. See “Rear cover removal” on page 221. Remove the operator panel. See “Operator panel removal (for CX310 and CX410 models only)” on page 283.
Page 126: Operator Panel (Display Blank) Service Check
7527 Operator panel (display blank) service check 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. For CX310 models: •...
Page 127 7527 Actions Step 2 Replace the controller Problem resolved. board. See “Controller Replace the operator panel assembly. See “Operator panel removal (for board removal” on CX310 and CX410 models only)” on page 283 page 239. Is the operator panel still blank? For CX510 models: Actions Step 1...
Page 128: Operator Panel (One Or More Operator Panel Buttons Fail) Service Check
7527 Operator panel (one or more operator panel buttons fail) service check 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. For CX310 models: •...
Page 129: Operator Panel Usb Cable Service Check
7527 Steps in solving the problem Actions Enter Diagnostics Menu (turn the printer off, press and hold 3 and 6, turn Replace the UICC card. Problem resolved. the printer on, and then release the buttons when the installed memory and processor speed displays). Perform the Button Test.
Page 130: Usb Service Check
7527 USB service check Actions Step 1 Go to step 2. Properly connect the cable at both ends. Is the USB cable properly connected to the printer and host PC? Step 2 Issue fixed. Go to step 3. Try a different USB cable. Does this fix the issue? Step 3 Replace the controller...
Page 131 7527 Actions Step 4 Go to step 5. Go to step 6. Inspect the paperfeed pick tires on the tray that fails to pick. Do they appear worn or damaged? Step 5 Problem resolved. Go to step 6. Replace the pick tires on the faulty tray, and then print a page with media from the affected tray.
Page 132: Tray 2 Service Check
7527 Actions Step 11 Contact your next level Replace the controller of support. board. See “Controller Turn off the printer. board removal” on Remove the rear cover. See “Rear cover removal” on page 221. page 239. Disconnect the cable at JOPT1 on the controller board. Turn the printer on.
Page 133 7527 Actions Step 3 Replace the option tray Contact the next level present sensor. of support. Check for a dislodged tray present sensor. • If the 650‑sheet tray is affected, Is the sensor dislodged? then replace the 650‑sheet drawer assembly. •...
Page 134: 550 And 650 Input Option Service Check
7527 550 and 650 input option service check Action Step 1 Go to step 2. Go to step 3. Is the machine using both 650 and 550 input option tray? Step 2 Go to step 7. Go to step 3. Make sure the sequence of the input option trays is correct.
Page 135: Scan/Fax/Copy Symptoms
7527 Action Step 6 Go to step 7. • For 550 input option, replace the Check the input option drawer and the following for any damage or optional 550-sheet contamination: drawer. • Top and bottom autoconnector • For 650 input •...
Page 136: Black Or Blank Page Copy Service Check
7527 Symptom Action Machine dials a number but fails to make a connection with another The other fax machine may be turned off. Ask the fax fax machine. recipient to check their machine. Incoming fax has blank spaces or poor quality. •...
Page 137: Ccd Service Check
7527 CCD service check Actions Step 1 Go to step 2. No issue. Restart the device, and retry the scan / copy job. Repeat this step with a few copy jobs. Does the error return? Step 2 Go to step 3. Properly connect the ribbon cable to JCCD1.
Page 138: Adf Cover Open Service Check
7527 Actions Step 3 Go to step 4. Properly connect the cable. Check JFBM1 on the controller for proper connection. Is it connected properly? Step 4 Go to step 5. Replace the controller board. See “Controller Check pin 1 in JFBM1 for voltage. The voltage is only present when a board removal”...
Page 139: Adf Streak Service Check
7527 Actions Step 6 Go to step 7. Go to step 8. Remove the ADF rear cover and inspect the ADF cover closed sensor for dirt and debris. Is there dirt and debris present? Step 7 Issue resolved. Go to step 8. Clean the dirt and debris from the sensor.
Page 140 7527 Actions Step 1 Clean them with a lint Replace the separator free cloth and isopropyl pad, restraint pad, and If the ADF is multi-feeding or shingle feeding, then check for dirt on the alcohol. ADF pick roll. ADF separator pad, restraint pad, and ADF separator rollers. Are they dirty? Step 2 Go to step 3.
Page 141: Adf Feed Errors Service Check
7527 Actions Step 10 Clean the sensors, or Go to step 8. remove debris from the Is there dirt in the sensors, or is the paper present actuator stuck? actuators. Step 11 Replace the ADF. Go to step 9. Are the sensor actuators on the ADF mechanism cover damaged? Step 12 Go to step 10.
Page 142: Adf Duplex Service Check
7527 Actions Step 5 Go to step 6. Go to step 8. Perform the ADF pick motor and ADF feed motor tests. Are the motors working properly? Step 6 Go to step 7. Go to step 8. Perform the ADF paper present sensor test. See “Scanner tests”...
Page 143: Modem/Fax Card Service Check
7527 Actions Step 1 Go to step 2. Go to step 4. Perform the ADF motor tests to verify that the motors are working properly. See “Motor tests” on page 184. Are the motors operating properly? Step 2 Go to step 3. Go to step 4.
Page 144: Fax Reception Service Check
7527 Actions Step 1 Go to step 2. Go to step 3. Is the phone line properly connected to the modem card and the wall jack? Step 2 Problem resolved. Go to step 3. Properly connect the phone line to the modem card and wall jack. Did this fix the problem? Step 3 Go to step 5.
Page 145 7527 Actions Step 1 Go to step 2. Go to step 3. Is the phone line properly connected to the modem card and the wall jack? Step 2 Problem resolved Go to step 3. Properly connect the phone line to the modem card and wall jack. Did this fix the problem? Step 3 Go to step 5.
Page 146: Fax Transmission Service Check
7527 Actions Step 13 Go to step 14. Stop here. The issue is with the other device. Check the device that cannot receive a fax. Can it send a fax? Step 14 Problem resolved. Go to step 15. Press **411 to enter the Fax/SE Menu. Select “Print Logs”. Print the T30 transmission log.
Page 147 7527 Actions Step 5 Go to step 7. Go to step 6. Use a telephone handset to verify the phone line is free of static or external noise. Is the phone line noise-free? Step 6 Problem resolved. Go to step 7. Use the MFP on a properly functioning phone jack.
Page 148: Fax Error Log Codes
7527 Actions Step 16 Problem resolved. Go to step 17. Disable Block No Name Fax user setting. Did this fix the issue? Step 17 Go to step 18 Go to step 19. Go to the Administrator menu. Enter the Fax settings - Analog Fax Settings submenu.
Page 149 7527 Error code Description Action Error occurred when receiving image data. • Check line quality. • Adjust ‘Receive Threshold’. • Select a lower ‘Max Speed’ value under Fax Receive settings. Error occurred when sending image data. • Check line quality. •...
Page 150 7527 Error code Description Action Too many errors when transmitting in ECM • Check line quality. mode. • Adjust ‘Transmit Level’. • Select a lower ‘Max Speed’ value under Fax Send settings. Remote device failed to respond to the CTC •...
Page 151 7527 Error code Description Action Failure to transmit training successfully in V17, • Select a lower “Max Speed” under Fax V29 terminal modulation schemes. Send settings. • Adjust the “Transmit Level”. • Check line quality. Failure to transmit training successfully in V17, •...
Page 152: Escalating A Fax Issue To Second-Level Support
7527 Error code Description Action Busy tone detected. Check with remote end if successive attempts fail. Hardware error detected. “Modem/fax card service check” on page 143. A timeout occurred after dialing the number Check with remote end if successive and waiting for a response. attempts fail.
Page 153 7527 In the Web browser address bar, type http://MFP/<IP address>/se. Click Report a Fax Problem. The fax check list displays. Fill in the requested information. This is where you will type in the information you retrieved in step 3. Second-level support can assist you if you have questions about the information requested on the page.
Page 154 7527...
Page 155: Service Menus
7527 Service menus • “Understanding the operator panel and menus” on page 155 • “Understanding the scanner” on page 160 • “Diagnostics menu” on page 161 • “Configuration menu” on page 188 • “Entering invalid engine mode” on page 197 •...
Page 156: Using The Operator Panel For Cx410 Models
7527 Start button Starts a job, depending on which mode is selected Back button Returns to the previous screen. Home button Goes to the home screen Indicator light Checks the status of the printer Using the operator panel for CX410 models Using the operator panel Display •...
Page 157: Using The Operator Panel For Cx510 Models
7527 Using the operator panel for CX510 models Using the operator panel Display • Views printing, copying, e‑mailing, faxing, and scanning options • Views the printer status and error messages Home button Goes to the home screen Sleep button Enables Sleep mode or Hibernate mode Keypad Enters numbers, letters, or symbols Indicator light...
Page 158: Understanding The Home Screen For Cx410 And Cx510 Models
7527 Blinking amber The printer is waking from entering hibernation mode. Blinking amber for 0.1 second, then goes completely off for 1.9 The printer is in hibernation mode. seconds in pulsing pattern. Understanding the home screen for CX410 and CX510 models When the printer is turned on, the display shows a basic screen, referred to as the home screen.
Page 159 7527 For CX510 models Home screen for CX510 models Touch Change language Launches the Change Language pop‑up window that lets you change the primary language of the printer Copy Accesses the Copy menus and makes copies Accesses the Fax menus and sends faxes E‑mail Accesses the E‑mail menus and sends e‑mails Accesses the File Transfer Protocol (FTP) menus and scan documents directly to an FTP server...
Page 160: Understanding The Scanner
7527 Search Held Jobs Searches for one or more of the following items: • Use name for held or confidential print jobs • Job names for held jobs, excluding confidential print jobs • Profile names • Bookmark container or print job names •...
Page 161: Diagnostics Menu
7527 When using the ADF: When using the scanner glass: • Load the document into the ADF tray faceup, short edge • Place a document facedown on the scanner glass in the first corner of the green arrow • • Load up to 50 sheets of plain paper into the ADF tray Scan or copy documents from 216 x 296.9 mm (8.5 x 11.69 inches) dimension...
Page 162: Entering Diagnostics Mode
7527 The Diagnostics menu group contains the settings and operations used while manufacturing and servicing the printer. Entering diagnostics mode Turn off the printer. Press and hold 3 and 6. Turn on the printer. Release the buttons when the installed memory and processor speed displays. Select Exit Diags to exit Diagnostics mode and return to the printer home screen.
Page 163 7527 DRAM Test “DRAM Test” on page 172. Duplex Tests (if installed) Quick Test “Quick Test” on page 166 Top Margin “Duplex Top Margin” on page 174. Left Margin “Duplex Left Margin” on page 174. Input Tray Tests Feed Tests “Feed Tests”...
Page 164: Registration
7527 Reset Fuser Count “Reset Fuser Count” on page 179. EP Setup EP Defaults “EP Defaults” on page 180. Fuser Temperature “Fuser temperature” on page 180. DC Charge Adjust “DC Charge Adjust, Bias Adjust, Transfer Adjust” on page 180. Dev Bias Adjust Transfer Adjust TPS Setup Right...
Page 165: Adjusting Margins
7527 Adjusting margins Description Value Direction of change Top margin -50 to +50 A positive change moves the image down the page and increases the top margin. A negative Each increment corresponds to 8 scans at a 600 change moves the image up and decreases the dpi scan rate (0.0133 inches or 0.339 mm).
Page 166: Skew
7527 Skew One printhead houses the four color planes. The black plane is aligned to the printer, and the other color planes are internally aligned to black. Electronic alignment fine tunes the alignment of the color planes to the black plane once the printhead is installed.
Page 167 7527 To print the Quick Test page: Note: Print the Quick Test Page on letter or A4 paper. Select Registration from Diag Menu, and press Select Select Quick Test Page, and press Select The message Printing... appears on the display. Once the Quick Test Page completes printing, the Registration screen displays again.
Page 168: Alignment Menu
7527 Alignment Menu Use the alignment menu to align the image on the page for cyan, yellow, and magenta. The black image should be aligned using REGISTRATION before the individual colors are aligned. Warning—Potential Damage: Read the instructions for the alignment carefully. Setting alignment for color From the Diagnostics menu, touch Alignment Menu.
Page 169: Misc Tests
7527 These should only be used to manually adjust a replacement scanner. To adjust a calibration value, perform the following steps: Navigate to Diagnostics>Scanner Calibration, and touch Scanner Calibration. Select scanner calibration values. Select the value to be adjusted by touching it. Increment up from 0 to darken a value.
Page 170: Print Tests
7527 Select MISC TESTS in the Diag Menu, and press Select. Select Motor Detect, and press Select. If you press Select before closing the front cover, then a message appears: Close Cover. Press Select. Motor Detection In Progress… appears. The motor detection process takes about 10 seconds, and stops automatically. Detect Complete.
Page 171: Print Quality Test Pages
7527 Print quality test pages 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. Note: This test may be printed from either the Configuration Menu or the Diagnostics Menu.
Page 172: Duplex Tests
7527 DRAM Test This test checks the validity of DRAM, both standard and optional. The test repeatedly writes patterns of data to DRAM to verify that each bit in memory can be set and read correctly. To run the DRAM Test: From the Diagnostics menu, navigate to HARDWARE TESTS >...
Page 173 7527 You must use either Letter or A4 paper. To run the duplex quick test: From the Diagnostics menu, touch DUPLEX TESTS >Duplex Quick Test. Select Single or Continuous. The single test cannot be canceled. The printer attempts to print the Quick Test Page from the default paper source. If the default paper source supports only envelopes, then the page is printed from Tray 1.
Page 174: Duplex Left Margin
7527 Duplex Top Margin This setting controls the offset between the first scan line on the front of the duplex page and the first scan line on the back of the page. Therefore, be sure to set the top margin in REGISTRATION before setting the duplex top margin. See “REGISTRATION”...
Page 175: Input Tray Tests
7527 Press Select to save the new value. Print the Quick Test (duplex) again (steps 1–4) to verify the adjustment. Repeat if necessary. INPUT TRAY TESTS • “Feed Tests” on page 175 • “Sensor Test” on page 175 Feed Tests Any installed input tray can be tested.
Page 176: Base Sensor Test
7527 BASE SENSOR TEST These tests allow you to verify the correct functioning of the front door, input, and output sensors. CAUTION—SHOCK HAZARD: Do not use your hand to toggle these switches. Use a nonconducting item. To run the Base Sensor Test. Select Base Sensor Test from Diag Menu, and press Select Select the sensor you want to test, and press Select The following tests are available:...
Page 177: Device Tests
7527 DEVICE TESTS Flash test This menu item appears only if the flash card is installed. Data is written to the flash card and read back to check the accuracy. Warning—Potential Damage: This test deletes all data stored on the flash device. After the test is over, reformat the flash using Format Flash in the customer Utilities Menu.
Page 178: Serial Number
7527 Printer default values US value Non-US value PCL Symbol Set PC-8 PC-850 PPDS Code Page Universal Units of Measure Inches Millimeters Warning—Potential Damage: Modification of the printer setting Defaults causes the NVRAM space to be restored to the printer’s factory settings. PAGE COUNTS This menu lets you view the total page counts of the printer or the page counts broken down into color and mono pages printed.
Page 179: Transfer Module Barcode
7527 To set the configuration ID: Select Printer Setup from Diag Menu, and press Select . Select Configuration ID, and press Select . The current value for Configuration ID 1 is displayed. Enter the Configuration ID 1. • Change the left character or digit first. •...
Page 180: Ep Setup
7527 To reset the fuser count: Select Printer Setup from Diag Menu, and press Select. Select Reset Fuser Cnt, and press Select. Select Reset, and press Select. Reset Resetting… appears. To cancel a reset, press Back. EP SETUP • “EP Defaults” on page 180 •...
Page 181: Tps Setup: Right Or Left
7527 TPS Setup: Right or Left The value of the toner density sensor (also called toner patch sensor or TPS) is set at manufacturing. If a sensor is replaced, enter the 32-digit hexadecimal toner density value (TPS) value from the bar code next to the sensor. To enter the value: Select TPS Setup from Diag Menu, and press Select .
Page 182: Reports: Menu Settings Page
7527 To reset the programmed value: Select TPS Setup from Diag Menu, and press Select. Select Reset Color Cal, and press Select. Resetting appears. When the reset is complete, the screen is automatically returned to TPS Setup. Reports: Menu Settings Page To print the Menu Settings Page: Select Reports from Diag Menu, and press Select.
Page 183: Scanner Tests
7527 • Additional debug information in some cases 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 Diag Menu, and press Select . Select Print Log, and press Select.
Page 184: Motor Tests
7527 • “Sensor tests” on page 185 • “Scanner calibration reset” on page 188 • “ADF magnification” on page 188 ASIC test This setting initiates a scan of the scanner ASIC’s memory. To perform this test, do the following: Navigate to Scanner Tests > ACIS Tests. Select ACIS Tests.
Page 185: Sensor Tests
7527 ADF feed motor backward When Motor On is selected, the device runs the motor forward continuously until Motor Off is selected. To perform this test, do the following: Navigate to Scanner Tests > Motor Tests. Select ADF Feed Motor Backward. The test will run.
Page 186 7527 Select the sensor to be tested. Actuate the sensor you selected. The screen will toggle between 0 and 1 if the sensor is properly functioning. Select Exit to leave the test To test the Paper FB long test, place a sheet of legal paper on the flatbed and close the cover. If the sensor is working properly, the indicator will change from 0 to 1 To test the Home sensor, perform the following steps: Exit the sensor test.
Page 187 7527 ADF cover open Flatbed cover open Paperfeed sensor Service menus...
Page 188: Exit Diagnostics
7527 Scanner calibration reset This is test is run to reset the scanner calibration. This test should only be run after a flatbed or ADF unit has been replaced. To perform this operation, do the following: Navigate to Scanner Tests. Select Scanner Calibration Reset.
Page 189: Entering Configuration Mode
7527 • “Color Trapping” on page 191 • “Reports” on page 192 • “Panel Menus” on page 192 • “PPDS Emulation” on page 192 • “Download emuls” on page 192 • “Safe Mode” on page 192 • “Demo Mode” on page 193 •...
Page 190: Action For Prompts
7527 PPDS Emulation “PPDS Emulation” on page 192. Demo Mode “Demo Mode” on page 193. Factory Defaults “Factory Defaults” on page 193. Energy Conserve “Energy Conserve” on page 194. Auto Color Adj “Auto Color Adjustment” on page 196. Font Sharpening “Font Sharpening”...
Page 191: Size Sensing
7527 Size sensing B5/Executive Due to engine limitations, Trays 1 through 4 cannot simultaneously sense executive and JIS-B5-size paper. The value of this setting determines which of the two paper sizes these trays will sense automatically. This setting will apply to all automatic trays, but not to the MP Feeder.
Page 192: Reports
7527 Reports The Reports setting contains the Menu Settings Page and Event Log. Menu Settings Page Print the menu settings pages to list the customer settings and to verify printer options are installed correctly. If is helpful to print the customer settings before you restore the factory defaults or make major changes. To print the menu settings: Select Reports from the Config Menu, and press Select.
Page 193: Demo Mode
7527 To change the setting: From the Configuration menu, navigate to Safe Mode. Select On or Off to change the setting. Select Submit. POR the printer. Demo Mode The Demo Mode lets marketing personnel or merchandisers demonstrate the printer to potential customers by printing the demo page.
Page 194: Energy Conserve
7527 Energy Conserve Energy Conserve affects the values that appear in the Power Saver menu in the customer Setup Menu. This menu item appears only when the printer model does not support Automatic Power Saver or has deactivated Automatic Power Saver.
Page 195: Flatbed Edge Erase
7527 To change this setting: Select Format Fax Storage from the Configuration Menu. Note: If an advanced password has been established, then you must enter this password to change the setting. If no advanced password exists, then you can establish one by using the keyboard that appears on the LCD. Select Submit to save the change.
Page 196: Disable Scanner
7527 Use the plus or minus to increase or decrease the settings value for horizontal adjust and top margin. Note: Each button press moves the margin values one pixel in the respective direction. Select Submit to accept the value. Verify the changes by placing the print quick test page face down and selecting Copy Quick Test. Repeat steps 13, 14, and 15 as needed.
Page 197: Font Sharpening
7527 When an event other than page count triggers this calibration, the count that monitors the maximum number of pages printed will be reset. For example, if the user replaces an empty toner cartridge, the next time the printer is started, it will sense the new cartridge and perform the automatic color adjustment, even though the page counter for Auto Color Adj is fewer than required.
Page 198: Accessing The Service Engineer (Se) Menu
7527 Accessing the service engineer (SE) menu From a Web browser on a host PC, add /se to the printer IP address. Accessing the fax SE menu The Fax SE menu is used for the Fax transmission service check and the Fax reception service check. It should only be used under the direction of your next level of support.
Page 199: Repair Information
7527 Repair information • “Removal precautions” on page 199 • “Removal procedures” on page 215 • “Cover removals” on page 215 • “Base printer removals” on page 229 • “Options removal” on page 306 Removal precautions CAUTION—SHOCK HAZARD: For personal safety and to prevent damage to the printer, remove the power cord from the electrical outlet before you connect or disconnect any cable, electronic board, or assembly.
Page 200: Controller Board/Control Panel Replacement
7527 Controller board/control panel replacement This procedure should be followed only if both the controller board and the operator panel fail. If you need to replace only one of the FRUs, follow the startup procedure described in the FRU’s removal procedure. CAUTION—POTENTIAL INJURY The lithium battery in this product is not intended to be replaced.
Page 201: Ribbon Cable Connectors
7527 There is a size limit on the export file - 128kb. Because of this, it is recommended that you don't use the “global” backup found in Settings > Import/Export > Export Shortcuts File, Export Settings File, Export Embedded Solutions Settings File and Export Security Setups File.
Page 202: Horizontal Top Contact Connector
7527 Horizontal top contact connector This FRU contains a horizontal top contact cable connector. Read the instructions before proceeding. The horizontal top contact connector uses a back flip locking actuator to lock the ribbon cable into the Zero Insertion Force (ZIF) connector. The cable is inserted horizontally into the connector. Warning—Potential Damage: When opening or closing this type of actuator, gently lift or close the two tabs located on each end of the actuator.
Page 203 7527 Inserting a cable into the horizontal top contact connector When installing the cable, check the locking actuator to ensure it is in the unlocked position. The tabs on the ends of the actuator are vertical when the actuator is unlocked. Insert the cable with the contacts on the cable facing up.
Page 204 7527 Rotate the locking actuator to the locked position. The cable should not move while this step is performed. If the cable moves, open the actuator, reposition the cable, and then close the actuator to the down position. Repair information...
Page 205: Horizontal Bottom Contact Connector
7527 Horizontal bottom contact connector The FRU contains a horizontal bottom contact cable connector. Read the instructions before proceeding. The horizontal bottom contact connector uses a flip locking actuator to lock the ribbon cable into the Zero Insertion Force (ZIF) connector. The cable is inserted horizontally into the connector. Warning—Potential Damage: When opening or closing this type of actuator, gently lift the center of the actuator using your finger.
Page 206 7527 Inserting a cable into the horizontal bottom contact connector Check the actuator to verify it is in the open position. Insert the cable into the ZIF connector with the contacts facing downward and away from the locking actuator. The cable needs to be inserted below the actuator.
Page 207 7527 Place your finger in the middle of the actuator, and then rotate the locking actuator to the locked position. Repair information...
Page 208: Vertical Mount Contact Connector
7527 Vertical mount contact connector This FRU contains a vertical mount contact connector. Read the instructions before proceeding. The vertical mount contact connector uses a back flip locking actuator to lock the ribbon cable into the Zero Insertion Force (ZIF) connector. The cable is inserted vertically into the connector. Warning—Potential Damage: When opening or closing this type of actuator, gently lift the center of the actuator using your finger.
Page 209 7527 Inserting a cable into the vertical mount contact connector When installing the cable, check the locking actuator to verify it is in the open position. Insert the cable with the contacts on the cable away from the locking actuator. Insert the cable on top of the actuator. Note: Verify that the cable is installed squarely into the connector.
Page 210 7527 Rotate the locking actuator to the locked position by pressing down on both ends of the actuator. The cable should not move when this step is performed. If the cable moves, open the actuator, reposition the cable, and then close the actuator to the down position.
Page 211: Horizontal Sliding Contact Connector
7527 Horizontal sliding contact connector This FRU contains a horizontal sliding contact connector. Read the instructions before proceeding. The horizontal sliding contact connector uses a slide locking actuator to lock the ribbon cable into the Zero Insertion Force (ZIF) connector. The cable is inserted horizontally into the connector. Warning—Potential Damage: When opening or closing this type of actuator, gently push or pull the two tabs located on each end of the actuator.
Page 212 7527 Inserting a cable into the horizontal sliding contact connector When installing the cable, check the locking actuator to verify it is in the open position. If you are opening the connector, pull back on both end tabs using equal force to avoid breaking the connector. Insert the cable with the contacts on the cable facing away from the locking actuator.
Page 213 7527 Slide the locking actuator towards the connector, locking the cable into place. The cable should not move when this step is performed. If the cable moves, open the actuator, reposition the cable, and then close the actuator to the down position. Repair information...
Page 214: Low Insertion Force (Lif) Connector
7527 Low Insertion Force (LIF) connector This FRU contains a Low Insertion Force (LIF) connector. Read the instructions before proceeding. Warning—Potential Damage: When installing a cable into an LIF connector, care must be taken to avoid bending the edges of the cables and damaging the contacts on the cables. Inserting a cable into the LIF connector Looking at the connector, take note on which side the contacts are located.
Page 215: Removal Procedures
7527 Removal procedures Keep the following tips in mind as you replace parts: • Some removal procedures require removing cable ties. You must replace cable ties during reassembly to avoid pinching wires, obstructing the paper path, or restricting mechanical movement. •...
Page 216: Output Bin Tray And Exit Bail Removal
7527 Output bin tray and exit bail removal Rotate the output bin tray forward. Lift the output bin tray, and remove. Repair information...
Page 217: Front Cover Assembly Removal
7527 Pull out the legs of the exit bail one at a time, and lift to remove. Front cover assembly removal Remove the media tray. Open the front cover. Remove the front middle cover (optional). See “Front middle cover removal” on page 219.
Page 218 7527 Remove the two screws (C) securing the interlock and cable. Route the cable through the right hinge. Note: Pay close attention to the routing of the interlock sensor cable through the right hinge and front door. Remove the screw (D) securing the restraining strap to the left side of the front door. Lower the front cover to align the flats on the hinges, and remove the front cover.
Page 219: Front Middle Cover Removal
7527 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 to remove. Left cover assembly removal Remove the two screws (A) from the rear of the printer.
Page 220 7527 Remove the screw (B) beneath the right cover. Position the right side of the printer over the edge of the table to have enough room to swing the right cover out. Disconnect the right cover assembly from the right side of the printer, and remove. Repair information...
Page 221: Rear Cover Removal
7527 Rear cover removal Remove the eight screws (A). Swing the side of the cover out, and slide to the right to remove. Remove the rear cover. Installation note: When installing the rear cover, be sure that the ear (C) is inserted into the bracket (B). Repair information...
Page 222: Rear Scanner Cover Removal
7527 Rear scanner cover removal Remove the two screws (A) from the rear scanner cover. Use a flat‑blade screwdriver to pry the bottom part of the cover out first. Repair information...
Page 223: Right Cover Assembly Removal
7527 Remove the rear scanner cover. Right cover assembly removal Open the toner supply door. Open the front door. Release the latches (A), and lift off the cover. Right scanner cover removal Remove the imaging unit in the print engine. See “Imaging unit (IU) removal”...
Page 224 7527 Remove the four screws (A) securing the right scanner cover to the flatbed unit. Repair information...
Page 225: Top Cover Assembly Removal
7527 While holding the ADF away from the flatbed, use the other hand to lift and disengage the right scanner cover from the flatbed unit. Top cover assembly removal Remove the rear cover. See “Rear cover removal” on page 221. Remove the flatbed scanner assembly.
Page 226 7527 Remove the two screws (A) from the rear of the top cover assembly. Remove the six screws (B) from the right side of the top cover assembly. Repair information...
Page 227 7527 Disconnect the belt (C). Disconnect the fan, and remove. Repair information...
Page 228 7527 Disconnect the left flag (D) and the right flag (E). Lift the top cover up and away from the printer frame to remove. Installation note: Install the narrow media flag to the fuser before rotating the fuser into the printer. Repair information...
Page 229: Top Cover Adf Sheet Feed Removal
7527 Top cover ADF sheet feed removal Separate the top cover sheet feed from the top of the printer. Remove the top cover sheet feed. Base printer removals • “ADF assembly removal” on page 231 Repair information...
Page 230 7527 • “ADF input tray removal” on page 233 • “ADF separator roll removal” on page 234 • “ADF separator pad removal” on page 234 • “AIO toner cover removal” on page 235 • “AIO link removal” on page 236 •...
Page 231: Adf Assembly Removal
7527 • “Waste toner bottle removal” on page 304 • “Waste toner bottle contact block removal” on page 305 ADF assembly removal Remove the exit tray. See “Output bin tray and exit bail removal” on page 216. Remove the rear cover. See “Rear cover removal”...
Page 232 7527 Fold the cable connector (D) parallel to the cable (E). Pull the cable through the opening in the top of the printer. Repair information...
Page 233: Adf Input Tray Removal
7527 Lift the ADF assembly, and remove. Note: After replacing this part, a scanner manual registration must be performed. See “Scanner manual registration” on page 195. A scanner calibration reset must also be performed. See “Scanner calibration reset” on page 188.
Page 234: Adf Separator Roll Removal
7527 ADF separator roll removal Open the ADF top cover. Pinch the ADF separator retaining tabs (A). Lift the ADF separator roll to the vertical position. Pull the ADF separator roll up and out of the ADF unit. ADF separator pad removal Open the ADF top cover.
Page 235: Aio Toner Cover Removal
7527 Disconnect the ADF separator pad tabs (B) from the printer, and remove. AIO toner cover removal Life 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 (C).
Page 236: Aio Link Removal
7527 Rotate the AIO toner cover so the tab (D) on the cover lines up with the hole on the AIO toner cover. Pull the AIO toner cover to the left, and remove it from the printer. AIO link removal Lift the scanner to the up position.
Page 237: Aio Release Lever Removal
7527 Remove the screw (B) securing the AIO link to the flatbed unit. AIO release lever removal Remove the right scanner cover. See “Right scanner cover removal” on page 223. Remove the screw (A) securing the AIO link to the flatbed unit. Disengage the AIO link from the flatbed unit.
Page 238: Bin-Full Flag Removal
7527 Remove the screw (B) securing the AIO release lever to the flatbed. Slide the AIO release lever towards the back of the flatbed. Remove the spring and AIO release lever. Installation note: When reinstalling the AIO release lever, place the release lever on the flatbed, and then inset the spring before replacing the screw.
Page 239: Controller Board Removal
7527 Controller board removal CAUTION—SHOCK HAZARD: After disconnecting the high-voltage power cable from the controller board, always check that the HVPS connection was not loosened. Make this check anytime you are working near the HVPS cable. Warning—Potential Damage: Observe all ESD precautions while handling electrostatic discharge sensitive parts. See Handling ESD‑sensitive parts on page 4‑1.
Page 240: Developer Unit Removal
7527 Remove the controller board. Warning—Potential Damage: When replacing the controller board, verify the cable from the high-voltage power supply is seated properly. The cable may have come loose from the HVPS. Print a few pages to verify the installation. If the pages are blank, then confirm that the high-voltage power supply cable is properly seated. The connector may have been loosened at the HVPS.
Page 241: Duplex Reference Edge Removal
7527 Remove the developer unit(s). Duplex reference edge removal Open the front door. Remove the two screws (A), the two screws (B), the two screws (C), and the two screws (D) in the back of the duplex aligner. Repair information...
Page 242 7527 Lift the duplex aligner on the right side, and disengage the gears (E) on the left. Remove the three screws (F) from the duplex reference guide, and remove the guide. Installation notes: Align the duplex reference guide so that the tabs are inserted into the slots, and the top of the reference guide fits under the door ribs.
Page 243 7527 Align the duplex aligner guide so that the gears (H) mesh on the left. Replace the eight screws in the duplex aligner. Close the front door. Repair information...
Page 244: Duplex Sensor Removal
7527 Duplex sensor removal Remove the imaging unit. See “Imaging unit (IU) removal” on page 266. Remove the two screws (A) from the cable cover. Pull the corner of the cable cover (B) away from the right side to access the two sensor posts (C). Repair information...
Page 245: Ep Drive Assembly Removal
7527 Remove the sensor plate (D). Push in on the latches to disconnect the duplex sensor from the printer. Disconnect the cable (E) from the duplex sensor. Installation notes: Clean the contact surface where you removed the sensor retaining plate, or where you need to install the new one.
Page 246 7527 Disconnect the three cables (A) from the LVPS. Remove the ADF assembly. See “ADF assembly removal” on page 231. Remove the flatbed scanner assembly. See “Flatbed scanner assembly removal” on page 252. Remove the two top screws (B) holding the top cover to the LVPS shield. Remove the narrow media sensor flag.
Page 247 7527 Disconnect the cable (D) from the narrow media sensor, and unroute the cable from its retainer. Unhook the springs (E) from both sides of the fuser. Disconnect the thermistor cables (F), and pull them over the retainer. Repair information...
Page 248 7527 Remove the screw and grounding washer (G) on the right side of the frame. Note: Be careful to not lose the grounding washer. Rotate the top of the fuser toward the front, and then slide to the left to align the fuser side frames with the flat area of the shaft.
Page 249 7527 Disconnect the fuser exit cable (I). Lift the front left corner of the top cover, and tilt the LVPS cage (J) to remove. There are two posts at the bottom of the cage on the left side that need to be disengaged. Note: Be careful to not damage the fuser exit sensor as it remains in the cage.
Page 250 7527 Remove the two screws (M) from the rear, and unroute all of the cables. Remove the two screws (N) from below the EP drive assembly, and the two screws (O) from the right of the EP drive assembly. Lift the EP drive assembly, and remove. Repair information...
Page 251: Flatbed Pivot Link Removal
7527 Flatbed pivot link removal Remove the AIO link. See “AIO link removal” on page 236. Remove the right scanner cover. See “Right scanner cover removal” on page 223. Remove the AIO release lever. See “AIO release lever removal” on page 237.
Page 252: Flatbed Scanner Assembly Removal
7527 Flatbed scanner assembly removal Remove the waste toner bottle. See “Waste toner bottle removal” on page 304. Remove the right cover assembly. See “Right cover assembly removal” on page 223. Lift the ADF assembly. Remove the screw (A) from the right rear side lift lock. Repair information...
Page 253 7527 Unlock the lift lock (B) at the top of the scanner, lower the flatbed scanner assembly until there is resistance, and disconnect the lift lock arm from the joint (C). Remove the two screws (D) from the front left scanner hinge. Repair information...
Page 254 7527 Use a screwdriver to disconnect the left hinge (E) from the left side of the printer. Remove the ground screw (F), and disconnect the four cables (G) and the ribbon cable (H.) Note: Disconnect the ribbon cable by using a screwdriver to pull the pivot (I) out and rotate up. See “Ribbon cable connectors”...
Page 255 7527 Note: After replacing this part, a scanner manual registration must be performed. See “Scanner manual registration” on page 195. A scanner calibration reset must also be performed. See “Scanner calibration reset” on page 188. Installation note: To install the ribbon cable, rotate the latch down and push it back into the connector. Be careful to not damage the latch.
Page 256 7527 Lift the flatbed scanner assembly, and slide the latch (J) out of place. Remove the flatbed scanner assembly. Note: Gently pull the flatbed scanner assembly cables through the opening when removing the flatbed scanner assembly. Repair information...
Page 257: Front Logo Cover Removal
7527 Front logo cover removal Grasp the front logo, and pull sharply. Note: A flat-tipped screw may have to be used at the outer edges on the CX510. This cover part does not give access to any other part and therefore does not need to be removed except for replacement Fuser assembly removal Remove the right cover assembly.
Page 258 7527 Disconnect the cable (B) from the bin‑full/narrow media sensor, and unroute the cable from its retainer. Unhook the springs (C) from both sides of the fuser. Disconnect the thermistor cables (D), and pull them over the retainer. Repair information...
Page 259: Fuser Drive Motor Assembly Removal
7527 Remove the screw and grounding washer (E) on the right side of the frame. Note: Be careful to not lose the grounding washer. Rotate the top of the fuser toward the front, and then slide to the left to align the fuser side frames with the flat area of the shaft.
Page 260: Fuser Exit Sensor Removal
7527 Remove the two screws (C). Remove the fuser drive motor assembly. Fuser exit sensor removal Remove the left cover assembly. See “Left cover assembly removal” on page 219. Remove the fuser cables from the retainer to give needed slack. Disconnect the cable (A) from the bin‑full/narrow media sensor, and unroute the cable from its retainer.
Page 261 7527 Unhook the springs (B) from both sides of the fuser. Disconnect the thermistor cables (C). Remove the screw and grounding washer (D) on the right side of the frame. Note: Be careful to not lose the grounding washer. Rotate the top of the fuser toward the front to gain access to screw (E). Disconnect the cable (F), and remove the screw (E) from the fuser exit sensor.
Page 262: High-Voltage Power Supply (Hvps) Removal
7527 Remove the lower end of the sensor with a flat‑blade screwdriver, and gently pull the sensor from the frame. High‑voltage power supply (HVPS) removal Remove the rear cover. See “Rear cover removal” on page 221. Remove the controller board. See “Controller board removal”...
Page 263 7527 Remove the cable cover (A). Note: Leave the cable attached to the HVPS until the HVPS has been removed. Remove the transfer module. See “Transfer module removal” on page 300. Remove the waste toner bottle. See “Waste toner bottle removal” on page 304.
Page 264 7527 Press down on the spring mount, and carefully slide the HVPS out by pulling from one side and pushing from the other. Release the pressure on the spring mount, and pull the HVPS the remaining distance. Slide the HVPS out to remove. Press down on the latch (C) to disconnect the cable from the HVPS board.
Page 265 7527 Installation notes: To install the new HVPS board, insert the spring end of the HVPS board while compressing the spring, as shown below. Slide the HVPS into position while holding its sides, as shown below. Do not allow the card to flex and touch the cage.
Page 266: Imaging Unit (Iu) Removal
7527 Check the position of the card at the left side of the printer. The small vertical post (D) in the endcap has to be positioned in the hole above it, as show below. Install the new cable, making sure the connector to the board is locked into position. Note: Reinstall the screw to hold the HVPS to the right side of the printer.
Page 267 7527 Lift the two latches (A) to unlock the imaging unit. Pull the two latches until the imaging unit meets resistance. Press and hold the handles (B) on the right and left sides, and pull the imaging unit straight out. Note: Avoid touching the bottom of the imaging unit.
Page 268: Low-Voltage Power Supply (Lvps) Assembly Removal
7527 Low‑voltage power supply (LVPS) assembly removal Remove the left cover assembly. See “Left cover assembly removal” on page 219. Press in on the latches to disconnect the three cables (A) from the LVPS. Repair information...
Page 269 7527 Remove the six screws (B). Remove the LVPS. Warning—Potential Damage: If you receive a new low-voltage power supply with a voltage selector switch (C), then be sure to set the switch to the correct setting for your voltage requirements before installing the low-voltage power supply.
Page 270: Lower Left Frame Removal
7527 Lower left frame removal Note: The right and left lower frames are in the same FRU. Remove the media tray, and remove the screw (A) from the front. Remove the waste toner bottle. See “Waste toner bottle removal” on page 304.
Page 271 7527 Remove the two top screws (C) near the front holding the top cover to the LVPS shield. Position the fuser cable (D) so that it can be pulled through from the front of the printer, and guide the cable through to the front.
Page 272 7527 Disconnect the cable (E) from the bin‑full/narrow media sensor, and unroute the cable from its retainer. Unhook the springs (F) from both sides of the fuser. Disconnect the thermistor cables (G), and pull them over the retainer. Repair information...
Page 273 7527 Remove the screw and grounding washer (H) on the right side of the frame. Note: Be careful to not lose the grounding washer. Rotate the top of the fuser toward the front, and then slide to the left to align the fuser side frames with the flat area of the shaft.
Page 274 7527 Place the printer on its right side. Remove the tray 2 connector (K) by pinching the tabs together and pushing the connector into the printer. Repair information...
Page 275 7527 At the rear of the printer, remove the two screws (L) from the AC receptacle, and the ground screw (M), and the two screws (N) holding the plastic shield. Remove the AC receptacle from the left lower frame. Remove the three screws (O) securing the left lower frame. Repair information...
Page 276: Lower Right Frame Removal
7527 Remove the screw (P) above the frame. Swing the left lower frame away from the printer, and remove. Lower right frame removal Remove the waste toner bottle. See “Waste toner bottle removal” on page 304. Remove the imaging unit. See “Imaging unit (IU) removal”...
Page 277 7527 Remove the screw (A) in the waste toner bottle sensor contact to allow access to the cable cover, and remove the four screws (B) securing the cable cover. Notes: • The waste toner bottle sensor contact does not need to be unplugged. •...
Page 278 7527 Next to screw, lift the right lower frame pin (E) out of the hole in the printer frame. Swing the rear part away from the printer to access the spring, and remove the spring (F) from the right lower frame.
Page 279 7527 Disconnect the cable (G) from the tray present sensor. Swing the rear of the lower frame away from the printer, and remove the right lower frame. Note: There are parts in the right lower frame that are not included in the frame. The following instructions show how to remove them.
Page 280: Narrow Media Sensor Removal
7527 Installation notes: Reinstall the spring bracket. Connect the cable to the tray present sensor, and put the spring in place before installing the right lower frame. Narrow media sensor removal Open the front cover. Unroute the cable (A) from its retainer. Note: Be sure to pay close attention to the routing of the cable for re‑installation.
Page 281: Narrow Media Sensor Flag Removal
7527 Remove the sensor retaining plate (C). Gently remove the sensor from the bracket by pressing in on the latches (D). Installation notes: • Clean the contact surface where you removed the sensor retaining plate, or where you need to install the new one. •...
Page 282: Operator Panel Bezel Removal
7527 Operator panel bezel removal Lift the flatbed scanner on the right side. Lift the bezel away from the operator panel, and remove. Note: The picture below shows the bezel removal for the CX310 and CX410 models. The bezel for CX510 models is removed the same way.
Page 283: Operator Panel Removal (For Cx310 And Cx410 Models Only)
7527 Operator panel removal (for CX310 and CX410 models only) Installation 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 may be rendered inoperable: •...
Page 284 7527 Remove the two screws (B) from the left top side of the operator panel, and the two screws (C) from the right top side of the operator panel using a #2 Phillips screwdriver. Disconnect the name plate cover from the operator panel. Remove the operator panel bezel.
Page 285 7527 Remove the screw (D) from beneath the logo plate. Remove the operator panel cover from the front of the printer. Repair information...
Page 286 7527 Remove the two screws (E) from the operator panel. Lift the operator panel from the user interface support bracket. Disconnect the ribbon cable from the cable connector on the operator panel board by sliding the two prongs forward. Repair information...
Page 287 7527 Remove the five screws (F) from the operator panel board. Remove the two screws (G) from the display bracket. Repair information...
Page 288 7527 Disconnect the cable (H) from the operator panel board. Installation note: When replacing the operator panel board, be sure to also replace the washer (I) that holds the display bracket in place. Repair information...
Page 289: Operator Panel Removal (For Cx510 Models Only)
7527 Operator panel removal (for CX510 models only) Installation 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 may be rendered inoperable: •...
Page 290: Paper Pick Motor Drive Assembly (Standard Tray) Removal
7527 Remove the two screws (B) at the top left and right holding the operator panel assembly, the upper front cover, and the user interface bracket together. Pull the left and right sides of the upper front cover out enough to slide the operator panel assembly and bracket away from the cover.
Page 291 7527 Place the printer on its rear, and remove the two screws (D) from the bottom. On the right side, loosen the screw (E) with a screwdriver, and hold the paper feed roller assembly in place as you use your fingers to remove the screw. Move the right side of the paper feed roller assembly out to free the shaft from the opening in the frame.
Page 292: Printhead Removal
7527 Install the right spring (F). Printhead removal Remove the top cover assembly. See “Top cover assembly removal” on page 225. Remove the four screws (A). Remove the printhead. Repair information...
Page 293: Redrive Unit Removal
7527 Redrive unit removal Remove the flatbed scanner assembly from the MFP. See “Flatbed scanner assembly removal” on page 252. 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.
Page 294: Speaker Removal
7527 Speaker removal Note: The speaker (only in CX410 and CX510) is in the operator panel module. See “Operator panel removal (for CX310 and CX410 models only)” on page 283and “Operator panel removal (for CX510 models only)” on page 289. System fan removal Remove the rear cover.
Page 295 7527 Remove the four screws (B) securing the cable cover, and remove the cable cover. Rotate the printer to view the right side. Lay the printer on its left side, and remove the screw (C) securing the spring contacts. Release the tabs (D) on the spring contact, and slide to the left to remove. Repair information...
Page 296: Toner Density Sensor (Tds) (Left Or Right Sensor) Removal
7527 Disconnect the cable (E) from the controller board at JSC1. Installation note: Notice the assembly of the cable and toroid (if used), and reassemble the new contacts in the same manner. Remove the cable from the retainer on the bottom of the printer. Toner density sensor (TDS) (left or right sensor) removal Note: The toner density sensor is also called the toner patch sensor (TPS).
Page 297 7527 Disconnect the toner density sensor cable from JTDS1 connector (A) or JTDS2 connector (B) on the controller board. If you are removing the left toner density sensor, also disconnect the thermistor from JFUSES1 connector (C) on the controller board. Note: Be sure to pay close attention to the routing of all cables for reinstallation.
Page 298: Toner Meter Cycle (Tmc) Card Removal
7527 To enter a character or digit: Press Left to decrease or Right to increase the blinking value. Pause for several seconds without pushing any buttons. The blinking value becomes solid. If the value is incorrect, then press Back to go back and reenter the number. Continue until the last value is reached.
Page 299 7527 Remove the two plastic screws (B), and the two metal screws (C). Slide a flat‑blade screwdriver into the left side of the frame, and pry the card loose to remove. Repair information...
Page 300: Transfer Module Removal
7527 Installation notes: • Be sure the cable (D) 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. Transfer module removal Write down the number of the new transfer module before installing it.
Page 301 7527 Disconnect the two springs from the side frames, leaving the right spring (A) attached to the transfer module or transfer module spring clamp. Rotate the left spring (B) and the cam away from the transfer module so that the cam is held out of the transfer module path.
Page 302: Tray Present Sensor Removal
7527 Rotate the release lever (C) in a counterclockwise direction with a springhook or needlenose pliers to decouple the transfer module while pulling the transfer module toward the front. Hold the release lever as you pull out the transfer module for the first four inches (100 mm), but a quick, firm pull should overcome the latch at this point.
Page 303: Usb Port Connector Removal
7527 Remove the sensor retaining plate (C), and then pinch the latches together to remove the tray present sensor. Disconnect the tray present sensor cable. Installation notes: Clean the contact surface where you removed the sensor retaining plate, or where you need to install the new one.
Page 304: Waste Toner Bottle Removal
7527 Waste toner bottle removal Note: The waste toner bottle is not a FRU. Remove the right cover assembly. See “Right cover assembly removal” on page 223. Press the two tabs (A) to remove the waste toner bottle. Repair information...
Page 305: Waste Toner Bottle Contact Block Removal
7527 Waste toner bottle contact block removal Note: The waste toner bottle is not a FRU. Remove the waste toner bottle. See “Waste toner bottle removal” on page 304. Remove the screw (A) from the back of the waste toner bottle block. Remove the rear cover.
Page 306: Options Removal
7527 Disconnect the waste toner bottle contact block (B) from the controller board. Remove the waste toner bottle contact block. Options removal • “650‑sheet duo drawer tray assembly removal” on page 307 • “650‑sheet duo drawer assembly removal” on page 307 •...
Page 307: 650-Sheet Duo Drawer Tray Assembly Removal
7527 650‑sheet duo drawer tray assembly removal Pull out the drawer tray assembly to remove it. 650‑sheet duo drawer assembly removal Warning—Potential Damage: Make sure the printer is turned off before removing the drawer assembly. Repair information...
Page 308 7527 Carefully lift the printer, and set it aside on a flat surface to remove the drawer assembly from the printer. Repair information...
Page 309: Dust Cover Removal
7527 Dust cover removal Raise then pull the dust cover to remove it. Pick tires removal Note: You will need to have a soft, padded work surface for this removal. Warning—Potential Damage: Remove only the rubber tires and not the paper pick tire assembly to avoid losing small parts.
Page 310 7527 Remove the rubber tire (A) from the pick roll assembly (B). Repeat for the other tire. Installation note: Install the new rubber tires with the surface texture turning in the direction as shown below. Note: Feel each rubber surface to verify it turns properly in the direction shown. The smoother surface pushes the paper toward the front of the printer.
Page 311: Component Locations
7527 Component locations Controller boards CX310 models Component locations...
Page 312 7527 CX410 models Component locations...
Page 313 7527 CX510 models Component locations...
Page 314 7527 Connector information Controller board connectors for CX310, CX410, and CX510 models Connector Connects to Pin no. Signal JADF1 Auto document feeder 15, 22 +3 V 14, 16 +24 V 17, 18, 23 Ground JBIN1 Narrow media sensor and fuser exit sensor +3.3 V dc S_BIN_FB •...
Page 315 7527 Connector Connects to Pin no. Signal JFUSES1 +24 V dc V_FUSER_PHA+ (doors closed) • Fuser • Motor pins—1–4 +24 V dc V_FUSER_PHA– (doors closed) • Thermistor—black wire 5–6 +24 V dc V_FUSER_PHB+ (doors closed) • Duplex sensor (S1)—7–9 +24 V dc V_FUSER_PHB– (doors closed) •...
Page 316 7527 Connector Connects to Pin no. Signal JLVPS1 Low-voltage power supply +5 V dc Ground +5 V dc Ground +5 V dc Ground +24 V dc Ground +24 V dc Ground +24 V dc Ground ZERO_XING_IN Ground JMIRR1 Mirror motor connector +3.3 V dc MM_LOCK Ground +24 V dc...
Page 317 7527 Connector Connects to Pin no. Signal JSP1 Smart pick drive (paper pick motor drive ANODE (no wire) assembly) +24 V dc M1_OUT1 (0 V dc with door open) • Encoder—pins 1, 3, 5, 7, and 9 Ground (no wire) •...
Page 318 7527...
Page 319: Maintenance
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 • Printer and input options are sitting flat (for example, not sitting on cables or hanging over a ledge) •...
Page 320 Clean Remove all toner spillage from the printer. Pick tires Inspect, clean Inspect, clean if Check for toner contamination. if needed needed Lexmark CX510 EVERY EVERY 200K NOTES SERVICE CALL Media tray - All Media tray side guides Inspect Inspect Check for correct positioning.
Page 321: Scheduled Maintenance
7527 Scheduled maintenance The operator panel displays the message 80 or Scheduled Maintenance when it reaches certain page counts. It is necessary to replace the appropriate maintenance kit at certain intervals to maintain the print quality and reliability of the printer. If needed, reset the maintenance counter after performing scheduled maintenance. Maintenance kits After 85,000 printed pages (sides) a maintenance kit may be required.
Page 322: Lubrication Specification
7527 Parts needed to perform preventive maintenance Part number Description Maintenance interval 40X0392 LCD cleaning kit As needed Lubrication specification Lubricate only when parts are replaced or as needed, not on a scheduled basis. Use of lubricants other than those specified in this service manual can cause premature failure.
Page 323: Cleaning The Scanner Glass
7527 Cleaning the scanner glass Clean the scanner glass if you encounter print quality problems, such as streaks on copied or scanned images. Slightly dampen a soft, lint-free cloth or paper towel with water. Open the scanner cover. Wipe the areas shown below, and let them dry. Scanner areas Callout Description White underside of the ADF cover...
Page 324: Cleaning The Printhead Lenses
7527 ADF glass Close the scanner cover. Cleaning the printhead lenses Open the front door. Slide the release lever to the left to unlock the cover. Open the cover. Locate the printhead wipers. Gently pull the printhead wiper out until it stops, and then slowly slide it back into place. Close the cover.
Page 325 7527...
Page 326: Parts Catalog
7527 Parts catalog • “Legend” on page 326 • “Assembly 1: Covers” on page 327 • “Assembly 2: Scanner” on page 329 • “Assembly 3: Paperpath” on page 331 • “Assembly 4: Operator panels” on page 335 • “Assembly 5: Electronics” on page 339 •...
Page 327: Assembly 1: Covers
7527 Assembly 1: Covers Parts catalog...
Page 328 7527 Assembly 1: Covers Asm-index Units/mach Units/FRU Description Removal procedure 40X7811 Output bin tray “Output bin tray and exit bail removal” on page 216 40X7810 Back AIO cable cover 40X7845 Rear cover, CX310 “Rear cover removal” on page 221 40X7846 Rear cover, CX410 “Rear cover removal”...
Page 329: Assembly 2: Scanner
7527 Assembly 2: Scanner Parts catalog...
Page 330 7527 Assembly 2: Scanner Asm-index Units/mach Units/FRU Description Removal procedure 40X9054 ADF input tray “ADF input tray removal” on page 40X5872 Bin full flag “Bin‑full flag removal” on page 238 40X7833 Redrive assembly “Redrive unit removal” on page 293 40X7829 Flatbed scanner assembly “Flatbed scanner assembly removal”...
Page 331: Assembly 3: Paperpath
7527 Assembly 3: Paperpath Parts catalog...
Page 332 7527 Assembly 3: Paperpath Removal Asm-index Units/mach Units/FRU Description procedure 40X7627 Printhead “Printhead removal” on page 292 40X7629 Fuser drive motor assembly “Fuser drive motor assembly removal” on page 259 40X7646 Lower left frame and lower right frame with cable cover “Lower left frame removal”...
Page 333 7527 Removal Asm-index Units/mach Units/FRU Description procedure 40X7652 Miscellaneous springs • Front cover latch (2x) • ITU holddown (2x) • Fuser holddown (2x) • Primary tray bias (2x) 40X7610 Transfer module “Transfer module removal” on page 300 40X7614 Paper pick motor drive assembly “Paper pick motor drive assembly...
Page 334 7527 Parts catalog...
Page 335: Assembly 4: Operator Panels
7527 Assembly 4: Operator panels Parts catalog...
Page 336 7527 Assembly 4: Operator panels Asm-index Units/mach Units/FRU Description Removal procedure 40X7835 UICC to controller board cable (CX310, CX410) N/A 40X7837 UICC to controller board cable (CX510) 40X7836 USB cable (CX410) “Operator panel removal (for CX310 and CX410 models only)” on page 283 40X5480 USB cable (CX510)
Page 337 7527 Asm-index Units/mach Units/FRU Description Removal procedure 40X7861 Display (CX510) “Operator panel removal (for CX510 models only)” on page 289 40X7838 Upper front cover (CX510) “Operator panel removal (for CX510 models only)” on page 289 40X7839 Upper front cover (CX310, CX410) “Operator panel removal (for CX310 and CX410 models only)”...
Page 338 7527 Parts catalog...
Page 339: Assembly 5: Electronics
7527 Assembly 5: Electronics Parts catalog...
Page 340 7527 Assembly 5: Electronics Asm-index Units/mach Units/FRU Description 40X7804 Controller board, CX310 “Co 40X7805 Controller board, CX410 “Co 40X7806 Controller board, CX510 “Co 40X7620 Toner meter cycle card assembly “To 40X7625 High‑voltage power supply “Hi 40X7301 Photo sensor and retainer (one per package), used for: “Tr •...
Page 341 7527 Asm-index Units/mach Units/FRU Description 40X6517 Speaker “Sp 40X1766 Power cord, 2.5 m (straight): Bolivia, Peru 40X0269 Power cord, 2.5 m (straight): USA, Canada, APG, LAD 40X0288 Power cord, 2.5 m (straight): Argentina 40X0301 Power cord, 2.5 m (straight): Australia 40X4596 Power cord, 2.5 m (straight): Brazil 40X0273...
Page 342 7527 Parts catalog...
Page 343: Assembly 6: Cables And Sensors
7527 Assembly 6: Cables and sensors Parts catalog...
Page 344 7527 Assembly 6: Cables and sensors Removal Asm-index Units/mach Units/FRU Description procedure 40X5429 Transfer module paper path thermistor 40X5414 Toner density sensors, left or right (one in package) 40X7046 Waste toner bottle sensor 40X7636 Toner cartridge contacts (Pogo pin) 40X7835 UICC to controller board cable (CX310, CX410) 40X7837 UICC to controller board cable (CX510)
Page 345: Assembly 7: Media Drawers And Trays
7527 Assembly 7: Media drawers and trays Parts catalog...
Page 346 7527 Assembly 7: Media drawers and trays Removal Asm-index Units/mach Units/FRU Description procedure Optional 650‑sheet duo drawer (complete) ‑ (includes 100‑sheet MPF) 40X8089 “650‑sheet drawer assembly removal” page 307 40X5168 Pick tires “Pick tires removal” page 309 40X8091 650‑sheet Duo Drawer tray assembly “650‑sheet drawer tray...
Page 347: Assembly 8: Options And Miscellaneous
7527 Assembly 8: Options and miscellaneous Removal Asm-index Units/opt Units/FRU Description procedure 40X7615 115 V Maintenance kit (fuser, transfer module) 40X7616 230 V Maintenance kit (fuser, transfer module) 40X7617 100 V Maintenance kit (fuser, transfer module) 40X8555 256MB DDR DRAM DIMM card assembly 40X8568 Korean font card assembly 40X8557...
Page 348: Screw And Retainer Identification Table
7527 Screw and retainer identification table The following table contains screw and fastener descriptions, locations, and quantities necessary to service the printer. Pay careful attention to each screw type location when performing a removal. You must install the correct screw type in each location during reassembly.
Page 349 7527 3001435 M3x8 screw Lower right frame 3003334 3.5x6 mm flat top screw CX410 display bracket CX510 UICC card 3005980 3.5x8 mm flat top screw Front door 3068020 Taptite M3 L4.5 Panhead screw Lower right frame 88A0154 M3x8LG W‑HD MCH screw Printhead 88A0481 M3.5x8 SEMS MACH screw...
Page 350 7527 88A0322 Plastic ROLN 3.5 6L screw AC receptacle Cable cover CX510 Display support bracket Duplex aligner Duplex reference edge Front door CX410 and CX510 Front USB connector HVPS Left cover Lower left frame Operator panel CX510 Operator panel back cover CX510 speaker Toner meter cycle Toner supply door...
Page 351: Appendix A: Printer Specifications
7527 Appendix A: Printer specifications • “Power specifications” on page 351 • “Electrical specifications” on page 351 • “Operating clearances for CX310 models” on page 352 • “Operating clearances for CX410 and CX510 models” on page 353 • “Acoustics” on page 353 •...
Page 352: Operating Clearances For Cx310 Models
7527 Operating clearances for CX310 models Note: Allow additional clearance around the printer for adding options, such as additional input trays. Operating clearances for CX310 models Right side 152 mm (6 in.) Front 508 mm (20 in.) Left side 76 mm (3 in.) Rear 102 mm (4 in.) 254 mm (10 in.)
Page 353: Operating Clearances For Cx410 And Cx510 Models
7527 Operating clearances for CX410 and CX510 models Note: Allow additional clearance around the printer for adding options, such as additional input trays. Operating clearances for CX410 and CX510 models Right side 305 mm (12 in.) Front 508 mm (20 in.) Left side 76 mm (3 in.) Rear...
Page 354: Environment
Acoustic measurements for CX410 and CX510 models Status 1‑meter average sound pressure dBA Printing 50 dBA Ready Inaudible Note: Values are subject to chance. See http://support.lexmark.com for current values. Environment Printer Temperature and Humidity • Operating – Temperature: 60 to 90° F (15.6 to 32.2° C) –...
Page 355: Appendix B: Options And Features
“Option configurations” on page 356 Lexmark CX310, CX410, and CX510 support only Lexmark CX310, CX410, and CX510 paper-handling options. These options are not compatible with any other Lexmark printer. Some of the following options are not available in every country or region.
Page 356: Option Configurations
7527 Output options Printer control panel Automatic document feeder (ADF) Standard bin Top door latch Right side cover Standard 250‑sheet tray (Tray 1) Manual feeder Optional 650‑sheet duo tray with integrated multipurpose feeder (Tray 2) Option configurations The CX310, CX410, and CX510 optional drawers can be configured to run in a stacked configuration. Unlike the C544n and C544dn printers, the CX310, CX410, and CX510 printers support a maximum of two stacked optional drawers—...
Page 357: Supported Configurations
7527 Supported configurations These configurations are valid and supported. The options are designed and tested according to these types of configurations. C544n, C544dn CX310, CX410, CX410, Printers CX510 Printers CX510 Printers C546dtn Printer C546dtn Printer CX310, CX410, CX510 CX310, CX410, CX510 CX310, CX410, CX510 CX310, CX410, CX510 CX310, CX410, CX510...
Page 358 7527...
Page 359: Appendix C: Theory Of Operation
7527 Appendix C: Theory of operation • “Paper path and transport components” on page 359 • “Print engine theory” on page 362 • “ADF theory” on page 366 • “Color theory” on page 368 Paper path and transport components • “Paper path information”...
Page 360: Transport Components
7527 There is a duplex unit on the printers. The duplex unit is built into the front cover and Tray 1. Note: The ACM is also known as the paper feed roller assembly. Transport components The paper is fed from the tray into the printer by a pick roll and sent to two sets of feed rollers which time the paper to enter the Electrophotographic Process (EP Process) at just the right moment.
Page 361: Duplexing
7527 The redrive bubble sensor, located before the fuser exit rollers in the paper path, senses the bubble in the paper as it exits the fuser. It then adjusts the fuser motor speed as necessary to avoid jams and smearing on the trailing edge of the paper.
Page 362: Print Engine Theory
7527 Once the image is transferred, the media travels to the fuser (D), the fuser exit rolls (E), and then to the output bin. Print engine theory • “Electrophotographic process (EP process)” on page 362 • “Electrophotographic process basics” on page 362 Electrophotographic process (EP process) The method that all laser and LED printers use to print is called the electrophotographic process.
Page 363 7527 During the printing process, the printer follows the six basic EP Process steps to create its output to the page. Charge the photoconductor. Expose the photoconductor with the laser. Develop toner on the photoconductor. First transfer to the ITU, and second transfer to the paper. Fuse the toner to the paper.
Page 364 7527 Service tips • The laser beam passes through a glass lens as it exits the laser unit. If this lens gets contaminated with toner or other debris, it will cause vertical streaking of white/lightness on the page. Cleaning the lens will solve the problem. •...
Page 365 7527 The HVPS sends voltage to the transfer roll to create a positive charge. When the image on the transfer belt reaches the transfer roll, the negatively charged toner clings to the paper and the entire image is transferred from the transfer belt to the paper.
Page 366: Adf Theory
7527 ADF theory ADF theory of operation ADF cross section ADF cross section Document sensor Pickup roller Separator roller Stage and interval sensors Paperfeed 1 roller Paperfeed 2 roller Feed sensor Scan area Duplex sensor Eject 2 roll Exit roller Appendix C: Theory of operation...
Page 367 7527 The 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 DC motors with encoder wheels, and a series of sensors to determine the media’s position in the paper path during the scan process.
Page 368: Color Theory
7527 After actuating the duplex sensor, eject2 roll moves the media to the paper feed 1 roll, and the feed sensor. Like the first pass of the media, the image acquisition process is repeated for the second side of the media. When the trailing edge of the media reaches the reverse point the second time, the swing gear again moves the diverter gate to the down position and the exit roll reverses.
Page 369: What Is Manual Color Correction
7527 The printed page appears tinted. Can I adjust the color? Sometimes a printed page may appear tinted (for example, everything printed seems to be too red). This can be caused by environmental conditions, paper type, lighting conditions, or user preference. In these instances, adjust the Color Balance setting to create a more preferable color.
Page 370 7527 Color conversion tables Object type Color conversion tables RGB Image • Vivid—Produces brighter, more saturated colors and may be applied to all incoming color formats. RGB Text • sRGB Display—Produces an output that approximates the colors displayed on a RGB Graphics computer monitor.
Page 371 7527 What are detailed Color Samples and how do I access them? Detailed Color Samples sets are available only through the Embedded Web Server of a network printer. A detailed Color Samples set contains a range of shades (displayed as colored boxes) that are similar to a user-defined RGBor CMYK value.
Page 372 7527...
Page 373: Appendix D: Acronyms
7527 Appendix D: Acronyms Acronyms ASIC Application-Specific Integrated Circuit BLDC Brushless DC Motor Black Only Retract Cyan Charge Coupled Device Carbonless Copy Paper Cyclic Redundancy Check Customer Setup DIMM Dual Inline Memory Module DRAM Dynamic Random Access Memory Enhanced Data Out Electrophotographic Process EPROM Erasable Programmable Read-Only Memory...
Page 374 7527 Nonvolatile Memory NVRAM Nonvolatile Random Access Memory Original Equipment Manufacturer Optical Sensor Photoconductor pel, pixel Picture element Power-On Reset POST Power-On Self Test Position Sensing Device Pulse Width Modulation Raster Imaging Processor Read Only Memory SDRAM Synchronous Dual Random Access Memory SIMM Single Inline Memory Module SRAM...
Page 375: Index
7527 Index min copy memory num pad job assist acronyms Panel Menus action for prompts PPDS Emulation adf assembly removal Print Quality Pages ADF Edge Erase Reports adf input tray removal safe mode adf magnification scanner manual registration adf separator pad removal Tray [x] sensing adf separator roll removal configuration mode...
Page 376 7527 electrophotographic process horizontal bottom contact connector electrostatic‑sensitive parts horizontal sliding contact connector embedded solutions horizontal top contact connector Energy Conserve engine setting 1 through 4 environment specifications imaging unit (IU) removal ep defaults inspection guide EP drive assembly removal invalid code, fixing EP process invalid engine mode...
Page 377 7527 operator panel removal (for CX310 and CX410 models preprinted forms, selecting only) preventive maintenance operator panel removal (for CX510 models only) print quality option configurations initial check supported configurations Print Quality Pages unclaimed configurations print quality service unsupported configurations checks 30, 31, 32, 33, 34, 35, 36, Options Print quality background service check...
Page 378 7527 printhead removal operator panel logo plate processor specifications output bin tray and exit bail paper pick motor drive assembly (standard tray) pick tires printhead quick test rear cover rear scanner cover redrive unit rear cover removal right cover assembly rear scanner cover removal right scanner cover recovery mode...
Page 379 7527 service checks troubleshooting 110.xx printhead service check test 121.xx fuser service check duplex option top margin 133.xx toner meter sensors (Y, C, M, K) on TMC card tests service check base printer sensors 147.xx paper pick motor drive assembly service feed tests check flash memory...
Page 380 7527 121.xx fuser service check 133.xx toner meter sensors (Y, C, M, K) on TMC card waste toner bottle contact block removal service check waste toner bottle removal 147.xx paper pick motor drive assembly service check 171.xx fan error service check zero insertion force (ZIF) connectors 1xx service error messages 200.xx input (S2) sensor service check...
Page 381: Part Number Index
7527 Part number index Part name Page 3049485 Field relocation package assembly......................347 40X0269 Power cord, 2.5 m (straight): USA, Canada, APG, LAD................341 40X0271 Power cord, 2.5 m (straight): United Kingdom..................341 40X0273 Power cord, 2.5 m (straight): Chile, Uruguay, Italy................341 40X0275 Power cord, 2.5 m (straight): Israel......................341 40X0288 Power cord, 2.5 m (straight): Argentina....................341...
Page 382 7527 Part name Page 40X7060 MarkNet N8352 802.11b/g/n Wireless print server (external)..............347 40X7116 Display (CX410)............................337 40X7229 Power cord, 2.5 m (straight): India......................341 40X7301 Photo sensor and retainer........................340 40X7445 2GB x 32 DDR3 RAM..........................347 40X7567 1GB x 32 DDR3 RAM..........................347 40X7610 Transfer module.............................333 40X7614 Paper pick motor drive assembly......................333...
Page 383 7527 Part name Page 40X7802 Toner AIO cover.............................328 40X7803 Operator panel bezel (CX410)........................337 40X7804 Controller board, CX310.........................340 40X7805 Controller board, CX410.........................340 40X7806 Controller board, CX510.........................340 40X7807 Operator panel assembly (CX310)......................336 40X7808 Front logo cover (CX310, CX410)......................337 40X7809 Top cover assembly (includes fan)......................328 40X7810 Back AIO cable cover..........................328...
Page 384 7527 Part name Page 40X7836 USB thumbdrive cable (CX410)......................330 40X7837 UICC to controller board cable (CX510)..................336, 40X7838 Upper front cover (CX510)........................337 40X7839 Upper front cover (CX310, CX410)......................337 40X7840 User interface support bracket (CX310, CX410)..................337 40X7841 User interface support bracket (CX510)....................337 40X7842 Simplex top cover assembly........................330 40X7843 Duplex ADF top cover...
Page 385 7527 Part name Page 40X9054 ADF input tray............................330 40X9108 Duplex separator roller assembly......................330 40X9110 Restraint pad............................330 40X9114 PCBA (CX410)............................337 40X9115 Interface card (CX510)..........................336 40X9130 PCBA MFP UICC (CX510).........................336 Operator panel cable..........................330 Part number index...
Page 386 7527 Part number index...
Page 387: Part Name Index
7527 Part name index Part name Page 40X7617 100 V maintenance kit...........................333 40X7617 100 V Maintenance kit (fuser, transfer module)..................347 40X7615 115 V maintenance kit...........................333 40X7615 115 V Maintenance kit (fuser, transfer module)..................347 40X7857 160+ GB hard disk..........................347 40X7567 1GB x 32 DDR3 RAM..........................347 40X7616 230 V maintenance kit...........................333...
Page 388 7527 Part name Page 40X8668 CX510 Card for PRESCRIBE........................347 40X8664 CX510 Forms and Bar Code Card......................347 40X7116 Display (CX410)............................337 40X7861 Display (CX510)............................337 40X7821 Display and PCBA (CX310)........................337 40X7830 Duplex ADF assembly..........................330 40X7843 Duplex ADF top cover assembly......................330 40X9108 Duplex separator roller assembly......................330 40X7852 Fax card..............................341...
Page 389 7527 Part name Page 40X7628 Main gear drive assembly with motors....................333 40X7060 MarkNet N8352 802.11b/g/n Wireless print server (external)..............347 40X7812 Media bail...............................328 40X0411 Narrow media flag..........................333 40X7807 Operator panel assembly (CX310)......................336 40X7800 Operator panel assembly (CX410)......................336 40X7815 Operator panel assembly (CX510)......................336 40X7817 Operator panel bezel (CX310)........................337...
Page 390 7527 Part name Page 40X0271 Power cord, 2.5 m (straight): United Kingdom..................341 40X0269 Power cord, 2.5 m (straight): USA, Canada, APG, LAD................341 40X7627 Printhead..............................332 40X8670 Printhead‑to‑controller board cable......................344 40X7845 Rear cover, CX310..........................328 40X7846 Rear cover, CX410..........................328 40X7814 Rear cover, CX510..........................328 40X7833 Redrive assembly...........................330 40X2252 Redrive spacer...
Page 391 7527 Part name Page 40X5480 USB cable (CX510)..........................336 40X1368 USB Cable, packaged (2 m)........................347 40X7836 USB thumbdrive cable (CX410)......................330 40X5480 USB thumbdrive cable (CX510)......................330 40X7840 User interface support bracket (CX310, CX410)..................337 40X7841 User interface support bracket (CX510)....................337 40X7046 Waste toner bottle sensor........................344 Part name index...
Page 392 7527 Part name index...
Page 393 ETHERNET WASTE TONER SENSOR JWT1 JUSB1 JETH1 TONER METER SMART CHIP JCTM1 JSC1 COVER OPEN JCVR1 SAFETY INTERLOCK JINT1 PRINTHEAD MIRROR TRAY PRESENT JMIRR1 JTRAY1 TONER PATCH SENSOR1 JTPS1 FUSER JFUSES1 BIN FULL SENSOR JPJP1 NARROW MEDIA FUSER EXIT JBIN1 PRINTHEAD CONNECTS TO DEV/TRANSFER HVPS JPH1...
Page 394 ETHERNET WASTE TONER SENSOR JWT1 JBUSB1 JUSB1 JETH1 TONER METER SMART CHIP JCTM1 JSC1 JFPUSB1 COVER OPEN JCVR1 SAFETY INTERLOCK JINT1 JHD1 Hard Drive PRINTHEAD MIRROR TRAY PRESENT JMIRR1 JTRAY1 TONER PATCH SENSOR1 JTPS1 FUSER JFUSES1 BIN FULL SENSOR JPJP1 NARROW MEDIA FUSER EXIT JBIN1 PRINTHEAD...

This manual is also suitable for:

Cx310dn Cx410e Cx510e Cx410de Cx510de

Lexmark CX310n Service Manual

Product Information

Edition Notice

Notices and Safety Information

Preface

General Information

Diagnostic Information

Service Menus

P

Repair Information

Component Locations

Maintenance

Parts Catalog

Quick Links

Service Manual

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Summary of Contents for Lexmark CX310n