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Lexmark X543, X544 and X546 7525-xxx Service Manual

1. These menus do not require a POR to access them Network SE Menu FAX SE Menu SE Menu Invalid Engine Code Mode Additional error message information Firmware update from USB Enter Customer Network Ports menu press and hold Left 4 and Right p gt ad gt Release the buttons when the menu appears Enter 411 while in the Home Prime screen From a web browser on a host PC add se to the printer IP address Turn off the MFP 2 press and hold Back Left 4 While error displays on panel press Back and Right gt The Configuration Menu group contains a set of menus settings and operations which are infrequently required by a user Generally the options made available in this menu group are used to configure a printer for operation Goto Configuration Menu on page 3 31 for more information The Diagnostics Mode group contains the settings and operations used while manufacturing and servicing the printer Go to Diagnostics Menu Diag Menu on page 3 2 for more information This menu contains settings for fine tuning the communication settings for the network interfaces and protocols This should be used only under the guidance of second level support See Fax transmission service check on page 2 72 and Fax reception service check on page 2 74 T
2. 7 9 X546 Turkish operator panel bezel 40X2682 7 9 X546Hungarian operator panel bezel 40X2686 7 9 I 10 Service Manual 7525 XXX Part number index l 11
3. rere er rr rr ee ee ee ee eee 7 11 R Redrive assembly 40X5492 En 7 7 Redrive spacer screws 40X2252 r reer rrr ree er rr re ee eee ee ee eee eee eee e eee 7 9 Right AIO cover 40X5486 e 7 5 Right scanner cover 40X5487 r rrr ee eee ee ee eee eee ee eee 7 7 S Screw packet 40X5424 7 11 Separator pad assembly 40X5472 een 7 9 Separator roll assembly40X5471 rrr er ee er ree ee ee eee eee eee 7 9 Simplex ADF assembly 40X5469 EEN 7 9 Simplified Chinese font card assembly 40X5970 rrr err eee eee ee 7 18 T Toner density sensor 40X5414 eee eee 7 15 Toner meter card assembly 40X5404 eee eee errr ee ee ee eee eee 7 13 Top cover assembly 40X5482 rrr rer rr er ee ee ee eee 7 5 Traditional Chinese font card assembly 40X5971 7 18 U USB cable packaged 2 m 40X1368 rrr re rt rr re eres 7 18 USB thumbdrive cable 40X5480 reer e errr re e eeeeee eee 7 7 W Waste toner bottle contact block 40X7046 ere errr rr rr rr re eee cece 7 15 Wireless antenna 40X5319 EE 7 13 Part number index l 9 7525 XXX Wireless card assembly 40X5036 errr rec errr rrr eee eee ee eee eee 7 13 X X546 Braz Por operator panel bezel 40X2515
4. rrr rrr re rr rr rr re ee ee ee ee ee eee eee 7 5 Left scanner cover 40X5488 rrr rere ee ee rr re ee ee ee eee eee eee 7 9 Legal extender cover 40X5441 EE 7 5 Logo cover 40X5491 7 7 Low voltage power supply 40X5409 reer eee errr ee ee ree ee eee ee eee 7 13 M Main drive gear assembly w motors 40X5412 ec errr re rr eee er eee eee eee 7 11 N Narrow media flag 40X0411 ee ee eee eee eee eee 7 11 O Op panel bezel 3 1 Braz Por 40X5502 EE 7 9 Op panel bezel 3 1 Czech 40X5526 e reer reer ee ee ee eee eee 7 9 Op panel bezel 3 1 Dansh 40X5412 re reer ee eee ee eee eee eee ee eee 7 7 Op panel bezel 3 1 Dutch 40X5520 ee eeeeeeeeee eeeeee ee 7 7 Op panel bezel 3 1 English 40X5494 eee eee eee eee eee eee e 7 7 Op panel bezel 3 1 English 40X5518 eee eee ee 7 7 Op panel bezel 3 1 Finnish 40X5514 eee eee eee eee eee eee 7 7 Op panel bezel 3 1 French40X5496 rere eee ee ee eee eee eee 7 7 Op panel bezel 3 1 German 40X5500 2 rrr cer r rer eee eeee 7 7 Op panel bezel 3 1 Hungarian 40X5530 ree ee eee eee eee eee 7 9 Op panel bezel 3 1 Italian 40X5510
5. Operator panel and menus on page 2 2 POR Power On Reset sequence on page 2 2 Print engine theory on page 3 57 Diagnostic information 2 1 7525 XXX POR Power On Reset sequence The following is an example of the events that occur during the POR sequence for the base machine with no paper handling options installed When you turn the printer on it performs a Power On Self Test Check for correct POST functioning of the base printer by observing the following The LED turns on The main fan turns on The operator panel turns on A partial row of pixels appears The operator panel display clears Another row of pixels appears The operator panel display clears again The operator panel displays system information For example 206MB 500Mhz 9 The fuser lamp turns on The fuser takes longer to warm up from a cold start than a warm start 10 The operator panel LED starts blinking The following errors or messages may appear e Close Door or Insert Cartridge display if the upper front cover is open or the print cartridge is missing e Any cartridge errors such as Defective Cartridge or Missing Cartridge 11 Ready appears on the display 12 The main drive motor turns on 13 The EP drive assembly drives the developer shaft located in the toner cartridge 14 The exit rollers turn 15 The printer calibrates Seay gt 2 2 Service Manual 7525 XXX Symptom tables Printer symptom
6. 0000 cee es 4 29 High voltage power supply HVPS assembly removal es 4 31 High voltage power supply HVPS with no spring removal 0000 cece eee 4 32 High voltage power supply HVPS with spring 4 33 made WansSier uni ITU cscs Weken A EE 4 35 Magina UNI IU TEMOVEl 6s oe 00 ced ceoshers F064 RARA HOS Od ES OO HE OS COREG ET OS 4 40 Developer UNM removal A 9 444 chose cere EE SR RER Ree AAA ees 4 42 Low voltage power supply LVPS assembly 00 cece eee ees 4 43 Lower frame removal right and left 2 0 cee 4 45 Ei Oe hae eee 644 E ee oe ebay E eek ye Ghee ees 4 45 Pe nh oe bis ek a he ee Pe a 4 48 Main drive gear assembly with motor removal 4 53 Pick tires removal integrated 250 sheet media tray 000 cece eee e ees 4 55 DEEG ES csi AER RARAS A AAA AAA 4 56 imaging Unit TU TEMGCVAl miii rra rr 4 57 Toner REESEN risa era ENEE AR AAA AAN 4 59 Toner meter cycle TMC card removal ococcocccoc es 4 61 Toner density sensor TPS left and right removal 00 0c eee eee ees 4 63 Tray present sensor removal sa Ee EE EE EE EEN EE EE e EE EE 4 64 USB GOMNCCIOlTOMNOVE narrar rd AAA 4 67 Waste LONG DOUG cda ate ARA AAA A ERA AAA RARA AA 4 67 Waste toner bottle contact block removal ooooooooomornnraran 4 68 Wireless network antenna 0ocococcocco es 4 69 KAES HEIWOIK CSIC oro eee ee EE AAA A ATA A eee 4 71 Scanner component removal procedures e 4 72 SEE
7. eee eee eee eee 7 9 Op panel bezel 3 1 Japanese 40X5504 err eee eee eee eee 7 9 l 8 Service Manual 7525 XXX Op panel bezel 3 1 Korean 40X5532 n o 7 9 Op panel bezel 3 1 Norwegian 40X5516 o 7 7 Op panel bezel 3 1 Polish 40X5522 eee eee eee eee eee 7 9 Op panel bezel 3 1 Russian 40X5524 eee eee eee eee eee ee 7 9 Op panel bezel 3 1 Simplified 40X5506 eee eee 7 9 Op panel bezel 3 1 Spanish 40X5498 er eee eee eee eee eee eee 7 7 Op panel bezel 3 1 Traditional Chinese 40X5508 eee 7 9 Op panel bezel 3 1 Turkish 40X5528 eee ee eee eee eee eee 7 9 Op panel bezel 4 1 Braz Por 40X5501 7 9 Op panel bezel 4 1 Czech 40X5525 rr eee ree ee eee eee eee ee 7 9 Op panel bezel 4 1 Danish 40X5511 o 7 7 Op panel bezel 4 1 English 40X5493 eee eee eee eee eee ee eee ee eee 7 7 Op panel bezel 4 1 Finnish 40X5513 eee eee ee eee eee eee eee eee 7 7 Op panel bezel 4 1 French 40X5495 eee ee eee eee eee 7 7 Op panel bezel 4 1 Hungarian 40X5529 H 7 9 Op panel bezel 4 1 Italian 40X
8. K 25 Remove the flatbed link it will be used on the replacement flatbed unit Note The redrive cable covers operator panel assembly scanner flatbed guides op panel cable and USB cable need to be transferred to the replacement flatbed unit Note After replacing the flatbed unit you will need to perform the flatbed registration procedure See Scanner Manual Registration on page 3 35 Repair information 4 77 7525 XXX Preparing and installing the new flatbed 1 Unbox the scanner and place it top down on a non marring surface 2 Unfold the ribbon cable and replace the toroid A from the old flatbed 4 78 Service Manual 7525 XXX 3 Locate the folding guide line B and remove the paper from the adhesive strip located next to the folding guide line on the scanner B 4 Fold the ribbon cable at a 90 degree angle align the fold of the cable with the fold line on the flatbed and press the cable down on the adhesive so it adheres to the flatbed Repair information 4 79 7525 XXX 5 Locate the second folding guide line C and remove the paper from the adhesive strip C 6 Fold the ribbon cable a second time at a 90 degree angle align the fold of the cable with the fold line on the flatoed and press the cable down on the adhesive so it adheres to the flatbed The ribbon cable should lie flat against the flatoed and there should be no slack on the ribbon cable between the two folds
9. Diagnostic information 2 63 7525 XXX Replace the ADF unit See Duplex ADF Go to step 8 Stop Problem solved removal on page 4 83or Simplex ADF removal on page 4 84 POR the machine into configuration mode Go to the disable scanner menu item See Disable Scanner on page 3 36 Select Enable ADF FB Enabled and press v to save the change POR the MFP to operating mode Run a copy from the ADF Did the 840 xx error recur Inspect JFBM1 JHS1 and JCCD1 on the Go to step 10 Go to step 9 controller board Are the connections properly connected Properly connect all the connections Stop Problem solved Go to step 10 Did the 840 xx error recur Replace the flatbed unit See Flatbed Go to step 11 Stop Problem solved removal on page 4 72 POR the machine into configuration mode Go to the disable scanner menu item See Disable Scanner on page 3 36 Select Enable ADF FB Enabled and press v to save the change POR the MFP to operating mode Run a copy from the flatbed Did the 840 xx error recur Replace the controller board See Problem solved Contact second level Controller board removal on page 4 18 support Did this fix the problem 2 64 Service Manual 7525 XXX Black or blank page copy service check Print a menu page or a page from the host See Print quality solid Go to step 2 Is the pag
10. Disable Scanner on page 3 36 Select Enable ADF FB Enabled and press v to save the change POR the MFP to operating mode Try running a copy from the ADF and flatbed Did the 840 xx error recur Re enter Configuration mode scroll to and Go to step 3 Go to step 8 select the Disable Scanner menu item Does the screen display ADF Disabled or Auto Disabled Check the ADF cable connections on the Go to step 5 Go to step 4 ADF relay card and the controller board Also inspect JFBM1 JHS1 and JCCD1 on the controller board Are the connections properly connected Properly connect the connections on the Go to step 5 Stop Problem solved ADF relay card and controller board POR the machine into configuration mode Go to the disable scanner menu item See Disable Scanner on page 3 36 Select Enable ADF FB Enabled and press y to save the change POR the MFP to operating mode Try running a copy from the ADF and flatbed Did the 840 xx error recur Check the continuity on the ADF cable Go to step 7 Go to step 6 Is there continuity Replace the ADF cable POR the machine Go to step 7 Stop Problem solved into configuration mode Go to the disable scanner menu item See Disable Scanner on page 3 36 Select Enable ADF FB Enabled and press to save the change POR the MFP to operating mode Try running a copy from the ADF and flatbed Did the 840 xx error recur
11. Note Make sure the clips on the posts extend onto the surface of the plate A 5 Connect the cable to the tray present sensor and place the spring in place before installing the right lower frame 4 52 Service Manual 1525 XXX Main drive gear assembly with motor removal A 1 Remove the left cover See Left cover removal on page 4 4 2 Remove the LVPS See Low voltage power supply LVPS assembly on page 4 43 3 Remove the screws A on the top cover gt 5 Disconnect the cable from the fuser exit sensor Repair information 4 53 7525 XXX 6 Remove the screws securing the LVPS shield 7 Unplug the cables C from the motors and remove all cables from the retainer D Note Observe the cable routing for reinstallation 8 Remove the two screws E from the rear dd Ee 9 Remove the two screws F from below the main drive gear assembly 10 Remove the two screws G from the right of the main drive gear assembly al o 11 Lift the main drive gear assembly with motor and remove 4 54 Service Manual 7525 XXX Pick tires removal integrated 250 sheet media tray Note You will need to have a soft padded work surface Warning Remove only the rubber tires and not the paper pick tire assembly to avoid losing small parts The paper pick tires are located in the base printer There are also tires in the optional 550 page media tray If you have this additional
12. Perform a POR If the problem persists go to Printhead service check on page 2 57 Perform a POR If the problem persists go to Printhead service check on page 2 57 Perform a POR If the problem persists go to Printhead service check on page 2 57 7525 XXX Service error messages 1XX 8XX and 9xx continued e rem CN 109 02 Service The black printhead failed to complete Perform a POR If the problem persists go Black Printhead servo to Printhead service check on page 2 57 109 03 Service The black printhead mirror motors Perform a POR If the problem persists go Black Printhead failed to achieve lock to Printhead service check on page 2 57 109 04 Service The black printhead mirror motors lost Perform a POR If the problem persists go Black Printhead PLL motor lock to Printhead service check on page 2 57 109 05 Service Failure reading NVRAM from Perform a POR If the problem persists go Black Printhead printhead to Printhead service check on page 2 57 109 08 Service The black laser showed bad in EMS Perform a POR If the problem persists go Black Printhead testing to Printhead service check on page 2 57 109 11Service Failure writing data to printhead Perform a POR If the problem persists go Black Printhead to Printhead service check on page 2 57 109 12 Service Failure reading data from the printhead Perform a POR If the problem persists
13. Open the front cover Lift the toner cover by sliding the latch to the left Remove the waste toner bottle See Waste toner bottle on page 4 67 Remove the cartridge bottles Lift the two latches A to unlock the imaging uni MAIN LD EN e d KR 6 Pull back on the latches until the imaging unit meets resistance I O E ES E So Mi 4 40 Service Manual 1525 XXX 7 Press and hold the release lever B and pull the imaging unit straight out Warning When pulling the imaging unit out Only grab the release levers B of the imaging unit Do not touch the photoconductors in the bottom of the imaging unit Repair information 4 41 7525 XXX Developer unit removal The developer units are not FRUs 1 Raise the scanner unit and remove the toner cartridges 2 Remove the imaging unit See Imaging unit IU removal Warning Do not touch the underside of the imaging unit This could damage the developer units 3 Remove the developer unit you need 4 42 Service Manual 1525 XXX Low voltage power supply LVPS assembly A 1 Remove the left cover See Left cover removal on page 4 4 2 Disconnect the three cables A from the LVPS A 3 Remove the six screws B and the ground cable connected to the LVPS cage Ka E 4 3 _ F a i pp s Ce 4 Remove the LVPS Repair information 4 43 7525 XXX If you receive a
14. to clear the message and continue printing 88 Replace lt color gt The term lt color gt includes black cyan magenta and yellow Cartridge e Replace the toner cartridge and press Select to clear the message and continue printing Scanner ADF cover The cover to the ADF is open pe e Close the ADF cover If this doesn t remedy the problem Go to ADF cover open service check on page 2 67 Scan job too long The scan job exceeds the maximum number of pages e Break the scan job into multiple small jobs e Cancel the scan job Paper cleared Paper is cleared from ADF e Cancel job e Restart job This can only be performed if job recovery is enabled and the job can be restarted A new job with the same parameters is started 2 12 Service Manual 7525 XXX Paper Jam messages Paper jam messages 2xx en CC 2xx paper jams 200 xx Paper Jam A single page of media jam at the input Remove the tray1 unit open the front door Check lt area gt sensor and remove the print cartridge to access the jam area Remove the jammed page See 200 paper jams on page 3 41 200 xx Paper Jam Multiple pages of media are jammed at Open the front door and remove the print lt x gt Pages Jammed the input sensor cartridge to access the jam area Remove all the jammed pages See 200 paper jams on page 3 41 201 xx Paper Jam A single page of media is jammed Open the front doo
15. Disable ADF only Auto Disabled The device restarts Font Sharpening This setting is 7525 XXX used to set a text point size value below which the high frequency screens will be used when printing data This setting affects only PCL PostScript and PDF emulators Settings are in the range of 0 150 24 is the default For example if the value is set to 24 then all fonts sized 24 points or less use the high frequency screens To adjust the Font Sharpening setting perform the following steps 1 Inthe configuration menu scroll to the Font Sharpening menu item and press y 2 Usethe y pressing or p to increase or decrease the settings value pressing lt q decreases the value and increases the value 3 press y to accept the setting Pel Blurring The Pel Blurring setting is used if step artifacts are noticed by the customer on copies and scans When set to On Pel Blurring smooths out the artifacts to produce a higher quality image To change the setting perform the following steps In the Configuration menu use the arrow keys to scroll to the Pel Blurring menu item press y press 4 or p to select the desired setting press y to accept the change press Te oes ee press y Exit Config Menu to exit the Pel Blurring menu item Scroll to Exit Config menu The device restarts Wi
16. Max Speed under Fax Send settings e Adjust the Transmit Level e Check line quality e Select a lower Max Speed under Fax Send settings e Adjust the Transmit Level e Check line quality e Select a lower Max Speed under Fax Send settings e Adjust the Transmit Level e Check line quality e Select a lower Max Speed under Fax Send settings e Adjust the Transmit Level e Check line quality e Select a lower Max Speed under Fax Send settings e Adjust the Transmit Level e Check line quality e Select a lower Max Speed under Fax Send settings e Adjust the Transmit Level e Check line quality e Adjust Transmit Level e Check line quality Failed to connect at the minimum e Adjust Transmit Level speed supported by the MFP e Incompatible connection e Check line quality e Adjust to a lower modulation scheme e Adjust Transmit Level Receive Threshold values e Verify destination phone number e Verify that the remote fax is authorized to receive faxes e Check by enabling Behind a PABX setting e Check phone line e Check MFD modem hardware Busy tone detected Check with remote end if successive attempts fail See Modem fax card service check on page 2 71 A timeout occurred after dialing the Check with remote end if successive number and waiting for a response attempts fail Fax can
17. Memory Full cannot After a start there is no memory to do the fax job Attempted fax is cancelled send faxes Insert Duplex Page in Reload printed page in tray lt x gt Cancel Job appears if the job can be cancelled Tray lt x gt Install Tray lt x gt or Printer detects that tray lt x gt is missing where x is 1 or 2 This message appears if the Cancel job job was begun but the paper has not yet been retrieved The tray is no longer detected Replace the indicated tray Load lt source gt lt custom Printer does not detect media meeting the description lt custom string gt in lt source gt string gt iise lt source gt is Tray 1 Tray 2 Tray 3 Multi Page Feeder MP feeder or Envelope eeder e Load the input source with the correct type and size media e Cancel the current job 2 6 Service Manual 7525 XXX User status and attendance messages continued User primary message Explanation Load lt source gt Printer does not detect media meeting the description lt custom type gt in lt source gt lt custom type gt where lt source gt is Tray 1 or Tray 2 Tray 3 e Load the input source with the correct type and size media e Cancel the current job Load lt source gt Printer does not detect media meeting the size requested in the source indicated lt Size gt e Load the input source with the correct type and size media e Cancel the current job Load lt source gt Printer
18. P Panel Menus 3 32 Panel Test 3 13 paper guidelines 1 13 input size 1 9 input sources 1 8 input type 1 11 output capacity 1 11 recycled 1 14 unacceptable paper 1 13 weights 1 12 Paper jams 3 39 paper jams avoiding 3 39 Paper path thermistor parts catalog 7 14 parts catalog covers 7 4 media drawers and tray 7 16 scanner 7 6 7 8 password panel menus 3 32 pel blurring 3 37 photoconductor unit description 4 57 imaging kit 4 57 pick tires parts catalog 7 16 pick tires integrated 250 sheet media tray removal 4 55 POR sequence 2 2 Power cords parts catalog 7 12 power on sequence POR 2 2 PPDS Emulation 3 32 preparing the new flatbed for installation 4 78 l 4 Service Manual print quality background 2 49 blank page 2 50 blurred or fuzzy print 2 52 half color page 2 52 horizontal banding 2 52 horizontal line 2 53 insufficient fusing 2 53 missing image at edge 2 53 mottle 2 5mm speckles 2 53 narrow vertical line 2 54 random marks 2 54 residual image 2 55 solid color page 2 56 vertical banding 2 56 print quality symptoms 2 5 print tests 3 11 printer registration 3 4 printhead parts catalog 7 10 removal 4 56 service check 2 32 printhead service check 2 32 Prt Quality Pgs configuration menu 3 31 diagnostic menu 3 11 Q Quick Test duplex 3 15 quick test page 3 6 R rear shield 4 7 redirve unit removal 4 91 redrive unit parts catalog 7 6 registration printer 3 4 quick test 3 6 skew 3 5 removal 4 7
19. Replace the plastic front hinge from the old scanner Replace the cable cover plates and scanner alignment guides from the old scanner Replace the steel hinge stud from the old scanner Replace the redrive unit AlO release lever side covers and operator panel SORA 4 80 Service Manual 1525 XXX Flatbed pivot link removal Remove the AIO link See AlO link on page 4 96 Remove the right scanner cover See Cover scanner right on page 4 93 Remove the AIO release lever See AIO release lever on page 4 95 Remove the screws A securing the flatbed link to the flatbed a T 5 Remove the flatbed pivot link Repair information 4 81 7525 XXX Duplex ADF rear cover 1 While lifting the ADF use a flatblade screwdriver to pry open the three tabs A on the bottom of the ADF cover 4 82 Service Manual 1525 XXX Duplex ADF removal 1 Remove the duplex ADF rear cover from the ADF assembly See Duplex ADF rear cover on page 4 82 Save the cover for use on the new ADF unit 2 Disconnect the ground cable A from the ADF assembly d A B 3 Disconnect the ADF cable B from the ADF card located on the ADF assembly 4 Carefully pull the ADF cable and grommet away from the ADF assembly 5 Liftthe ADF to an upright position 6 Use a screwdriver to release the right hinge C from the flatbed unit 7 Remove the ADF assembly Note After installing the new ADF unit you will need
20. Turn off the printer and remove the rear shield See Rear shield removal on page 4 7 Disconnect the cable at JOPP1 on the controller board Verify the following values JOPP1 1 O V dc 5 V de 0 V de Ground 5 V dc EN 3 3 V de Ground Are all these values approximately correct Pin Voltage WA Check continuity of the operator panel assembly cable Is there continuity 2 Check for continuity in the operator panel cable connector Do all the conductors indicate continuity Go to step 2 Replace the operator panel See Operator panel removal on page 4 98 Replace the controller board See Controller board removal on page 4 18 Replace the operator panel cable See Op panel cable on page 4 101 Diagnostic information 2 43 7525 XXX Operator panel displays all diamonds no beeps Turn off the printer and remove the rear shield Go to step 2 Replace the controller See Rear shield removal on page 4 7 board See Controller Disconnect the cable at JOPP1 on the board removal on controller board Verify the following values page 4 18 Pin Voltage o svae Are all these values approximately correct Check for continuity in the operator panel cable Replace the operator panel Replace the operator panel connector See Operator panel cable See Op panel Do all the conductors indicate continuity removal on page 4 98 cable on page 4 1
21. secrete secre See ds ee eee Ee eee ae 7 9 X546 Czech operator panel bezel 40X2689 en 7 9 X546 Danish operator panel bezel 40X2519 2 creer eee reer cece ec u 7 7 X546 Dutch operator panel bezel 40X2518 rrr rer rrr rr eee 1 7 X546 English operator panel bezel 40X1537 rrr rrr rrr rr RAA NARSA DANT REA SANA 7 7 X546 Finnish operator panel bezel 40X2602 7 9 X546 French operator panel bezel 40X2513 lt eres 7 7 X546 German operator panel bezel 40X2516 o 7 7 X546 Italian operator panel bezel 40X2517 renee rr rrr rrr eee 7 9 X546 Japanese operator panel bezel 40X2723 rrr rrr rrr rr rene 7 9 X546 Koeran operator panel bezel 40X2784 7 9 X546 Norwegian operator panel bezel 40X2520 7 7 X546 Polish operator panel bezel 40X2624 rrr errr rrr rr rr ree 7 9 X546 Russian operator panel bezel 40X2681 errr rrr rrr rr rr rrr ree 7 9 X546 Simplified Chinese operator panel bezel 40X2724 7 9 X546 Spanish operator panel bezel 40X2514 EE 7 7 X546 Swedish operator panel bezel 40X2521 gt 7 7 X546 Traditional Chinese operator panel bezel 40X2783
22. waste toner bottle removal 4 67 waste toner bottle contact removal 4 68 Wireless card parts catalog 7 12 wireless network antenna removal 4 69 wireless network card removal 4 71 7525 XXX Part number index P N Description Page 100V fuser assembly 40X5408 o 7 11 110V fuser assembly 40X5406 7 11 128MB DDR DRAM DIMM card assembly 40X5937 7 18 220V fuser assembly 40X5407 rere er rrr ee rr rr ee ee 7 11 250 sheet tray assembly 40X5419 2 2 ee ee ere ee eee eee eee 7 5 256MB DDR DRAM DIMM card assembly 40X5938 eee 7 18 3 1 op panel DBCS 40X54 75 ee 7 7 3 1 op panel 40X5473 errr ee re rr ee re ee eee eee ee ee eee 7 7 40X0270 Power cord 1 77M straight Japan eee eee eee eee 7 13 40X0271 Power cord 6 foot United Kingdom _ e ee ee 7 13 40X0274 Power cord 6 foot Switzerland eee ee ee eee 7 13 40X0275 Power cord 6 foot straight Israel 7 13 40X0276 Power cord 6 foot South Africa eee ee eee 7 13 40X0278 Power cord 6 foot straight Europe and others 7 13 40X0
23. y Select the sensor you want to test open the toner door remove the corresponding toner cartridge and press Select v Note whether the operator panel shows a change in state Note If the reflective disk is not showing on the cartridge rotate the gear clockwise to expose the reflective surface For additional information about the Base Sensor Test see Base Sensor Test on page 3 18 Does the operator panel display a change of state Toner sensors Y C M K on TMC card Step Questions actions Yes No Remove the toner cartridge and inspect the Repair or replace the TMC Go to step 2 lenses on the toner meter cycle TMC card card See Toner meter cycle TMC card removal Are the lenses blocked damaged or dirty on page 4 61 Turn off the printer and remove the rear shield Replace the controller Replace the TMC card See See Rear shield removal on page 4 7 board See Controller Toner meter cycle TMC Disconnect the cable at the JSP1 connector on board removal on card removal on the controller board Turn the printer on and page 4 18 page 4 61 measure the voltages below JSP1 Voltage Pin Ground 3 3 V de 3 3 V de 3 3 V de 3 3 V de 6 0 0 V de Are any of the voltage values incorrect 2 58 Service Manual 7525 XXX Transfer roll service check Remove the ITU See Image transfer unit Replace the IT
24. 00 D s Loft L Bow P Coarse Adjustment Right R sa Wu Coarse Coarse i E E Adjustment d Adjustment a 240 260 Wat 30 40 40 20 0 20 40 60 e 190 p La NM gt D e Bow P Fine Adjustment ei x 120 120 180 HEI 4 20 240 z 4 s H e R T g V 12 md 6 4 E np TI dar z y R 0 HU 4 A A 20 4 q s Current New Current New 12 Cyan Cyan Cyan Cyan 12 L value L value P R value A value 3 fe 24 Mm d Ao 4 e e ae P 03 aa bos A A A a a Current New i a KTM Cyan Cyan an P value P value H 4 Z 0 9 Continue on to the other two colors in the same manner Diagnostic aids 3 9 7525 XXX Factory Scanner Note This setting is not used by field service Factory Manual Note This setting is not used by field service Miscellaneous Tests Motor Detect This test initiates an automatic motor detection process that should be performed whenever the controller board is replaced To run Motor Detect 1 Select MISC TESTS in the Diag Menu and press Select v Remove Cartridge press Select appears 2 Select Motor Detect Note Do not press Select yet 3 Remove all toner cartridges and the imaging unit 4 Close the front cover If you press Select before closing the front cover a message appears Close Cover press Select 5 press Select y Motor Detection In Progress appears The motor detection process takes about 10 secon
25. Jams in the ADF unit Remove the jam from the top or bottom of the ADF unit Media not supported in the Load the tray with the correct paper size duplex 3 40 Service Manual 7525 XXX 200 paper jams 1 Remove the standard 250 sheet tray tray 1 2 Remove the jam Note Make sure all paper fragments are removed 3 Insert the tray 4 press Select lt lt 201 paper jam 1 Grasp the front door at the side handholds and then pull it toward you to open it 2 Remove the jammed paper Note Make sure all paper fragments are removed 3 Close the top door 4 press Select A Diagnostic aids 3 41 7525 XXX 202 paper jam 1 Raise the scanner assembly to the up position 2 Grasp the front door at the side handholds and then pull it toward you to open it 3 Grasp the green lever and pull the fuser cover toward you i SH VAN 4 Hold the fuser cover down and then remove the jammed paper The fuser cover closes when released 5 Close the fuser cover 6 Close the front door 7 press Select y to continue 3 42 Service Manual 230 paper jam 1 Grasp the front door at the side handholds and pull it toward you to open it 2 Remove the jam 3 press Select Alto continue printing 235 paper jam 1 Load the tray with the correct paper size 2 Insert the tray 3 Close the front door 4 press Select A
26. Open an FTP session with printer s IP address Use a Put command to send the updeng fls also known as 2 fls file to the printer The printer will start the update process Various status and progress messages will display on the operator panel The FTP session will terminate Warning DO NOT TURN THE MACHINE OFF until the update is complete When the update is completed the printer will automatically reboot and return to Ready e a i Scanner Firmware 10 On a networked computer open an FTP client 11 Using the FTP client navigate to the directory containing the firmware updates 12 Open an FTP session with printer s IP address 13 Use a Put command to send the scanner fls also known as 3 fls file to the printer The printer will start the update process Various status and progress messages will display on the operator panel The FTP session will terminate Warning DO NOT TURN THE MACHINE OFF until the update is complete When the update is completed the printer will automatically reboot and return to Ready 3 54 Service Manual 7525 XXX Using the printer s internal Web server Before updating the firmware download the zip file containing the firmware files from http support lexmark com printerfirmware and inputting keycode x54x all lowercase Note You will need the IP address of the printer on the network This can be obtained from the Network Settings page found under Network Setup menu under Reports in the Administr
27. RARR M KO 4 4 s g GIE Service tips e Never touch the surface of the ITU belt with your bare hand The oil from your skin will cause a charge differential on the surface and toner will not stick properly The result would be repeating blotches of voids light print on a page Then the ITU belt will have to be replaced e Don t use solvents or other cleaners to clean the ITU belt surface No matter how careful you are the surface will be compromised causing scratches or a charge differential that will produce a void or light blotch on the printed page Then the ITU belt will need to be replaced Diagnostic aids 3 61 7525 XXX Step 4b Second transfer Once the four planes of color are transferred to the transfer belt from the photoconductors the image is carried towards the transfer roll E This transfer roll is also part of the ITU Based on the speed of the transfer belt the proper time to send the signal to pick the media from an input source is determined The timing of the pick is such that the media reaches the point where the transfer belt and transfer roll meet The paper passes between the transfer belt and transfer roll when the image on the belt reaches the second transfer area The high voltage power supply sends voltage to the transfer roll E to create a positive charge Once the image on the transfer belt reaches the
28. Receive Threshold 7XX Error occurred when sending a frame e Check line quality e Adjust Transmit Level e Select a lower Max Speed value under Fax Send settings 800 Received EOT unexpectedly from If error persists disable V34 modulation the modem in V34 mode scheme 802 Too many timeouts occurred If error persists disable ECM mode during ECM reception 803 Fax cancelled by user No action needed 804 Unexpectedly received a disconnect e Check line quality command from the remote end e Adjust Transmit Level Receive Threshold values e Remote device could be requesting an unsupported feature 805 Remote fax device failed to respond to e Adjust Transmit Level Receive the DCS command Threshold values e Remote device could be malfunctioning 808 T1 timeout occurred when trying to e Adjust Transmit Level Receive establish a connection with a remote Threshold values fax device 809 T2 Timeout occurred due to loss of e Adjust Transmit Level Receive command response synchronization Threshold values Diagnostic information 2 27 7525 XXX Fax error log codes continued e Error code 80A T5 Timeout occurred when transmitting Check line quality image data to remote fax device Adjust Transmit Level Select a lower Max Speed value under Fax Send settings 80B Too many errors when transmitting in Check line quality ECM mode Adjust Transmit Level Select a
29. Remove the imaging unit See Imaging unit IU removal on page 4 40 Remove the rear cover See Right cover removal on page 4 7 Remove the rear screw A in the waste toner bottle sensor contact to allow access to the cable cover Note The waste toner bottle sensor contact does not need to be unplugged or removed Remove the four screws B securing the cable cover ST ee e B A 7 Turn the printer on the left side 8 Remove the screw C securing the spring contacts 9 Release the tabs D on the spring contact to release the spring contacts Repair information 4 59 7525 XXX 10 Disconnect the cable E from the controller board at JSC1 E 11 Remove the cable from the retainer on the bottom of the printer 12 Extract the cable through the frame and remove the cable with the spring contacts 4 60 Service Manual 7525 XXX Toner meter cycle TMC card removal Remove the right cover See Right cover removal on page 4 7 Remove the waste toner container See Waste toner bottle on page 4 67 Remove the imaging unit IU See Imaging unit IU removal on page 4 40 Remove the rear shield See Rear shield removal on page 4 7 Disconnect and remove the toner meter cycle card cable A Note Observe the routing for reinstallation aS eee E 3 u ZE EE e KK af a peger d DE E g SS vi Repair information 4 61 7525 XXX Installation note Be sure the
30. Simplex ADF Up to 5 ppm Duplex ADF Up to 5 ppm page sides ADF Document handling ADF input capacity 50 sheets ADF output capacity 50 sheets ADF document width 4 9 125mm to 8 5 216mm ADF document length 5 127mm to 14 0 356mm Resolution and color depth e Resolution 1200 dpi optical e CDD 1200 dpi and 600 dpi Selectable through electronics e Color depth 48 bit RGB output 16 bit channel Flatbed document specifications e Document size Up to A4 and letter 4 5 x 5 5 to 8 5 x11 SEF Flatbed speed 3 seconds to scan 3 seconds to return Scanner operating environments e Temperature 10C to 35C e Humidity 15 RH to 85 RH Storage environments e Temperature 20C to 43C e Humidity 5 RH to 95 RH Tilt This device should operate within the stated parameters when it is level within 10mm from front to back and 10mm side to side 1 16 Service Manual 7525 XXX Scan and copy specific specifications Scan Resolutions Optical 600 dpi Local Twain only e Enhanced vial Lexmark Scan Center 1200 X 1200 dpi 2400 X 2400 dpi 4800 X 4800 dpi 9600 X 9600 dpi 19200 X 19200 dpi Output resolutions e Mono 600 X 600 dpi e Color 300 X 300 dpi Duplex scan Duplex and copy is available only on X544 and X546 series machines Scan file output formats e TIFF e JPEG e PDF Supported compressions e PDF 1 bit JBIG2 CCIT G4 Flate 8 24 bit Flate JPEG
31. between the flatbed and top cover Note Some units don t have the springs installed 4 74 Service Manual 7525 XXX 17 Gently push the front flatbed hinge G towards the front of the top cover to disengage it from the top cover guide Pin 18 Carefully pull the flatbed unit towards the front of the MFP while using your other hand to route the cables through the top cover 19 Remove the CCD ribbon route cover and homing guide attachment 20 Disconnect the op panel ground termination from the LVPS Note This completes the removal of the flatoed assembly from the print engine The removals for the FRUs attached to the flatoed are covered under different removal procedures In addition to the FRUs the following steps illustrate the additional parts that need to be removed from the old flatbed and transferred to the new flatbed Repair information 4 75 7525 XXX 21 Remove the steel hinge stud H Save this for use on the replacement flatbed H e 22 Remove the redrive I See Redrive unit on page 4 91 23 Remove the cable cover plates and scanner homing plates J These will be used on the replacement flatbed unit I J Warning When replacing the rear cable cover plate the cables must be routed as shown above Failure to do so could damage the cables and lead to possible paper skews and jamming 4 76 Service Manual 1525 XXX 24 Remove the screws K securing the flatbed link to the flatbed
32. or to low Go to CCD service check on page 2 65 Go to CCD service check on page 2 65 7525 XXX Service error messages 1XX 8XX and 9xx continued Front calibration strip has excessive Front excessive variability for Mono Red dark area Green or Blue Go to CCD service check on page 2 65 846 06 Front magnification exceeds limits Rear excessive variability for Mono Red Green or Blue Go to CCD service check on page 2 65 Modem Failure The Configuration ID bit that describes the 847 device s modem doesn t match the actual modem installed in the device Fax Storage The amount of flash storage available on the device is too small Note The NAND Flash partition can shrink as bit failures 847 01 cause blocks to be invalidated Go to Format Fax Storage on page 3 34 If the issue is not fixed replace the controller board Go to Controller board removal on page 4 18 Fax Storage The devices flash partition is invalid or unavailable Go to Format Fax Storage 847 02 on page 3 34 If the issue is not fixed replace the controller board Go to Controller board removal on page 4 18 846 07 Modem Config ID Mismatch A device doesn t have a modem installed 848 even though its Configuration ID indicates that a modem should be present Modem Config ID Mismatch A device has a modem installed but its 848 01 Configuration ID indicates that a modem shouldn t be present
33. to exit the test and return to the Scanner sensor tests Home sensor test This test verifies the functionality of the home position sensor To test this sensor perform the following steps In the sensor test menu press lt q or to scroll to the Home sensor test press Select 7 Starting Test displays Home Closed displays Home Open should display if the sensor is working properly press Back 5 to exit the test and return to the Scanner sensor tests CoS eT ADF Cover closed sensor test This test verifies the functionality of the ADF cover closed sensor To test this sensor perform the following steps In the sensor test menu press lt or to scroll to the ADF Cover closed sensor test press Select x Starting Test displays ADF Cover Closed displays Lift the ADF top cover ADF Cover Open should display if the sensor is working properly press Back 5 to exit the test and return to the Scanner sensor tests oe eS a T Diagnostic aids 3 27 7525 XXX Sensor 1 test This test verifies the functionality of scan sensor 1 To test this sensor perform the following steps 1 Inthe sensor test menu press 4 or to scroll to the Sensor1 test 2 press Select A Starting Test displays Sensor 1 Closed displays 3 Lift the ADF top cover and close the ADF cover sensor by pressing down on the ADF sensor actuator A with a small fl
34. verify that the ethernet cable is properly connected on both ends If the network is wireless got to step 3 Is the cable properly connected Connect the ethernet cable Problem resolved Go to step 3 Did this fix the problem Check the printer s online status under Printers Go to step 5 Go to step 4 and Faxes on the host computer Delete all print jobs in the print queue Is the printer online and in a Ready state Change the printer status to online Problem resolved Go to step 5 Did this fix the issue Does the IP address displayed on the network Goto step 10 Go to step 6 settings page match the IP address in the port of the drivers using the printer Does the LAN use DHCP Go to step 7 Go to step 9 Note A printer should use a static IP address on a network Are the first two segments if the IP address Go to step 8 Go to step 9 169 254 Go to step 10 POR the printer Problem resolved Is the problem resolved Reset the address on the printer to match the Problem fixed Go to step 10 IP address on the driver Did this resolve the issue Have the network admin verify that the printer Go to step 12 Go to step 11 and PC s IP address have identical subnet addresses Are the subnet addresses the same Go to step 12 Using the subnet address supplied by the Problem resolved network admin assign a unique IP address to the printer Note The printer IP address should match the
35. 2 68 293 02 Flatbed cover The MFP senses that the flatbed cover Close the flatbed cover See ADF cover open is Open open service check on page 2 67 294 04 Scanner jam Jam at the ADF exit sensor Remove all paper from the ADF If the error remove all originals recurs ADF paper jam service check from the scanner on page 2 68 294 05 Scanner jam A jam is detected at the ADF exit remove all originals sensor from the scanner 2 14 Service Manual 7525 XXX Service error messages Service error messages 1XX 8XX and 9xx moe oom e 106 xx Service Yellow Printhead 106 01 Service Yellow Printhead 106 02 Service Yellow Printhead 106 03 Service Yellow Printhead 106 04 Service Yellow Printhead 106 05 Service Yellow Printhead 106 08 Service Yellow Printhead 106 11Service Yellow Printhead 106 12 Service Yellow Printhead 106 13 Service Yellow Printhead 107 xx Cyan Printhead Error 107 01 Service Cyan Printhead 107 02 Service Cyan Printhead 107 03 Service Cyan Printhead 107 04 Service Cyan Printhead 107 05 Service Cyan Printhead Yellow printhead error The yellow printhead lost HSYNC The yellow printhead failed to complete servo The yellow printhead mirror motors failed to achieve lock The yellow printhead mirror motors lost PLL motor lock Failure reading NVRAM from printhead The yellow laser showed bad in EMS testing Failure writing da
36. 57 Perform a POR If the problem persists go to Printhead service check on page 2 57 Perform a POR If the problem persists go to Printhead service check on page 2 57 Perform a POR If the problem persists go to Printhead service check on page 2 57 Perform a POR If the problem persists go to Printhead service check on page 2 57 Diagnostic information 2 15 7525 XXX Service error messages 1XX 8XX and 9xx continued re rom rm 107 08 Service Cyan Printhead 107 11Service Cyan Printhead 107 12 Service Cyan Printhead 107 13 Service Cyan Printhead 108 xx Service Magenta Printhead 108 01 Service Magenta Printhead 108 02 Service Magenta Printhead 108 03 Service Magenta Printhead 108 04 Service Magenta Printhead 108 05 Service Magenta Printhead 108 08 Service Magenta Printhead 108 11Service Magenta Printhead 108 12 Service Magenta Printhead 108 13 Service Magenta Printhead 109 xx Service Black Printhead 109 01 Service Black Printhead 2 16 Service Manual The cyan laser showed bad in EMS testing Failure writing data to printhead Failure reading data from the printhead Printhead declared error Magenta printhead error The magenta printhead lost HSYNC The magenta printhead failed to complete servo The magenta printhead mirror motors failed to achieve lock The magenta printhead mirror motors lost PLL motor lock Fail
37. 8 foot straight Argentina Power cord 8 foot straight United Kingdom Power cord 6 foot straight Israel Switzerland South Africa Traditional Italy Power cord 6 foot straight Power cord 6 foot straight Denmark Power cord 6 foot straight Power cord 6 foot straight E y Brazil PRC Power cord 2 5M straight Japan Power cord 1 8M straight Power cord 8 foot straight Power cord 1 8M straight Korea Power cord 1 8M straight Taiwan Power cord 1 8M straight Australia Fax interface cable Fax PCBA Parts catalog 7 13 7525 XXX Assembly 5 Electronics 2 7 14 Service Manual 7525 XXX Assembly 5 continued Electronics 2 Part Units Units Describtion number option FRU H 40X5429 40X5414 40X7046 40X5421 40X5423 ITU paper path thermistor Toner density sensors left or right one in package Waste toner bottle contact block Imaging unit contact Pogo pin Cable packet used for AC power in Low voltage power supply High voltage power supply Fuser S1 CMY K motors Option tray Fuser exit narrow media bin full Wire tie 1 0mm A B C D E F G H Tray present cable Parts catalog 7 15 7525 XXX Assembly 6 Media drawers and trays 7 16 Service Manual 7525 XXX Assembly 6 Media drawers and trays Part Units Units Description number opt FR
38. Copag 2001 2004 Lexmark International Inc 24 Click Start The printer will start the update process Various status and progress messages will appear on the printer s operator panel Warning Warning Do not turn the machine off until the update is complete When the firmware update is completed the printer will automatically reboot and return to a Ready state 3 52 Service Manual 7525 XXX Updating the firmware using a USB thumb drive If a USB thumbdrive is available it can be used to update the printer firmware Before updating the firmware download the zip file containing the firmware files from http support lexmark com printerfirmware and inputting keycode x54x all lowercase Warning Before performing a firmware update on the printer contact the technical service center or second level of support to verify the correct firmware and keycode The wrong firmware or wrong level of firmware could lead to a malfunction or render the printer inoperable Unzip the X54x zip file and copy the firmware files to the thumb drive You do not need to copy the USBFlash executable to the flash drive Note A printer that is in Invalid Code mode cannot be updated from a USB thumb drive Note Verify the Enable Drive and Update Code settings are enabled These settings are in the Flash Drive menu under the Settings Menu in the Administrative menus To update the printer firmware perform the following steps 1 Insert the flash d
39. EE 1 1 COOTIONS GNC CONNES A 6 666 AE EE EELER EE EE EE AAA 1 2 cs e oo ee EC 1 2 PONE reitir ririri eke wk A A 1 3 Connectivity network Support 2 0 ee 1 3 Opera MOES sicario A bbw EARTE AINARA POE Red ee ON 1 4 DITA SISI Bice oe EE ee ea ee ee eee eee en eee oe eee wee ae 1 4 EMSS ARA 1 5 CIOOANCES ers 64664 FEE OSes AAA RAS AA 8 he Os 1 5 Power and electrical specifications 0 00 ccc es 1 6 RA 06050 04056 ORE 0 0 6804052400 A EELER 85945 SRO 1 7 Environment specifications rar rca RARA NAAA eee ee eee eee es 1 7 MES RANGING 2 rrd 86s 0 AAA RA TARA RARA ARA AAA Ok A EA ARA RARA 1 8 IPT and output SOUrCES ciccrrraaranEAARACAARAAAA SORE Oe eee es 1 8 als CARON MAA 1 9 Media input size specifications 0 0 0 ce es 1 9 Media input type specifications 020s 1 11 Media output size and type A8 REENEN NEEN e ECH Ne HE RRR ROR eR eR 1 11 MECA QUIICINES 5 40 46 66 4 454646 HEGRE RRA GREK RA NARA ED 1 13 Per i SNCS e eg ege A be es 1 13 IMAN DADO 94 visas ic ARA AAA AA dd 1 13 o A A oe ee es 1 14 Selecting preprinted forms and letterhead 1 14 6 6 eege Fs ih oe oe Ob a ee ee eee A 1 14 Using recycled paper and other office paper 1 14 Digital imaging SPECITICATIONS 6 csi A AE ERR AER RER AAA AAA ARA ORO AAA 1 16 General Specifications resina rr RANIA AAA AAA 1 16 QUIN ONO aa Fra ra Ad ci a E T E 1 16 ADF DOCUMEN NANGING WEEN 1 16 Mesoluton and COM GODIN sa 49 496 44546 AE ESET SEES SOAS E ROO SHE
40. Print quality is maintained at factory default level e Speed is reduced Eco Mode Off is default Designed for customers where the environment is a key factor There are three options Energy Paper and Energy Paper e Duplex is on if Energy Paper or Paper is selected duplex models only can be overwritten by the driver e Energy e Print quality is maintained e Power Saver is set to one minute e Fuser standby is off e The operator panel back light is off e Power supply energy consumption is reduced e Energy Paper All of the above Data streams Y Supported Leal K Not supported X544n X544dn Lexmark Lexmark Data streams Lexmark X543 X544dtn X544dw X546dtn PostScript Level III emulation ki Y Y Y Version 3011 of the Adobe definition of PostScript 3 is supported PDF Supports version 1 6 PPDS By default the PPDS interpreter is inactive A user can activate the data stream by PJL or by the PPDS Emulation setting in the Configuration Menu Directimage Devices that support Directimage support all of the following graphics formats TIFF TIF JPEG JPG GIF PNG BMP PCX and DCX Host Based Printing HBP Graphics Device Interface GDI Version 3 color uses PCL XL 1 4 Service Manual 7525 XXX Dimensions Lexmark X543 291 mm 11 5 in 424 mm 16 7 in 400 mm 15 7 in 21 kg 46 2 Ibs Lexmark X544n X544dn 422 mm 16 6 in 424 mm 16 7 in 416 mm 16 4 in 25 kg 54 9
41. Remove the ground wire from the op panel Repair information 4 99 7525 XXX Op panel bezel removal 1 Place a flatbed screwdriver under the front of the bezel LEXM ai RR 4 100 Service Manual 7525 XXX Op panel cable 1 Remove the operator panel bezel cover 2 Remove the operator panel See Operator panel removal on page 4 98 3 Remove the flatbed assembly See Flatbed removal on page 4 72 4 Remove the CCD cable cover 5 Unroute the operator panel cable through the tabs B Warning When replacing the op panel and USB cables the cables must be routed in the exact same route with no overlapping of the cables Failure to do so can result in the crimping of the cables In addition the redrive unit on the scanner might not make proper contact with the redrive rolls on the top cover This could result in a paper jam under the flatbed unit Logo cover 1 Remove the op panel bezel cover See Op panel bezel removal on page 4 100 2 Use a flatbed screwdriver to depress the four tabs A securing the logo cover to the op panel bezel cover Repair information 4 101 7525 XXX 3 Pull the logo cover away from the op panel bezel cover Fax card removal 1 Remove the rear shield See Rear shield removal on page 4 7 2 Disconnect the fax interface cable from the fax card See Fax interface cable on page 4 102 3 Remove the three screws A which secure the fax card to the standoff
42. SW VCC Ground no wire Ground CATHODE VOUTA 5V VOUTB ANODE Ground no wire ANODE dl lt CATHODE Ground Locations 5 13 7525 XXX Controller board Connector JLVPS1 JOPT1 5 14 Service Manual vo eo eo 7525 XXX HVPS Locations 5 15 7525 XXX Connectors HVPS board Connection from controller board Contacts to machine 5 16 Service Manual re Remap e How ooo re owon e fese oo fs IN e fse 7525 XXX LVPS LL ioe O 2 O i od AL Locations 5 17 7525 XXX Connectors LVPS board ice ne E E SO SSES e fom SE e fom SSES In fowm SSES e fowm e ewo o w few e ege e Im o CS e p ES 5 18 Service Manual 7525 XXX Toner meter card Toner meter card connectors Toner meter card een Rr Cart_Meter_K_IN e round Locations 5 19 7525 XXX Wireless card FRONT CON1 GG O V13 Ts Connectors Wireless card BACK O From JUSBW1 on controller Ground 5 20 Service Manual EN Wireless POR 7525 XXX 6 Preventive maintenance This chapter describes procedures for printer preventive maintenance Follow these recommendations to help prevent problems and maintain optimum performance Safety inspection guide The purpose of this inspection guide is to aid you in identifying unsafe conditions If any unsafe conditions exist find out how serious the hazard co
43. Service tips e If the fuser rollers are damaged they can cause toner to be pulled off the page or cause paper jams e Toner that rubs off a printed page can be a sign of a malfunctioning fuser or an improper media setting Always check the paper type setting before replacing the fuser A common mistake is to print on heavier media such as cardstock with the paper type set to plain paper e When removing paper jams from the fuser be sure to use the fuser release tabs to relieve the pressure on the page In addition never pull unfused toner through the fuser if you can help it try to back the jammed page out of the fuser in the opposite direction it was travelling Diagnostic aids 3 63 7525 XXX Step 6 Clean Erase There are two main cleaning processes that take place during the EP Process One process cleans the transfer belt and the other cleans the photoconductors Transfer Unit Clean Once the toner image on the transfer belt has been transferred to the page the transfer belt rotates around and is cleaned by the cleaning blade G This occurs for every page that is printed After the toner is moved to the cleaning blade the toner is moved from the cleaning blade G to the waste toner area using an auger system AO A A SI CA 3 64 Service Manual 7525 XXX Photoconductor Clean Erase After each plane of color h
44. Step 1 Top T Coarse Adjustment Skew Z Coarse Adjustment B0 60 40 20 0 20 40 60 50 0 60 40 20 0 20 40 60 60 Top T Fine Adjustment Skew Z Fine Adjustment 20 18 15 1 12 10 WE T 0 Z 0 d d d Current New Current New Cyan Cyan Cyan Cyan T value T value Z value Z value STEP 1 Adjust the Top T margin and Skew Z then confirm before going to Step 2 Press the up or down buttons until a check appears at the setting in need of adjusiment as Press Select Then use the lt and gt buttons to enter the new value Press Select to save E NOTE H the alignment values cannot be determined by using the fine adjustment L l scales then use the coarse adjustment scales at the top of the page STEP 2 Go to the next page to adjust the Left L margin Right R margin and Bow P STEP 3 Reprint these pages to confirm final settings Go To Step 2 Diagnostic aids 3 7 7525 XXX 4 Select Top Margin and press Select y 5 Select the best choice for fine or coarse adjustment in Step 1 first page and add it to the current value for the Top Margin Top T Coarse Adjustment 240 If the alignment is not close enough to use the fine adjustment get close to the ideal value by using the coarse adjustment marks Select the block that is most filled by the color on the left or approximate if 80 60 40 20 O 20 40 60 80 none of the blocks are completely filled and enter it for the new v
45. Transmit Level setting inthe SE Stop Problem resolved Go to your second level of menu press 411 to enter the SE menu support See Escalating a enter Modem settings and select Transmit fax issue to second level Level support on page 2 76 Test by adjusting the transmitted signal strength by decreasing increasing the Transmit Level setting in steps of 1db For example if default value is 11 db changing it to 12db will decrease the signal strength by 1db and changing it to 10db will increase the signal strength by 1db Recommended adjustment range is 5 db in 1db steps from the default value Did this fix the problem Diagnostic information 2 73 7525 XXX Fax reception service check 1 Is the phone line properly connected to the Go to step 2 Go to step 3 modem card and the wall jack 2 Properly connect the phone line to the Problem resolved Go to step 3 modem card and wall jack Did this fix the problem Check for a dial tone Go to step 4 Go to step 6 Is there a dial tone Use a telephone to test the phone line s Go to 7 Go to step 5 ability to send and receive calls Did the phone line work properly Use a telephone handset to verify the phone Go to step 7 Go to step 6 line is free of static or external noise Is the phone line noise free Use the MFP on a properly functioning Problem resolved Go to step 7 phone jack Did this fix the problem In l
46. XXX Controller board CN CC CM o ICH ewon a fom IN ECN owon s fom a ewon SS e ewoo fom 5 8 Service Manual 7525 XXX Controller board JCCD1 CCD ribbon cable e mmm e mem fe mem foes G G D D FB AFE VSMP_R FB AFE RSMP R 20 Ion FB CCD CLK R FB CCD CLAMP R D D D 6 D 8 9 0 1 2 3 4 s eoe e Im 7 8 000 rms e Im O FeR OOO TRANSFER ooo JN EN 2 3 4 5 6 N N N N N N N N 5V E JUN E E SUN KS KS 2 Lmeopmenn ES KS KE KS ES KS KS e ER LAMD ON Locations 5 9 7525 XXX Controller board JHS Home Sensor wv eA ee No oma OF DIRA_ADF_C JFBM1 Flatbed Motor JADF ADF connector lOB_ADF_C l11B_ADF_C DIRB_ADF_C E E AAA E EA E _ E TA C E ECN KS KS KS fom 5 10 Service Manual Controller board Connector JOPP1 JWT1 JCVR1 JINT1 JTRAY 1 JTPS2 JFUSES1 7525 XXX l2C_DATA 5V dc V_PANEL 5V l2C_CLK Ground OP_IRQ_N 4 5V de 3 3 Ground SENSE VREF VAC G V_24V_CVR 24V de COVER_OPEN cover open 0V dc closed 24V dc 5V Fused Ground VS_INT 5 V de door closed OV dc door open ANODE to 5V_SW DUPLEX_ENT 5 V de CATHODE Ground ANODE CATHODE Ground TPS2_ON 5V_SW Ground V_FUSER_PHA 24V dc doors closed V_FUSER_PHA 24V dc doors closed V_FUSER_PHB 24V dc doors closed V_FUSER_PHB 24V dc doors closed
47. a POR and returns to normal mode USB Scan to Local USB Scan to Local enumerates a USB simple device or USB composite device In the off position the simple USB device is enumerated in the on position the composite USB device is enumerated Prt Quality Pages The Prt Quality Pages can be printed from both the Configuration Menu and the Diagnostics Menu The Configuration Menu is limited in information compared to the pages printed from the Diagnostics Menu To help isolate print quality problems print the Print Quality Test Pages The pages are formatted The Printing Quality Test Pages message appears then the pages print The message remains on the operator panel until all the pages print press Select y to print the pages The Print Quality Test Pages contain several pages The first page which is printed in English text contains only a mixture of text and graphics The information includes values of the Quality Menu settings in Settings and printer and toner cartridge configuration information The remaining pages only contain graphics For samples of the pages see Print quality test pages Prt Quality Pgs on page 3 11 Color Trapping Diagnostic aids 3 31 7525 XXX Uses an algorithm to compensate for mechanical incorrect registration in the printer When small black text or fine black lines are being printed the printer checks to see if they are being printed on top of a colored background If so rathe
48. a negative change moves the image to the right Right margin 50 to 50 Each increment corresponds to an approximate shift of 4 pixels at 600 dpi The default is O 100 to 100 Each increment corresponds to 1 1200 of an inch The default is O A positive value causes the left end of the scan line to move down the page A negative value causes the left end of the scan line to move up the page The right end stays fixed There is no compression or expansion of the image 5 Print another copy of the Quick Test to verify your changes 6 Continue changing the settings by repeating steps 3 through 5 To exit REGISTRATION press Back 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 See Alignment on page 3 7 for instructions on setting printhead alignment This must be performed before color skew adjustment is attempted The following illustration shows proper alignment versus skewed alignment UT Diagnostic aids 3 5 7525 XXX Quick test The Quick Test contains the following information e Print registration settings e Alignment diamonds at the left right top and
49. and unchanging 2 45 Op panel USB cable service Check 0 2 cee eee es 2 45 o srira gt EE NEE Dh AES RERA eh ee eed 2 45 Networking Service CHECK EEN EIERE RENE EEN ER ENER NEE ER ee eee ee ees 2 46 Print QUAINY service CNGCK cd dane RARA RARA RA AA AAA A RARA AMIA AA 2 48 Sii EE 2 49 FAN GOAI TIRA ee a oe ee id id 2 50 Print quality blurred or fuzzy print ass coi so oe a OS Oe eh ede 2 52 Prnt CU OCI page eros oe ee ep di Pos wes POG tee 2 52 Print quality horizontal banding WEE 2 52 PAA GUAY Ot IN AA E r N Sh es ey 2 53 Print gualty insuficient TUSINO e cc RARA ii aa dene een ies 2 53 Print quality missing image at edge 1 ee ee ee ees 2 53 Print quality mottle 2 5mm speckles 2 0 00 cee eee eee eee eee 2 53 Print quality narrow vertical line 8 es EEN RE E AE EE dE ods 2 54 Singel o e ee eG haan Seow eda 2 54 PTO Guay Tesla MAS 64s ode ae tose ote SF Err ET DESKS T CREE ESR IERIE SSE 2 55 FINCA ISSO EDIT PAGO iia di adi de 2 56 Print quality vertical banding WEEN 2 56 PrininGad EEN CNGK EE EE 46600006000 EE AFA AA 2 57 iv Service Manual 7525 XXX Toner Meter cycle TMC Card civic AAA ARA RAN RE da 2 58 Toner sensors Y C M K on TMC Card ccccccc ees 2 58 Transfer roll service check crab A AA AA ARA A 2 59 Tray DO Sensor Servite CHECK EE 2 60 Option trays 2 and 3 Service Check 0 o oooooocccoo 2 61 cir AAA O 2 63 Black or blank page copy Service CheckK o oo
50. be similar to using glue to write on a can and then rolling it over glitter The glitter sticks to the glue but won t stick to the rest of the can Service tips e Never touch the surface of the developer roller with your bare hand The oil from your skin may cause a charge differential on the surface and toner will not stick properly The result would be repeating blotches of voids light print on a page Then the affected cartridge will have to be replaced e If the developer roller is damaged it will not contact the surface of the photoconductor properly The result could be repeating marks thin vertical voids or thin vertical lines of color on the printed page Check the surface of the developer for damage 3 60 Service Manual 7525 XXX Step 4a First transfer When the latent images are developed on each Photoconductor the high voltage power supply sends voltage to the 1st Transfer Rollers inside the ITU D The charge difference between the developed toner image on the Photoconductor surface and the ist Transfer Roller causes the images to transfer to the surface of the ITU belt for each color This takes place by a direct surface to surface contact between the Photoconductors and the ITU belt EE D z gt A ege E gt DN PE EE AA J NA SIISE 4 Q SE A
51. bottom e Horizontal lines to check for skew e General printer information including current page count installed memory serial number and code level wick Tee Device Information RAR SETTINGS To print the Quick Test page Note Print the Quick Test Page on letter or A4 paper 1 Select REGISTRATION from DIAGNOSTICS 2 Use or to select Quick Test and press y The message Quick Test Printing appears on the display Once the Quick Test Page completes printing the Registration screen displays again 3 6 Service Manual 7525 XXX Alignment Aligns each of the color planes to the black plane Print the Quick Test under each color Cyan Yellow and Magenta and adjust the Top Margin Left Margin Right Margin Skew and Bow Prints the Print Alignment Pages and requires that the best line in each set of lines must be selected To get started 1 Select Alignment Menu from the Diag Menu and press Select y 2 Selecta color Cyan Yellow or Magenta and press Select y Note The yellow alignment page markings are more difficult to see so you might not want to pick it first 3 Select the Quick Test and press Select to begin printing The message Printing appears on the display A page similar to the following prints Cyan Alignment
52. cable runs through the retainer The toner meter cycle card is a tight fit Insert the bottom edge inside the frame and then push down on the top edge to clear the top cover e n some cases the top cover will have to be loosened so the right edge of the top cover can be lifted to get the toner meter cycle card back into position 1 A 2 Remove the two screws B 3 Push in on the cover above the locating Pin C while lifting to disengage the cover Carefully lift the cover just enough for clearance for the toner meter cycle card 4 Position the toner meter cycle card 5 Replace the screws D and replace the top cover 4 62 Service Manual 7525 XXX Toner density sensor TPS left and right removal The toner patch sensors are similar but the left sensor includes an extra cable and sensing device Remove them the same way 1 Remove the ITU See Image transfer unit ITU on page 4 35 2 Remove the rear shield See Rear shield removal on page 4 7 3 Disconnect the toner density sensor cable from JTDS1 connector A Right or JTDS2 connector A Left on the controller board If you are removing the left toner density sensor also disconnect the thermistor from JFUSES1 connector B on the controller board Note Observe the routing of the cable for reinstallation 4 Remove the two screws C securing the sensors C Left sensor C Right sensor Note Observe the routing of the cable for reinstallatio
53. careful not to interfere with the exit sensor on the left side Reroute the cables back through their retainers When you replace a new fuser be sure to reset the Fuser Page Count 1 Enter Diagnostics Menu turn the printer off press and hold Left 4 and Select 4 turn the printer on and release the buttons when the installed memory and processor speed displays 2 Select Printer Setup and press Select y 3 Select Reset Fuser Cnt and press Select 4 lt lt Reset Fuser Cnt Reset appears on the display Select Back 5 twice and select Exit Diags and press Select lt a Repair information 4 27 7525 XXX Fuser drive motor assembly removal 1 Open the front cover 2 Remove the right cover See Right cover removal on page 4 7 3 Disconnect the cable A from the fuser drive motor assembly Note If you remove the toroid B from the cable be sure to return the toroid to the cable when you re install 4 Remove the two screws C 5 Remove the fuser drive motor assembly 4 28 Service Manual 7525 XXX Fuser exit sensor removal mo a 5 6 7 Open the front cover Remove the right cover assembly See Right cover removal on page 4 7 Remove the left cover See Left cover removal on page 4 4 Disconnect the two wire fuser cable A from the LVPS Note You do not have to extract the cable Remov
54. conditions Lexmark has found no reason to discourage the use of today s recycled office papers but generally the following property guidelines apply to recycled paper e Low moisture content 4 5 e Suitable smoothness 100 200 Sheffield units or 140 350 Bendtsen units European Note Some much smoother papers such as premium 24 lb laser papers 50 90 Sheffield units and much rougher papers such as premium cotton papers 200 300 Sheffield units have been engineered to work very well in laser printers despite surface texture Before using these types of paper consult your paper supplier e Suitable sheet to sheet coefficient of friction 0 4 0 6 e Sufficient bending resistance in the direction of feed 1 14 Service Manual 7525 XXX Recycled paper paper of lower weight lt 60 g m 16 Ib bond and or lower caliper lt 3 8 mils 0 1 mm and paper that is cut grain short for portrait or short edge fed printers may have lower bending resistance than is required for reliable paper feeding Before using these types of paper for laser electrophotographic printing consult your paper supplier Remember that these are general guidelines only and that paper meeting these guidelines may still cause paper feeding problems in any laser printer for example if the paper curls excessively under normal printing conditions General information 1 15 7525 XXX Digital imaging specifications General specifications ADF Scan speed
55. display on the operator panel Warning DO NOT TURN THE MACHINE OFF until the update is complete When the update is completed the printer will automatically reboot and return to Ready O oS If your flash drive is inserted into the USB port located on the operator panel USB Menu Print from USB displays Note If Print from USB doesn t display by default use the lt Left or p Right buttons to navigate to the Print from USB command 10 Press y Select The flash drive s directory structure displays 11 Use the y or p buttons to navigate to the scanner fls also known as 3 fls firmware file 12 Press y Select Program Device Yes displays 13 Press y Select The printer will start the update process Various status and progress messages will display on the operator panel Warning DO NOT TURN THE MACHINE OFF until the update is complete When the update is completed the printer will automatically reboot and return to Ready Diagnostic aids 3 53 7525 XXX Updating the firmware using a networked computer Using FTP Before updating the firmware download the zip file containing the firmware files from http support lexmark com printerfirmware and inputting keycode x54x all lowercase Note To update the printer using FTP you should have an understanding of how to use an FTP client Note You will need the IP address of the printer on the network This can b
56. does not detect media meeting the size or type requested in the source lt type gt lt size gt indicated e Load the input source with the correct type and size media e Cancel the current job Load single sheet Printer does not detect media meeting the description lt custom type gt in the single lt custom type gt sheet feeder manual feeder The following actions can be taken e Load paper and the job continues e press Select y and choose an alternate source for media e Cancel the current job Load single sheet Printer does not detect media meeting the description lt custom string gt in the single lt custom string gt sheet feeder manual feeder The following actions can be taken e Load paper and the job continues e press Select v and choose an alternate source for media e Cancel the current job Load single sheet Printer does not detect media meeting the description lt size gt in the single sheet lt size gt feeder manual feeder The following actions can be taken e Load paper and the job continues e press Select v and choose an alternate source for media e Cancel the current job Load single sheet Printer does not detect media meeting the description lt type gt and lt size gt in the single lt type gt lt size gt sheet feeder manual feeder The following actions can be taken e Load paper and the job continues e press Select v and
57. go Black Printhead to Printhead service check on page 2 57 109 13 Service Printhead declared error Perform a POR If the problem persists go Black Printhead to Printhead service check on page 2 57 122 xx Service Fuser error Go to Fuser service check on Fuser Error page 2 39 122 01 Service EWC error Attempting to print with Go to Fuser service check on Fuser Error estimated power at or below minimum page 2 39 power 122 02 Service Fuser over temperature Go to Fuser service check on Fuser Error page 2 39 122 03 Service Fuser open thermistor check failed Go to Fuser service check on Fuser Error page 2 39 122 04 Service EWC Error Did not reach EWC start Goto Fuser service check on Fuser Error temperature in time page 2 39 122 05 Service EWC Error Did not change Go to Fuser service check on Fuser Error temperature within expected time page 2 39 122 06 Service EWC Error Did not reach EWC stop Go to Fuser service check on Fuser Error temperature in time page 2 39 930 09 Service Fuser zero crossings out of range Zero Goto Fuser service check on LVPS crossing detected page 2 39 122 10 Service Fuser failed to warm up Go to Fuser service check on Fuser Error page 2 39 122 11 Service Fuser under temperature error while in Go to Fuser service check on Fuser Error standby page 2 39 122 12 Service Fuser under temperature error while Go to
58. mismatch between the operator panel assembly and the controller board Reload the firmware and try Replace the controller board again with a new and not previously installed controller board See Controller board removal on page 4 18 Go to step 2 Did reloading the firmware correct the Problem resolved Replace the controller board problem with a new and not previously installed controller board See Controller board removal on page 4 18 Autocompensator mechanism service check Note The input S2 sensor is part of the autocompensator mechanism ACM and is not available separately Turn the printer off and then remove the rear Go to step 3 Properly connect the cables shield See Rear shield removal on and POR the printer page 4 7 Check the cable at JSP1 on the controller board for proper connection Go to step 2 Is the cable properly connected Did the printer function correctly after Problem resolved Go to step 3 reconnecting the cables Diagnostic information 2 33 7525 XXX Turn the printer on and then verify the following approximate values at JSP1 JSP1 Pin Vue efem Are the values approximately correct Bin full sensor service check Replace the controller board See Controller board removal on page 4 18 Replace the autocompensator mechanism See Autocompensator mechanism ACM standard tray removal on page 4 12 Inspect the
59. or three second pause in a fax number In the fax to field a pause is represented by a comma e From the home screen press the key to redial a fax e This key only works in the fax menu or fax function When the MFP is in another mode pressing this key will generate a beep Resolution press to change the fax resolution press options to change the size broadcast delayed send and cancel options for a fax job Options Hook press this to take the line off the hook press a second time to hang up RR E Enter numbers letters and symbols IER ES E EN EN Go Be ES ES Shortcuts press to enter the shortcut screen be 2 78 Service Manual Menu map 7525 XXX This menu map identifies menus available to customers The diagram shows the menus on the operator panel and items available under each menu Some menu items or values are displayed only if a specific option or feature is installed on your printer Other menu items may be effective only for a particular printer language You can select these values at any time but they affect printer function only when you have the optional equipment feature on your model or the specified printer language Supplies Menu Cyan Cartridge Magenta Cartridge Yellow Cartridge Black Cartridge Imaging Kit Waste Toner Bottle Paper Menu Default Source Size Type Paper Texture Paper Weight Paper Loading Custom Types Custom Scan Sizes Universal Setup Uni
60. or wrong level of firmware could lead to a malfunction or render the printer inoperable There are three options to update firmware on your printer The instructions for all three options are listed below Using the host computer to update the firmware over USB This procedure uses the program USBFlash USBFlash is a utility that can also be used to update firmware from a host computer via USB To use the USBFlash utility the printer must be installed on the host computer so a USB virtual printer port can be established on the host computer The virtual printer port is needed so the host computer can communicate with the printer Note Make sure the printer is attached over USB and Ready or Invalid Engine Code posts on the operator panel If the printer cannot go to the Ready state or is not in the Invalid Engine Code state power the unit off Power the unit back on while holding down Back 5 and Left lt on the operator panel until 128MB posts on the operator panel Once the printer powers up Invalid Engine Code should be posted on the operator panel The firmware can now be updated To update the firmware perform the following steps 1 Download the USBFlash utility and firmware files to the host PC these files can be found in the X54x zip file found by going to http support lexmark com printerfirmware and inputting keycode x54x Unzip the ZIP file to a new folder on the host
61. position Is the input S2 sensor flag damaged Watch the display while rotating the flag Problem resolved Go to step 3 Does the display indicate Media Clear and Media Present Turn the printer off and remove the rear shield Go to step 4 Reseat the connector See Rear shield removal on page 4 7 Is the JSP1 cable connector properly connected to the controller board Turn the printer on and check the voltage at Replace the Replace the controller JSP1 pin 15 autocompensator board See Controller mechanism See board removal on Autocompensator page 4 18 mechanism Is the voltage approximately 5 V dc ACM standard tray removal on page 4 12 2 40 Service Manual 7525 XXX Main drive gear assembly EP drive service check Turn the printer off and remove the rear shield Replace the JCARTB1 Go to step 2 See Rear shield removal on page 4 7 cable Check the cable at JCARTB1 for proper connection to the controller board the cable for pinch points and the cable or connector for any other damage Is the cable damaged Disconnect the cable at JCARTB1 on the Go to step 3 Replace the controller controller board and verify the following board See Controller values board removal on page 4 18 JCARTB1 Pin Voltage 24 V dc 24 V dc ES e fava o Ground Ground 13 24 V dc Are the voltages correct Replace the main drive assembly S
62. remove Repair information 4 47 7525 XXX Right lower frame Note Remove the duplex sensor the tray present sensor the spring spring holder and the wireless antenna plate which are not part of the right and left lower frames The cable cover is part of the right lower frame FRU Note To properly reinstall the duplex sensor and the tray present sensor also order two sensor retaining plates Open the front cover Remove the right cover assembly See Right cover removal on page 4 7 Remove the waste toner bottle See Waste toner bottle on page 4 67 Remove the imaging unit See Imaging unit IU removal on page 4 40 Remove the rear shield See Rear shield removal on page 4 7 Remove the rear screw A in the waste toner bottle sensor contact to allow access to the cable cover Note The waste toner bottle sensor contact does not need to be unplugged or removed Remove the four screws B securing the cable cover Note The cable cover is part of the right lower frame FRU oo a te N 8 Carefully place the printer on its left side 4 48 Service Manual 1525 XXX 9 Remove the screw C securing the wireless antenna Wireless models only to access the right frame Do not remove the antenna C 10 Remove the duplex sensor See Duplex sensor removal on page 4 23 11 Remove the three screws D securing the lower right frame to the printer 12 Remove the screw E close to
63. second transfer to the media Fuse the toner to the media Clean erase the photoconductor and the ITU A Ee In summary the printer s controller board receives print data and the command to print The controller board then initiates the print process The controller board is the command center for the EP process and coordinates the various motors and signals The high voltage power supply sends charge to various components in the EP process The laser fires on the photoconductors and alters the surface charge relative to the planed image for each photoconductor Each photoconductor rotates past its respective developer roll and toner is developed on the surface of each photoconductor The four separate color images are then transferred to the transfer belt on the ITU as it passes under the photoconductors After the image is transferred to the transfer belt the photoconductors are cleaned and recharged The transfer belt carries the four colored image towards the transfer roll Media is picked up from the tray and carried to the transfer roll where the image is transferred from the transfer belt to the media The timing of the paper pick is determined by the speed of the transfer belt The media is carried to the fuser rollers where heat and pressure are applied to the page to permanently bond the toner to the page The fuser rollers push the media into the output bin The transfer unit is cleaned and the process begins again for the next pag
64. selected the custom type from those types the duplex unit supports Media output size and type There is a single 100 sheet output bin available for this printer and no additional output options General information 1 11 7525 XXX Weight ranges for each media type Ce e Specialty papers Gloss Book 88 to 176 g m grain long 60 to 120 Ib book Labels upper limit 131 g m 35 Ib bond Paper gt 7 8 Xerographic or 60 to 74 9 g m grain long Light Paper business paper 16 to 19 9 Ib bond E 75 to 89 9 g m grain long Plain Paper 20 to 23 8 Ib bond 90 to 104 9 g m grain long Heavy Paper 23 9 to 27 8 Ib bond 105 to 176 g m grain long Card stock 27 9 to 47 lb bond Card stock upper limit grain long Envelopes Sulfite wood free or 60 to 105 g m to 28 lb bond 4 Multipurpose P 100 cotton feeder or manual slot only For 60 to 176 g m paper grain long fibers are recommended Paper less than 75 g m 20 Ib must be printed with Paper Type set to Light Paper 100 cotton content maximum weight is 24 Ib bond 28 Ib bond envelopes are limited to 25 cotton content The duplex unit supports paper weights between 60 105 g m 16 28 pound grain long bond The duplex unit does not support card stock transparencies envelopes and labels Lexmark transparency part numbers 12A8240 and 12A8241 are supported from the standard tray manual slot and the multipurpose feeder Paper 90 to 104 9 g
65. sensitive parts when cold weather heating is used because low humidity increases static electricity Testing generic FRUS The X54xx series MFP s controller board and op panel can be tested after installation When testing the board it is critical that the machine only be PORd into Diagnostics mode DO NOT POR THE MACHINE TO A READY STATE In Diagnostics mode machine specific information is not written to the NVRAM on the replacement part To properly test a replacement generic FRU perform the following steps MoN Replace the faulty controller board Start the machine into diagnostics mode See Menu key combinations on page 3 1 Turn the machine off If the replacement part is not the cause of the issue remove the replacement part Repair information 4 1 7525 XXX Removal procedures CAUTION Remove the power cord from the electrical outlet before you connect or disconnect any cable or electronic board or assembly for personal safety and to prevent damage to the printer Disconnect any connections between the printer and PCs peripherals Notes e 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 e Remove the waste toner bottle color toner cartridges imaging unit and media tray before removing other printer parts The imaging unit should be carefully set on a clean smooth an
66. sheet Duo Drawer complete C544n C544dn C544dw C540n C543dn 7 17 40X5435 650 sheet Duo Drawer tray only C544n C544dn C544dw C540n C543dN 7 17 40X5496 Power cord 6 foot straight Brazil 7 13 4 1 X544 X546 controller board 40X1524 7 13 4 1 op panel 40X5474 ee ee ee ee ee eee eee 7 7 4 1 op panel DBCS 40X5476 reer rrr rr rr re er rr re ee eee eee 7 7 512MB DDR DRAM DIMM card assembly 40X5939 7 18 64MB Flash card assembly 40X1455 7 18 650 sheet drawer assembly 40X5434 7 5 650 sheet tray assembly 40X5435 7 5 A ACM paper pick motor assembly 40X1557 ere rece rr rr ee ee eee eee eee 7 11 ADF cable 40X5479 o 7 7 ADF input tray 40X5470 7 7 ADF rear duplex cover 40X5478 rere eer rere er re ee eee ee eee eee 7 7 ADF rear simplex cover 40X5477 errr errr rrr rr rr ee ee eee eee eee eee 7 7 AIO back cable cover 40X5489 e 7 5 AIO Link 40X5587 7 5 AIO release lever 40X5536 r eee rrr re ee eee ee ee eee eee 7 7 AIO toner cover 40X5534 eee ere ree ee ree ee eee eee eee 7 5 Part number index l 7 7525 XXX B Bezel cov
67. shield removal on page 4 7 2 Remove the controller board See Controller board removal on page 4 18 3 Disconnect the high voltage power supply HVPS cable at the HVPS Repair information 4 33 7525 XXX 4 Remove the screw A securing the HVPS A 5 Press down on the spring mount and carefully slide the HVPS out Release the pressure on the spring mount when the LVPS slides out about 25mm Installation notes CAUTION 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 Connect the high voltage power supply HVPS cable to the high voltage power supply before sliding the board into the printer Pull the HVPS cable through the access hole and plug into the controller board Be careful not to dislodge the cable from the HVPS 4 34 Service Manual 7525 XXX Image transfer unit ITU 1 Write down the number on the new ITU before installing it You will need the 16 digit numeric value from the barcode after the installation and it is easier to see at this point Remove the right cover See Right cover removal on page 4 7 Remove the rear shield See Rear shield removal on page 4 7 Remove the waste toner container See Waste toner bottle on page 4 67 Remove the imaging unit IU See Imaging unit IU removal on page 4 40 Note T
68. table Dead printer Go to Dead printer service check on page 2 35 Operator panel one or more buttons do Go to One or more operator panel buttons fail on not work page 2 42 Operator panel display is blank Printer Go to Operator panel display blank five beeps on sounds five beeps page 2 42 Operator panel display is blank Go to Operator panel display blank five beeps on page 2 42 Operator panel continuously displays all Go to Operator panel display blank five beeps on diamonds and does not complete POST page 2 42 Pages print blank after replacing the When replacing the controller board verify the cable from the controller board high voltage power supply is seated properly The cable may have come loose from the HVPS Warning A blank page that should have toner on it could be an indication that toner is applied to the ITU belt but not transferred Therefore the toner goes into the ITU cleaner which cannot process massive amounts of toner It is important to prevent extensive blank pages from being processed if they should have toner on them Tray linking does not work e Check that the same size and type of paper are in each tray e Check the location of the paper guides e The multipurpose feeder does not automatically sense the paper size You must set the size from the Paper Size Type menu e Print a menu settings page compare the settings for each tray and adjust on the operat
69. the area of the product where you are working Unplug the product before you begin or use caution if the product must receive power in order to perform the task eThis product contains mercury in the lamp lt 5mg Hg Disposal of mercury may be regulated due to environmental considerations For disposal or recycling information contact your local authorities or the Electronic Industries Alliance www eiae org Consignes de s curit La s curit de ce produit repose sur des tests et des agr ations portant sur sa conception d origine et sur des composants particuliers Le fabricant n assume aucune responsabilit concernant la s curit en cas d utilisation de pieces de rechange non agr es Les consignes d entretien et de r paration de ce produit s adressent uniquement a un personnel de maintenance qualifi Le demontage et l entretien de ce produit pouvant presenter certains risques lectriques le personnel d entretien qualifi devra prendre toutes les pr cautions n cessaires ATTENTION Ce symbole indique la pr sence d une tension dangereuse dans la partie du produit sur laquelle vous travaillez D branchez le produit avant de commencer ou faites preuve de vigilance si l ex cution de la t che exige que le produit reste sous tension Norme di sicurezza La sicurezza del prodotto si basa sui test e sull approvazione del progetto originale e dei componenti specifici Il produttore non e responsabile per la sicurezza
70. the message Tray x Missing fail to Go to step 5 Problem resolved appear when the tray is pulled out Turn off the printer and remove the rear shield Problem resolved Replace the controller Rear shield removal on page 4 7 board See Controller Disconnect the cable at JTRAY1 connector for board removal on tray1 or JOPT1 for tray 2 and 3 on the page 4 18 controller board Turn the printer on and Is the sensor dislodged measure the voltages below Pin vonage Check these voltages for Tray 2 and 3 JOPT1 for tray 2 or 3 Pin vonage e Ground o Ground Are the voltage values approximately correct 2 60 Service Manual 7525 XXX Option trays 2 and 3 service check Are two option trays being used Go to step 2 Go to step 4 If two option trays are being used is the 550 Go to step 4 Go to step 3 sheet tray on the bottom Switch the order of the trays so the 500 sheet Problem resolved Go to step 4 tray is on the bottom and print a page from both trays Did the pages print from both trays Inspect the paperfeed tires on the tray that fails Goto step 5 Go to step 6 to pick Do they appear worn Replace the paperfeed tires on the faulty tray Problem resolved Go to step 6 and print a page with media from the affected tray Did the page print Check the option cable connected to JOPT1 Go to step 8 Go to step 7 for continuity Is there continuity Replace the cab
71. to continue printing 24x paper jam 1 Remove the 650 sheet Duo Drawer tray 2 out 2 Remove the jam Note Make sure all paper fragments are removed 3 Align the tray and insert it 4 press Select 7 to continue 250 paper jam 1 Push the lever to remove the media jam in the multipurpose feeder Note Make sure all paper fragments are removed 2 press Select y 7525 XXX Diagnostic aids 3 43 7525 XXX 29x ADF paper jam 1 Remove all original documents from the ADF input tray 2 Open the ADF top cover Remove the jammed paper 3 Close the ADF cover 4 Open the flatbed cover Remove any jammed pages 5 Close the scanner lid D Press y 3 44 Service Manual 7525 XXX 291 xx ADF paper jams 1 Remove all original documents from the ADF input tray 2 Remove the ADF input tray See ADF input tray on page 4 84 Remove the original from the ADF by pulling the lower of the two sheets A from the ADF exit 4 Replace the ADF input tray Diagnostic aids 3 45 7525 XXX Updating printer firmware The latest firmware can be found by going to http support lexmark com printerfirmware and inputting keycode x54x all lowercase Warning Before performing a firmware update on the printer contact the technical service center or second level of support to verify the correct firmware and keycode The wrong firmware
72. to perform the duplex ADF registration procedure See Scanner Manual Registration on page 3 35 Repair information 4 83 7525 XXX Simplex ADF rear cover 1 While lifting the ADF use a flatblade screwdriver to pry open the two tabs on the bottom of the ADF cover 2 Lift and remove the rear cover from the ADF assembly Simplex ADF removal Tilt the flatoed cover to the upright position Lift the ADF up and away from the flatbed Remove the simplex ADF rear cover from the ADF assembly See Simplex ADF rear cover on page 4 84 Save the cover for use on the new ADF unit Disconnect the ADF cable from both the ADF relay card located on the ADF assembly Disconnect the ground cable from the ADF assembly Carefully pull the ADF cable and grommet away from the ADF assembly Lift the ADF to an upright position Use a screwdriver to release the left hinge from the flatbed unit Remove the ADF assembly Note After installing the new ADF unit you will need to perform the ADF registration procedure See Scanner Manual Registration on page 3 35 eee SN ADF input tray 1 Firmly grasp the ADF input tray on both sides 2 Pull the ADF input tray out of the ADF 4 84 Service Manual 7525 XXX ADF cable removal Remove the simplex or duplex ADF rear cover See Remove the left cover See Left cover removal on page 4 4 Remove the AIO back cable cover See AlO back cable cover removal on page 4 8 Rem
73. to scroll through menu lists d gt Indicator light Indicates the printer status The power is off Blinking green The printer is warming up processing data or printing a job Solid green The printer is on but idle Solid red Operator intervention is needed Back Returns the display to the previous screen Start Color press to start a job in color Diagnostic information 2 77 7525 XXX Button or indicator Start Black and White press to start a job in black and white Stop Cancel Stops all printer activity x A list of options is offered once Stopped appears on the display Operating modes Copy Selecting this option enables copy mode Scan E mail Selecting this enables scan and scan to E mail mode Fax Selecting this option puts the MFP into fax mode Fax models only USB Direct interface Note The USB connector is available on some models Copy mode setup Content E Darkness This adjusts the darkness level of the output Duplex press this to output a copy job with printing on both sides of the output sheet Address book press this key to enter the address book Fax mode setup Redial Pause de This setting is used to enhance output quality Choose from Text Text Photo or Photo The current content setting is displayed by the LEDs to the right e press this to initiate a two
74. to step 8 to Scanner Tests on page 3 25 Does the sensor work properly On the bottom of the ADF cover inspect the Go to step 6 Go to step 5 ADF cover closed sensor actuator Does it move freely Fix the actuator so it moves freely Issue resolved Go to step 6 Does this fix the problem Remove the ADF rear cover and inspect the Go to step 7 Go to step 8 ADF cover closed sensor for dirt and debris Is there dirt and debris present Clean the dirt and debris from the sensor Issue resolved Go to step 8 Does this fix the issue Inspect the connections on the ADF relay Go to step 9 Secure all the connections card in the ADF Are all the connections properly connected Check the ADF cable for continuity Is there Go to step 10 Replace the ADF cable Go continuity to ADF cable removal on page 4 85 Check for signals or voltages from JADF1 Replace the ADF Go to Replace the controller on the controller board Pin 11 and 12 Duplex ADF removal on board Go to Controller should measure 24VDC Pin 5 should page 4 83 or Simplex board removal on measure 14VDC Are there signals or ADF removal on page 4 18 voltages present page 4 84 Do streaks appear on the middle of Clean the ADF glass on the No issue to fix scans when using the ADF flatbed using a lint free cloth Also clean the separator roll and pad with a damp cloth Diagnostic information 2 67 7525 XXX ADF paper jam s
75. toner bottle on page 4 67 e press Select v to clear the message and continue printing Order the waste toner bottle so it will be available when the replacement message is displayed Once the replacement message is displayed the printer will not continue until the waste toner is replaced 82 Waste Toner Missing Waste toner box must be present Install the waste toner bottle e Replace the specified toner cartridge Diagnostic information 2 11 7525 XXX User status and attendance messages continued User primary message Explanation 82 xx Waste toner The following actions can be taken nearly full e Replace the waste toner bottle and then press Select x to clear the message and continue printing See Go to Waste toner bottle on page 4 67 e Press Select v to clear the message and continue printing e Order the waste toner bottle so it will be available when the replacement message is displayed Once the replacement message is displayed the printer will not continue until the waste toner is replaced 88 lt color gt Toner Low The term lt color gt includes black cyan magenta and yellow e Replace the specified toner cartridge e press Select y to clear the message and continue printing 88 lt color gt Cartridge The term lt color gt includes black cyan magenta and yellow Early Warning e Replace the toner cartridge and press Select
76. transfer roll the negatively charged toner clings to the media and the entire image is transferred from the transfer belt to the media Service tips e If the transfer roller has nicks pits or flat spots on it the surface doesn t come into contact with the media and transfer unit properly This will cause voids or light spots on the page or repeating voids light areas because the toner can t be fully transferred due to the charge difference in the areas of damage e If the transfer roller does not engage the transfer unit or does not have voltage coming from the high voltage power supply the toner will not fully transfer from the transfer unit the entire page will be very light or blank Any toner that does transfer will be due to a contact transfer instead of a charge transfer Check the high voltage power supply contacts to the transfer roller 3 62 Service Manual 7525 XXX Step 5 Fuse Once the image has been fully transferred to the media the transfer roll helps move the paper into the fuser area The fuser F applies heat and pressure to the page to melt the tiny toner particles and bond them permanently to the media The fuser moves the paper to the redrive rolls which move the paper to the output bin
77. xx Service Magenta TMC Sensor 942 xx Service Yellow TMC Sensor 943 xx Service Black TMC Sensor 948 xx Service Engine Card 949 xx Service Engine Card 2 22 Service Manual Timeout waiting for bullet serial data to be updated NVM_OK was not received from NV2 server for successfully submitted request Over temperature condition detected Main fan stalled The printer doesn t register a transition on the toner sensor for a set period of time Either the printer s toner sensor is faulty or its print cartridge is defective Low voltage power supply did not detect zero crossing The cyan cartridge toner meter cycle TMC switch error 01 Recoverable 02 non recoverable The magenta cartridge toner meter cycle TMC switch error 01 Recoverable 02 non recoverable The yellow cartridge toner meter cycle TMC switch error 01 Recoverable 02 non recoverable The black cartridge toner meter cycle TMC switch error 01 Recoverable 02 non recoverable The pel clock check failed Delay line calibration failure Go to 925 01 Fan error service check on page 2 31 The Servicer should follow these steps to resolve this problem 1 Use the base sensor test in Diagnostics mode to inspect the toner sensor s operation 2 If the toner sensor is operating correctly then the problem is the print cartridge Replace the LVPS See Low voltage power supply LVPS
78. 01 Operator panel displays all diamonds five beeps Turn off the printer and remove the rear shield Go to step 2 Replace the controller See Rear shield removal on page 4 7 board See Controller Disconnect the cable at JOPP1 on the board removal on controller board Verify the following values page 4 18 JOPP1 Voltage Pin ENER 5 V de O V de Ground 5 V de ER 3 3 V de Ground Are all these values approximately correct Check for continuity in the operator panel cable Replace the operator panel Replace the operator panel connector See Operator panel cable See Op panel Do all the conductors indicate continuity removal on page 4 98 cable on page 4 101 2 44 Service Manual Operator panel display is dim and unchanging Turn off the printer and remove the rear shield Go to step 2 See Rear shield removal on page 4 7 Disconnect the cable at JOPP1 on the controller board Verify the following values JOPP1 Pin Voltage elo Are all these values approximately correct Check for continuity in the operator panel cable Replace the operator panel connector See Operator panel Do all the conductors indicate continuity removal on page 4 98 Op panel USB cable service check Questions actions Check the op panel USB cable for continuity Replace the controller board See Controller Is there continuity board removal on 7525 XXX Replace
79. 1 Pour les autres pays cette imprimante r pond aux normes IEC 60825 1 relatives aux produits laser de Classe I Les produits laser de Classe sont consid r s comme des produits non dangereux Cette imprimante est quip e d un laser de Classe lllb 8b ars niure de gallium d une puissance nominale de 5 milliwatts mettant sur des longueurs d onde comprises entre 770 et 795 nanometres Limprimante et son systeme laser sont con us pour impossible dans des conditions normales d utilisation d entretien par l utilisateur ou de revision exposition a des rayonnements laser sup rieurs a des rayonnements de Classe Avvertenze sui prodotti laser Questa stampante certificata negli Stati Uniti per essere conforme ai requisiti del DHHS 21 CFR Sottocapitolo J peri prodotti laser di classe 1 ed e certificata negli altri Paesi come prodotto laser di classe 1 conforme ai requisiti della norma CEl 60825 1 prodotti laser di classe non sono considerati pericolosi La stampante contiene al suo interno un laser di classe IIb 3b all arseniuro di gallio della potenza di 5mW che opera sulla lunghezza d onda compresa tra 770 e 795 nanometri ll sistema laser e la stampante sono stati progettati in modo tale che le persone a contatto con la stampante durante il normale funzionamento le operazioni di servizio o quelle di assistenza tecnica non ricevano radiazioni laser superiori al livello della classe 1 Notices and safety information Xi 7
80. 19 banned fax list Did this fix the problem Adjust the Receive Threshold setting in the Problem resolved Go to step 20 SE menu press 411 to enter the SE menu enter Modem settings and select Receive Threshold Test by adjusting the received signal level by decreasing increasing the Receive Threshold setting in steps of 2db For example if default value is 43 db changing it to 45db will decrease the received signal level by 2db and changing it to 41db will increase the received signal level by 2db Recommended adjustment range is between 33db and 48db in 2db steps Did this fix the problem press 411 to enter the SE Menu Select Problem resolved Contact your second level Print Logs of support See Print the T30 transmission job log Check Escalating a fax issue to the error code being reported See Fax second level support on error log codes on page 2 27 Perform page 2 76 the suggested resolution for the error Did this fix the problem Diagnostic information 2 75 7525 XXX Escalating a fax issue to second level support Before contacting the second level support go to the SE menu on the MFP and generate a Fax error file This file contains machine settings information and debug information that will help second level support determine the cause of a failure To generate the fax error file perform the following steps 1 Ina Web browser type http MF
81. 2 Solr ARAS 3 22 o A PP 4460 09 400 eg eRe EEN 3 22 va ASA 3 22 Sc LOD ee ee ee ee ee ee ee ee ee ee ee ee ee 3 23 Doo ee ss ee Soe A owed dado eds 3 23 mle WEE EE 3 23 E AA A bee een eee 3 24 SERGE o AA ee A 3 25 E AA A a a E E we as 3 25 Fee Wel e sah ea 5k CG RE eene oh oS eee dE ed 3 25 Pe N bso bs oe a he ee ees 3 25 So AA 3 30 CONTQUESTION MEM ira RARA AR A EA e ere Ee ee 3 31 AVANADE TOSTIS eii RA ARANA ARA AMARA AAA 3 31 USO SCAN TO LOCAL 26 6 6666668455 REEL SERA AAA RAI 60 44050 5 0002405 3 31 At gl ee es ee EE ee eee 3 31 Color Ru 6655565065 6s ore rre rare AAA AA AAA ee eee EE 3 31 o 8 get e y oe ee eee 3 32 MSI SeUINGS PAGO cerraron riores ers bee 3 32 A EEN 3 32 Pole MENUS 26 eg Ree Erre a EOS AREA OEE ege 3 32 EK EUAN Aere rid RG dida AREA Ae e ehhh 4s ence Raeees 3 32 DEMO A eee a ee 3 33 SEENEN tte oka ARRASATE AA 3 33 Ai e AAA 3 33 e Aa dE ere EE EE EE tae E ER See Aes 3 34 PRG os o sateen os peer no bee bee eee EE ee end Ee 3 34 AMO Ol AG ss AER risit t rt 694 0659500 eeh Ee Eeer geheie E 3 34 ALP EI EISE sisi AREA oe a RRA AS BOSSES A A ARA ee ees 3 34 so AA T ee 3 35 Scanner Manual Registration 0 oooooooorona 3 35 To manually register a Duplex ADF perform the following steps 3 35 To manually register the flatbed perform the following steps o oooooooo 3 36 DISADIO SCANNED EE 3 36 FOME SADO nia ERA CERNE EERE EARE RANA ARA BS Re eRe 3 37 PELO sarr
82. 279 Power cord 6 foot straight Denmark eee eee 7 13 40X0280 Power cord 1 77M straight Korea eee ee eee 7 13 40X0281 Power cord 1 77M straight Taiwan 7 13 40X0282 Power cord 1 77M straight PRC eee 7 13 40X0287 Power cord 6 foot straight Traditional Italy 7 13 40X0288 Power cord 6 foot Argentina e eee ee eee eee 7 13 40X0289 Power cord 1 77M straight USA Canada 7 13 40X0296 Power cord 1 8M straight Australia 7 13 40X1538 Optional 550 sheet drawer complete C546dtn only 7 17 40X1569 Flatbed pivot link lt lt o oo er re eee ee ee eee eee eee 7 9 40X2254 115 V Maintenance kit e ee 7 18 40X2255 230 V Maintenance kit 2 eer ee eer rr re ee eee eee eee 7 18 40X2261 100 V Maintenance kit eee eee ee 7 18 40X2284 Optional 650 sheet Duo Drawer complete C546dtn only 7 17 40X2285 650 sheet Duo Drawer tray assembly C546dtn only 7 17 40X2512 550 sheet MPF latch cover o 7 17 40X5168 Pick tires En 7 17 40X5434 Optional 650
83. 4 68 wireless network antenna 4 69 wireless network card 4 71 reports 3 32 event log 3 32 menu settings page 3 32 Print Quality Pages 3 11 3 31 Quick Test duplex 3 15 skew 3 5 right scaner cover removal 4 93 S S1 sensor 2 36 safety information ii xvii safety inspection guide 6 1 scan and copy specifications 1 17 7525 XXX scan fax and copy symptoms 2 4 Scanner ASIC test 3 25 scanner covers parts catalog 7 6 Scanner manual registration 3 35 SE Menu 3 38 sensor 2 test 3 29 Sensor test 3 28 sensors bin full Base Sensor Test standard bin 3 18 duplex service check 2 36 front door service check 2 37 fuser exit Base Sensor Test 3 18 service check 2 38 input Base Sensor Test 3 18 service check 2 40 parts catalog 7 12 S1 Base Sensor Tests 3 18 service check 2 36 S2 Base Sensor Tests 3 18 service check 2 40 toner meter cycle Base Senor Tests 3 18 tray present removal 4 64 service checks 90x xx error 2 31 925 01 fan error 2 31 931 xx 935 xx printhead errors 2 32 950 xx NVRAM failure 2 33 ADF paperfeed 2 68 ADF streak 2 67 autocompensator mechanism 2 33 bin full sensor 2 34 black page 2 65 dead printer 2 35 duplex manual feed sensor S1 2 36 flatbed 2 66 flatbed motor 2 65 front door sensor or switches 2 37 fuser 2 39 fuser exit sensor 2 38 input sensor S2 2 40 main drive gear assembly 2 41 modem fax card 2 71 networking 2 46 op panel USB cable 2 45 operator panel 2 42 print quality 2 48 pri
84. 525 XXX Avisos sobre el laser Se certifica que en los EE UU esta impresora cumple los requisitos para los productos laser de Clase 1 establecidos en el subcapitulo J de la norma CFR 21 del DHHS Departamento de Sanidad y Servicios y en los demas paises reune todas las condiciones expuestas en la norma IEC 60825 1 para productos laser de Clase 1 Los productos l ser de Clase no se consideran peligrosos La impresora contiene en su interior un l ser de Clase IIIb 3b de arseniuro de galio de funcionamiento nominal a 5 milivatios en una longitud de onda de 770 a 795 nan metros El sistema l ser y la impresora est n dise ados de forma que ninguna persona pueda verse afectada por ning n tipo de radiaci n l ser superior al nivel de la Clase durante su uso normal el mantenimiento realizado por el usuario o cualquier otra situaci n de servicio t cnico Declarac o sobre Laser A impressora est certificada nos E UA em conformidade com os requisitos da regulamenta o DHHS 21 CFR Subcap tulo J para a Classe 1 de produtos laser Em outros locais est certificada como um produto laser da Classe I em conformidade com os requisitos da norma IEC 60825 1 Os produtos laser da Classe nao sao considerados perigosos Internamente a impressora cont m um produto laser da Classe lllb 8b designado laser de arseneto de pot ssio de 5 milliwatts operando numa faixa de comprimento de onda entre 770 e 795 nan metros O sis
85. 5509 eee 7 9 Op panel bezel 4 1 Japanese 40X5503 7 9 Op panel bezel 4 1 Korean 40X5531 eer eee ree ee eee eee eee 7 9 Op panel bezel 4 1 Norwegian 40X5515 eer eee eee 7 7 Op panel bezel 4 1 Polish 40X5521 eee ee re ee ee ee eee eee eee 7 9 Op panel bezel 4 1 Simplified Chinese 40X5505 7 9 Op panel bezel 4 1 Spanish 40X5497 eee re ere ee eee ee eee eee 7 7 Op panel bezel 4 1 Swedish 40X5517 er eee re errr e 7 7 Op panel bezel 4 1 Traditional Chinese 40X5507 eee ee eee 7 9 Op panel bezel 4 1 Turkish 40X5527 errr eee rr re eee eee eee 7 9 Op panel bezel 4 1Dutch 40X5519 eee eee ee eee eee eee 7 7 Op panel bezel 4 1German 40X5499 rere ere ee ee ee eee eee eee 7 7 Op panel bezel 4 1 Russian 40X5523 7 9 Op panel cable 40X5481 e reer e ee ree ee ee ee ee eee eee eee 7 7 Output bibn tray 40X5484 eee eee eee eee eee eee eee 7 5 D Photo sensor 40X5426 EE 7 13 Pick tires 40X5168 2 eer rrr er rr re rr 7 5 Printhead 40X5411
86. 6 to the image transfer unit ITU e Image transfer unit Is a problem found ITU See Image transfer unit ITU on page 4 35 High voltage power supply HVPS See High voltage power supply HVPS assembly removal on page 4 31 Reseat the cable in the JHVPS1 connector Problem resolved Go to step 7 Does this fix the problem Replace the HVPS See High voltage power Problem resolved Go to step 8 supply HVPS assembly removal on page 4 31 Does this fix the problem Diagnostic information 2 49 7 7525 XXX Clean the printhead Problem resolved Replace the printhead See Printhead removal on Does this fix the problem page 4 56 Print quality blank page Is all the packing material for the imaging unit Go to step 2 Remove the packing in question removed material Print a document that requires all four colors Replace the developer unit Go to step 3 with just a few characters to verify if one for the missing color specific color is a problem For example print the Print Quality Test Pages 1 Enter Diagnostic mode Turn the printer off press and hold Left 4 and Select x turn the printer on and then release the buttons when the installed memory and processor speed displays 2 Select PRINT TESTS and press Select y 3 Select Prt Qual Pgs and press Select y Is only one color missing Replace the imaging unit See Ima
87. 6 to 32 2 C 60 to 90 F and 8 to 80 RH Web bulb temperature power off 26 70 C 80 10 F Maximum In some cases performance specifications such as paper OCF EP cartridge usage are specified to be measured at an ambient condition General information 1 7 7525 XxXX Media handling Input and output sources Lexmark Sheet numbers are assuming X544dw Lexmark 20 Ib xerographic paper MA AS X544dn EE X546dtn X544dtn Standard input sources Standard input tray 250 250 sheets 250 sheets 250 sheets 250 sheets sheet tray Manual feed slot 1 sheet 1 sheet 1 sheet Second tray capacity 650 550 sheets 550 sheets 550 sheets 550 sheets sheet Duo Drawer Multipurpose try capacity 100 sheets 100 sheets 100 sheets 100 sheets 650 sheet Duo Drawer Optional 550 sheet drawer 550 sheets 550 sheets Optional input sources maximum 1 total of all inputs is 4 650 sheet Duo Drawer 550 sheets 550 sheets 550 sheets includes 100 sheet MP or 100 sheets or 100 sheets in or 100 sheets in feeder in MP feeder MP feeder MP feeder Multipurpose try capacity 100 sheets 100 sheets N A N A 650 sheet Duo Drawer Optional third tray capacity N A N A N A 550 sheets 550 sheets tray 3 Maximum total input 901 901 901 1 451 capacity Type of duplex Integrated Integrated Integrated duplex duplex duplex Standard output sources no optional output sources are available a In the 650 sheet Duo Drawer the 550 sheet t
88. 72 What is manual color correction crsarcinidrdr idre dtar riada sedans cs 3 72 How can match a particular color such as a corporate logo o oooooo 3 73 What are detailed Color Samples and how do I access them 3 73 Repair WTOTNANON oi dEr ue dee EE dee e dE get 4 1 Handling ESD sensitive parts 0 ccc 4 1 Testa One FAVS asis need nee heads AR ERA EE A ATA 4 1 Removal procedureS A 4 2 Nuddele VIe Ze TITTEN 4 2 Front cover assembly removal e A Ee NEEN SEELEN we 4 2 Front middle Cover reMOVal aen cscee ERR eevee edie Rees CESS EERE AA 4 4 Table of contents Vil 7525 XXX es A Lewes Ke eee eee eee ees 4 4 RION COVEl TE MOV e eege rd RRA RN RARA ANA RR 4 7 Rear Sel SINO siria AA AAA AAA 4 7 AIO back cable cover removal ne os tind ees be nee eee AAA eee AAA AAA 4 8 TOD cover assembDiIy TEM OV El os ia 6 509 056 0900 9 09 44 AA AAA AA ARA AAA AAA 4 9 EE E E ok oe Chee eee eh OER E es 4 11 Autocompensator mechanism ACM standard tray removal e 4 12 AO UW RO ey one oe eee oe a AR ARA oe EE 4 15 Narrow media sensor flag removal 0 000 cece 4 16 Controller board removal 66 65 c06c55enke ce eddie bk de A ERR A RR RO CERO 4 18 Duplex reference edge removal 2 0 c eee eee 4 20 DUPIEX SENSO TEMOVO 666966654495 GRE EROS EIA ERO AKA ONES EO ARA ARA ARAS 4 23 Fuser assembly FGEC EEN Se Roe DR RA RARA RA AAA AA eens 4 25 Fuser drive motor assembly removal 0ooccococcoco 4 28 Fuser exit sensor removal
89. 7525 XXX Go to step 2 Replace the fuser cable Go to step 3 Go to step 4 Go to step 5 Repair or replace the LVPS cable See Low voltage power supply LVPS assembly on page 4 43 Repair the cables If the cables cannot be repaired replaced the fuser See Fuser assembly removal on page 4 25 Go to step 6 Replace the controller board See Controller board removal on page 4 18 Diagnostic information 2 39 7525 XXX Replace the fuser See Fuser assembly Problem resolved Replace the controller removal on page 4 25 board See Controller board removal on Does the error clear page 4 18 Input sensor S2 service check The Input sensor S2 is part of the autocompensator FRU and is not available otherwise Enter Diagnostics Menu turn the printer off Replace the Go to step 2 press and hold a and a turn the printer on autocompensator and then release the buttons when the mechanism See installed memory and processor speed Autocompensator displays mechanism ACM standard tray removal on page 4 12 Perform the Base Sensor Test See Base Sensor Test on page 3 18 1 Select Base Sensor Test and press Select y 2 Select S2 and press Select y 3 Pull tray 1 out and rotate the S2 sensor flag S2 is located in front of the center autocompensator mechanism housing It should rotate freely and return to its original
90. 96 4 Lift the flatbed unit to a 45 degree angle Be careful to avoid damaging or disconnecting the CCD ribbon cable on the rear of the flatbed 5 While holding the flatbed in place remove the three screws B securing the bezel cover to the op panel mounting frame and flatbed Repair information 4 89 7525 XXX 6 While holding the op panel mounting assembly remove the op panel bezel cover 4 90 Service Manual 7525 XXX Redrive unit 1 Remove the flatbed assembly from the MFP See Flatbed removal on page 4 72 2 Place the flatbed facedown on a soft surface to avoid scratching the glass or marring the covers 3 Remove the cable cover plate A 4 Remove the four screws B securing the redrive to the flatbed unit 5 Remove the bin full sensor flag located on the rear shaft Repair information 4 91 7525 XXX Cover scanner left 1 Remove the flatbed assembly See Flatbed removal on page 4 72 2 Release the tabs A securing the left flatbed cover to the flatbed unit using a small flatblade screwdriver 4 92 Service Manual 7525 XXX Cover scanner right 1 Remove the imaging unit in the print engine 2 Raise the scanner assembly to the up position and lock in place 3 Remove the four screws A securing the right scanner cover to the flatbed unit Repair information 4 93 7525 XXX 4 While holding the ADF away from the flatbed use the other hand to lift and disengage the ri
91. A L E L Oor T WH o A E A e SH OF PNA SHS ETS AS ae da ll AA a EA A di Dd o ee lo E ee gt he al le KEE e E ee O o1 HA Ol L Ef A A N ol 32 25 H 2 Al HI TO H TL H 93189 RAY HP Rela AST vies FRY A AE DER AAA EP IR AG AR A UE A E H AENA AVE AY AS RABE BEAZ M Ho AST m ED E SRS IRA AAA FATAL A AE ATA ESSE ARB EY TEES ERRA A A EURIA RIX RURA T T i FRA E FT Se ous 4 EA BUC erop WHER CIE IPA im DX I HER HLS AY TELE WEA REITI a AY FDL HF XX Service Manual EK BLED m ZOE FUER AT ES IN ADA 7525 XXX Preface This manual contains maintenance procedures for service personnel It is divided into the following chapters 1 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 Diagnostic information contains an error indicator table symptom tables and service checks used to isolate failing field replaceable units FRUs Diagnostic aids contains tests and checks used to locate or repeat symptoms of printer problems Repair information provides instructions for making printer adjustments and removing and installing FRUs Connector locations uses illustrations to identify the connector locations and test points on the printer Preventive maintenance contains the lubrication specifications and recomme
92. Assembly and Nyogel 744 to lubricate the ITU and Cartridge Drive assemblies Preventive maintenance 6 1 7525 XXX 6 2 Service Manual 7525 XXX 7 Parts catalog How to use this parts catalog The following legend is used in the parts catalog Units mach OR Description Units option Part number e Asm index Identifies the assembly and the item in the diagram For example 3 1 indicates Assembly 3 and item number 1 in the table Part number Identifies the unique number that identifies this FRU e Units mach Refers to the number of units actually used in the base machine or product Units option Refers to the number of units in a particular option It does not include the rest of the base machine Units FRU Refers to the number of units packaged together and identified by the part number e NS Not shown in the Asm Index column indicates that the part is procurable but is not pictured in the illustration e PP Parts Packet in the parts description column indicates the part is contained in a parts packet Model information used in the parts catalog 7525 131 Lexmark X543dn Network duplex print 7525 133 133 Lexmark X543dn Network duplex print DBCS op panel 7525 138 138 Lexmark X543dn Network duplex print wireless 7525 356 356 Duplex scan fax 7525 352 352 Duplex scan 7525 3361 336 Duplex scan print fax 7525 3321 332 Duplex scan print 7525 3371 337 Lexmark X544dn Duplex scan print fax DBCS
93. C Failure Cable SCC Failure Cable Failure Front calibration strip unusable Rear calibration strip unusable Front calibration strip too far left Front calibration strip too far right Front calibration strip has excessive skew Front calibration strip has excessive bow Rear Mono channel Rear Color channels Rear Red channel Rear Green channel and or Rear Blue channel is detected to have low lamp level Go to CCD service check on page 2 65 CCD failure Go to CCD service check on page 2 65 CCD channel failure Check each channel mono R G B for identical values indicating bad cable and or SCC card Excessive noise test for the dark data indicating some sort of CCD or analog electronics issue on that channel or channels Go to CCD service check on page 2 65 CCD channel failure Check each channel mono R G B for identical values indicating bad cable and or SCC card Excessive noise test for the dark data indicating some sort of CCD or analog electronics issue on that channel or channels Go to CCD service check on page 2 65 Front scan module connector or cable failure Go to CCD service check on page 2 65 Rear scan module connector or cable failure Go to CCD service check on page 2 65 The connector cable is defective Go to CCD service check on page 2 65 Go to CCD service check on page 2 65 The font calibration strip is placed to high
94. Changes appears on the operator panel and then the printer PORs restarts in Ready mode Energy Conserve Affects the values that appear in the Power Saver menu item in the Setup Menu This menu item appears only when the printer model does not support Automatic Power Saver or has deactivated Automatic Power Saver The menu item affects only the values that are displayed in the Power Saver menu item Select Off in Energy Conserve to allow Power Saver in the customer menu to display Disable as an option If Disable is selected in the customer Power Saver the printer deactivates the Power Saver feature Select On the default in Energy Conserve to prevent Disable from appearing as an option in the Power Saver setting and preventing the customer from turning off Power Saver Diagnostic aids 3 33 7525 XXX Min Copy Memory This setting allocates the amount of DRAM memory to be used for storing copy jobs in the queue 25 35 50 80 and 100 MB are the available settings To adjust the minimum copy memory perform the following steps 1 Inthe configuration menu scroll to the MinCopy Memory item and press y 2 Use the or p to increase or decrease the setting s value 3 When the desired value is displayed press y Format Fax Storage This setting allows the user to format non volatile fax storage memory While formatting is taking place Formatting Fax Flash DO NOT POWER OFF appears A
95. DIMM card assembly 512MB DDR DRAM DIMM card assembly 64MB Flash card assembly Korean font card assembly Simplified Chinese font card assembly Traditional Chinese font card assembly Japanese font card assembly USB cable packaged 2 m Field relocation package assembly Index Numerics 1xx service errors 2 15 1xx 8xx 9xx error codes 2 15 2xx paper jam messages 2 14 2xx paper jam messages locations 3 40 2xx error messages 2 13 550 sheet drawer parts catalog 7 16 650 sheet duo drawer parts catalog 7 18 650 sheet option tray parts catalog 7 18 650 sheet Duo Drawer parts catalog 7 16 650 sheet duo drawer description 1 2 840 xx service check 2 63 8xx error codes 2 19 9xx error codes 2 21 A ACM paper pick assembly parts catalog 7 10 acoustics 1 7 acronyms 1 20 ADF cable removal 4 85 ADF cover closed sensor test 3 27 ADF cover open service check 2 67 ADF duplex service check 2 70 ADF edge erase 3 34 ADF feed errors service check 2 69 ADF input tray removal 4 84 ADF manual registration 3 35 ADF paper jam service check 2 68 ADF paper present sensor test 3 26 ADF separator pad removal 4 87 ADF separator roll removal 4 88 ADF streak service check 2 67 ADF units parts catalog 7 6 AlO link removal 4 96 AlO release lever removal 4 95 AlO toner cover removal 4 97 alignment 3 7 antenna wireless network 7525 XXX removal 4 69 attendance messages 2 6 Auto Color Adj 3 34 autocompensator mecha
96. DO NOT POWER OFF message to clear Warning Do not turn the printer off while this message appears on the display Flushing buffer Wait for the message to clear Formatting Flash Wait for the message to appear ER Warning Do not turn the printer off while this message appears on the display Hex Trace This message appears between status messages and warnings Wait for the message to clear Imaging Kit Replace the imaging kit and then press Select to clear the message and continue printing Insert Tray lt x gt This message is displayed when the printer requests the user to insert tray x before it can continue printing the job The printer needs to pick media from the missing tray or the trays below it Tray x Tray 1 Tray 2 Tray 3 Note This message displays when refilling the trays during a job Before filling tray a tray take the printer offline by pressing Stop MI and wait for pages to stop feeding into the output bin The following actions can be taken e Insert the requested tray e Cancel the current job No Analog Phone Line An analog line is not detected as being plugged into the modem If the device is in Analog mode this has a source of Fax If the device is in Fax Server mode and the Enable analog receive Fax Server setting is set to On this has a source of Fax Receive If the device is in Fax Server mode and the Enable analog receive Fax Server setting is set to Off then this IR is not generated
97. ERS 1 16 Flatbed document specifications descarada RA a a AA 1 16 aore oie A A PE 1 16 Scanner Operating environments 1 16 Storage envViOnNMENMS rr d ss ewes eee Sas oes Sb OSE ower eee hee oe eens 1 16 Mir a eS E ae epee eae eee eege 1 16 Scan and copy specific specifications 0 00 cee es 1 17 SCOR I AA ea ee ee ees ee gek ee den 1 17 KEE EE oh a tte ee eG oe ENG oe Ee E ee e eee es 1 17 Bitte faa 5 os 64 di dis 1 17 scan a a AA eb oa ea bee 1 17 Supported COMPIESSIONS oc cc5 045 EELER EE EE E EELER ch KE 1 17 Supported scan destinations e cisco kasd 6 de 4 ee be bb A AAA eee A 1 17 A o She eh oh dk peace de Ee el eae eee tes toed ta ee 1 17 Se E EE 1 17 Table of contents iii 7525 XXX FUN OSCARS E ewes A ree A ARA ew ae oe 1 18 FRAN DEEN CONNGCIVNY gt e RER RER AAA 1 18 Bai co ee ee ee E ee ee ee ee E ee ee re eee ee ee ee 1 18 Miscellaneous FAX specifications 1 18 TOOIS TEGUIFER TOD SEVICE 66 i526 8656 656 086 85 4 AAA AAA AAA RARA AAA AA 1 19 ACTOS re eee ae ce ee ee ee ee E ee 1 20 Diagnostic Information 2 1 TA EE E E ose hee A EE 2 1 POR Power On Reset Sequence 0 0 0ccccccoc ees 2 2 Se we ol ee ee ee ee 2 3 PIO S VIDEO ADIOS var ARANA ARRE ORR ARANA NARA eee xe 2 3 Scan fax copy symptom table Au BS AN ei os eines rara ada AAA AAA 2 4 Prone QUGINY SVUIDION AUC 644404444000 Eed woe ee ee TRA AAA AR AAA ICAA 2 5 Error codes and messages inicia bei eee ne be eke ede dhs AAA da dade
98. Edition 10 29 09 Service Manual Lexmark X543 X544 X546 7525 XXX e Table of contents e Start diagnostics e Safety and notices e Trademarks e Index 7525 XXX Edition October 29 2009 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 Some states do not allow disclaimer of express or implied warranties in certain transactions therefore this statement may not apply to you This publication could include technical inaccuracies or typographical errors Changes are periodically made to the information herein these changes will be incorporated in later editions Improvements or changes in the products or the programs described may be made at any time Comments may be addressed to Lexmark International Inc Department D22A 032 2 740 West New Circle Road Lexington Kentucky 40550 U S A or e mail at ServicelnfoAndTraining Y Lexmark com Lexmark may use or distribute any of the information you supply in any way it believes appropriate without incurring any obligation to you References in this publication to products programs or services do not imply that the manufacturer intends to make these available in all countries in whi
99. Envelope 162 x 229mm 6 4 x 9 in B5 Envelope Other envelope Length 98 432mm 3 8 17 in Width 89 297mm 3 5 11 7 in a The MP feeder runs slower if A5 Statement B5 A6 Executive Statement Universal narrower than 210mm or envelopes are loaded Japanese Industry Standard e Although the user may select Universal paper size for these sources not all tray guides can be adjusted to all Universal media sizes 1 10 Service Manual 7525 XXX Media input type specifications Y Supported K Not supported Input type 250 sheet tray Optional Duo Drawer Optional 550 sheet drawer model C546dtn only MP feeder Duo Drawer Plain paper Card stock Transparency Recycled Glossy Paper backed labels Bond Envelopes Rough envelopes Letterhead Preprinted Colored paper Light paper Heavy paper Rough or cotton Custom type lt x gt SW oO Lo oO 2 c y IR E RE AE EE ee MES TEASER IE EARL AAA Eo a E CA A EE E O EEE e AE A RE GENEE AER AA SE KENE E AE E E KN EE AEN ere Ge CCOO AE AEN A RE AE A0 RE AE KEE EE Eso O EA ea se AAA LA A A A LALALA ed S E EE AEN AE EE GE a For MP feeder and manual feeders the Default Source Menu displays Manual Paper and Manual Env Select Manual Env for envelopes or when the type in Custom Type lt x gt is an envelope For other types use Manual Paper P The duplex unit supports this media type as long as the customer has
100. FUSER_HR_THM AVCC 2 3 V dc FUSER_HR_THM_RTN Ground 5V_ SW 5 V dc Z U Ground S1_MPF_SNS 3 3 V dc BELT_THM 2 5 V dc FUSER_HR_THM_RTN Ground 10 ch NO Ground no wire Locations 5 11 7525 XXX Controller board Connector JPJP1 JBIN1 JHVPS1 JTPS1 JTHM1 5 12 Service Manual 5V_SW PAPER_JAM_DET Ground V_BF S_BIN_FB Ground V_BIN_4 FUSER_EXIT_SNSR Ground M_DEV_PWM_OUT K_DEV_PWM_OUT C_DEV_PWM_OUT CMY_CHG_PWM_OUT Y_DEV_PWM_OUT K_CHG_PWM_OUT CMY_SRVO_OUT 3 3 V de ITM_TX_PWM_OUT CMY_TX_PWM_OUT ITM_SRVO_OUT 3 3 V de K_SRVO_OUT 3 3 V dc K_TX_PWM_OUT 24V 3 3V dc 3 3V dc i NO bh D Ground 5V_HVPS_REF Ground ANODE CATHODE Ground Anode no wire TPS2_ON 5V_SW Ground TPS_THERM_SNS 1 5 V de TPS_SNS_RTN Ground dl 16 Controller board Connector JCARTB1 JSP1 NO sch D sch or KI Oo Po sch A N or KI OINI al O O O N LO O i al N 0 N NO 13 4 bh 16 7525 XXX CART1_HALL_U NC_CARTB1_2 CART1_HALL_V V_CART2_WIND_W CART1_HALL_W V_CART2_WIND_V CART1_PG V_CART2_WIND_U Ground Ol Ol Ground V_CART1_WIND_U CART2_PG V_CART1_WIND_V V_CART1_WIND_W V_CART1_WIND_W V_CART1_WIND_V NC_JCARTR1_19 V_CART1_WIND_U ANODE no wire M1_OUT1 24 V dc OV de with door open CATHODE M1_OUT2 24 V dc OV de with door open 5V
101. Fuser service check on Fuser Error printing page 2 39 Diagnostic information 2 17 7525 XXX Service error messages 1XX 8XX and 9xx continued CN rom me 122 13 Service Fuser open thermistor check failed for Go to Fuser service check on Fuser Error second thermistor page 2 39 122 14 Service Fuser shorted thermistor check failed Go to Fuser service check on Fuser Error for hot roll thermistor page 2 39 122 15 Service Fuser started thermistor check failed Go to Fuser service check on Fuser Error for second thermistor page 2 39 122 16 Service EWC Error Estimated power is at or Go to Fuser service check on Fuser Error above maximum power page 2 39 122 17 Service Total failure to close fuser nip Go to Fuser service check on Fuser Error page 2 39 141 xx Service Staging motor error Go to 90x xx error on page 2 31 Staging Motor 141 01 Service Staging motor has exceeded the ramp Goto 90x xx error on page 2 31 Staging Motor up table 141 02 Service Staging motor has exceeded number Go to 90x xx error on page 2 31 Staging Motor of encoders at min PWM 141 03 Service Staging motor has exceeded number Go to 90x xx error on page 2 31 Staging Motor of encoders at max PWM 141 04 Service Motor encoder count did not change Go to 90x xx error on page 2 31 Staging Motor between interrupts 141 05 Service Staging motor has encountered a stall Goto 90x xx err
102. HD Config ID Mismatch A device doesn t have a hard drive 849 installed even though its Configuration ID indicates that a hard drive should be present HD Config ID Mismatch A device has a hard drive installed but its Configuration ID indicates that a hard drive shouldn t be present 849 01 9xx service errors 900 xx Service Unrecoverable RIP software error Go to 90x xx error on page 2 31 RIP Software illegal trap 902 xx Service A general engine software error Go to 90x xx error on page 2 31 Engine Software 903 xx Service A general engine software error Go to 90x xx error on page 2 31 Engine Software 904 xx Service A general engine software error Go to 90x xx error on page 2 31 Engine Software 905 xx Service A general engine software error Go to 90x xx error on page 2 31 Engine Software 906 xx Service A general engine software error Go to 90x xx error on page 2 31 Engine Software Diagnostic information 2 21 Service error messages 1XX 8XX and 9xx continued wae ee A general engine software error Go to 90x xx error on page 2 31 Board level was not obtained Error code 907 xx Service Engine Software 908 01 Service Engine Software 908 02 Service Engine Software 908 03 Service Engine Software 908 04 Service Engine Software 925 01 Service Main Fan 929 xx Service Toner Sensor 930 xx Service LVPS 940 xxService Cyan TMC Sensor 941
103. IP address on the printer driver Did this fix the problem Is the device physically connected ethernet Go to step 13 Go to step15 cable to the network 2 46 Service Manual 7525 XXX Try using a different ethernet cable Problem resolved Go to step 14 Did this remedy the situation Have the network administrator check the Replace the controller Contact the network network drop for activity board Go to Controller administrator board removal on page 4 18 Is the printer on the same wireless network as Goto step 17 Go to step 16 the other devices Assign the correct wireless network to the Problem resolved Go to step 17 printer Did this fix the problem 17 Are the other devices on the wireless network Go to step 18 Contact the network communicating properly administrator Verify that the wireless card is properly seated Goto step 20 Go to step 19 on the controller board Is the wireless card seated correctly Properly reseat the wireless card Problem resolved Go to step 20 Did this fix the problem Is the antenna damaged Go to step 22 Go to step 21 Is the drop functioning properly Verify that the antenna is properly connected Go to step 24 Go to step 23 to the wireless card Is it connected correctly Properly connect the antenna Problem resolved Go to step 24 Did this fix the problem Check pin 6 for 3 3V and Pin 5 for 5V on Replace the wireless card Replace the controller c
104. Ibs X544dtn X544dw Lexmark X546dtn 422 mm 16 6 in 424 mm 16 7 in 416 mm 16 4 in 25 kg 54 9 Ibs 550 sheet Duo Drawer 133 mm 5 2 in 424 mm 16 7 in 416 mm 16 4 in 4 kg 8 7 lb 650 sheet Duo Drawer 133 mm 5 2 in 424 mm 16 7 in 416 mm 16 4 in 4 kg 8 7 Ib Clearances Gd Description Clearances 1076 men in 508 rm 22 Right side 254 mm 10in Left side 76 2 mm 3 0 in 360 mm 14 in Add 133 mm 5 2 in to the top if you want to add an optional 650 sheet Duo Drawer Lexmark X544 6 models only A This does not include the 550 sheet tray height General information 1 5 7525 XXX Power and electrical specifications The following table specified nominal average power requirements for the base printer configurations All power levels are shown in Watts W Maximum current is given in Amperes A Lexmark Printing states Lexmark X544dw Lexmark Lexmark 543dn X544dn and X544n X546dtn X544dtn Average power while printing Continuous copy 480 W 510 W 510 W 510 W Continuous printing simplex 480 W 540 W 540 W 540 W Continuous printing automatic 340 W 370 W n a 370 W duplex Average power while idle Power Saver 2 24 W 23 W 23W 23 W dn only 50 W OW 2 W Off OW Automatic duplex is not supported on the X544n Low voltage models e 100 to 127 volts V 100 110 Japan at 50 to 60 hertz Hz nominal e 90 to 137 volts 90 110 Japan extreme 100 voltage mode
105. NEN session ETERS HERES Ad dear SEE ROE e SEs 4 72 Preparing and installing the new flatbed 4 78 Flatbed DEE HESE DEIER iros 4 81 DONS AUP EREECHEN SR 4 82 DUDIC AUP TEMO A sarria rar ria ARA RARA ARA 4 83 SS EE EENS reor COVE correr yeas oe oe ARANA AAA AAA 4 84 Simplex ADF TEMOVEl cesses tices tees E ree rasa AAA 4 84 ADE WOU HIV irradia dead Ee RARA AAA RR 4 84 a AA 4 85 sa A A EREM Oe ee ees 4 87 ADF separator roll assembly ooooooo 4 88 DOPICO 64665 sede SSPE ANSIA d Oded eee ANA 4 89 COORDINAR IEA AR A Aaa 4 91 COVE SCONE IGN acarrear rr AAA AAA AA AAA 4 92 E A PP E e AP eee esse ces 4 93 AIO TECOS INES sarao daria 4 95 GREEN AA E EEN ee 4 96 PIO IGHE COVE cir ri id AAA AE AAA eee 4 97 Operator pael TEM e is x cee eee ee eee ee ARAS 4 98 Op panel bezel removal 0 00 cc es 4 100 Vill Service Manual 7525 XXX DO DINARS EE 4 101 EOOD A 4 101 o 664685 Behe hed A 4 102 Fax nilerface cabl roer ek E er ee a es aa 4 102 KEES BIN SY d Ee RNs ori AIRE AAA AA E RER AAA 4 103 Eer TIGO romovia lt lt 40i 405kwese dwar eens eee ON KO ARA Ow RANA RANA 4 103 Rn LEE 5 1 EXITO ViGWS ui ari ii Roos hee ee AAA Ee Re AAA OOS Rea ee e eg 5 1 A EE II eee ead 5 1 EE are dbo ce eh sw he ee a oe eee eee ere eee eet e eee 5 2 St VES cease Gish O See wea re Ee 5 3 o TEE 5 4 Controler Board soii ARANA RA ERS 5 4 E AA 5 5 ee A LE EL A RA E AA AA a ae 5 15 Er A A E ee ee rte eae ee 5 16 LA gabe E eo oo ee
106. P disabled used PORs Enter the configuration menu and re enable the scanner module Go to 840 xx service check on page 2 63 Image Pipeline Image pipeline ASIC Go to CCD service check on page 2 65 Also Go to Flatbed home position service check on page 2 66 842 Scamner Failure Communication failure Go to CCD service check on page 2 65 Scanner Failure Carriage mechanical failure Go to Flatbed motor service check on page 2 65 843 01 Scanner Failure ADF mechanical failure Go to ADF paper jam service check on page 2 68 844 Scanner Failure Lamp failure Go to CCD service check YY on page 2 65 844 Front scan module output level error Go to CCD service check on page 2 65 844 01 Rear scan module output level error Front Mono channel Front Color channels Front Red channel Front Green channel and or Front Blue channel is detected to have low lamp level Go to CCD service check on page 2 65 Front scan module lamp level too low Diagnostic information 2 19 7525 XXX Service error messages 1XX 8XX and 9xx continued Cn Error code 844 03 845 yy 845 845 01 845 02 845 03 845 04 00 D O 846 01 846 02 846 03 846 04 846 05 2 20 Service Manual Rear scan module lamp level too low Scanner Failure Front scan module cable failure or SCC card failure Rear scan module cable failure or SCC card failure Cable SC
107. P ip address se 2 The MFP s SE menu page will display Click the Dump Job History link The following displays Fax Job Log Wednesday 2006 02 08 11 25 ke KA li LJ Action Date Time Job Length Station Name Number Pages Status SCAN 1969 12 31 19 00 9 OK SEND 2006 02 01 13 55 73 CANCELED SEND 2006 02 01 13 56 CANCELED Write down the type of connection the type of error and the job in which the error occurred In the Web browser address bar type http MFP ipaddress se Click Report a Fax Problem A 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 GE E Title Name of Tester Your Name Date of Event Date of Event mmiddiyyyy Customer Customer Name Time of Event Time of Event hh mm A P M Job ID Job ID Zeit Describe the Physical Connection Type Description Channel Quality Analog O VolP FolP Clear Digital LIPAB O OK Ip Some Noise Overy Noisy Note The fields requesting the code levels model number type of problem are auto filled If the information is not in the fields it can be retrieved from the SE menu The SE menu can be accessed by pressing 411 on the keypad or typing http MFP ipaddress se in a Web browser 7 After all the requested information is entered into the Fax Checklist Web page press
108. Replace the photoconductor unit part of the Problem resolved Go to step 2 imaging unit Remove the imaging unit and remove the developers Place the original developers in the new photoconductor and then replace the imaging unit See Imaging unit IU removal on page 4 40 Does this fix the problem A faulty printhead can cause the problem To Replace the printhead See Goto step 3 test the printhead for solid colors place a Printhead removal on narrow strip of paper over the gap between the page 4 56 developers Make sure the paper stays in place when you replace the imaging unit This will block the laser from discharging the photoconductors Print a Quality Test Page Does the page have a white vertical band Turn the printer off and check the continuity of Go to step 5 Replace the cable assembly the HVPS cable Is there continuity Replace the HVPS See High voltage power Problem resolved Replace the controller supply HVPS assembly removal on board See Controller page 4 31 board removal on Did this solve the problem page 4 18 Check the high voltage contact from the HVPS Replace the transfer contact Go to step 4 to the photoconductor charge roll Ensure the assembly See Toner contact springs are properly mounted and that cartridge contacts on the charge roll contact spring is making good page 4 59 contact with the HPVS spring that runs through the left pr
109. S 4 18 Service Manual 1525 XXX Print a few pages to verify the installation If the pages are blank confirm that the high voltage power supply cable is properly seated The connector may have been loosened at the HVPS A blank page that should have toner on it could be an indication that toner is applied to the ITU belt but not transferred Therefore the toner goes into the ITU cleaner which cannot process massive amounts of toner It is important to prevent extensive blank pages from being processed if they should have toner on them e When replacing the controller board make sure to route all of the cables through the correct openings e Tuck the printhead cable toroid as shown below Failure to do so can damage the controller board Repair information 4 19 7525 XXX Duplex reference edge removal 1 Open the front door 2 Remove the four short screws A in front and the four longer screws B in the back of the duplex aligner 4 20 Service Manual 1525 XXX 4 Remove the four screws D from the duplex reference guide and remove the guide Installation notes 1 Align the duplex reference guide so the tabs A are inserted into the slots and the top of the reference guide fits under the door ridges B A B 2 Replace the four screws in the duplex reference guide Repair information 4 21 7525 XXX 3 Be sure the shaft and bearing have not shifted out of the guide and that the bearing on the le
110. Service Go to Main drive gear assembly EP CMY Cartridge Motor drive service check on page 2 41 152 01 Service Failed to achieve lock for motor within Go to Main drive gear assembly EP CMY Cartridge Motor allotted time drive service check on page 2 41 152 02 Service Timeout waiting for SAP BLDC motor Go to Main drive gear assembly EP CMY Cartridge Motor to reach valid FG speed drive service check on page 2 41 152 03 Service Timeout waiting for Go to Main drive gear assembly EP CMY Cartridge Motor MP_NUM_INITIAL_SAP_HALLS drive service check on page 2 41 152 04 Service Timeout waiting for SAP BLDC motor Go to Main drive gear assembly EP CMY Cartridge Motor FG drive service check on page 2 41 152 05 Service Lost lock for motor Go to Main drive gear assembly EP CMY Cartridge Motor drive service check on page 2 41 152 06 Service Excessive SAP BLDC PWM Go to Main drive gear assembly EP CMY Cartridge Motor drive service check on page 2 41 152 07 Service Motor stalled in time based Go to Main drive gear assembly EP CMY Cartridge Motor commutation drive service check on page 2 41 8xx service errors 840 01 Scanner The scanner is disabled and can t be Enter the configuration menu and re disabled used enable the scanner module Go to 840 xx service check on page 2 63 840 02 Scanner auto The scanner is disabled and can t be This message is posted when the MF
111. The Code ROM or NAND flash failed Code CRC lt oc gt the Cyclic Redundancy Check CRC check or the NAND experienced an uncorrectible multi bit failure lt oc gt indicates the source of the failure and has one of the following values e CRC Failure The source is a failing package indicated by Pn where n is the package number This error could occur on a controller with ROM or NAND flash and could occur as a result of the CRC check done when the machine is powered on The range of package numbers is from 0 to 15 Error Correction Code ECC Failure The source is a failing page indicated by Bn where n is the page number This error occurs only if a multi bit failure is detected during the ECC execution Single bit failures will be corrected automatically and will not result ina service error The range of page numbers is from 0 to 1023 956 00 Service Controller board failure Processor Replace conrtroller board See Controller System Board failure board removal on page 4 18 956 01 Service Processor over temperature System Board 957 xx Service Controller board failure ASIC failure System Board Diagnostic information 2 23 7525 XXX Service error messages 1XX 8XX and 9xx continued CN rem CN 958 xx Service Printer has performed more than 100 NAND Failure shift and reflash operations as a result of ECC bit corrections 959 01 Service Controller verification failure of pen
112. The printer will start the update process Various status and progress messages will appear on the printer s operator panel Warning Warning Do not turn the machine off until the update is complete When the firmware update is completed the printer will automatically reboot and return to a Ready state 18 After the printer reboots confirm that it is on Ready or Invalid Engine Code mode If it isn t refer to the note on page 3 46 3 50 Service Manual 7525 XXX 19 Open the USBFlash utility This window will display Se USAFlach 2 0 SELECT PRINTER FROM LIST f l START BYTES SENT PL Copag 2001 2004 Lesmark Intemalional Inc 20 Click the Browse Files button The file browse dialog displays Look inc CD s54 firmware update el e EI rg Fee kurt fis E aner Pe IS updeng Type FLS File Date Modified 6 22 2009 10 04 AM Size 24 0 MB Filename f ullnet Open Files of type Flash Files P flac Be pill Cancel 21 In the file browse dialog browse to the scanner fls also known as 3 fls file The scanner fls file is the scanner firmware file This is the last file to be updated 22 Click Open The file browse dialog will close Diagnostic aids 3 51 7525 XXX 23 Select the printer needing the firmware update from the Select Printer From List dropdown menu e USBFlash 2 0 Al ENTER FILENAME TO FLASH TO PRINTER SELECT PRINTER FROM LIST E w START BYTES SENT az
113. To reset the programmed value 1 Select TPS SETUP from DIAGNOSTICS and press Select y 2 Select Reset Color Cal and press Select y Resetting appears When the reset is complete the screen is automatically returned to TPS SETUP Cal Ref Adj Used with Reset Color Cal which resets to a default value Cal Ref Adj allows you to fine tune the TPS function To set the Cal Ref Adj ii Select TPS Setup from Diag Menu and press Select y Select Cal Ref Adj and press Select y Select CMY or Black and press Select y press e to decrease or p to increase the value The values can be 8 to 8 and the default value is O To cancel and return to the menus press Back el Reports Main Settings Page To print the Menu Settings Page 1 Select Reports from Diag Menu and press Select v 2 Select Menu Settings Page and press Select y 3 22 Service Manual 7525 XXX Event Log Display Log The event log provides a history of printer errors It contains the 12 most recent errors that have occurred on the printer The most recent error displays in position 1 and the oldest error displays in position 12 if 12 errors have occurred If an error occurs after the log is full the oldest error is discarded Identical errors in consecutive positions in the log are entered so there may be repetitions All 2x
114. U See Problem resolved ITU on page 4 35 Check the contacts Image transfer unit ITU between the HVPS and the ITU Clean the on page 4 35 contacts and recheck Go to step 2 Does the error reoccur E Does the new ITU fix the problem Problem resolved Go to step 3 Turn the printer off and remove the rear shield Replace the HVPS High Replace the controller See Rear shield removal on page 4 7 voltage power supply board See Controller HVPS assembly board removal on Turn the printer on and check the cable at removal on page 4 31 page 4 18 JHVPS1 connector on the controller board without disconnecting it Verify the following voltage values JHVPS1 in vonage 3 3 V de 3 3 V dc 10 Are the values approximately correct Diagnostic information 2 59 7525 XXX Tray x sensor service check When the printer is in Ready state pull the Go to step 2 Go to step 4 standard tray out The display should indicate Tray x Missing Insert the tray Does the message remain on the display Check the vertical well at the right rear of the Replace the tray Go to step 3 tray for damage Is the tray damaged Contact the next level of support Check for a dislodged tray present sensor Replace the tray 1 sensor If the 650 sheet tray is affected replace the 650 sheet drawer assembly If the 550 sheet assembly is affected replace the entire 550 sheet assembly Does
115. U H Part Units Units number 40X5434 Optional 650 sheet Duo Drawer complete includes 100 sheet MPF 40X2284 Optional 650 sheet Duo Drawer complete X546dtn only includes 100 sheet MPF 40X5168 Pick tires 40X5435 1 1 650 sheet Duo Drawer tray assembly X544n X544dn X544dw X540n X543dn includes 100 sheet MPF tray assembly and three wear strips Note Use only with P N 40X2284 drawer assembly 40X2285 650 sheet Duo Drawer tray assembly X546dtn includes 100 sheet MPF and four wear strips Note Use only with P N 40X2284 drawer assembly 40X1538 Optional 550 sheet drawer complete C546dtn only 40X2512 550 sheet MPF latch cover This drawer has an autoconnect A on the bottom of the drawer assembly as shown below Use only P N 40X2285 tray with this drawer Description Use the chart below to match the correct trays with the drawers 40X5435 40X5434 without autoconnect All except X546dtn 40X2285 40X2284 with autoconnect A X546dtn wear strips Parts catalog 7 17 7525 XXX Assembly 7 Options Part Geng Units Describtion number FRU H 7 18 Service Manual 40X2254 40X2255 40X2261 40X5937 40X5938 40X5939 40X1455 40X5969 40X5970 40X5971 40X5972 40X1368 115 V Maintenance kit fuser ITU duplex reference edge 230 V Maintenance kit fuser ITU duplex reference edge 100 V Maintenance kit fuser ITU duplex reference edge 128MB DDR DRAM DIMM card assembly 256MB DDR DRAM
116. VE ASA PRMEAM AB E F AN amp fi A PR ER fh E ET DA TE OS XIV Service Manual 7525 XXX extlti 158 alo H CHS DHHS 21 CFR Subchapter 39 PAS 24311 ges olad 213424 12 2 LEHON E Eo 825 TSS Ete 15g alo SCBA 2138 pcia in d alo MESS US os YO e eet 5 aloe WE oke lol HO H A 770 795 Le BELO TAH OF A Ss Class Ill 3b o AS Lysol Zi Zell E ajo AAD BREE AY Ss SoLL FA EF S HES PAE MBA AEWA lt 7 9 Class BBL alo ESO Ajo SCH iOS Ass MASON UECH Notices and safety information XV 7525 XXX XVI Service Manual 7525 XXX Lithium warning CAUTION This product contains a lithium battery THERE IS A RISK OF EXPLOSION IF THE BATTERY IS REPLACED BY AN INCORRECT TYPE Discard used batteries according to the battery manufacturer s instructions and local regulations Safety information The safety of this product is based on testing and approvals of the original design and specific components The manufacturer is not responsible for safety in the event of use of unauthorized replacement parts The maintenance information for this product has been prepared for use by a professional service person and is not intended to be used by others There may be an increased risk of electric shock and personal injury during disassembly and servicing of this product Professional service personnel should understand this and take necessary precautions CAUTION When you see this symbol there is a danger from hazardous voltage in
117. WT1 on the controller board 7 Remove the waste toner bottle contact block 4 68 Service Manual 1525 XXX Wireless network antenna 1 Remove the rear shield See Rear shield removal on page 4 7 2 Lift to disconnect the wireless card A from the controller board 3 Carefully disconnect the antenna cable B from the wireless card at the card A B 4 Remove the screw C that secures the antenna cover D to the frame and remove the antenna cover and antenna Repair information 4 69 7525 XXX 5 Straighten the antenna perpendicular to the cover push against the cover with your fingers and gently squeeze the fastener E with needlenose pliers Slide the antenna cable and cable through the hole in the bracket E 6 If the fastener is damaged remove the fastener by pressing the tabs on each side Note Take note of the orientation of the fastener When reinstalling place the cover upright bend the antenna as it would be positioned and make sure the antenna can move about 30 in each direction from the perpendicular y 4 70 Service Manual 7525 XXX Wireless network card 1 Remove the rear shield See Rear shield removal on page 4 7 2 Lift to remove the wireless card A from the controller board 3 Carefully disconnect the antenna cable B from the wireless card at the card Repair information 4 71 7525 XXX Scanner component removal procedures Flatbed removal Remo
118. a oe oe Dia aos 3 10 Beg E a a ee ee ee ee ee 3 10 MISCCUANGOUS TESIS sere EC NAAA AAA ARA 3 10 eo de A O ae es 3 10 PIDE TESIS a a rar AAA 3 11 EEN ee e ee eee ee ee ee 3 11 Print quality test pages Prt Quality Pgs 3 11 el Tee TOSS seriedad AAA OO ROK eee wees 3 13 si AA EEGEN 3 13 A Ree Rs wa a eas we eee ee eee ae eS 3 13 A AA ae Sy oa ae Ba ier Sip A 3 13 A es on ad eee eae o nn A 3 14 DUG e 6 6 655 0 0660 56055 000656 22690 26S 1 AAA AAA 3 15 SE o nko ee edo a Bice ole ead eee eee od oe owe eh eer kg 3 15 Bug ee oe hs ee ee ee EE 3 15 Reeg e do A EE 3 16 WE TCR MAA eh Steg deeded eeu 3 17 PRONTA na kh ate Gas eee ridad de eee GR 3 17 S e M a4 5 6 654 2 8 awa A eee ee ee ee es ee ees 3 17 EE Ao ee ee eS 3 18 EE TORIO raro bene abe Ge era nea oe wee eo eed a di 3 18 ge OL Me ee re eee e ebe 3 18 PUNE SOND aria rin ARS eee se dee ow AO A ARA ANA 3 19 A A 3 19 Table of contents V 7525 XXX Pago COUMIS dc ci o o bathe bed Gee a dd a a ed a add 3 19 soa IGE obey E oe a be oe e OA od oh ees 3 19 PS Te nak ech oe bk iaa 3 19 Baod e RLY 94 ar Rhee ege ARA AIR ARA AA 3 19 a ey pg ee ee ee A 3 20 Enable Edge TO Edge GOW EEN 3 20 geo o dpi o Ann 3 21 A eegent EEN 3 21 EE Seo capes eke he ewe og A 3 21 SE OWN EE dida ad A ia 3 21 DC Charge Adjust Deve Bias Adj Transfer Adj 3 21 WES ei eee eae ACERO ee RRE AI ee MEAR ee Een 3 22 Pee dE aiae 55 56 409s Shoe eee oe 5 E be oe ae ee eae TAA TTE 3 22 SL EE a ee 3 2
119. age transfer unit ITU on page 4 35 Replace the developers that match the missing color black cyan magenta or yellow See Developer unit removal on page 4 42 Go to step 2 Go to step 3 Go to step 4 Check the various rollers in the printer for debris 7525 XXX Print quality horizontal line Either the photoconductor unit or one of the developer units that make up the imaging unit is defective Remove and inspect the imaging unit Replace the damaged part of the imaging unit See Imaging unit IU removal on page 4 40 Print quality insufficient fusing Questions actions Is the printer setup to use the correct media Go to step 2 Change the settings to indicate the correct media Check the fuser connections on the left and Go to step 3 Properly reconnect or right side of the printer replace the cables Are the cables and connection correct a Is the fuser properly installed Go to step 4 Install the fuser properly Replace the fuser See Fuser assembly Problem resolved Replace the LVPS see removal on page 4 25 Low voltage power Does this fix the problem said ed assembly Print quality missing image at edge Remove and reseat the following e Toner cartridge e Imaging unit e Developer units Print quality mottle 2 5mm speckles Keep running prints through and the problem normally clears up If the problem persists replace the developer cartri
120. al 7525 XXX User status and attendance messages continued User primary message 52 Flash Full 53 Unformatted Flash 54 Standard Network Software Error 54 Network lt x gt Software Error 56 Standard USB Port Disabled 58 Too many Flash Options Installed 58 Too Many Trays Installed 59 Incompatible Tray lt x gt 82 Waste Toner Nearly Full Explanation e press Select y to clear the message and continue printing e Delete fonts macros and other data stored on the flash memory e Install a larger capacity flash memory card press Select y to clear the message and continue printing You must format the flash memory before you can store any resources on it If the error message remains the flash memory may be defective and require replacing This message is displayed when the RIP software detects that a network port is installed but cannot establish communications with it e press Select y to clear the message and continue printing The job may not print correctly e Program new firmware for the network interface e Turn the printer power off and then back on to reset the printer The printer disables all communications to the associated network interface No data may be received or sent from or to the associated interface The user can program new firmware in the network using the parallel port after this message clears e press Select y to c
121. al on page 4 40 1 At the Ready prompt press Menu 2 Select Supplies Menu and press Select v 3 Select Imaging Kit and press Select y Does the display indicate OK Measure the distance from the original image Replace the developer Replace the imaging unit or to the same point on the residual image corresponding to the color of the photoconductor unit the image See Developer See Imaging unit IU unit removal on removal on page 4 40 page 4 42 Is the distance 43 9 mm the residual image 94 2 mm photoconductor See Developer unit removal on page 4 42 Run the Menu Setting Page twice to clear any Replace the fuser See Contact your next level of debris Fuser assembly removal support To print a menu settings page on page 4 25 1 press Menu on the operator panel 2 Select Reports from the Admin Menu and press Select Al 3 Select Menu Settings and press Select y Is there still any toner contamination on the fuser assembly Ki Is the distance between the original image and Replace the Diagnostic information 2 55 7525 XXX Print quality solid color page xo Service tip A solid color page is generally caused by a problem in the high voltage controller or an incorrect high voltage in the printing process resulting in toner development on the entire photoconductor drum
122. alignment color planes See Registration on page 3 4 and Alignment on page 3 7 4 56 Service Manual 1525 XXX Imaging unit IU removal The imaging unit is customer replaceable unit and is not a FRU Note The imaging unit contains e Photoconductor unit e Developer units To remove only the photoconductor remove the entire imaging unit remove the developer units place the original developer units in the new photoconductor and re install the imaging unit When you replace the imaging kit you are replacing both the photoconductor and the developer units Open the front cover Lift the toner cover by sliding the latch to the left Remove the right cover assembly See Right cover removal on page 4 7 Remove the waste toner bottle See Waste toner bottle on page 4 67 Remove the toner cartridges Lift the two latches A to unlock the imaging unit A Repair information 4 57 7525 XXX 7 Pull the two latches until the imaging unit meets resistance 8 Press and hold the handles B and pull the imaging unit straight out Note Do not wrap your fingers around the imaging unit Avoid touching the bottom Note Store the imaging unit in a dark place or cover it with a blanket 4 58 Service Manual 7525 XXX Toner cartridge contacts Remove the right cover assembly See Right cover removal on page 4 7 Remove the waste toner bottle See Waste toner bottle on page 4 67
123. alue Reprint the quick test page and then use the fine adjustment o di Mie Top T Fine Adjustment 20 18 5 First locate the line of the color that you 4 are aligning that lines up best with the 2 scale line In this example it is 18 If none 0 of the colored lines match up use the E coarse adjustment to get close reprint this A page and then use the fine adjustment 6 8 6 Use 4 or p to enter the sum of the numbers and press Select Submitting changes appears Print the Quick Test again to verify the observed value is the same as the current value no change is needed If change is still needed repeat the steps 4 6 When the observed values and the current value are the same continue to the next step T O 18 18 T M Current New Cyan Cyan T value T value 3 8 Service Manual 7525 XXX 7 Select the Skew value in the same way enter the value press Select and print the Quick Test to see if the observed values and the current values are the same 18 18 Z 0 _718 14 4 sh dl 1 Current New Current New Cyan Cyan Cyan Cyan T value T value Z value Z value 8 On the second page of the latest Quick Test you printed proceed to Step 2 adjust the left right and bow settings Continue printing the Quick Test after each adjustment to verify your settings Cyan Alignment Left L Fine Adjustment Right R Fine Adjustment Step 2
124. am Gerat den Netzstecker des Ger ts bzw arbeiten Sie mit gro er Vorsicht wenn das Produkt f r die Ausf hrung der Arbeiten an den Strom angeschlossen sein mu Pautas de Seguridad La seguridad de este producto se basa en pruebas y aprobaciones del diseno original y componentes especificos El fabricante no es responsable de la seguridad en caso de uso de piezas de repuesto no autorizadas La informacion sobre el mantenimiento de este producto esta dirigida exclusivamente al personal cualificado de mantenimiento Existe mayor riesgo de descarga el ctrica y de da os personales durante el desmontaje y la reparaci n de la m quina El personal cualificado debe ser consciente de este peligro y tomar las precauciones necesarias PRECAUCI N este s mbolo indica que el voltaje de la parte del equipo con la que est trabajando es peligroso Antes de empezar desenchufe el equipo o tenga cuidado si para trabajar con l debe conectarlo Informacoes de Seguranca A seguran a deste produto baseia se em testes e aprova es do modelo original e de componentes espec ficos O fabricante n o respons vel pela segunranca no caso de uso de pecas de substituic o n o autorizadas As informa es de seguran a relativas a este produto destinam se a profissionais destes servicos e nao devem ser utilizadas por outras pessoas Risco de choques el ctricos e ferimentos graves durante a desmontagem e manutenc o deste produto Os profis
125. as been transferred to the transfer belt from the photoconductors a cleaning blade H scrapes the remaining toner from the surface of each photoconductor This is the clean erase process Now the photoconductor surface is prepared to begin the EP cycle once again This cleaning erasing cycle happens after each plane of color is transferred to the transfer belt Diagnostic aids 3 65 7525 XXX Paper path transport components In order for an image to be printed the media has to be moved from an input source Such as a tray into the printer and eventually exit into an output source The most important component in this process is this media itself Old damaged or out of specification media can and will cause feed and transport problems If you encounter problems you should always check the media first Media guidelines on page 1 13 In addition it is always good practice to check the printer and driver settings to see if the media being used matches the user s settings It is not uncommon to find a user printing on cardstock with the printer programmed to print on a plain paper setting The printers feed and transport components can fail and cause paper jams or other feed and transport problems These components should be examined for damage or wear and replaced if necessary Below is a summary of the paperpath and transport compon
126. assembly on page 4 43 Go to Toner sensors Y C M K on TMC card on page 2 58 Go to Toner sensors Y C M K on TMC card on page 2 58 Go to Toner sensors Y C M K on TMC card on page 2 58 Go to Toner sensors Y C M K on TMC card on page 2 58 If this error message persists replace the controller board See Controller board removal on page 4 18 If this error message persists replace the controller board See Controller board removal on page 4 18 7525 XXX Service error messages 1XX 8XX and 9xx continued en rem CN 950 xx Service There is a mismatch between controller Go to 950 xx NVRAM failure service NVRAM Failure EEPROM and mirror check on page 2 33 e 950 00 through 950 29 codes mismatch between controller and mirror e 950 30 through 950 60 codes mismatch between secure and controller 951 xx Service Mismatch between controller EEPROM NVRAM Failure and mirror e 951 00 through 951 29 codes mismatch between controller and mirror e 951 30 through 951 60 mismatch between secure and controller 952 xx Service A recoverable MVRAM Cyclic Performing a POR will clear this error NVRAM Failure Redundancy Check CRC error occurred n is the offset at which the error occurred 953 xx Service NVRAM chip failure with mirror NVRAM Failure 954 xx Service The NVRAM chip failure with controller NVRAM Failure part 955 xx Service
127. at blade screwdriver P A 4 press the Sensor 1 actuator B located in the ADF paper path Sensor 1 Open should display if the sensor is working properly 5 press Back s to exit the test and return to the Scanner sensor tests 3 28 Service Manual 7525 XXX Sensor2 test This test verifies the functionality of scan sensor 2 To test this sensor perform the following steps 1 Inthe sensor test menu press 4 or to scroll to the Sensor 2 test 2 press Select A Starting Test displays Sensor 2 Closed displays 3 Lift the ADF top cover and close the ADF cover sensor A by pressing down on the ADF sensor actuator with a small flat blade screwdriver 4 Move the Sensor 2 actuator by inserting a small screwdriver into the hole B and gently toggling the actuator Sensor 2 Open should display if the sensor is working properly B 5 press Back 5 to exit the test and return to the Scanner sensor tests Diagnostic aids 3 29 7525 XXX EXIT Diags press Select 3 30 Service Manual d to exit Diag Menu The printer performs a power on reset and returns to normal mode 7525 XXX Configuration Menu Available tests The tests display on the operator panel in the order shown for all models Configuration menu Exit Config Menu This selection exits Configuration Menu and Resetting the Printer displays The printer performs
128. ative menu You can also navigate to Menu gt Network Ports gt Network Menu gt Network Setup gt TCP IP gt IP Address Warning Before performing a firmware update on the printer contact the technical service center or second level of support to verify the correct firmware and keycode The wrong firmware or wrong level of firmware could lead to a malfunction or render the printer inoperable To update the printer s firmware perform the follow steps RIP firmware update POR the printer to Ready On a computer attached to the network open a Web browser Enter the printers IP address in the Web browsers address bar Press Enter The printers homepage opens Click Settings The settings page opens Click the Update Firmware link The update firmware page opens Click the Browse button A file browser will open Browse to fullnet fls also known as 1 fls Warning fullnet fls must be updated first Failure to do so could render the printer inoperable Ge a eg Click Open 10 Click Submit Various status and progress messages will appear on the operator panel The printer will reboot The webpage will post File Transfer Complete The HTTP session will terminate Warning Do not turn the machine off until the update is complete When the firmware update is completed the printer will automatically reboot and return to a Ready state Engine firmware update 11 On a computer attached to the network open a Web brow
129. bed unit or controller card are replaced To manually register the ADF perform the following steps In the Configuration Menu scroll to the Scanner Manual Registration menu item Press y Scroll to the Print Quick Test Page menu item Press o To view and adjust the simplex ADF registration place the quick test page into the ADF scroll to the Copy Quick Test Page item and press y After the quick test page copies SS to ADF and press e Scroll to Horizontal Adjust and press y Use the or p to increase or decrease the settings value AN eS PS Note Each button press move the margin values one pixel in the respective direction 9 Press y to accept the value 10 Scroll to Top Edge and press y 11 Use the a or p to increase or decrease the settings value Note pressing q moves the margin up and pressing p moves the margin down 12 Press y to accept the value To manually register a Duplex ADF perform the following steps In the Configuration Menu scroll to the Scanner Manual Registration menu item Press Tal Scroll to the Print Quick Test Page menu item Press y To view and adjust the duplex ADF front side registration place the quick test pageface up into the ADF scroll to the Copy Quick Test Page item and press y After the quick test page copies scroll to ADF Frontside and press y Scroll to Horizontal Adjus
130. bin full sensor located towards the rear of the top cover assembly Is the bin full sensor dislodged or damaged With the scanner assembly in the down position perform the standard bin sensor base sensor test See Base Sensor Test on page 3 18 Toggle the bin full flag attached to the rear shaft of the redrive unit Does the flag rotate freely and interrupt the sensor beam when in normal position Turn the printer off and remove the rear shield See Rear shield removal on page 4 7 Turn the printer on and then check the values below at JBIN1 JBIN1 l gt 0 V dc 5V de during cycle 2 3 3 V dc beam blocked O V dc unblocked Are the values correct 2 34 Service Manual Repair or replace the bin full Go to step 2 sensor See Bin full sensor on page 4 15 Go to step 3 Reposition or replace the flag If the flag is broken replace the bin full flag See Bin full flag removal on page 4 103 Problem resolved Replace the controller board See Controller board removal on page 4 18 7525 XXX Dead printer service check A dead printer is a condition where the display is blank the LED on the operator panel is off the fan does not turn no motors turn and the fuser does not heat If a 650 sheet Duo Drawer is installed remove the option and check the base printer for correct operation If the base printer operates correctly replace the 650 sheet Duo Drawer Warning Obs
131. bjects However Color Correction must be set to Manual or no user defined color conversion will be implemented Manual color correction settings are specific to the type of object being printed text graphics or images and how the color of the object is specified in the software program RGB or CMYK combinations Notes e Manual color correction is not useful if the software program does not specify colors with RGB or CMYK combinations It is also not effective in situations in which the software program or the computer operating system controls the adjustment of colors e The color conversion tables applied to each object when Color Correction is set to Auto generate preferred colors for the majority of documents To manually apply a different color conversion table press Menu to open the Admin menus Select Settings and press Select x Select Quality and press Select Select Color Correction and press Select y Select Manual and press Select y The printer is in manual mode and you need to select a color conversion table press Back 5 to return to the Quality menu select Manual Color and press Select y Select the appropriate color conversion table for the affected object type Object type Color conversion tables RGB Image Vivid Produces brighter more saturated colors and may be applied to RGB Text all incoming color formats RGB Graphics sRGB Display Produces an output t
132. celled by user No action needed Diagnostic information 2 29 7525 XXX Fax error log codes continued ree rem e Modem detected a digital line Verify the MFP is connected to an analog connection line See Fax transmission service check on page 2 72 Phone line was disconnected Restore phone line connection Received request for unsupported No action needed function from remote fax device Received request for unsupported No action needed image width from remote fax device image resolution from remote fax device Received request for unsupported No action needed compression type from remote fax device Received request for unsupported No action needed image length from remote fax device Received request for unsupported No action needed 2 30 Service Manual 7525 XXX Service checks 90x xx error Turn the printer off and remove the rear shield Replace the controller Securely make all the See Rear shield removal on page 4 7 board See Controller connections POR the Check the cable connections board removal on printer Are all the cable connections secure page 4 18 925 01 Fan error service check Turn off the printer and remove the rear shield Replace the top cover Replace the controller See Rear shield removal on page 4 7 which includes the fan board See Controller Unplug the fan cable at JFAN1 and turn the See Top cover assembly board removal on p
133. ch it operates Any reference to a product program or service is not intended to state or imply that only that product program or service may be used Any functionally equivalent product program or service that does not infringe any existing intellectual property right may be used instead Evaluation and verification of operation in conjunction with other products programs or services except those expressly designated by the manufacturer are the user s responsibility Lexmark Lexmark with diamond design and MarkNet are trademarks of Lexmark International Inc registered in the United States and or other countries Optra Forms is a trademark of Lexmark International Inc PostScript is a registered trademark of Adobe Systems Incorporated PCL is a registered trademark of the Hewlett Packard Company All other trademarks are the property of their respective owners O 2006 Lexmark International Inc All rights reserved UNITED STATES GOVERNMENT RIGHTS This software and any accompanying documentation provided under this agreement are commercial computer software and documentation developed exclusively at private expense P N 12G9825 7525 XXX Table of contents Es eo AAA iii Notices and safety information 0 000 cee es xi Fehr ER ee Re ee ee xi LALOR OIG TR EE EE EE AAA CEE EE OOO SC xvii A o A O xvii a EEN EE RS e xxi Fila A xxi General information 2 0 0 0 anaana aaaea aeaaaee aaae EEEE Eaa 1 1 REENEN
134. choose an alternate source for media e Cancel the current job PJL ST Message Try one or more of the following e press Select y to clear the message and continue printing e Wait for the message to clear Power Saver The printer is saving power while it waits for the next print job e Send a job to print e Press Select y to warm the printer to normal operating temperature Afterwards Ready appears Programming Code The printer is receiving a file that is a code update Wait for the message to clear Warning Potential Damage Do not turn the printer off while this message appears on the display Programming Flash Fonts and macros are being written to flash Wait for the message to clear The printer is ready to print Diagnostic information 2 7 7525 XXX User status and attendance messages continued User primary message Explanation Remove Paper ADF This posts when there is paper detected in the ADF upon POR or when the cover is closed or any other situation that re inits the scanner Message clears when paper is removed Remove Paper The standard output bin is full or nearly full Remove the media from the bin Standard Bin Remove Packaging Packaging material is detected by the printer Remove the packaging material and Material press Continue Unplug and Change Camera is not in a proper mode to use the PictBridge feature Unplug the camera Mode cable to the prin
135. computer Open the new folder containing the files that were just unzipped Confirm the printer is in Ready or Invalid Engine Code mode If it is not in either mode refer to the note above a 3 46 Service Manual 7525 XXX 5 Open the USBFlash utility This window will display Se LSAFlach 2 0 SELECT PRINTER FROM LIST Po START BYTES SENT PL Copag E 2001 2004 Lesmnark International Inc 6 Click the Browse Files button The file browse dialog displays Look rc CO 54 femmare update wl ae ei ES Es Fullrvet P Sl updeng Type FLS File Date Modified 6 22 2009 10 04 AM Size 24 0 MB File nane ifullnet Open Files of lype Eisch Files T fa fle pill Cancel 7 Inthe file browse dialog browse to the fullnet fls also called 1 fls file The fullnet fls file is the RIP firmware file Warning It is critical that the RIP firmware gets updated first Failure to do so can render the printer inoperable 8 Click Open The file browse dialog will close Diagnostic aids 3 47 7525 XXX 9 Select the printer needing the firmware update from the Select Printer From List dropdown menu e USBFlash 2 0 Beles ENTER FILENAME TO FLASH TO PRINTER SELECT PRINTER FROM LIST CA w START BYTES SENT i Copyusghtk 2001 2004 Lexmark International Inc 10 Click Start The printer will start the update process Various status and progress messages will appear o
136. correct Diagnostic information 2 35 7525 XXX Duplex manual feed sensor S1 service check Note Before performing this service check ensure that the printer is on a hard level surface Enter Diagnostics Menu turn the printer off Go to step 2 Go to step 4 press and hold a and x turn the printer on and then release the buttons when the installed memory and processor speed displays Perform the Base Sensor Test See Base Sensor Test on page 3 18 1 Select Base Sensor Test and press Select y 2 Select S1 and press Select y 3 Install tray 1 Does the display indicate InputS1 Media Clear Pull tray 1 out The sensor is functioning Go to step 3 P E correctly Does the display indicate InputSl Media Present Remove the tray and inspect sensor Remove the obstruction and Go to step A l restart the test Is there something obstructing the sensor Inspect the spring loaded shaft flag in the tray Go to step 5 Replace the tray with a new The flag portion of the shaft intercepts the one sensor except when a sheet is being staged for duplexing Does the shaft rotate freely and return to home position flag at top of rotation Is the flag on the shaft broken Replace the tray Go to step 6 Is the cable correctly connected to JFUSES1 Go to step 7 Reconnect the cable on the controller board and to the sensor If the problem persi
137. ct the cable JADF1 on the system board to the system board Inspect the connections on the ADF relay Go to step 11 Secure all the connections card in the ADF Are all the connections properly connected Check the ADF cable for continuity Is there Go to step 11 Replace the ADF cable continuity Check for signals or voltages from JADF1 Replace the ADF unit See Replace the controller on the controller board Pin 11 and 12 Duplex ADF removal on board Go to Controller Properly close the top If the paper is jamming in cover the ADF go to step 6 D 10 1 zech k k should measure 24VDC Pin 5 should page 4 83 or Simplex board removal on measure 14VDC Are there signals or ADF removal on page 4 18 voltages present page 4 84 2 68 Service Manual ADF feed errors service check 7525 XXX 1 If the ADF is multi feeding check for dirt on the ADF separator pad and ADF separator rollers Are they dirty 2 If the paper is skewing when it is fed into the ADF check the paper guide width Is it set correctly 3 If paper is skewing when fed or jamming check to see if the top cover is open or ajar Is the ADF top cover open or ajar Clean them with a lint free cloth and isopropyl alcohol Replace the separator pad and ADF pick roll Go to step 3 Set the paper guides so they contact the edges of the paper If the paper is jamming in the ADF See ADF paper jam service ch
138. cuting the ADF scan sensor is being polled to determine if the trailing edge of the media has reached the sensor 8 Once the trailing edge of the scan media has reached the ADF scan sensor that sensor goes to the off position After the ADF scan sensor is switched off the image acquisition process continues for a predetermined length of time 9 When the image acquisition process is completed the trailing edge of the media continues to the reverse point If the scan job is simplex only the media continues to the exit roller and exits the ADF 10 If the scan job is a duplex scan job a solenoid on the ADF is actuated when the trailing edge of the media reaches the reverse point This solenoid moves a diverter gate to the down position and engages a reversing gear on the exit roll 11 The reversed exit roll pulls the paper back into the ADF The transport roll then moves the media to the duplex sensor When the duplex sensor is actuated the exit roll stops Also the duplex sensor indicates that this is the second side of the media to be scanned 12 After actuating the duplex sensor the transport roll moves the media to the take away roll and the ADF scan sensor Like the first pass of the media the image acquisition process is repeated for the second side of the media 13 When the trailing edge of the media reaches the reverse point the second time the solenoid again moves the diverter gate to the down position and reverses the exit r
139. d continue printing The job may not print correctly e Simplify the print job e press Menus to access the Busy Waiting Menu The following functions may be available Cancel Job Reset Printer Note Menu Lockout does NOT prevent access to the Busy Waiting Menu 40 lt color gt Invalid Refill Replace the toner cartridge with a new one change cartridge 50 PPDS Font Error This error only occurs when a printer is formatting PPDS print data The PPDS interpreter has detected a font error When a specific font which is not installed is requested based on a PPDS mode Set Font Global command a Select Code Page command or a Comprehensive Font Selection command and the printer Best Fit setting is off If Best Fit is on the printer performs a best fit search to find a similar font and this error does not occur This error also displays when the printer receives invalid PPDS download font data The following actions can be taken while this message is displayed e press Select y to clear the message and continue printing The job may not print correctly e press Menus e to access the Busy Waiting Menu The following functions may be available Cancel Job 51 Defective Flash press Select y to clear the message and continue printing Detected You must install different flash memory before you can download any resources to flash 2 10 Service Manu
140. d flat surface It should also be protected from light while out of the printer e Unless otherwise stated reinstall the parts in reverse order of removal e When reinstalling a part held with several screws start all screws before final tightening Print engine removal procedures Notes e Remove the waste toner container color toner cartridges imaging unit and media tray before removing other printer parts The imaging unit should be carefully set on a clean smooth and flat surface It should also be protected from light while out of the printer e We recommend disconnecting all external cables from the printer to prevent damage during service e Unless otherwise stated reinstall the parts in reverse order of removal e When reinstalling a part held with several screws start all screws before final tightening Front cover assembly removal 1 Remove the media tray 2 Open the front cover 3 Remove the front middle cover optional See Front middle cover removal on page 4 4 4 2 Service Manual 7525 XXX 4 Remove the five screws A from the cable cover C B A 5 Remove the cable cover 6 Remove the screw B securing the right restraining strap to the front cover Note Support the door with one hand after removing the screw holding the restraining strap This is the longest screw of the eight The two flat head Phillips screws are used in the door hinge 7 Remove the two screws C securing the interloc
141. d in NVRAM Goer A Fax from PC Yes Supported using PostScript driver for both local and network attach modes Junk FAX blocking Yes based on caller ID and remote station ID Text texipnote photo Text text photo photo Tone Pulse Tone Default Pulse Yes Yes es es es es es es es 1 18 Service Manual 7525 XXX Tools required for service Flat blade screwdrivers various sizes 1 Phillips screwdriver magnetic 2 Phillips screwdriver magnetic 2 Phillips screwdriver magnetic short blade 7 32 inch 5 5 mm open end wrench 7 0 mm nut driver Needlenose pliers Diagonal side cutters Spring hook Feeler gauges Analog or digital multimeter Parallel wrap plug 1319128 Flash light optional General information 1 19 Acronyms ac ACM ADF AFE AlO APS ASIC BLDC BOR BUD C CCD CCFL CCW CDB CMYK CPU CRC CRU CSU CW DBCS dc DIMM DLE DRAM DVM ECC ECM EDO EEPROM ENA EOL EP EPROM ESD FB FD FRU FU GB GFI GHz HBP HCF HCIT HCOF HCPF HTML HV HVPS 1 20 Service Manual Alternating Current Autocompensator Mechanism or paper feed Automatic document feeder Analog front end All In One Automatic Paper Size Application Specific Integrated Circuit Brushless DC Motor Black Only Retract Belt up down Cyan Charge Couple Device Cold Cathode Fluorescent Lamp Counter clockwise Command Descriptor Blocks Cyan yellow magenta black Central processing unit Cyclic red
142. d papers may also cause background problems Some problems occur with printers that run a large amount of graphics in a humid environment Read the current status of the imaging unit Reset the value To reset Go to step 2 from the customer menus this value To view the status of the photoconductor units 1 In Ready mode press Menus 2 Select Supplies Menu and press Select y 3 Select Replace Supply and press Select y 1 In Ready mode press Menus 2 Select Reports and press Select 3 Select Device Statistics and press Select y It is possible a new imaging unit was installed but the counter was not reset 4 Select the imaging unit you want to change and Has the imaging unit been recently replaced press Select y 5 Select Yes and press Select y If this does not fix the problem go to step 2 Is the background only one of the primary Replace the developer unit Go to step 4 colors yellow cyan magenta or black forthe background color and retest See Developer unit removal on page 4 42 Go to step 3 Did replacing the developer unit correct the Problem resolved Go to step 4 problem Replace the photoconductor unit Problem resolved Go to step 5 Does this fix the problem Check the high voltage contact from the HVPS Replace the failing part Go to step
143. dawn dae we 2 6 User status and attendance MessageS 0 0o oocoooooooo es 2 6 Paper Jam MESSAGES aiii dara G6 6 0b be AA ARA PI OE OA eR Res 2 13 Service error MESSADES AS EEN sews sade A A dae EE eas 2 15 Pe CIO log COGS go 8d 08 KEES OE AAA AAA AAA ARA 2 27 SSES COCOS caer AA EA AAA RCA RARA ARA EE RO ER 2 31 MISION ARA ARA AAA ARANA ARA 2 31 925 01 Fan error service Check o ooocoococc es 2 31 Printhead SETVICG CNGCK seso ren yess er eee ERO AREA seen ewe 2 32 950 xx NVRAM failure service Check 00 0c eee es 2 33 Autocompensator mechanism service Check 000 cee eee es 2 33 Bin full sensor service Check 2 34 Dead printer Service CHECK A NNN even ANE ANE ENER AAA AER ASR ROS 2 35 Duplex manual feed sensor S1 service check 2 36 Front door sensor or switches service check 2 37 Fuser exit sensor service check 2 38 So 6 EE 2 39 Input sensor S2 service Check 022 cece es 2 40 Main drive gear assembly EP drive service Check 00 cc eee eee eee es 2 41 Operator panel service Check ococococcccoc es 2 42 One or more operator panel buttons fa 2 42 Operator panel display blank five beepS 1 ee eens 2 42 Operator panel display blank printer beeps five times and oauses n nanan aana anaa 2 43 Operator panel displays all diamonds NO beepS 1 tes 2 44 Operator panel displays all diamonds five beepS 1 0 ees 2 44 Operator panel display is dim
144. der of the pages contain only graphics The test prints on the media in tray 1 Lexmark x54x Print Quality Test at ET E SES EE 3 o P Diagnostic aids 3 11 7525 XXX This test may be printed from either Configuration Menu or the Diagnostics Menu To run the print quality pages from the Diagnostics Menu 1 Select PRINT TESTS and press Select d 2 Select Print Quality Pgs and press Select The message Printing Quality Test Pages is displayed Note Once the test is started it cannot be cancelled d Y When the test pages print the printer returns to the original screen 3 12 Service Manual 7525 XXX Hardware Tests Panel Test This test verifies the operator panel LCD function To run the Panel Test 1 Select Hardware Tests from Diag Menu and press Select y 2 Select Panel Test and press Select CZ The Panel Test continually executes press Stop W to cancel the test Button Test This test verifies the operator panel button function To run the Button Test 1 Select Hardware Tests from Diag Menu and press Select y 2 Select Button Test and press Select v press count 0 appears press each operator panel button and watch to see if the number of press counts increases by one for each press Note If you press Stop W you end the test pre
145. dge Diagnostic information 2 53 7525 XXX Print quality narrow vertical line Questions actions Replace the photoconductor unit See Problem solved Replace the developer unit Imaging unit IU removal on page 4 40 EE Print quality random marks Service tip The primary cause of random marks is due to loose material moving around inside the printer and attaching to the photoconductor unit developer roll or transfer belt Is there any loose or foreign material on the Inspect the imaging unit by Go to step 2 imaging unit looking at the individual developers and photoconductors Clean or replace the faulty unit See Imaging unit IU removal on page 4 40 Is there any loose or foreign material on the Replace the developer unit Go to step 3 developer roll Is there any loose or foreign material on the Replace the image transfer Contact your next level of transfer belt unit See Image transfer support unit ITU on page 4 35 2 54 Service Manual 7525 XXX Print quality residual image Service tip Install a new print cartridge if available before doing this service check Residual image can be caused by the photoconductor cleaning blade and other parts inside the print cartridge Check the condition of the imaging unit using Go to step 2 Replace the imaging unit or the customer menus administrative menus the photoconductor unit See Imaging unit IU remov
146. dge may be empty Replace as necessary Invalid fax partition or fax partition too See Format Fax Storage on page 3 34 small Some words on an incoming fax are The sending fax machine had a temporary jam stretched Faxes fail to transmit Go to Fax transmission service check on page 2 72 Fax reception fails Go to Fax reception service check on page 2 74 Rattling noise coming from the ADF unit Inspect the ADF separator roll and ADF separator pad for proper installation If needed remove the separator pad and separator roll and reinstall them See ADF separator pad on page 4 87 and ADF separator roll assembly on page 4 88 for removal instructions 2 4 Service Manual 7525 XXX Print quality symptom table Mottle 2 5mm speckles Go to Print quality mottle 2 5mm speckles on page 2 53 Diagnostic information 2 5 7525 XXX Error codes and messages User status and attendance messages User status and attendance messages Explanation Wait for the message to clear The printer is performing a color adjustment Message clears when upper and lower doors are closed The printer configuration ID is invalid Message clears when a valid model name is set Message clears when a valid serial number is set Replace the toner cartridge and then wait for the message to clear Defragmenting Flash The printer is performing the defragmentation operation of flash memory Wait for the
147. ds and stops automatically Detect Complete Rebooting appears and the printer performs a POR Power On Reset 3 10 Service Manual 7525 XXX Print Tests Input source tests The purpose of the diagnostic PRINT TESTS is to verify that the printer can print on media from each of the installed input options The contents of the Print Test Page vary depending on the media installed in the selected input source Check each Test Page from each source to assist in print quality and paper feed problems To run the Print Test Page 1 Select PRINT TESTS from the Diag Menu and press Select A1 2 Select the media source Tray 1 Tray 2 Manual Feeder or MP Feeder and press Select v Se 3 Select Single or Continuous and press Select e if Single is selected a single page is printed e f Continuous is selected printing continues until Stop W is pressed to cancel the test If a source is selected that contains envelopes an envelope test pattern is printed If Continuous is selected the test pattern is printed only on the first envelope Note The Print Test Page always prints on one side of the paper regardless of the duplex setting 4 press Back 5 to return to PRINT TESTS Print quality test pages Prt Quality Pgs The print quality test consists of five pages Pages one and two contain a mixture of graphics and text The remain
148. e Diagnostic aids 3 57 7525 XXX Step 1 Charge During the charge step voltage is sent from the high voltage power supply to the charge roller A beside each of the four photoconductors The charge roller is part of the photoconductor unit The charge roller A puts a uniform negative charge over the entire surface of the photoconductor to prepare it for the laser beam Service tips e If the surface of the charge roller is damaged such as a nick or pit it will cause the charge to be uneven on the photoconductor This will cause a repeating mark on the printed page Check the service manual for the repeating marks table e If the charge roller is severely damaged the surface of the photoconductor will not be charged properly and heavy amounts of toner will be deposited on the photoconductor This will cause the printed page to be saturated with 100 of each color The imaging basket will need to be replaced sooner 3 58 Service Manual 7525 XXX Step 2 Expose During the expose step the laser fires a focused beam of light at the surface of each photoconductor B and writes an invisible image called a latent image or electrostatic image for each color The laser beam actually discharges the surface only where the beam hits the photoconductor This creates a difference in charge potential between the exposed area and the rest of the photocond
149. e TIFF 1 bit CCITT G4 8 24 bit Packbits LZW e JPG 8 24 bit JPG Supported scan destinations Temporary profile from a user s PC Scan to PC via network TWAIN Scan to PC using Web applet Scan to E Mail Scan to USB X544 models only Lexmark Scan Center Multiple copies 999 copies maximum Reduce Enlarge 25 to 400 General information 1 17 7525 XXX Fax specifications Phone network connectivity Phone networks types supported PSTN or analog PABX Ru 11 ITU COMPATIBILITY Group 3 ECM Standard Resolution 8 x 3 85 pels mm 200X100dpi 204x98 Fine 8 x 7 7 pels mm 200X200dpi 204x196 Superfine 11 8 x 11 8 pels mm 300x300 dpi 204x391 Ultrafine 15 7 x 15 7 pels mm 400x400 dpi 408x391 Coding ITU T 4 and T 6 MH MR MMR JPEG Modem speed V 34 2 400 33 600 BPS V 17 7 200 14 400 BPS V 27 2 400 4 800 BPS V 29 7 200 9 600 BPS Compression MH MR MMR JPEG Error correction ITU T 30 Line interface selection Modular Plug Dual RJ 11C Out Band Signal Level Guaranteed North American and Europe PTT standard Input Level Range 16dBm 59dBm Ring Detection Complies with all regulatory requirements Fax resolutions Receive 200x100 dpi 200x200 dpi 300x300 dpi 400x400 dpi 204x98 dpi 204x196 dpi 204x391 dpi 408x391 dpi Send 200x100dpi 200x200 dpi 300x300 dpi Miscellaneous FAX specifications 4 MB Flash More than 320 pages based on ITU chart 1 User selectable parameters are store
150. e X546 can also support a 550 sheet option while the 650 sheet duo drawer is attached Models The Lexmark X54x series MFPs are available in the following models mat eon CIEN Print copy duplex scan network fax Print copy duplex scan network Print copy duplex scan network fax Print copy duplex scan network fax DBCS op panel Print copy duplex scan network DBCS op panel X544dtn Print copy duplex scan network fax 7525 336 bundled w 650 sheet optional tray X544dtn Print copy duplex scan network 7525 332 bundled w 650 sheet optional tray X544dtn Print copy duplex scan network fax DBCS op panel 7525 337 bundled w 650 sheet optional tray X544dtn Print copy duplex scan network DBCS op panel 7525 333 bundled w 650 sheet optional tray X546dtn Print copy duplex scan network 7525 396 bundled w 550 sheet optional tray X546dtn Print copy duplex scan network DBCS op panel 7525 397 bundled w 550 sheet optional tray 1 Wireless network 2 Simplex printing only General information 1 1 7525 XXX Options and features Certain options are available on selected printer models only Available options include 650 Sheet Duo Drawer a 550 sheet drawer with a 100 sheet multipurpose feeder MP Feeder 550 Sheet Drawer X546 only Additional memory One 128 256 or 512MB memory card may be added Flash memory card One 64MB may be added Font cards One lang
151. e black color page on page 2 56 Is the copy an ADF scan Go to step 3 Gotostep4 to Gotostep4 4 Run a flat bed copy Go to step 5 Go to step 4 Is it blank or black Did the sheet feed into the ADF Go to step 5 5 Is the CCD ribbon cable properly connected Go to step 6 Properly connect the ribbon to JCCD1 on the controller board cable to JCCD1 Check for 14VDC on Pin 33 and 34 on Replace the flatbed unit Replace the system board connector JCCD1 Pin 31 and 32 are See Flatbed removal on See Controller board 5VDC Are the voltages present page 4 72 removal on page 4 18 CCD service check Restart the device and retry the scan copy Go to step 2 No issue job Repeat this step with a few copy jobs Does the error return Is the CCD ribbon cable properly connected Go to step 3 Properly connect the ribbon to JCCD1 on the controller board cable to JCCD1 Replace the flatbed unit See Flatbed Problem resolved Replace the system board removal on page 4 72 See Controller board removal on page 4 18 Did this resolve the issue Flatbed motor service check 1 Ensure that the flatbed motor cable JFB1 Go to step 2 Properly connect the cable is connected Is the cable Ge 2 Check pin 1 in JFBM1 for voltage The Replace the flatbed unit Replace the controller voltage is only present when a flatbed copy See Flatbed removal on board Go to Controller job is running The v
152. e correct offset between the placement of the first scan line on the front and back side of the duplexed sheet For information about changing the margin see Top Margin duplex on page 3 16 The single test stops automatically when a single duplex sheet is printed and the continuous test continues until you press Stop W Left Margin duplex This setting shifts the image on the backside of the duplex sheet to the left or right to correctly position it on the page Therefore be sure to set the top margin in REGISTRATION before setting the duplex top margin See Registration on page 3 4 To set the Left Margin duplex 1 Select DUPLEX TESTS from Diag Menu and press Select 2 Select Quick Test and press Select y 3 Select Single and press Select y Diagnostic aids 3 15 7525 XXX eS 7 8 Hold the page to the light to see whether the left margin of the back aligns with the left margin of the front Select Left Margin from DUPLEX TESTS Use or p to select the margin setting you need to change e Each increment shifts the duplex left margin by 4 pixels at 500 dpi 0 0067 inches or 0 1693 mm e The Left Margin duplex range is 25 to 25 and the default value is O e An increase in the value moves the backside left margin to the right and widens the left margin A decrease moves the backside left margin to the left and narrows the left margin press Sel
153. e main drive gear assembly or in the image transfer unit ITU Check the main drive gear assembly and ITU for correct operation Blurred print can also be caused by incorrect feeding from one of the input paper sources media trays or duplex paper path Check the high voltage spring contacts to ensure they are not bent corroded or damaged Replace the high voltage power supply as necessary See High voltage power supply HVPS assembly removal on page 4 31 Print quality half color page A photoconductor unit is not properly seated Reset the specific photoconductor unit Print quality horizontal banding Print the Print Defect Page 1 At the Ready prompt press Menu 2 Select Reports and press Select v 3 Select Print Defects and press Select Questions actions Measure the distance between repeating bands Is the distance between bands either 34 6 or 94 2 mm Does the distance measure 37 7 55 or 78 5 mm Does the distance measure 43 9 mm or 45 5 Does the distance measure 95 mm or 108 mm 2 52 Service Manual Replace the photoconductor unit Remove the imaging unit and remove the original developer units and then put them back into the new photoconductor unit and reinstall the imaging unit See Imaging unit IU removal on page 4 40 Replace the fuser See Fuser assembly removal on page 4 25 Replace the ITU See Im
154. e obtained from the Network Settings page found under Network Setup menu under Reports in the Administrative menu You can also navigate to Menu gt Network Ports gt Network Menu gt Network Setup gt TCP IP gt IP Address Warning Before performing a firmware update on the printer contact the technical service center or second level of support to verify the correct firmware and keycode The wrong firmware or wrong level of firmware could lead to a malfunction or render the printer inoperable To update the printer s firmware perform the follow steps RIP firmware POR the printer to Ready On a networked computer open an FTP client Using the FTP client navigate to the directory containing the firmware updates Open an FTP session with printer s IP address Use a Put command to send the fullnet fls also known as 1 fls file to the printer Warning fullnet fls must be the first file to be updated failure to update this file first could damage the machine or render it inoperable MA The printer will start the update process Various status and progress messages will display on the operator panel The FTP session will terminate Warning DO NOT TURN THE MACHINE OFF until the update is complete When the update is completed the printer will automatically reboot and return to Ready Engine Firmware On a networked computer open an FTP client Using the FTP client navigate to the directory containing the firmware updates
155. e of the leading edge When the S1 sensor is triggered the paper continues to the S2 sensor When the S2 signal is detected the speed of the paper is adjusted to accommodate the speed of the transfer belt ensuring the proper registration of the image on the media The paper travels to the ITU C and the second image is transferred to the reverse side of the media Once the imaged is transferred the media travels to the fuser D the fuser exit rolls E and the output bin 3 68 Service Manual 7525 XXX Scanner theory Duplex ADF The following illustration shows the paperpath rollers and sensors used in the X544 duplex ADF Duplex Document ADF sensor sensor Pick roll Paper path in Paper path out ADF scan Takeaway Scan Transport Reverse Exit sensor roll area roll point roll The X544 and X546 duplex ADF enables the user to create duplex scans automatically eliminating the need to stop the scanning process to flip the media being duplicated over The ADF uses a step motor and a series of sensors to determine the media s position in the paper path during the scan process The following steps are performed in creating a duplex scan on the X544 and X546 duplex ADF 1 The scanner control unit on the controller board receives a command to create a scan fax or copy 2 A signal is sent to the ADF to poll the paper present sensor to check if the media to be scanned is in the correct position The media must be placed
156. e 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 Color Balance provides the user with the ability to make subtle adjustments to the amount of toner being used in each color plane Selecting positive or negative values for cyan magenta yellow and black from the Color Balance menu will slightly increase or decrease the amount of toner used for the chosen color For example if a printed page has a red tint then decreasing both magenta and yellow could potentially improve the color balance Diagnostic aids 3 71 7525 XXX My color transparencies seem dark when they are projected Is there anything can do to improve the color This problem most commonly occurs when projecting transparencies with reflective overhead projectors To obtain the highest projected color quality transmissive overhead projectors are recommended If a reflective projector must be used then adjusting the Toner Darkness setting to 1 2 or 3 will lighten the transparency Make sure to print on the recommended type of color transparencies What is manual color correction When manual color correction is enabled the printer employs user selected color conversion tables to process o
157. e printer on and check page 4 28 board removal on the voltage values page 4 18 JBIN1 Pin Value o O V dc 5V dc during cycle 5 0 V dc unblocked 3 3 V dc unblocked elem Does the voltage values correct 2 38 Service Manual Fuser service check Questions actions Some low voltage power supply FRUs have a voltage selector switch If it does the switch needs to be set to the correct voltage for your area Has the LVPS been changed Turn the printer off and remove the rear shield See Rear shield removal on page 4 7 Check the cable at JFUSES1 for proper connection to the controller board the cable for pinch points and the cable or connector for any other damage Is the cable damaged 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 8 Check the power cable on the left side of the fuser and the thermistor cables and connections on the right side of the fuser Are the cables or connectors damaged Disconnect the cable at JFUSES1 on the controller board and check the following voltages JFUSES1 Pin Value o 1 24 V dc doors closed 24 V dc doors closed 24 V dc doors closed 4 24 V dc doors closed n erua towe Are the values approximately correct Check the switch on the side of the LVPS to verify the correct voltage is set
158. e the screw and grounding washer B on the right side of the frame Note Be careful not to lose the grounding washer Disconnect the thermistor cables C num N A Fa A Disconnect the narrow medial sensor cable and remove the cable from the fuser frame See Narrow media sensor flag removal on page 4 16 Note Observe the cable routing Repair information 4 29 7525 XXX 8 Unhook the springs D from both sides of the fuser p w e D D 9 Rotate the fuser toward the front of the printer until the screw E can be accessed and removed 10 Disconnect the cable G from the fuser exit sensor 11 Remove the screw F securing the fuser exit sensor 12 Remove the lower end of the sensor with a flat blade screwdriver and gently pull the sensor from the frame 4 30 Service Manual 1525 XXX High voltage power supply HVPS assembly removal 1 Remove the left cover 2 Is there a leaf spring A biasing the HVPS upward e Goto High voltage power supply HVPS with spring on page 4 33 Kr y Ni kb A e e f Wi A j l Na K q ETE 14 H H KK 5 A LR d Teel tis TPT Minli be d l Y 6162 Perrier ey on e 7 de Y S Sr yl GG apa A 50469580 ee o ses 1400393 gt D al e degt mg e If there is no spring go to High voltage power supply HVPS with no spring removal on page 4 32 below Repair information 4 31 7525 XXX High voltage
159. eck on page 2 68 Properly close the top cover 4 Is paper failing to feed into the ADF Go to step 5 5 Is the leading edge of the paper wrinkled or torn 7 Check the actuators to see if they are jammed or damaged Are they jammed or damaged Properly connect all the connections in the ADF relay card and controller board Did this fix the situation Check the ADF cable for continuity Perform the ADF paper present sensor test Go to Scanner Tests on page 3 25 Is the sensor working properly 10 Replace the ADF Go to Duplex ADF removal on page 4 83 or Simplex ADF removal on page 4 84 Does this fix the situation Use different media Go to step 6 Go to step 7 Properly connect all the connections in the ADF relay card Replace the ADF Go to Duplex ADF removal on page 4 83 or Simplex ADF removal on page 4 84 Go to step 8 Go to step 9 Problem resolved Go to step 6 Replace the ADF cable Go to ADF cable removal on page 4 85 Problem solved Replace the controller board Go to Controller board removal on page 4 18 Diagnostic information 2 69 7525 XXX ADF Duplex service check Perform sensor 1 and sensor 2 Go to step 2 Go to step 3 sensor tests Go to Scanner Tests on page 3 25 Are the sensors working properly Check the ADF sensor actuators to Go to step 3 Clean the actuators If any see if they are dirty or jamming actuator
160. ect x to save the new value Print the Quick Test duplex again steps 1 4 to verify the adjustment Repeat if necessary Top Margin duplex 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 on page 3 4 To set the Top Margin duplex eS SS Select DUPLEX TESTS from Diag Menu and press Select y Select Quick Test and press Select 7 Select Single and press Select y Hold the page to the light to see whether the top margin of the back aligns with the top margin of the front Select Top Margin from DUPLEX TESTS Use lt or p to select the margin setting you need to change e Each increment shifts the duplex top margin by 1 100 of an inch e The Top Margin duplex range is 50 to 50 and the default value is O e An increase in the value moves the backside top margin down and widens the top margin A decrease moves the top margin upward and narrows the top margin press Select to save the new value Print the Quick Test duplex again steps 1 4 to verify the adjustment Repeat if necessary 3 16 Service Manual 7525 XXX Input Tray tests Feed Tests This test allows you to observe the paper path of media as it passes through the print
161. ee Main Problem resolved Replace the controller drive gear assembly with motor removal board See Controller on page 4 53 board removal on Does the error clear page 4 18 Diagnostic information 2 41 7525 XXX Operator panel service check Warning Replace one of the following components and perform a POR before replacing a second component Never replace both of the components without performing a POR after installing each one or the printer will be rendered inoperable e Operator panel assembly e Controller board Warning Never install and remove components listed above as a method of troubleshooting components Once a component has been installed in a printer and the printer is powered on it cannot be used in another printer It must be returned to the manufacturer One or more operator panel buttons fail aer Questions actions Run the Button Test See Button Test on Replace the operator panel Go to step 2 page 3 13 in Diagnostics Menu assembly See Operator panel removal on page 4 98 Did any of the buttons fail the test Turn the printer off and remove the rear shield Replace the operator panel Replace the controller Rear shield removal on page 4 7 See Operator panel board See Controller Disconnect the operator panel assembly cable removal on page 4 98 board removal on at JOPP1 on the controller board Turn on the page 4 18 printer and verify the follo
162. elser Xii Service Manual 7525 XXX Laserilmoitus Tama tulostin on sertifioitu Yhdysvalloissa DHHS 21 CFR Subchapter J standardin mukaiseksi luokan 1 lasertuotteeksi ja muualla IEC 60825 1 standardin mukaiseksi luokan lasertuotteeksi Luokan lasertuotteita ei pidet haitallisina Tulostimen sis ll on luokan lllb 3b laser joka on nimellisteholtaan 5 mW n galliumarsenidilaser ja toimii 770 795 nanometrin aallonpituuksilla Laserjarjestelma ja tulostin ovat rakenteeltaan sellaisia etta kayttaja ei joudu alttiiksi luokkaa 1 suuremmalle s teilylle normaalin kayton yllapidon tai huollon aikana Huomautus laserlaitteesta Tama kirjoitin on Yhdysvalloissa luokan 1 laserlaitteiden DHHS 21 CFR Subchapter J maarityksen mukainen ja muualla luokan laserlaitteiden IEC 60825 1 m rityksen mukainen Luokan laserlaitteiden ei katsota olevan vaarallisia k ytt j lle Kirjoittimessa on sis inen luokan lllb 3b 5 milliwatin galliumarsenidilaser joka toimii aaltoalueella 770 795 nanometri Laserj rjestelm ja kirjoitin on suunniteltu siten ett k ytt j ei altistu luokan m rityksi voimakkaammalle s teilylle kirjoittimen normaalin toiminnan k ytt j n tekemien huoltotoimien tai muiden huoltotoimien yhteydess VARO Avattaessa ja suojalukitus ohitettaessa olet alttiina n kym tt m lle lasers teilylle l katso s teeseen VARNING Osynlig laserstr lning n r denna del r ppnad och sp rr
163. emory for receive jobs image 81A A timeout occurred during transmission Select a lower Max Speed value under of a page in ECM mode Fax Send settings 880 Failure to transmit training successfully Select a lower Max Speed under Fax in V17 V29 V27 terminal modulation Send settings schemes Adjust the Transmit Level Check line quality 881 Failure to transmit training successfully Select a lower Max Speed under Fax in V33 V29 V27 terminal modulation schemes Send settings Adjust the Transmit Level Check line quality 2 28 Service Manual Fax error log codes continued Error code 882 Failure to transmit training successfully in V17 V29 terminal modulation schemes 883 Failure to transmit training successfully in V17 V27 terminal modulation schemes 884 Failure to transmit training successfully in V29 V27 terminal modulation schemes 885 Failure to transmit training successfully in V17terminal modulation scheme 886 Failure to transmit training successfully in V29 terminal modulation scheme 887 Failure to transmit training successfully in V27 terminal modulation scheme 888 Failure to transmit training successfully at 2400 bps in V27 terminal modulation scheme 889 88A Failed to connect using V 34 modulation scheme 901 No fax tones detected from remote end 902 No dial tone detected 903 904 Hardware error detected 905 7525 XXX E lgge e Select a lower
164. en r urkopplad Betrakta ej str len Laser notis Denna skrivare r i USA certifierad att motsvara kraven i DHHS 21 CFR underparagraf J f r laserprodukter av Klass 1 andra l nder uppfyller skrivaren kraven for laserprodukter av Klass enligt kraven i IEC 60825 1 Laserprodukter i Klass anses ej h lsov dliga Skrivaren har en inbyggd laser av Klass IIIb 3b som best r av en laserenhet av gallium arsenid p 5 milliwatt som arbetar i v gl ngdsomr det 770 795 nanometer Lasersystemet och skrivaren r utformade s att det aldrig finns risk f r att n gon person uts tts f r laserstr lning ver Klass l niv vid normal anv ndning underh ll som utf rs av anv ndaren eller annan f reskriven service tg rd Laser melding Skriveren er godkjent i USA etter kravene i DHHS 21 CFR underkapittel J for klasse 1 laserprodukter og er i andre land godkjent som et Klasse I laserprodukt i samsvar med kravene i IEC 60825 1 Klasse l laserprodukter er ikke a betrakte som farlige Skriveren inneholder internt en klasse lllb 3b laser som bestar av en gallium arsenlaserenhet som avgir straling i bolgelengdeomradet 770 795 nanometer Lasersystemet og skriveren er utformet slik at personer aldri utsettes for laserstr ling ut over klasse I niva under vanlig bruk vedlikehold som utf res av brukeren eller foreskrevne serviceoperasjoner Notices and safety information XI 7525 XXX Av s sobre el L ser Segons ha estat ce
165. en the front cover 4 Release the green latches securing the door 5 Lower the right cover and remove it from the hinges Rear shield removal The rear shield is not a field replaceable unit FRU 1 Remove the six screws A 2 Remove the rear shield Repair information 4 7 7525 XXX AIO back cable cover removal 1 Remove the two screws A which secure the AIO back cable cover to the MFP 4 8 Service Manual 1525 XXX Top cover assembly removal 1 Remove the flatbed assembly Go to Flatbed removal on page 4 72 2 Remove the AIO toner cover Go to AlO toner cover on page 4 97 3 Remove the five screws A from the left front side 4 Remove one screw B from the top right side of the cover Repair information 4 9 7525 XXX 5 Remove the four screws C on the right side of the top cover 6 Remove the toroid holder D and two screws E from the rear The toroid holder will be used on the new top cover 4 10 Service Manual 1525 XXX 7 Detach the re drive belt F from the pulley on the fuser exit roll shaft e F 8 Disconnect the fan power cable from JFAN1 on the controller board 9 Disconnect the bin full sensor cable from JPJ1 on the controller board 10 Remove the top cover being careful to route the bin full sensor cable through the top of the controller board cage Installation Warning Make sure the belt is attached to the gear B Also check
166. ents Paper path Information The MFP has a simple C shaped paper path see the picture below The paper paths are shown in red Paper is fed from the bottom of the printer from the paper tray or manual feed and travels upward through the front cover There is a duplex unit on this MFP The duplex unit is built into the front cover and drawer 1 Duplexing is described later Fuser exit sensor Fuser exit rolls Duplex entry Printhead Toner cartridges Paper redrive rollers Front cover ai Transfer Tray 1 Paper path 3 66 Service Manual Pick roller Lr om bin 3 Controller Ee board A SSS OS oC rad ee JEJE IEIES pe ERAS SEN panor unit ITU Tray 1 sensor Paper pick motor drive asm 7525 XXX Transport components In summary the media is fed from the tray into the printer by a feed roll and carried to the transfer roll ITU The pick rollers time the media to enter the EP process at just the right moment The pick rollers push the media to the ITU where the image is transferred to the page The transfer roller moves the media to the fuser where heat and pressure are applied to the page The fuser rollers push the media toward the exit bin and past the exit sensor The exit rollers guide the paper into the output bin Note If
167. enu and press Select A1 2 Select Print Log and press Select to begin printing the log Panel Menus Lets the system support person enable or disable the operator panel menus Selecting On the default allows users to change values for the printer Off disables the users access to menus If a user presses Menu they receive a message that the panel menus are locked When set to Off this setting restricts all menu access even to menus or items set for PIN access However when set to On all PIN restrictions are in restored This menu item appears only when the PUL PASSWORD Environment variable is set to O PPDS Emulation Activates or deactivates the Personal Printer Data Stream PPDS emulation language This menu item appears only if the PPDS interpreter is available 3 32 Service Manual 7525 XXX Demo Mode Lets marketing personnel or merchandisers demonstrate the printer to potential customers by printing the demo page Selections include Deactivate default and Activate Select Deactivate to turn Demo Mode off or select Activate to turn Demo Mode on Factory defaults Sets the majority of printer values back to their factory default settings Warning This selection cannot be reversed so this operation should be used only as a last resort to fix any printer problem When factory default settings are restored e All downloaded resources fonts macros symbol sets in the pri
168. er 40X5533 EE 7 7 Bin full flag 40X5872 rr reer rr rr re er ee re eee eee ee 7 7 Bottom left and right cable frame cover 40X5422 7 11 C Cable packet 40X5423 EE 7 15 Controller board 3 1 X543 40X1523 reer eee eee e 7 13 D Duplex ADF assembly 40X5468 En 7 9 F Fax interface cable 40X5485 En 7 13 Fax PCBA 40X4820 re re ee eee eee eee eee 7 13 Flatbed assembly 40X5467 r rere errr ee rr re rr re eee eee eee 7 7 Front cover 40X5538 ree ee rr rr ee ee ee ee ee eee eee 7 5 Front flatbed hinge 40X2253 2 2 ee ee ere ee re ee ee ee eee 7 5 Front middle cover 40X5490 eee 7 5 Fuser drive motor assembly 40X5415 o 7 11 Fuser exit sensor 40X5413 o eee 7 13 H H flatbed cushion 40X5535 En 7 9 High voltage power supply 40X5405 o eee 7 13 Image transfer unit ITU assembly 40X5403B EE 7 11 Imaging contact unit 40X5421 eee ee ee ee eee eee eee eee 7 15 ITU paperpath thermistor 40X5429 2 2 eee eee er eee ee eee eee eee 7 15 Japanese font card assembly 40X5972 lt 7 18 K Korean font card assembly 40X5969 En 7 18 L L flatbed cushion 40X5539 En 7 9 Left cover 40X5417
169. er Any installed input tray can be tested The pages fed through the printer are blank To run the Feed Test RODT G i Select INPUT TRAY TESTS from Diag Menu and press Select y Select Feed Tests and press Select y Select the tray to be tested Choices are installed trays including Tray 1 Tray 2 and MP Feeder Open the upper rear door to view the paper path Note Do not open the upper front door The test will not run if the front door is open Select Single or Continuous and press Select y e Single a single sheet of blank paper is fed and the test stops e Continuous sheets are fed continuously until Stop MW is pressed Sensor Test This test is used to verify that the sensors are working correctly for an individual input tray 1 2 3 Select INPUT TRAY TESTS from Diag Menu and press Select y Select Sensor Tests and press Select Select the tray where you want to test the sensors Depending on the tray selected you may have Empty Sensor Low Sensor or Pass thru Sensor Sensors will be displayed with either Open or Closed Toggle the sensor you want to test and note the change of state of that sensor Tray 1 Tray 2 650 sheet duo tray MP Feeder To Exit the test press Back 5 or Stop MH Diagnostic aids 3 17 7525 XXX Base Sensor Test These tests allow you to verify the correct f
170. er rom the ADF Feed Jam page to the ADF interval sensor Retry the job If the error recurs Go to ADF paper jam service check on page 2 68 290 10 Scanner Scanner ADF detects paper at the first Remove all paper from the ADF Retry the Static Jam scanner sensor while the ADF is in an job If the error recurs Go to ADF paper idle state jam service check on page 2 68 290 20 Scanner This message occurs when paper is Remove original documents from the ADF Static Jam Paper detected in the ADF during a POR or Present when the MFP is starting up 290 30 Scanner This message displays when paper is Remove original documents from the ADF Static Jam Paper inserted past the paper stop on the Stop ADF 291 00 Scanner Jam Scanner ADF detects paper at the remove all originals second scanner sensor while the ADF from the scanner is in an idle state 291 01 Scanner Jam This message is posted if a jam is remove all originals detected at the first scanner sensor from the scanner 292 Scanner jam This message appears if the ADF Remove the paper from the ADF and close remove all originals cover is open while paper is fed the ADF cover If the error recurs Go to from the scanner through the ADF ADF cover open service check on page 2 67 293 Replace all No paper sensed in the ADF Ensure that the paper present actuator is originals if restarting in the correct position See ADF paper job jam service check on page
171. er while removing the ITU 4 38 Service Manual 1525 XXX Installation note EE Ze Write down the 16 digit numeric value of the new FRU before you begin to install it You may have to rotate the release lever again to install the new ITU Rotate the spring clamp so it hooks over the new ITU E Note The spring should be on the right side of the gear shaft te D When you have replaced the ITU be sure to enter the 16 digit numeric value from the barcode on the new Enter the Diagnostics Menu a Turn off the printer b press and hold 4 and dy C Turn on the printer d Release the buttons when the installed memory and processor speed displays Select PRINTER SETUP from Diag Menu and press Select y Select ITU Barcode and press Select v To enter the 16 digit numeric value Use lt q to decrease the leftmost digit value or p to increase the value press Select x to advance to the next digit If a digit is already correct press Select to accept the number and to continue When the last number is entered press Select v and Submitting changes should appear if the entered number is incorrect Check Sum Does Not Match displays Check and re enter the number lt Repair information 4 39 7525 XXX Imaging unit IU removal The Imaging unit is customer replaceable unit and is not a FRU
172. erve all necessary ESD precautions when removing and handling the controller board or any installed option cards or assemblies See Handling ESD sensitive parts on page 4 1 CAUTION When you see this symbol there is a danger from hazardous voltage in the area of the product where you are working Unplug the product before you begin or use caution if the product must receive power in order to perform the task Remove any input paper handling options from the printer Check the AC line voltage Go to step 2 Inform the customer Is the line voltage correct Is the AC line cord damaged Replace the line cord Go to step 3 Is the JLVPS1 cable correctly connected at Go to step 5 Reconnect the JLVPS1 JLVPS1 on the controller board cable and go to step 4 Turn the printer off and then on Go to step 5 Problem resolved Does the problem persist Warning Damage to the printer is possible Replace the controller Replace the LVPS Be careful to touch only one conductor at a board See Controller See Low voltage power time Rest the probe against the connector to board removal on supply LVPS assembly steady it page 4 18 on page 4 43 With the printer on verify the following values at JLVPS1 JLVPS1 exposed conductors Value Pin Valu 1 5V dc 2 eround sve a Ground s avec 6 Ground 7 waves 8 Ground o rava 10 Ground ir avae 12 erona TI Ligen Are the values approximately
173. ervice check Note This service check should be used if the paper feeds and jams in the ADF If the paper is not feeding into the ADF see ADF feed errors service check on page 2 69 1 If the ADF is multi feeding check for dirt on Clean them with a lint free Replace the separator pad the ADF separator pad and ADF separator cloth and isopropyl alcohol and ADF pick roll rollers Are they dirty If the paper is skewing when it is fed into the Go to step 3 Set the paper guides so ADF check the paper guide width Is it set correctly they contact the edges of the paper If paper is skewing when fed or jamming check to see if the top cover is open or ajar Is the ADF top cover open or ajar Is paper failing to feed into the ADF Go to step 5 Perform the ADF paper present scan 1st Go to step 6 Go to step 9 and scan 2nd sensor tests Go to Scanner Tests on page 3 25 Are the sensors working properly Check the leading edge of the paper to Bad media Go to step 7 ensure the paper is not curled or bent ina way that would keep it from contacting the paper present sensor actuator Is the paper damaged Is there dirt in the sensors or is the paper Clean the sensors or Go to step 8 present actuator stuck remove debris from the actuators Are the sensor actuators on the ADF Replace the ADF Go to step 9 mechanism cover damaged Is the ADF connector properly connected to Go to step 10 Properly conne
174. figuration Menu scroll to the Scanner Manual Registration menu item Scroll to the Print Quick Test Page menu item y To view and adjust the flatbed registration place the quick test page into the flatbed scroll to the Copy Quick Test Page item and press y After the quick test page copies Soll to Flatbed and press y Scroll toLeft Edge and press y Use the or p to increase or decrease the settings value Note Each button press moves the margin values one pixel in the respective direction 9 Press 10 Scroll to Top Edge and press y y to accept the value 11 Use the a or p to increase or decrease the settings value Note Pressing q moves the margin up and pressing p moves the margin down 12 Press d to accept the value To exit RESGISTRATION press BACK fsi or STOP gg Disable Scanner This menu item is used to disable the MFP scanner if it is malfunctioning The MFP must be powered off and on for the new settings to take effect To change the setting perform the following steps Press Press eee PAN Press 3 36 Service Manual d d Press BACK 5l Scroll to Exit Config Menu y In the configuration menu use the arrow keys to scroll to the Disable Scanner menu item Use the arrow key to scroll to the desired setting The options are Enable ADF FB Disable ADF FB
175. ft is aligned with the slot C facing down towards the front door Note Improperly aligned bearings or shafts incorrectly seated may cause vibration and noise in the front door 4 Align the duplex aligner guide so the ge i ars D mesh on the left S 5 Replace the eight screws in the duplex aligner 6 Close the front door 4 22 Service Manual 1525 XXX Duplex sensor removal 1 Remove the waste toner container See Waste toner bottle on page 4 67 2 Remove the two screws A from the cable channel cover A 3 Pull the corner of the cable channel cover B away from the right side to access the sensor posts C gt e WE 0 a S a po a Io Repair information 4 23 7525 XXX 4 If there is a plate on the side the latches of the sensor connected remove the old adhesive plate D D 5 Unlatch the sensor by pushing on the latches 6 Remove the sensor and disconnect the cable E from the duplex sensor Note Close the front cover and slightly lift the front of the printer to get better access 7 If there is plate on the side where the sensor latches connect remove the old adhesive plate E Installation notes 1 Clean the contact surface where you removed the sensor retaining plate or where you need to install the new one 2 Install the new sensor 3 Remove the backing from the new plate and place the plate on the surface between the sensor mounting leg
176. fter formatting is complete the display reverts to the main menu Auto Color Adj Sets the suggested number of pages which the printer should print between consecutive calibrations Selections are Off and the values between 100 and 1000 in increments of 50 The default is 500 pages If the printer exceeds the set value while printing a job it completes the current job and any other jobs received while printing the current job before it initiates a calibration The printer does not cancel or suspend an active job in order to perform a calibration If a user is using the menus including the Configuration Menu and the Diagnostics Menu an automatic color adjust calibration does not occur 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 The Auto Color Adj page counter is then reset Note An automatic color adjust can also be initiated manually This calibration procedure should be performed when the MFPs internal print settings are changed To perform and automatic color adjust perform the following steps press gt to enter the Administration menu press q or p to scroll to the Settings menu press y press
177. ght scanner cover from the flatbed unit 4 94 Service Manual 1525 XXX AlO release lever 1 Remove the right scanner cover See Cover scanner right on page 4 93 2 Remove the screw A securing the AIO link to the flatbed unit 3 Disengage the AIO link from the flatbed unit 4 Remove the screw B securing the AIO release lever to the flatbed 5 Slide the AIO release lever towards the back of the flatbed 6 Remove the spring and AIO release lever Note When reinstalling the AIO release lever place the release lever on the flatbed and then inset the spring before replacing the screw Repair information 4 95 7525 XXX AIO link 1 Lift the scanner to the up position Use a phillips screwdriver to remove the screw A securing the AIO link to the AlO toner cover 2 Return the flatbed to the down position 3 Remove the screw B securing the AIO link to the flatbed unit 4 96 Service Manual 7525 XXX AIO toner cover ul LU Lift the scanner unit to the up position 2 Remove the screw A fastening the AIO toner cover to the scanner unit a F f Td min 3 Remove the screws B securing the AIO hinge to the MFP B D Remove the hinge C Save this for the new AlO toner cover or top cover Rotate the AlO toner cover so the tab D on the cover lines up with the hole on the AlO toner cover Pull the AlO toner cover to the left and remove it from the prin
178. ging unit Problem resolved Go to step 4 IU removal on page 4 40 Does this fix the problem 2 50 Service Manual 7525 XXX Remove the image unit and waste toner Go to step 5 Replace the Main drive gear assembly See Main drive gear assembly with motor removal on page 4 53 bottle Replace the right cover and close the front door Enter the Diagnostics Menu turn the printer off press and hold lt and y turn the printer on and release the buttons when installed memory and processor speed displays and run the appropriate cartridge drive motor test for the missing color Select MISC TESTS in the Diag Menu and press Select y Select Motor Detect Remove Cartridge press Select appears Note Do not press Select yet Remove all toner cartridges and the imaging unit Close the front cover If you press Select before closing the front cover a message appears Close Cover press Select press Select v Motor Detection In Progress appears The motor detection process takes about 10 seconds and stops automatically Detect Complete Rebooting appears and the printer performs a POR Power On Reset Did the motor run Remove the developer unit See Developer Go to step 6 Clean the developer unit removal on page 4 42 Check the cartridge contacts See developer cartridge contacts from the HVPS to De
179. hat approximates the colors displayed on a computer monitor Black toner usage is optimized for printing photographs Display True Black Produces an output that approximates the colors displayed on a computer monitor Uses only black toner to create all levels of neutral gray SRGB Vivid Provides an increased color saturation for the sRGB Display color correction Black usage is optimized for printing business graphics Off No color correction is implemented Ara ae teg ND CMYK Image US CMYK Applies color correction to approximate the SWOP CMYK Text Specifications for Web Offset Publishing color output CMYK Graphics Euro CMYK Applies color correction to approximate EuroScale color output Vivid CMYK Increases the color saturation of the US CMYK color correction setting Off No color correction is implemented 3 72 Service Manual 7525 XXX How can match a particular color such as a corporate logo From the printer Quality menu nine types of Color Samples sets are available These are also available from the Color Samples page of the Embedded Web Server Selecting any sample set generates a multiple page printout consisting of hundreds of colored boxes Either a CMYK or RGB combination is located on each box depending on the table selected The observed color of each box is obtained by passing the CMYK or RGB combination labelled o
180. he ITU FRU includes a spring clamp kit If the printer does not have this kit installed perform the following steps to prepare for the later installation Continue below with Removal of ITU without the spring clamp kit on page 4 35 If the spring clamp kit is not installed skip to Continuing the removal with or without the spring clamp kit on page 4 37 aS Removal of ITU without the spring clamp kit 1 Pull the gear A straight out to unsnap it and then discard it A new gear is included in the spring clamp kit and must be used with the new spring clamp HAY gt ea 2 Remove the rubber pad C 3 Place the spring clamp onto the shaft D Repair information 4 35 7525 XXX 4 Snap the new gear onto the shaft D The installation is the same as the old gear uv 4 36 Service Manual 1525 XXX Continuing the removal with or without the spring clamp kit 1 Disconnect the one spring A from the side frames leaving them attached to the ITU or spring clamp A 2 Rotate the left spring B and pivot the cam away from the ITU so the spring is held out of the ITU path aw of Mies ees meee en wm tt e RF magu vw Or curr SE Repair information 4 37 7525 XXX 3 Rotate the release lever C in a counter clockwise direction with a spring hook or needlenose pliers to decouple the ITU while pulling the ITU toward the front 4 Hold the release lev
181. he amount of moisture in paper affects both print quality and the ability of the printer to feed the paper correctly Leave paper in its original wrapper until it is time to use it This limits the exposure of paper to moisture changes that can degrade its performance Condition paper before printing by storing it in its original wrapper in the same environment as the printer for 24 to48 hours before printing Extend the time several days if the storage or transportation environment is very different from the printer environment Thick paper may also require a longer conditioning period Grain direction Grain refers to the alignment of the paper fibers in a sheet of paper Grain is either grain long running the length of the paper or grain short running the width of the paper For 60 to 176 g m 16 to 47 Ib bond paper use grain long fibers Fiber content Most high quality xerographic paper is made from 100 chemically treated pulped wood This content provides the paper with a high degree of stability resulting in fewer paper feeding problems and better print quality Paper containing fibers such as cotton possesses characteristics that can negatively affect paper handling Unacceptable paper The following paper types are not recommended for use with the printer Preprinted papers with chemicals that may contaminate the printer Preprinted papers that can be affected by the temperature in the printer fuser Coated papers erasable bond syn
182. hee be 5 17 COR et NNE TEENER TSETERE TETEN eS Oe GS oe ea eee bas 5 18 ET MEIT COTO iria ADA IA 9 0 ee 5 19 Toner meter card CONMECIONS cascara 40 SHEERS EA EREERS EKER AEDS Oe Re ee 5 19 Pigg ilo e ee ee re ee ee eee o Ar ee a ee eee ee ee ee 5 20 A o A A 5 20 Preventive maintenance 6 1 SAI LORSE GUIE Aide tere e AAA IA A AAA A RADA ARAS 6 1 Scheduled Maintenant CR EN AE AAC ERA RARA AAA AAA ARANA 6 1 Al A A IEA 6 1 KSE EERSTEN A A AR AA AAN 6 1 Parts catalog EE iii raices 7 1 How to use this parts catalog 8 gt AI RA AR A A AA 7 1 Assembly 1 COVEIS EE 7 4 pos BE ice oar hb Non a Ce dE Ee e E EE E 7 6 Assembly 3 Paperpath 460k sd bode oe ieee bbw code eed wee eee hie eh ede ORE A eee AA 7 10 AssembIy a en WEE 7 12 Assembly 5 Electronics A iic ing bebe dE EE eee ia a Sho OG we AAA Hd ES A 7 14 Assembly 6 Media drawers and trays 000 ccc eee tenes 7 16 Assembly 7 Options a 6cdak sewitenwkh desed ioe kiin AAA ARA AAA 7 18 o A E ee ee ae EE Li Part number indeX ge e dE Ee EE KREE EEN 9 EE AeEN l 7 Table of contents Ix 7525 XXX X Service Manual 7525 XXX Notices and safety information The following laser notice labels may be affixed to this printer Laser notice The printer is certified in the U S to conform to the requirements of DHHS 21 CFR Subchapter J for Class 1 laser products and elsewhere is certified as a Class laser product conforming to the requirements of IEC 60825 1 Class
183. his mode is used if the machine has invalid code and needs the correct code loaded After entering this mode the firmware code can be updated Access secondary debug information For use on machines with See Updating printer firmware on page 3 46 operator panel USB Diagnostic aids 3 1 7525 XXX Diagnostics Menu Diag Menu Note Tray 2 refers to the 650 sheet tray located in the 650 sheet Duo Drawer assembly Diagnostics menu Structure When the Diagnostics mode is entered each Diagnostics main menu item displays on the operator panel When a diagnostic test is selected from the main menu a sub menu displays and each individual test displays in the order shown Any options that are referred to in the menus are displayed when the option is installed Available tests The tests display on the operator panel in the order shown Diagnostics mode tests REGISTRATION Top Margin These tests are performed to adjust the print head registration See l Available tests on page 3 2 Bottom Margin Left Margin Right Margin Quick Test ALIGNMENT Menu color alignment Cyan These testes are performed to align the color planes See Alignment on page 3 7 Yellow Magenta Factory Scanner A summary page for all the color alignment settings Can be used in place Factory Manual of alignment pages for each individual color MISC TESTS Motor Detect See Motor Detect on page 3 10 Tray 1 See Print Tests o
184. ia ara AREA AAA AR ARA 3 37 Exi CON MONG arica RAR RARA RARAS 3 37 ACI rara ri iria ia ar nes eu 3 38 a nn A 3 38 o ge e EE e EE N 3 38 COS REV O aia a Art cta pci ici oon ee 3 38 A A PP TEO A AS 3 38 EE rr rl o Ea AS AAA se cers 3 38 A EE EEN 3 38 es ee ee ee ee ee eee EIA REA PARA 3 38 Vi Service Manual 7525 XXX pa AA A 3 38 Poe I sia reir AAA AAA A A AAA AA AAA AA AAA 3 39 KEE AO serranas EEA ARA AN RA E RA 3 39 Understanding jam numbers and locations o oooooooonncrnr 3 40 Pe ee INS iris A a AA AAA AA AAA 3 41 A A gege 3 41 EDIC rra aaa ee ee ees ee 3 42 e A lt 4 5 he A EE A E E RE ee E E 3 43 o Eege Gow ho keete ee oe ee Fes 3 43 Pee o A bo ee be ae 3 43 Po OAS IAG A EE 20d WHEE DHEA SPE SSERES EOE SEPEO SOLS E 54435 544055 3 43 eee are WAN as oa hi he di A a AAA Rs 3 44 SERA er EE NARA ARA AAA 3 45 ORANG prnier MWAO coo dee RE AE he wee eae MOR AAA eh A NEEN 3 46 There are three options to update firmware on your printer The instructions for all three options Ore HSO nn 86S S S456 8S or HE eRe eee Sees ese ness 3 46 Using the host computer to update the firmware over USB 0 000 e eee eee 3 46 Updating the firmware using a USB thumb drive 3 53 Updating the firmware using a networked Computer 0000 eee eee ees 3 54 i yc aft anes lt r ae ee ee eee Se eee re ee ee eee eevee ee eae eee ee eee E 3 54 Using the printer s internal Web Server 0 0 cc cece eee eee eens 3 55 Theory OIDO ria r
185. ian operator panel bezel Bezel op panel 4 1 Simplified Chinese Bezel op panel 3 1 Simplified Chinese X546 Simplified Chinese operator panel bezel Bezel op panel 4 1 Traditional Chinese Bezel op panel 3 1 Traditional Chinese X546 Traditional Chinese operator panel bezel Bezel op panel 4 1 Korean Bezel op panel 3 1 Korean X546 Korean operator panel bezel Bezel op panel 4 1 Braz Por Bezel op panel 3 1 Braz Por X546 Braz Por operator panel bezel Bezel op panel 4 1 Japanese Bezel op panel 3 1 Japanese X546 Japanese operator panel bezel Bezel op panel 4 1 Turkish Bezel op panel 3 1 Turkish X546 Turkish operator panel bezel Cover scanner left Asm Duplex ADF Asm Simplex ADF Asm Separator pad Asm Separator roll Cushion L flatbed Cushion H flatbed Flatbed pivot link Redrive spacer screws Parts catalog 7 9 7525 XXX Assembly 3 Paperpath EN es os o Mt ABS oe C D r Ss dl 4 i J re A bal y gt Le f T SE we gt I Per i d P C Sa e Ce d Geh wir S e S 7 10 Service Manual Assembly 3 Paperpath 7525 XXX Part Units Units Description number mach FRU i 40X5411 40X5415 40X5422 40X5424 40X2263 40X5403 40X1557 40X5412 40X5406 40X5407 40X5408 40X0411 40X2261 40X2254 40X2255 ch ee sch mb mb mb sch sch wech sch Printhead Fuser drive motor assembly Bottom left and right frame and cable cover Screw packet miscel
186. idated Submitting Selection appears and a check y appears next to Printer Setup 5 Restart the printer A POR is not automatically performed ITU Barcode The 16 digit numeric value matches the ITU installed in the printer If you replace the ITU re enter this value Stop el exits the menu To enter the ITU barcode 1 2 Select ITU Barcode and press Select v Select PRINTER SETUP from Diag Menu and press Select 7 3 To enter the 16 digit numeric value Use lt q to decrease the leftmost digit value or p to increase the value press Select y to advance to the next digit If a digit is already correct press Select y to accept the number and to continue When the last number is entered and you press Select Submitting changes should appear if the entered number is incorrect Check Sum Does Not Match displays Check and re enter the number Enable Edge to Edge Copy This setting is set to either on or off Off is the default setting 3 20 Service Manual 7525 XXX Reset Fuser Count Resets the fuser count value to zero The Event Log records each time that a user executes the Reset Fuser Count operation See Event Log on page 3 32 for more information This setting appears only if the Maintenance Warning and Intervention function is enabled in the printer Configuration ID To reset the fuser count 1 Select Pri
187. in caso di sostituzione non autorizzata delle parti Le informazioni riguardanti la manutenzione di questo prodotto sono indirizzate soltanto al personale di assistenza autorizzato Durante lo smontaggio e la manutenzione di questo prodotto il rischio di subire scosse elettriche e danni alla persona e piu elevato Il personale di assistenza autorizzato deve quindi adottare le precauzioni necessarie ATTENZIONE Questo simbolo indica la presenza di tensione pericolosa nell area del prodotto Scollegare il prodotto prima di iniziare o usare cautela se il prodotto deve essere alimentato per eseguire l intervento Lithium warning XVII 7525 XXX XVIII Service Manual 7525 XXX Sicherheitshinweise Die Sicherheit dieses Produkts basiert auf Tests und Zulassungen des urspr nglichen Modells und bestimmter Bauteile Bei Verwendung nicht genehmigter Ersatzteile wird vom Hersteller keine Verantwortung oder Haftung f r die Sicherheit bernommen Die Wartungsinformationen fur dieses Produkt sind ausschlie lich fur die Verwendung durch einen Wartungsfachmann bestimmt Wahrend des Auseinandernehmens und der Wartung des Gerats besteht ein zusatzliches Risiko eines elektrischen Schlags und k rperlicher Verletzung Das zustandige Fachpersonal sollte entsprechende Vorsichtsmaf3nahmen treffen ACHTUNG Dieses Symbol weist auf eine gefahrliche elektrische Spannung hin die in diesem Bereich des Produkts auftreten kann Ziehen Sie vor den Arbeiten
188. in the ADF input tray so it actuates the paper present sensor If the ADF paper present sensor isn t actuated a flatbed scan is run by default 3 If the media has actuated the paper present sensor an ADF scan is executed At this point the roller on the pick arm assembly drops and advances the paper into the ADF actuating the document sensor Actuating this sensor determines that this will be the first side of the document to be scanned 4 When the document sensor is actuated a signal is sent to flatbed to move the CCD imaging unit to the ADF scan area When the CCD reaches the ADF scan area a calibration is performed on the CCD 5 The media is advanced to ADF scan sensor which is located by the takeaway roll If the paper does not reach the ADF scan sensor in a predetermined length of time a jam error will be generated 6 When the ADF scan sensor is actuated the paper advances to the scan area While the paper is advancing to the scan area the ADF motor generates pulses which are stored in an on board counter These counts along Diagnostic aids 3 69 7525 XXX with the ADF scan sensor ensure that the media is travelling at the correct speed through the scan area The speed the document travels through the ADF scan area is dependent on the image DPI specified by the user 7 After a predetermined number of counts the media reaches the scan area and the image acquisition process is initiated While the image acquisition process is exe
189. inda oo ode iii A Ke AAA A AAA 3 57 PRG CNG INGO ge Arel Eege et E eer A ARA AA 3 57 Electrophotographic Process EP Process 1 A5 ANNE UN NEIE EEN ER ees NEEN EE 3 57 MFP slectrophotographic process basics a cc NNN bake rr eee eee ee ew EK eM 3 57 A Ae 3 58 EE A ee ede ewe eee eee aoe ae deseo 3 59 EE SA 3 60 EEN aa daa o E eee eS 3 61 Siep 4D Second Waele abe sec ke eis Rb ade ideada ode ee bees 3 62 Pe EEN AS ee ebe os eee eee cea ees 3 63 Step 6 Clean Erase saxos RR ARA AA ARA EES ER Oe whe ESOS 3 64 Paper path transport components 0 ccoccccccco es 3 66 Poper ESCHER e E aretes aca Pi 3 66 TRAN SOON COMPASS 6440054446 5445550945 AA RA AAA AAA 3 67 Duplexing models with duplex support only 3 67 o A ones ends geet 3 69 Pia yas haa a ee ee ee oe Oe eS bd oh ode eee 3 69 Ea bone 5 caw ek be oo eas hese bean eee eh ee Se eo eR RES eee eee eee 3 71 Whal DRODD COI a rs E ee ee en eee ee 3 71 We E E 3 71 How is color specified in a document to be prmted ooo 3 71 How does the printer know what color to print o ooooococonoono nooo ooo o 3 71 Should use PostScript or PCL emulation What settings produce the best color 3 71 Why doesn t the printed color match the color see on the computer screen 3 71 The printed page appears tinted Can adjust the color ooooooooomo ooo 3 71 My color transparencies seem dark when they are projected Is there anything can do to improve the A 3
190. inter frame See Toner cartridge contacts on page 4 59 to view the proper mounting and for removal procedures Are the spring s defective Print quality vertical banding Replace the developer cartridge 2 56 Service Manual 7525 XXX Printhead service check This service check includes the following errors Turn the printer off and remove the rear shield Replace the printhead See Go to step 2 See Rear shield removal on page 4 7 Printhead removal on Check the cable at JMIRR1 for proper page 4 56 connection to the controller board the printhead cable for pinch points and the cable or connector for any other damage Is the cable damaged Turn the printer on and then wait until the Replace the controllerboard Replace the printhead See printer posts an error Using a voltmeter check See Controller board Printhead removal on the following values at JMIRR1 removal on page 4 18 page 4 56 JMIRR1 Are the values approximately correct Diagnostic information 2 57 7525 XXX Toner meter cycle TMC card Replace the toner cartridge Replace the toner meter cycle TMC card See Toner meter cycle TMC card removal on page 4 61 1 Enter Diagnostics menu turn off the printer press and hold a and Select turn on the printer and release the buttons when the installed memory and processor speed displays Select Base Sensor Test and press Select
191. ioning Problem resolved Go to step 5 phone jack Did this fix the problem 5 Is the phone line being used by the MFP an Goto step 8 Go to step 6 analog line Is the line being used a VOIP line Go to step 7 Go to step 8 Have the system administrator verify that Go to step 8 Stop here The issue is the VOIP server is configured to receive VOIP related The VOIP faxes provider needs to change Is the server properly configured the server configuration Is the MFP on a PABX Go to step 9 Go to step 10 Enable Behind a PABX under fax settings Problem fixed Disable Behind a PABX in the Administration menu and go to step10 Did this fix the issue 0 Is a dial prefix needed to get an outside Go to step 11 Go to step 12 line Try sending a fax using a dial prefix Problem fixed Go to step 12 Did the fax transmit Is the fax failing to send to one specific Go to step 13 Go to step 14 destination Check the device that cannot receive a fax Go to step 14 Stop here The issue is with Can it send a fax the other device press 411 to enter the Fax SE Menu Problem resolved Go to step 15 12 13 14 Select Print Logs Print the T30 transmission log Check the error being reported with the fax error code table See Fax error log codes on page 2 27 Perform the suggested resolution for the error Did this fix the problem 2 2 Service Manual 7525 XXX Adjust the
192. is complete When the firmware update is completed the printer will automatically reboot and return to a Ready state 3 56 Service Manual 7525 XXX Theory of operation Print engine theory Electrophotographic Process EP Process The method that all laser and LED printers use to print is called the electrophotographic process These machines use differences in charge to manipulate and move toner from the toner cartridge to the printed page Even though the basic EP process is the same for every laser and LED printer the specifics for each printer are different We will discuss the X54x series print engine and its particular method of printing MFP electrophotographic process basics These MFPs are single laser MFPs that use four toner cartridges cyan yellow magenta and black to create text and images on media The MFP has four photoconductors called a photodeveloper cartridge or PC unit and an image transfer unit ITU Each color toner is painted to it s respective photoconductor at the same time The transfer belt passes under the four photoconductors and the four color image is produced and transferred to the media in one pass During the printing process the MFP follows the six basic EP Process steps to create its output to the page These six steps are Charge the photoconductor PC unit Expose the photoconductor PC unit with the laser Develop toner on the photoconductor PC unit First transfer to the ITU and
193. it N O AR E E IS aN 7 a og 1 WER e Tray 1 Duplex sensor Paper path Tray 1 sensor Paper pick motor drive asm Locations 5 3 7525 XXX Printer boards Controller Board JEAN JMOD2 1 JADF1 1 EJ mT a T i O OT rit 1 1 GE gi O O JLVPS1 JOPT1 1 oo ols JCCD1 JCARTB1 oooo oo 0000 oooo 00000 0 J 6 Q JHVPS1 JBOOT1 o O O EEN JFUSES1 O JTPS1 JSRSEL1 7 Ol AN 1 JTRAY1 JMIRR1 7 JWIN1 2 4 JINT1 JCTM1 ooo0oo0o0 Eee keee de oo0o0o00 JOPP1 0000000 O lt A A sol 000000 po00000000000000 0000000000000000 SE A E pes mr oo0000 0000000000000000 0000000000000000000000000000 E JSC1 ES j JNET1 JUSB1 A MANU AULA LANA LAN LAA LAA LANA ALA HUH 5 4 Service Manual Connectors Controller board Connector JUSB1 Port JUSBW1 JMIRR1 7525 XXX IAE A ICI ees CN en es e es EN mm IN mme ICON tock eave GND 5V 2 CART METER CIN e CART METER MIN pa CAR METER YIN CI ommen ooo Locations 5 5 7525 XXX Controller board fewer mine e emm ps eeu IC fom JMOD2 5 6 Service Manual 7525 XXX Controller board Locations 5 7 7525
194. itioned over the home sensor IN rr ADF cover open Closed ADF cover closed ere AA Scan 1st sensor Closed Paper isn t above this sensor eer oper Paper vang ta Ton e AD an the top edge passes nt soreo Scan 2nd sensor Closed Paper isn t above this sensor Open Paper is being fed from the ADF and the top edge passes over this sensor Diagnostic aids 3 25 7525 XXX ADF paper present sensor test This test should be used if the ADF fails to feed paper when a scan is performed To test this sensor perform the following steps 1 Inthe sensor test menu press 4 or to scroll to the ADF paper present test 2 press Select Starting Test displays ADF Paper Closed displays 3 press the ADF paper present sensor actuator A the top of the ADF unit ADF Paper Open should display if the sensor is working properly A 4 press Back 5 to exit the test and return to the Scanner sensor tests 3 26 Service Manual 7525 XXX FB Cover closing sensor test This test verifies the functionality of the FB cover closed sensor To test this sensor perform the following steps 1 In the sensor test menu press 4 or to scroll to the FB Cover closing sensor test 2 press Select A Starting Test displays FB Cover Closed displays 3 Lift the flatbed cover and depress the FB cover actuator A A 4 FB Cover Open should display if the sensor is working properly 5 press Back 5
195. its Each ID can contain a combination of the digits O through 9 and the letters A through F Note When the printer detects a Configuration ID that is not defined or invalid the following occurs e The default standard model Configuration ID is used instead e Configuration ID is the only function available in DIAGNOSTICS Diagnostic aids 3 19 7525 XXX e Unless the menu is in DIAGNOSTICS Check Config ID displays To set the configuration ID Select PRINTER SETUP from DIAGNOSTICS and press Select y 2 Select Configuration ID and press Select The current value for Configuration ID 1 appears with the left character or digit underlined 3 Enter the Configuration ID 1 4 Repeat the steps for entering the Configuration ID 2 and press Select y Change the left character or digit first To change a character or digit press lt to decrease or to increase the underlined value and press Select y To move to the next character or digit press lt or gt and press Select v When you press Select y on the last digit the value will be submitted If Invalid ID appears the entry is discarded and the previous Configuration ID 1 is displayed on the screen If the process is successful Submitting Selection appears on the display followed by the current value for Configuration ID 2 If the Configuration ID 2 is val
196. k and cable 8 Route the cable through the right hinge Note Make a note of the interlock sensor cable routing through the right hinge and front door 9 Remove screw D securing the restraining strap to the left side of the front door T aN d eeng ebben nh nl 2 at A oD ho D 10 Lower the front cover to align the flats on the hinges and remove the front cover Repair information 4 3 7525 XXX Front middle cover removal 1 Open the front cover 2 Remove the five screws A attaching the front middle cover to the lower front cover 3 Pull the front middle cover away from the front cover Left cover removal 1 Remove the media tray 2 Open the front cover 3 Position the printer with the left side hanging over the edge of the table 4 4 Service Manual 1525 XXX 4 Remove the three screws A on the rear side of the left cover Repair information 4 5 7525 XXX 5 Remove the screw B on the bottom of the cover B 6 With a hand on the bottom of the cover ease the cover over the off on switch and rotate the cover away from the printer Warning Be careful not to damage the rear tab at the upper rear side of cover Installation note When replacing the left cover flex the cover slightly to engage the tab near the power switch 4 6 Service Manual 1525 XXX Right cover removal 1 Remove the media tray 2 Lift and lock the flatbed assembly to the raised position 3 Op
197. laneous screws TAPTITE M3 L6 PANHD 4 Tray Bias 2 Fuser Latch 2 ITU Front Hold Down 1 Front Cover Latch Spring 2 M3 x 6 Pan Head 2 M3 x 6 Shoulder 1 M3 5 X 5 Flat Head Plastite 1 METAL ROLN M3 5 8L 2 PLAST ROLN 2 9 8L 2 PLAST ROLN 3 5 6L 4 Duplex reference edge Image transfer unit ITU assembly ACM Paper pick motor drive assembly Main drive gear assembly with motors Fuser assembly 110 V Fuser assembly 220 V Fuser assembly 100 V Narrow media flag 100V Maintenance Kit 115V Maintenance Kit 230V Maintenance Kit Parts catalog 7 11 7525 XXX Assembly 4 Electronics 1 7 12 Service Manual Assembly 4 Electronics 1 7525 XXX Part Units Units Description number option FRU 40X1524 40X1523 40X5319 40X5036 40X5404 40X5405 40X5426 40X5409 40X5413 40X0289 40X0278 40X0288 40X0271 40X0275 40X0274 40X0276 40X0287 40X0279 40X5496 40X0282 40X0270 40X0280 40X0281 40X0296 40X5485 40X4820 7 8 9 9 9 9 9 9 9 9 9 9 9 9 9 9 9 Controller board X544 X546 Controller board X543 Wireless antenna Wireless card assembly Toner meter cycle card assembly High voltage power supply Photo sensor one per package used for A Tray present B Duplex C Narrow Media D Exit bin Low voltage power supply universal power supply Fuser exit sensor Power cord 1 8M straight USA Canada Power cord 6 foot straight Europe and others Power cord
198. laser products are not considered to be hazardous The printer contains internally a Class lllb 3b laser that is nominally a 5 milliwatt gallium arsenide laser operating in the wavelength region of 770 795 nanometers The laser system and printer are designed so there is never any human access to laser radiation above a Class level during normal operation user maintenance or prescribed service condition Laser Der Drucker erf llt gem amtlicher Best tigung der USA die Anforderungen der Bestimmung DHHS Department of Health and Human Services 21 CFR Teil J fur Laserprodukte der Klasse 1 In anderen Landern gilt der Drucker als Laserprodukt der Klasse l der die Anforderungen der IEC International Electrotechnical Commission 60825 1 gem amtlicher Best tigung erf llt Laserprodukte der Klasse gelten als unsch dlich Im Inneren des Druckers befindet sich ein Laser der Klasse Illb 3b bei dem es sich um einen Galliumarsenlaser mit 5 Milliwatt handelt der Wellen der Lange 770 795 Nanometer ausstrahlt Das Lasersystem und der Drucker sind so konzipiert da im Normalbetrieb bei der Wartung durch den Benutzer oder bei ordnungsgem er Wartung durch den Kundendienst Laserbestrahlung die Klasse bersteigen w rde Menschen keinesfalls erreicht Avis relatif l utilisation de laser Pour les Etats Unis cette imprimante est certifi e conforme aux provisions DHHS 21 CFR alin a J concernant les produits laser de Classe
199. le and print from both option Problem resolved go to step 8 trays Did the pages print from both trays Print a menu settings page Go to step 9 If the 550 sheet option failed Are all the attached option trays listed on the 10 appear JOU SED first page of the menu settings pages If the 650 sheet tray failed to Note If two option trays are used appear go to step 10 the 650 sheet will appear as tray 2 and the 550 sheet tray will appear as tray 3 Remove the 650 sheet tray from the printer Go to step 11 Replace the 550 sheet tray attach the 550 sheet tray directly to the printer and print a page from the 550 sheet tray Did the page print With only the 650 sheet tray attached to the Go to step 11 Replace the 650 sheet tray printer print a page from the 650 sheet tray Did the page print Diagnostic information 2 61 7525 XXX Turn off the printer and remove the rear shield Consult your second level Replace the controller Rear shield removal on page 4 7 support board See Disconnect the cable at JOPT1 on the controller board Turn the printer on and measure the voltages below Are the voltages correct JOPT1 Voltage 2 Ground 3 Ground 5 24V Ground 5V Ground 10 Ground 2 62 Service Manual 7525 XXX Scanner Copy Fax service checks 840 xx service check POR the machine into configuration mode Go to step 2 Stop Problem resolved Go to the disable scanner menu item See
200. lear the message and continue printing The job may not print correctly e Program new firmware for the network interface e Turn the printer power off and then back on to reset the printer This message may appear when data is sent to the printer across a USB port but the port is disabled Note Once the error is displayed the first time reporting of further errors is suppressed until the printer is reset or menus are entered The following actions can be taken e press Select v to clear the message Any data received on the USB port is discarded e press Menus to access the Busy Waiting Menu The following functions may be available Turn the printer power off and then back on to reset the printer Reset Active Bin Check Supply Levels Make sure the USB Buffer menu item is not set to Disabled press Menus access the Administrative Menus select Network Ports USB Menu and USB Buffer Turn off and unplug the printer Remove the excess flash memory Plug in the printer and turn it on Turn off and unplug the printer Remove the additional trays Plug in the printer and turn it on Turn off and unplug the printer Remove the specified incompatible tray Plug in the printer and turn it on Try one or more of the following e Replace the waste toner bottle and then press Select y to clear the message and continue printing See Go to Waste
201. lower Max Speed value under Fax Send settings 80C Remote device failed to respond to the Select a lower Max Speed value CTC command under Fax Send settings Adjust Transmit Level 80D Received too many requests from Check line quality remote end to repeat the previous Adjust Transmit Level command sent Check if line conditions on remote end will facilitate a good connection 80E Functional limitation Remote fax No action needed Issue with the remote device does not support G3 receive device capability 811 Failed to detect a fax device at the e Verify MFD is answering to fax call and remote end not a voice call e Decrease value of Rings To Answer setting 812 No more data rates available in V34 e Adjust to a lower modulation scheme modulation scheme 813 Timeout occurred after waiting too long e Adjust Receive Threshold to receive a good frame 814 Tried too many times at selected speed e Adjust Transmit Level using V34 modulation scheme e Adjust to a lower modulation scheme 815 Fax transmission was interrupted due e Troubleshoot MFP if error persists See to power failure Modem fax card service check on page 2 71 818 Fax transmission failed due to Adjust Memory Use setting to allocate insufficient memory to store scanned more memory for send jobs image 819 Fax transmission failed due to Adjust Memory Use setting to allocate insufficient memory to store received more m
202. ls e 100 Vac at 47 to 63 hertz Hz nominal e 90to 110 V ac extreme High voltage models e 220 to 240 V ac at 50 to 60 hertz Hz nominal not available in all countries e 198 to 259 V ac extreme Notes Using a 220 V ac to 110 V ac power converter with a low voltage printer is not recommended Using an inverter to change DC to AC voltage 12 V to 120 V for example is not recommended All X54x MFP models will comply with the ENERGY STAR All models ship with Power Saver Mode On The default timeout to Power Saver 60 minutes 220V Power Saver can be adjusted to 1 240 minutes Power Saver mode cannot be disabled from the operator panel 1 6 Service Manual 7525 XXX Acoustics All acoustic measurements are made in accordance with ISO 7779 1999 and reported in conformance with ISO9296 1988 04 15 Operating mode 1 Meter average sound pressure at 4800 CQ Lexmark Lexmark Lexmark X543 X544 X546 dtn Printing simplex mono 46 dBA 46 dBA 47 dBA Printing simplex color 47 dBA 47 dBA 48 dBA Printing automatic 50 dBA 50 dBA 50 dBA duplex mono Printing automatic 50 dBA 51 dBA 51 dBA duplex color Scan ADF Mono 45 dBA Quiet Mode simplex 45 dBA 45 dBA 45 dBA mono Quiet Mode simplex 45 dBA 45 dBA 45 dBA duplex Environment specifications Wet bulb temperature operating 22 80 C 73 0 F maximum Web bulb temperature power off 26 70 C 80 10 F maximum Ambient operating environment 15
203. m 23 9 to 27 8 Ib must be printed with Paper Type set to Heavy Paper 8 Paper 105 to 176 g m 27 9 to 47 Ib must be printed with Paper Type set to Cardstock 1 12 Service Manual 7525 XXX Media guidelines Paper characteristics The following paper characteristics affect print quality and reliability Consider these characteristics when evaluating new paper stock Weight The printer can automatically feed paper weights from 60 to 176 g m 16 to 47 Ib bond grain long Paper lighter than 75 g m 20 Ib might not be stiff enough to feed properly causing jams For best performance use 80 g m 21 Ib bond grain long paper For paper smaller than 182 x 257 mm 7 2 x 10 1 in we recommend 90 g m or heavier paper Curl Curl is the tendency for paper to curl at its edges Excessive curl can cause paper feeding problems Curl can occur after the paper passes through the printer where it is exposed to high temperatures Storing paper unwrapped in hot humid cold or dry conditions even in the trays can contribute to paper curling prior to printing and can cause feeding problems Smoothness Paper smoothness directly affects print quality If paper is too rough toner cannot fuse to it properly If paper is too smooth it can cause paper feeding or print quality issues Always use paper between 100 and 300 Sheffield points however smoothness between 150 and 200 Sheffield points produces the best print quality Moisture content T
204. n Installation notes Whether you replace the left or right toner density sensors be sure to perform the TPS Setup Enter the 32 digit TPS value set at the factory and printed on the barcode on the toner density sensor 1 Enter the Diagnostics Menu a Turn off the printer b press and hold lt and yj dy C Turn on the printer d Release the buttons when the installed memory and processor speed displays 2 Select TPS SETUP from Diag Menu and press Select y 3 Select Right or Left and press Select y TPS Right 1 16 or TPS Left 1 16 appears above a blinking O in the left position 4 To enter a character or digit a press lt q to decrease or to increase the blinking value b Pause for several seconds without pressing any buttons The blinking value becomes solid If the value is incorrect use Back to go back and re enter the number C Continue until the last value is reached d When the last of the 16 values is entered and becomes solid TPS Right 17 32 or TPS Left 17 32 appears Repair information 4 63 7525 XXX e Continue entering and pausing 5 After the 32nd number is entered and becomes solid the number is automatically entered e If the number is incorrect Checksum does not match appears and the original screen appears to re enter the value e If the number is correct Saving changes to NVRAM appears Tray present
205. n the printer s operator panel Warning Do not turn the machine off until the update is complete When the firmware update is completed the printer will automatically reboot and return to a Ready state 11 After the printer reboots confirm the printer is in Ready or Invalid Engine Code mode If it is not in either mode refer to the note on page 3 46 3 48 Service Manual 7525 XXX 12 0pen the USBFlash utility This window will display Se USBFlach 2 0 SELECT PRINTER FROM LIST f l START BYTES SENT PL Copag 2001 2004 Lesmark Intemalional Inc 13 Click the Browse Files button The file browse dialog displays Look inc CD s54 firmware update el e EI rg Fee kurt fis E aner Pe IS updeng Type FLS File Date Modified 6 22 2009 10 04 AM Size 24 0 MB Filename f ullnet Open Files of type Flash Files P flac Be pill Cancel 14 In the file browse dialog browse to the updeng fls also known as 2 fls file The fullnet fls file is the engine firmware file This is the second file to be updated 15 Click Open The file browse dialog will close Diagnostic aids 3 49 7525 XXX 16 Select the printer needing the firmware update from the Select Printer From List dropdown menu e USBFlash 2 0 Beles ENTER FILENAME TO FLASH TO PRINTER SELECT PRINTER FROM LIST w START BYTES SENT i Copyusghtk 2001 2004 Lexmark International Inc 17 Click Start
206. n page 3 11 Tray 2 if installed Manual Feeder if installed MP Feeder if installed Prt Quality Pgs See Print quality test pages Prt Quality Pgs on page 3 11 HARDWARE TESTS Panel Test See Panel Test on page 3 13 DRAM Test See DRAM Test on page 3 13 DUPLEX TESTS if installed See Quick Test duplex on page 3 15 Left Margin See Left Margin duplex on page 3 15 Top Margin See Top Margin duplex on page 3 16 3 2 Service Manual 7525 XXX Diagnostics mode tests continued INPUT TRAY TESTS if Tray 2 is installed Feed Tests See Feed Tests on page 3 17 Sensor Tests BASE SENSOR TEST Front Door Input S1 Input S2 Fuser Exit Standard Bin C TMC Sensor M TMC Sensor Y TMC Sensor K TMC Sensor DEVICE TESTS See Device Tests on page 3 18 rens PRINTER SETUP Defaults See Defaults on page 3 19 See Sensor Test on page 3 17 See Base Sensor Test on page 3 18 Prt Color Page Count Prt Mono Page Cnt Perm Page Count See Page Counts on page 3 19 Serial Number See Serial Number on page 3 19 Engine Setting 1 through 4 Model Name See Model Name on page 3 19 Configuration ID See Configuration ID on page 3 19 ITU Barcode Enable Edge to Edge Copy See Enable Edge to Edge Copy on page 3 20 Reset Fuser Cnt EP SETUP EP Defaults See EP Defaults on page 3 21 Fuser Temp See Fuser Temp o
207. n page 3 21 DC Charge Adjust See DC Charge Adjust Deve Bias Adj Transfer Adj on page 3 21 Dev Bias Adj See DC Charge Adjust Deve Bias Adj Transfer Adj on page 3 21 Transfer Adjust See DC Charge Adjust Deve Bias Adj Transfer Adj on page 3 21 TPS SETUP Right See Right or Left TPS on page 3 22 Left Reset Color Cal Cal Ref Adj See Cal Ref Adj on page 3 22 REPORTS Main Settings Page See Main Settings Page on page 3 22 EVENT LOG Display Log See Display Log on page 3 23 Diagnostic aids 3 3 7525 XXX Diagnostics mode tests continued Print Log See Print Log on page 3 23 Clear Log See Clear Log on page 3 24 Development Menu Do not use For development use only ASIC Test See ASIC Test on page 3 25 Feed test See Feed Test on page 3 25 Sensor Test See Sensor Test on page 3 25 EXIT DIAGNOSTICS This selection exits Diagnostics mode and Resetting the Printer displays The printer performs a POR and returns to normal mode Registration Printer Print registration makes sure the black printing is properly aligned on the page This is one of the steps in aligning a new printhead See Alignment on page 3 7 It is also the first step in aligning the duplex registration See Quick Test duplex on page 3 15 To set print registration 1 Select REGISTRATION from the DIAGNOSTICS menu 2 Use 4 or to select Quick Test and pre
208. n page 4 18 959 25 Service Insufficient device space during Replace controller board See Controller System Board hardware programming board removal on page 4 18 959 26 Service Incremental counter reset exceeds Replace controller board See Controller System Board maximum value board removal on page 4 18 959 27 Service Increment count failed due to Replace controller board See Controller System Board maximum value limit board removal on page 4 18 959 28 Service Invalid SP memory configuration Replace controller board See Controller System Board board removal on page 4 18 960 xx Service RAM memory error RAM soldered on Replace controller board See Controller Memory Error the board is bad board removal on page 4 18 961 xx Service RAM memory error slot 1 RAM is bad Check RAM If RAM is ok replace the Memory Failure controller See Controller board removal on page 4 18 962 xx Service RAM memory error slot 2 RAM is bad Check RAM If RAM is ok replace the Memory Failure controller See Controller board removal on page 4 18 2 24 Service Manual 7525 XXX Service error messages 1XX 8XX and 9xx continued CN rem CN 964 xx Service Emulation Error 975 xx Service Standard Network or 975 xx Service Network Card x 976 xx Service Standard Network or 976 xx Service Network Card x 978 xx Service Standard Network or 978 xx Service Network Card x 979 xx Se
209. n the box through the selected color conversion table To print Color samples from the printer press Menu gt to open the Admin menus Select Settings and press Select y Select Quality and press Select y Select Color Samples and press Select y Select the Color Conversion table to print and press Select y A ae By examining Color Samples sets a user can identify the box whose color is the closest to the desired color The color combination labelled on the box can then be used for modifying the color of the object in a software program For more information see the software program Help topics Manual color correction may be necessary to utilize the selected color conversion table for the particular object Selecting which Color Samples set to use for a particular color matching problem depends on the Color Correction setting being used Auto Off or Manual the type of object being printed text graphics or images and how the color of the object is specified in the software program RGB or CMYK combinations When the printer Color Correction setting is set to Off the color is based on the print job information and no color conversion is implemented Note The Color Samples pages are not useful if the software program does not specify colors with RGB or CMYK combinations Additionally certain situations exist in which the software program or the comp
210. nction Printer Message handling Motor interface Millimeter Modified modified read Multipurpose feeder Modem ready Masked Read Only Memory Microswitch NAND usage NAND gate Nonvolatile Memory Nonvolatile Random Access Memory Operator correctable failure Oil coating roll Original Equipment Manufacturer Overhead projector Optical photo conductor Optical Sensor Photoconductor Portable Document Format Problem isolation charts Personal identification number Picture element Printer Job Language Power on reset Power on self test Personal Printer Data Stream Pages per minute Print Quality Enhancement Technology Peoples Republic of China Parallel Synchronous Communications Position Sensing Device Participating Standards Organization 7525 XXX General information 1 21 7525 XXX 1 22 Service Manual PWM RAM RFID RH RIP ROM ROS RPM SCC SDRAM SEF SIMM SOL SOS SRAM TAR TPS TTM TVOC UAT UPR USB V ac V de VOIP VOM VTB XPS Pulse Width Modulation Random access memory Radio frequency identification Relative humidity Raster image processor Read only memory Read only storage Revolutions Per Minute Scanner Control Card Synchronous Dynamic Random Access Memory Short edge feed Single Inline Memory Module Solenoid Start of scan Static random access memory Toner Add Roll Toner Patch Sensing Tandem Tray Module Total Volatile Organic Compound Universally Adjustable Tray U
211. ndations to prevent problems Parts catalog contains illustrations and part numbers for individual FRUs Appendix A contains service tips and information Appendix B contains representative print samples oe ee ON Conventions Note A note provides additional information Warning A warning identifies something that might damage the product hardware or software There are several types of caution statements CAUTION A caution identifies something that might cause a servicer harm CAUTION This type of caution indicates there is a danger from hazardous voltage in the area of the product where you are working Unplug the product before you begin or use caution if the product must receive power in order to perform the task CAUTION This type of caution indicates a hot surface Preface XXI 7525 XXX XXII Service Manual 7525 XXX 1 General information The Lexmark X54x series are color laser MFPs that combine print scan copy and fax functions The X54x series are the ideal MFPs for presentations business graphics line art and text They use laser diode electrophotographic technology to deliver remarkable quality print images and text The scan and copy functions work with A4 letter and legal ADF only size paper Photographic quality images are possible with scan function The FAX function delivers a wide range of functionality to the office user The MFPs can be used as shared network or desktop devices Th
212. new low voltage power supply with a voltage selector switch C be sure to set the switch to the correct setting for your voltage requirements before installing the low voltage power supply The switch can be set for either 115 V or 230 V Failure to do so will result in damage to the power supply Note Some LVPS FRUs are auto sensing and do not have the switch even though the opening may still be present in the shield Warning 4 44 Service Manual 1525 XXX Lower frame removal right and left The right and left lower frames are in the same FRU Left lower frame 1 Remove the media tray and remove the screw A in front A Remove the waste toner bottle See Waste toner bottle on page 4 67 Remove the imaging unit See Imaging unit IU removal on page 4 40 Remove the low voltage power supply See Low voltage power supply LVPS assembly on page 4 43 Place the printer on the right side Remove the tray 2 connector B by pinching the tabs together and lowering the connector into the printer of PR Repair information 4 45 7525 XXX 7 At the rear of the printer remove the two screws C from the AC receptacle and the ground screw D we D C 8 Remove the three screws E securing the left lower frame 9 Remove the LVPS See 4 46 Service Manual 1525 XXX 10 Remove the screw F on top of the frame 11 Swing the left lower frame away from the printer and
213. ngs for the 241 xx Paper Jam media lt x gt Pages Jammed e Fan the media or Check the condition of the pick tires 242 xx Paper Jam A single or multiple page media jam in See 24x paper jam on page 3 43 Check lt area gt the 650 sheet Duo Drawer tray 2 242 xx Paper Jam Multiple pages of media are jammed in See 24x paper jam on page 3 43 lt x gt Pages Jammed the 650 sheet Duo Drawer tray 2 243 xx Paper Jam A single or multiple page media jam in Open the door and remove all the jammed Check lt area gt the optional 550 sheet drawer tray 3 pages See 24x paper jam on page 3 43 or Multiple pages of media are jammed in 243 xx Paper Jam the optional 550 sheet drawer tray 3 lt x gt Pages Jammed Diagnostic information 2 13 7525 XXX Paper jam messages 2xx continued ree Omen om 250 xx Paper Jam A single page of media is jammed in Open tray 2 to access the jam area Check Manual the multipurpose feeder Remove the jammed page See 250 Feeder paper jam on page 3 43 250 xx Paper Jam Multiple pages of media are jammed in Open tray 2 to access the jam area lt x gt Pages Jammed the multipurpose feeder Remove all the jammed pages See 250 paper jam on page 3 43 271 22 Paper Jam Output bin 1 declared jam Check lt area gt or 271 22 Paper Jam lt x gt Pages Jammed 290 02 Scanner ADF The scanner ADF has failed to feed a Remove the sheet of pap
214. nism ACM service checks 2 33 B bezel cover removal 4 89 bin full flag removal 4 103 bin full sensor service check 2 34 bin full sensor removal 4 15 Button Test 3 13 C cable packet parts catalog 7 14 CACHE Test 3 14 CCD service check 2 65 clearances printer 1 5 color trapping 3 31 Config Menu description 3 1 configuration menu 3 31 ADF edge erase 3 34 Auto Color Adj 3 34 available tests 3 31 color trapping 3 31 Demo Mode 3 33 disable scanner 3 36 Energy Conserve 3 33 Event Log 3 32 Exit Config Menu 3 37 Factory Defaults 3 33 FB edge erase 3 35 font sharpening 3 37 format fax storage 3 34 min copy memory 3 34 Panel Menus 3 32 pel blurring 3 37 PPDS Emulation 3 32 Prt Quality Pages 3 31 prt quality pages 3 31 Reports Menu Settings Page 3 32 reports 3 32 menu settings page 3 32 scanner manual registration 3 35 USB scan to local 3 31 Controller board parts catalog 7 12 controller board removal 4 18 covers Index l 1 7525 XXX removals 4 4 D data streams 1 4 dead printer service check 2 35 defaults factory defaults 3 33 Demo Mode 3 33 developer unit removal 4 42 developer units description 4 57 diagnostics 2xx paper jam message table 2 13 paper jam messages 2 13 service error codes 2 15 user attendance message table 2 6 diagnostics menu Alignment Menu 3 7 available tests 3 2 Base Sensor Test 3 18 Base Sensor Tests C TMC Sensor 3 18 Fuser Exit 3 18 Input 3 18 K TMC Sensor 3 18 M TMC Sen
215. nks that are oxidation set or oil based generally meet these requirements latex inks might not When in doubt contact the paper supplier Preprinted papers such as letterhead must be able to withstand temperatures up to 200 C 392 F without melting or releasing hazardous emissions Storing paper Use these paper storage guidelines to help avoid jams and uneven print quality e For best results store paper where the temperature is 21 C 70 F and the relative humidity is 40 Most label manufacturers recommend printing in a temperature range of 18 to 24 C 65 to 75 F with relative humidity between 40 and 60 e Store paper in cartons when possible on a pallet or shelf rather than on the floor e Store individual packages on a flat surface e Do not store anything on top of individual paper packages Using recycled paper and other office papers As an environmentally conscious company Lexmark supports the use of recycled office paper produced specifically for use in laser electrophotographic printers In 1998 Lexmark presented to the US government a study demonstrating that recycled paper produced by major mills in the US fed as well as non recycled paper However no blanket statement can be made that all recycled paper will feed well Lexmark consistently tests its printers with recycled paper 20 100 post consumer waste and a variety of test paper from around the world using chamber tests for different temperature and humidity
216. nsitive parts use the following instructions in addition to all the usual precautions such as turning off power before removing logic boards Keep the ESD sensitive part in its original shipping container a special ESD bag until you are ready to install the part into the machine Make the least possible movements with your body to prevent an increase of static electricity from clothing fibers carpets and furniture Put the ESD wrist strap on your wrist Connect the wrist band to the system ground point This discharges any static electricity in your body to the machine Hold the ESD sensitive part by its edge connector shroud cover do not touch its Pin If you are removing a pluggable module use the correct tool Do not place the ESD sensitive part on the machine cover or on a metal table if you need to put down the ESD sensitive part for any reason first put it into its special bag Machine covers and metal tables are electrical grounds They increase the risk of damage because they make a discharge path from your body through the ESD sensitive part Large metal objects can be discharge paths without being grounded Prevent ESD sensitive parts from being accidentally touched by other personnel Install machine covers when you are not working on the machine and do not put unprotected ESD sensitive parts on a table If possible keep all ESD sensitive parts in a grounded metal cabinet case Be extra careful in working with ESD
217. nter Setup from Diag Menu and press Select v 2 Select Reset Fuser Cnt and press Select A 3 Select Reset and press Select A Resetting Fuser Count Value appears To cancel a reset press Back el EP Setup EP Defaults This setting is used to restore each printer setting listed in EP SETUP to its factory default value To restore EP Defaults 1 Select EP Setup from Diag Menu and press Select y 2 Select EP Defaults and press Select v 3 Select Restore to reset the values to the factory settings and select Do Not Restore to exit without changing the settings To cancel and return to the menus press Back Fuser Temp This adjustment can be used to help solve some customer problems with paper curl on low grade papers and problems with letterheads on some types of media The fuser temperature can be adjusted to Low Normal High The default is Normal To restore EP Defaults 1 Select EP Setup from Diag Menu and press Select y 2 Select Fuser Temp and press Select A 3 Select Normal High or Low The default is Normal DC Charge Adjust Deve Bias Adj Transfer Adj Each of these three settings enables you to adjust the high voltage levels controlling the electro photographic process You will use these settings to compensate for unusual operating circumstances such as high humidity The
218. nter memory RAM are deleted e All menu settings return to the factory default setting except The Display Language setting in the Setup Menu All settings in the Parallel Menu Serial Menu Network Menu Infrared Menu Local Talk Menu and USB Menu To print current menu settings It is recommended that you first print the customers current settings by printing a copy of the Menu Settings pages Customer settings are available from the Ready prompt Diagnostics Menu settings are available in the Diagnostics Menu and Config Menu settings are available in the Config Menu Turn off the printer or select Exit Config Menu At the Ready prompt select Menus and press Select y Select Reports and press Select y Select Menu Settings Page and press Select y Enter the Diagnostic Menu select Reports Menu Settings Page and press Select v See Menu Settings Page on page 3 32 Turn off the printer or select Exit Diags Enter Configuration Menu select Reports Menu Settings Page and press Select v See Menu Settings Page on page 3 32 A a ND To reset factory defaults h Select Reports from the Config Menu and press Select y 2 Select Factory Defaults and press Select y 3 Select Restore Base for locally attached printers or Restore STD NET if you have integrated network support Submitting
219. nthead service check 2 32 scanner fax copy 2 63 840xx error check 2 63 Index l 5 7525 XXX ADF cover open 2 67 ADF duplex service check 2 70 ADF feed errors 2 69 ADF paper am 2 68 black page or blank page 2 65 CCD service check 2 65 escalating a fax issue to second level support 2 76 fax reception service check 2 74 fax transmission service check 2 72 flatoed home position 2 66 flatbed motor 2 65 modem service check 2 71 USB 2 45 service error codes 2 15 simplex ADF rear cover removal 4 84 simplex ADFunit removal 4 84 specifications acoustics 1 7 clearances 1 5 connectivity network 1 3 data streams 1 4 digital imaging 1 16 dimensions 1 5 duplex capability 1 9 environmental 1 7 fax 1 18 memory 1 2 operating modes 1 4 print quality 1 3 scan and copy 1 17 specifications power and electrical 1 6 symptom tables 2 3 symptoms print quality 2 5 printer 2 3 scan fax and copy 2 4 T test pages print quality test pages 3 11 3 31 Quick Test duplex 3 15 theory color theory 3 71 theory of operations color theory 3 71 toner cartridge contacts removals 4 59 toner density sensor L amp R removal 4 63 Toner density sensors parts catalog 7 14 Toner meter card assembly parts catalog 7 12 toner meter cycle TMC card Base Sensor Tests 3 18 toner meter cycle card removal 4 61 tools required 1 19 l 6 Service Manual tray x parts catalog 7 16 U USB connector removal 4 67 USB scan to local 3 31 W
220. odes 2xx paper jams 2 13 fax 2 21 fax error log 2 27 Error codes and messages 2 6 ESD sensitive parts 4 1 event log configuration menu 3 32 Exit config menu 3 37 F Factory Defaults 3 33 Lexmark confidential until announce factory defaults 3 33 fax card removal 4 102 fax interface cable removal 4 102 fax reception service check 2 74 fax specifications 1 18 miscellaneous 1 18 phone network connectivity 1 18 scan resolutions 1 18 fax transmission service check 2 72 FB cover closing sensor test 3 27 FB edge erase 3 35 Flash Test 3 18 flatbed removal 4 72 flatbed home position service check 2 66 Flatbed home sensor test 3 27 flatbed motor service check 2 65 flatbed pivot link removal 4 81 flatbed unit parts catalog 7 6 font cards parts catalog 7 18 Font sharpening 3 37 format fax storage 3 34 frame lower left removal 4 45 right removal 4 45 4 48 front door sensor service check 2 37 fuser removal 4 25 fuser assembly parts catalog 7 10 service check 2 39 fuser drive motor parts catalog 7 10 fuser drive motor assembly removal 4 28 fuser exit sensor removal 4 29 service check 2 38 fuser exit sensor service check 2 38 H High voltage power supply parts catalog 7 12 removal 4 31 image transfer unit removal 4 35 image transfer unit ITU ITU Barcode 3 20 imaging unit IU description 4 57 removal 4 40 4 57 Imaging unit contact parts catalog 7 14 7525 XXX ITU parts catalog 7 10 J jam loca
221. oftware program Help topics How does the printer know what color to print When a user prints a document information describing the type and color of each object is sent to the printer The color information is passed through color conversion tables that translate the color into the appropriate amounts of cyan magenta yellow and black toner needed to produce the desired color The object information determines the application of color conversion tables For example it is possible to apply one type of color conversion table to text while applying a different color conversion table to photographic images Should I use PostScript or PCL emulation What settings produce the best color The PostScript driver is strongly recommended for best color quality The default settings in the PostScript driver provide the preferred color quality for the majority of printouts Why doesn t the printed color match the color see on the computer screen The color conversion tables used in Auto Color Correction mode generally approximate the colors of a standard computer monitor However because of technology differences that exist between printers and monitors there are many colors that can also be affected by monitor variations and lighting conditions For recommendations on how the printer color sample pages may be useful in solving certain color matching problems see How can match a particular color such as a corporate logo on page 3 73 Th
222. oll The paper goes back into the ADF unit for a third time The paper passes through the paper path but no imaging occurs This pass is to turn the paper over to the original side up On the third pass of the media trailing edge over the reverse point the solenoid is not actuated and the paper passes out of the ADF 3 70 Service Manual 7525 XXX Color theory What is RGB color Red green and blue light can be added together in various amounts to produce a large range of colors observed in nature For example red and green can be combined to create yellow Televisions and computer monitors create colors in this manner RGB color is a method of describing colors by indicating the amount of red green or blue needed to produce a certain color What is CMYK color Cyan magenta yellow and black inks or toners can be printed in various amounts to produce a large range of colors observed in nature For example cyan and yellow can be combined to create green Printing presses inkjet printers and color laser printers create colors in this manner CMYK color is a method of describing colors by indicating the amount of cyan magenta yellow and black needed to reproduce a particular color How is color specified in a document to be printed Software programs typically specify document color using RGB or CMYK color combinations Additionally they allow users to modify the color of each object in a document For more information see the s
223. oltage should measure page 4 72 board removal on 24V AC Is voltage present page 4 18 Diagnostic information 2 65 7525 XXX Flatbed home position service check POR the MFP Does the CCD move and Problem solved Go to step 2 return to the home position Perform the home position sensor test Go Go to step 3 Go to step 5 to Scanner Tests on page 3 25 Is the sensor working properly Check JFBM1 on the controller for proper Go to step 4 Properly connect the cable connection Is it connected properly Check pin 1 in JFBM1 for voltage The Go to step 5 Replace the controller voltage is only present when a flatbed copy board Go to Controller job is running The voltage should measure board removal on 24V AC Is voltage present page 4 18 Ensure that the home position cable JHS1 Go to step 6 Properly connect the cable is connected Is the cable connected Check pin 1 in JHS1 for voltage The voltage Replace the flatbed unit Replace the controller should measure 5V DC Pin 2 should be See Flatbed removal on board Go to Controller GND Is voltage present and is it correct page 4 72 board removal on page 4 18 2 66 Service Manual 7525 XXX ADF cover open service check Is the ADF cover properly closed Go to step 3 Go to step 2 2 Close the ADF cover Issue resolved Go to step 3 Does the problem go away Perform the ADF cover open sensor test Go Go to step 4 Go
224. on the controller board CR 4 Remove the fax card Fax interface cable 1 Carefully detach the fax interface cable from the fax card 2 Carefully detach the fax interface cable from the connector JMOD2 on the controller board Note Save any toroids for use on the new cable 4 102 Service Manual 1525 XXX Output bin tray 1 Grasp and lift the rear output bin tray away from the MFP Bin full flag removal 1 Lift the scanner assembly and lock it into the up position 2 Gently disconnect the three snaps A from the rear shaft of redrive unit 3 Remove the bin full flag Repair information 4 103 7525 XXX 4 104 Service Manual 7525 XXX 5 Locations Exterior views Front Front view Part name Operator panel ADF input tray Output bin AIO release Right imaging unit cover right cover Primary paper tray Manual feeder Multipurpose feeder Locations 5 1 7525 XXX Rear Rear view 5 2 Service Manual Interior view Fuser exit sensor 7525 XXX Fuser exit rolls Duplex entry Printhead Toner cartridges Paper redrive rollers Y C M K HA bin Controller Front cover poar duplex TOINK SS Fessc o Developers Sie est ul TE a j Vi I Yi J S MOF O EI NO x Lekt WK HEI ES Lo LO mt ES ES JE or GEN un
225. onnector JUSBW1 of the controller board Pin Go to Wireless network board Go to Controller 1 and 4 are GND card on page 4 71 board removal on page 4 18 Replace the antenna Problem resolved Go to step 22 Did this fix the problem Are the voltages and GNDs correct Diagnostic information 2 47 7525 XXX Print quality service check 2 48 Note This symptom may require replacement of one or more CRUs Customer Replaceable Units designated as supplies or maintenance items which are the responsibility of the customer With the customer s permission you may need to install a developer toner cartridge or photo conductor unit Service tip Before troubleshooting any print quality problems do the following 1 Print a menu settings page and check the life status of all supplies Any supplies that are low should be replaced To print a menu settings page a b C press Menu on the operator panel Select Reports from the Admin Menu and press Select y Select Menu Settings and press Select y Note Be sure and keep the original menu page to restore the customer s custom settings if needed 2 On the menu page make sure the following is set to the default level Color Correction Set to Auto Print Resolution Set to 1200 dpi print quality problems should be checked at different resolution settings Toner Darkness Set to 4 default Color Saver Se
226. ooooooooocorn 2 65 Ser N 2 65 Flatbed motor service check sccecivievs tease ease be ee bane AAA ARA 2 65 Flatbed home position service check 000 cece eee es 2 66 ADF cover open Service check 2 00 cece es 2 67 ADF Streak service Check NEE ORR TARA A ee CN 2 67 ADF paper jam service check 2 cee es 2 68 ADF Teed errors service CHECK iii ccs cand nce che cee eee hd Re ee a ee ee 2 69 ADF Duplex service check cocos chk eb k eee RE ERE EEE ERE EEK ee OER REE RO 2 70 Modem fax card service Check 0 cee es 2 71 Fax transmission service CHECK ax sau KN o exe ad ew NC KS NIR RENE KLS eee eee NN 2 72 Fax reception service CNECK 6 666668666406 64 AE AE AE AE AE TRG be STEER 2 74 Escalating a fax issue to second level Support 000 c eee es 2 76 User operator panel menus and messages 0 0ccccocccoc 2 77 Understanding the operator panel oococococoo es 2 77 Operator panel buttons 0cccccccc eee 2 77 EA A E RRA AR AAA EAS AAN dE AR AS 2 78 MOON rave IEEE ARRE AA AAA ENDS EAS AAA 2 79 Diagnostic e EE 3 1 Menu key COMIDA ONG marcara ra Seeker eee 3 1 Diagnostics Menu Diag Menu 2 0 cee 3 2 Diagnostics EE TEEN 3 2 AROMAS IOSIS siii arta ip AER A i An ARRE RARA 3 2 HOUSE EREKE Aer A hes 3 4 la EE E TOSET A O ESO E Gea A E a ee E TE 3 4 ENER A EE E E EO E E A N E E E E ee eres oes 3 5 2 A nn enn A E AEEA E TREE 3 6 Py a ee ee ee ee AA ee 3 7 eC Oe aras Goa es WE RE ds Soe ee
227. op panel 7525 3331 333 Lexmark X544dn Duplex scan printDBCS op panel 7525 386 386 Lexmark X544dw Duplex scan print fax wireless 7525 382 382 Lexmark X544dw Duplex scan print wireless 7525 387 387 Lexmark X544dw Duplex scan print fax wireless DBCS op panel 7525 383 383 Lexmark X544dw Duplex scan print wireless DBCS op panel 7525 392 Lexmark X546dtn Duplex scan print Parts catalog 7 1 7525 XXX 7525 393 393 Lexmark X546dtn Duplex scan print DBCS op panel 7525 396 396 Lexmark X546dtn Duplex scan print Fax 7525 397 397 Lexmark X546dtn Duplex scan print DBCS op panel Fax 1 A dtn version of this model is available This version includes the 650 sheet tray 7 2 Service Manual 7525 XXX Parts catalog 7 3 7525 XXX Assembly 1 Covers 7 4 Service Manual Assembly 1 Covers 7525 XXX Part Units Units Description number mach FRU P 40X5484 40X5489 40X5482 40X5537 40X5534 40X5486 40X5419 40X5168 40X5538 40X5490 40X5417 40X5434 40X5435 40X5441 40X2253 Tray Output Bin Cover AIO Back Cable Assembly Top Cover Link AIO Cover AIO Toner Cover Right AIO Tray Asm 250 sheet Pick tires Cover Front Cover Front Middle Cover Left Drawer 650 sheet Tray Asm 650 sheet Cover Legal extender Front flatbed hinge Parts catalog 7 5 7525 XxXX Assembly 2 Scanner 7 6 Service Manual Assembly 2 Scanner 7525 XXX Part Units Units Description n
228. option and you are having problems with media picking replace these tires also Always replace the paper pick tires in pairs The tires come in a package of two Remove the media tray Place the printer so the front edge extends over the edge of the table or desk Lower the autocompensator mechanism Remove the rubber tires A from the pick roll assembly B Repeat for the other tire Warning Be very careful not to unlatch the right side hub or the clutch may be damaged If the ball bearings come out of the clutch it will have to be reassembled on a flat surface ma en B A Installation notes Install the new rubber tires with the surface texture turning in the direction as shown NE PAPER Note Feel each rubber surface to verify it turns properly in the direction shown Repair information 4 55 7525 XXX Printhead removal 1 Remove the scanner assembly See Flatbed removal on page 4 72 2 Remove the top cover See Top cover assembly removal on page 4 9 3 Disconnect the cables 4 Remove the toroid A from the ribbon cable a P 8 i Rae aa D E i sa olja pal aff BRTH W ulfe n L a ER i A D ik 1 T e ajaj ii j a i T aim 5 Remove the three screws B Teone er ee ef See eg 6 Remove the printhead Installation note When the printhead is replaced perform the registration black planes and
229. or on page 2 31 timeout Staging Motor 150 xx Service Black ITU cartridge Motor 150 01 Service Black ITU cartridge Motor 150 02 Service Black ITU cartridge Motor 150 03 Service Black ITU cartridge Motor 150 04 Service Black ITU cartridge Motor 150 05 Service Black ITU cartridge Motor 150 06 Service Black ITU cartridge Motor 150 07 Service Black ITU cartridge Motor 2 18 Service Manual Black ITU Cartridge Motor Failed to achieve lock for motor within allotted time Timeout waiting for SAP BLDC motor to reach valid FG speed Timeout waiting for MP_NUM_INITIAL_SAP_HALLS Timeout waiting for SAP BLDC motor FG Lost lock for motor Excessive SAP BLDC PWM Motor stalled in time based commutation Go to Main drive gear assembly EP drive service check on page 2 41 Go to Main drive gear assembly EP drive service check on page 2 41 Go to Main drive gear assembly EP drive service check on page 2 41 Go to Main drive gear assembly EP drive service check on page 2 41 Go to Main drive gear assembly EP drive service check on page 2 41 Go to Main drive gear assembly EP drive service check on page 2 41 Go to Main drive gear assembly EP drive service check on page 2 41 Go to Main drive gear assembly EP drive service check on page 2 41 7525 XXX Service error messages 1XX 8XX and 9xx continued 152 xx
230. or panel if necessary Unexpected page breaks occur e Increase the Print Timeout value on the operator panel Settings gt General Settings gt Timeouts gt Print Timeout Multipurpose feeder has constant misfeeds Remove and flex the paper in the tray Reload the paper and or jams try printing Turn the paper over inside the tray Make sure the feeder is properly installed Make sure the paper is loaded correctly in the tray Make sure the paper is not damaged Make sure the paper meets specifications See Media input type specifications on page 1 11 Make sure the paper guides are positioned correctly for the paper size loaded in the tray Page that jammed does not reprint after Jam Recovery may be set to Off Change the setting to Auto or you clear the jam On on the operator panel Settings gt General settings gt Print Recovery gt Jam Recovery Printing speed reduced for more than 10 Check the narrow media sensor cable is correctly connected at pages May happen after a service call the sensor and the cable is correctly connected to JBIN1 on the controller board Pages print blank after replacing the When replacing the controller board verify the cable from the controller board high voltage power supply is seated properly The cable may have come loose from the HVPS Warning A blank page that should have toner on it could be an indication that toner is applied to the ITU belt but not transferred The
231. ove the rear shield See Rear shield removal on page 4 7 Disconnect the ADF cable A from the relay card in the ADF unit Se ee B A 6 Disconnect the ground B from the ADF 7 Disconnect the ADF cable from connector JADF1 on the controller board 8 Disconnect the ground C from the print engine Repair information 4 85 7525 XXX 9 With your right hand pull the relay card end of the ADF cable up and away from the ADF while using your left hand to guide the ADF cable up through the card cage opening Note Be careful to avoid contact with the CCD ribbon cable 10 Feed the ADF cable up between the left flatbed cover and flat bed unit and gently pull the cable up 4 86 Service Manual 7525 XXX ADF separator pad 1 Remove the ADF separator roll See ADF separator roll assembly on page 4 88 2 Pinch the two tabs on each side of the pad inward 3 Tilt the pad up and lift it out of the ADF assembly F Repair information 4 87 7525 XXX ADF separator roll assembly 1 Lift the locking lever A A 2 Slightly lift the separator roll assembly and pull it out of the mount B on the opposite side 4 88 Service Manual 7525 XXX Bezel cover 1 Remove the op panel bezel See Op panel bezel removal on page 4 100 2 Remove the two screws A securing the bezel cover to the top of the op panel mounting frame 3 Remove the AIO link See AlO link on page 4
232. pletion of the POR the following screen is displayed CACHE Test x100 PA F H HHHHH P represents the number of times the CACHE Test has passed finished successfully Initially 000000 is displayed The maximum pass count is 999 999 F represents the number of times the CACHE Test has failed finished with errors Initially 000000 is displayed The maximum fall count is 999 999 3 To stop the test turn the printer off 3 14 Service Manual 7525 XXX Duplex Tests Quick Test duplex This test prints a duplex version of the Quick Test that can be used to verify the correct placement of the top margin on the back side of a duplex page och Fer Device information RAR SETTINGS Note Before you set the duplex top margin be sure to set the registration See Registration on page 3 4 The paper you choose to print the page on should be either Letter or A4 To run the Quick Test duplex 1 Select DUPLEX TESTS from Diag Menu and press Select 7 2 Select Quick Test and press Select y 3 Select Single or Continuous and press Select y e The single Duplex Quick test prints the Quick Test on front and back e The printer attempts to print the Quick Test Page from the default paper source e Check the Quick Test Page for th
233. power supply HVPS with no spring removal Note This removal requires a magnetized long shank Phillips screwdriver at least 8 in or 200 mm long Remove the top cover assembly See Top cover assembly removal on page 4 9 Remove the rear shield See Rear shield removal on page 4 7 Remove controller board See Controller board removal on page 4 18 Disconnect the high voltage power supply HVPS cable at the HVPS oe T e 5 Remove the screw A The screw is accessible from the top of the printer and requires a long shank magnetized Phillips screwdriver It is the only screw without a flanged head ITU Side frame Main drive with motors 4 32 Service Manual 1525 XXX 6 Remove the screw B securing the HVPS 7 Carefully slide the HVPS out Installation notes CAUTION 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 Connect the high voltage power supply HVPS cable to the high voltage power supply before sliding the board into the printer Pull the HVPS cable through the access hole and plug into the controller board Be careful not to dislodge the cable from the HVPS Loosely replace screw C replace and tighten screw B and then tighten screw C High voltage power supply HVPS with spring 1 Remove the rear shield See Rear
234. printer uses the value of these settings together with other settings to calculate printing soeed and media selection Diagnostic aids 3 21 7525 XXX TPS Setup Right or Left TPS The value of the TPS sensor is set at manufacturing If a sensor is replaced enter the 32 digit hexadecimal TPS value from the barcode next to the sensor To enter the value 1 Select TPS SETUP from Diag Menu and press Select v 2 Select Right or Left and press Select y TPS Right 1 16 or TPS Left 1 16 appears above a blinking O in the left position 3 To enter a character or digit a b C d e press to decrease or gt to increase the blinking value Pause for several seconds without pressing any buttons The blinking value becomes solid If the value is incorrect use Back to go back and re enter the number Continue until the last value is reached When the last of the 16 values is entered and becomes solid TPS Right 17 32 or TPS Left 17 32 appears Continue entering and pausing 4 After the 32nd number is entered and becomes solid the number is automatically entered If the number is incorrect Checksum does not match appears and the original screen appears to re enter the value If the number is correct Saving changes to NVRAM appears Reset Color Cal This setting allows the device to adjust the alignment of the color planes using pre programmed default values
235. q or p to scroll to the Quality menu press y press q or p to scroll to the Color Adjust menu item press y Calibrating displays Ready will display when the calibration procedures complete press le twice to exit the Administration menu Oe a eg ADF Edge Erase This menu item sets the size in millimeters of the no print area around an ADF scan job All copy jobs have a minimum of a two millimeter border Copy jobs will use the setting or two millimeters whichever is larger To adjust the ADF edge erase setting perform the following steps 1 In the Configuration menu select the ADF Edge Erase menu item 2 Press qor p to increase or decrease the setting s value 3 When the desired value is displayed press y 3 34 Service Manual 7525 XXX FB Edge Erase This menu item sets the size in millimeters of the no print are around a flatbed scan job Copy jobs will use the setting or two millimeters whichever is larger To adjust the flatbed edge erase setting perform the following steps 1 In the Configuration menu select the FB Edge Erase menu item 2 Usethe or p to increase or decrease the settings value 3 When the desired value is displayed press y Scanner Manual Registration This item is used to manually register the flatbed and ADF on the MFP s scanner unit Registration should be performed whenever the ADF unit flat
236. r Remove the narrow media sensor flag Remove the cable from the retainer Note Be sure to note the routing for re installation Disconnect the cable A from the narrow media sensor E e 4 16 Service Manual 1525 XXX 5 If there is a sensor retaining plate B remove the plate B 6 Pinch the retainers on the rear of the sensor and gently remove the sensor from the bracket by hand Installation note 1 Clean the contact surface where you removed the sensor retaining plate or where you need to install the new one Guide the latches that hold the sensor in the bracket into place Remove the backing from the new plate and place the plate on the surface between the sensor mounting legs Squeeze the latches together until they extend onto the surface of the plate Reconnect the cable and reroute the cable through the retainer wae Ph Repair information 4 17 7525 XXX Controller board removal Warning Observe all ESD precautions while handling electrostatic discharge sensitive parts See Handling ESD sensitive parts on page 4 1 Warning When replacing any one of the following components e Operator panel assembly e Controller board Replace only one component at a time Replace the required component and perform a POR before replacing a second component listed above If this procedure is not followed the printer will be rendered inoperable Never replace both of the components listed abo
237. r Log from the Event Log menu and press Select v 2 Select YES to clear the Event Log or NO to exit the Clear Log menu If YES is selected Deleting EVENT LOG displays on the screen press Back el to return to EVENT LOG 3 24 Service Manual 7525 XXX Scanner Tests ASIC Test This test initiates a scan of the scanner ASIC s memory While this test is executing ASIC Test Running is displayed When the test is complete ASIC Test Passed is displayed if the ASIC memory is ok ASIC Test Failed is displayed if the test fails press the Back or Stop buttons to clear the display message Feed Test This test executes a continuous feed test from ADF or flatbed Note Neither test produces printed output or increments any MPS counters After selecting this test lt DISPLAY gt is displayed Running Flatbed xxxx ADF xxxx is displayed while the feed test is executing To stop the test press Back or Stop H an error occurs during the test Feed Test failed Flatbed xxxx ADF xxxx is displayed press Return or Stop to clear the message Sensor Test A series of sensor tests are available to test the scanner s ADF and flatbed sensor functionality The following table lists the available tests Scanner sensor tests Sensor ogge sare anades ADF paper present Closed Paper not present in the ADF Tee FB cover closing Closed Flatbed cover in process of closing Jee a O Home sensor Closed Scanner carriage not pos
238. r and remove the print Check lt area gt between the input and exit sensors cartridge to access the jam area Remove the jammed page See 201 paper jam on page 3 41 201 xx Paper Jam Multiple pages of media are jammed Open the front door and remove the print lt x gt Pages Jammed between the input and exit sensors cartridge to access the jam area Remove all the jammed pages See 201 paper jam on page 3 41 202 xx Paper Jam A single page of media is jammed at Open the printer rear door to access the Check lt area gt the exit sensors jam area Remove the jammed page See 202 paper jam on page 3 42 202 xx Paper Jam Multiple pages of media are jammed at Open the printer rear door to access the lt x gt Pages Jammed the exit sensor jam area Remove all the jammed pages See 202 paper jam on page 3 42 230 xx Paper Jam A single page of media is jammed at Remove the jammed page See 230 Check lt area gt the inner door paper jam on page 3 43 230 xx Paper Jam Multiple pages of media are jammed at Remove all the jammed pages See 230 lt x gt Pages Jammed the inner door paper jam on page 3 43 235 Paper Jam Paper jam in the duplex area Remove all pages See Go to 235 paper Check Duplex jam on page 3 43 241 xx Paper Jam Paper jam in the primary tray e Open the door and remove all the Check lt area gt jammed pages See 24x paper jam on page 3 43 e Verify the proper tray setti
239. r than remove the color from beneath the black content the printer leaves the color around the edge of the text or line The hole in the colored region is reduced in size which prevents the characteristic white gap that is caused by incorrect registration Values include Off and numbers 1 5 the default is 2 Values 1 through 5 indicate the amount of color remaining beneath the black content The default is each setting increments by 1 600 of an inch The more inaccurate the registration setting the higher the setting needs to be adjusted Selecting Off disables color trapping Reports Menu Settings Page Print the menu settings pages to list the customer settings and to verify printer options are installed correctly It is helpful to print the customer settings before you restore factory defaults or make major changes To print the menu settings 1 Select Reports from the Config Menu and press Select 2 Select Menu Settings Page and press Select v lt Event Log Lets the system support person print a limited set of the information contained in the Diagnostics Menu version of the printed Event Log For a sample of a printout see Event Log on page 3 23 The limited Configuration log and the full Diagnostics log printed versions show the same operator panel messages when they print and follow the same layout guidelines To print the event log 1 Select Reports from the Config M
240. rator panel bezel Bezel op panel 4 1 Norwegian Bezel op panel 3 1 Norwegian X546 Norwegian operator panel bezel Bezel op panel 4 1 Finnish Bezel op panel 3 1 Finnish Parts catalog 7 7 7525 XXX Assembly 2 continued Scanner 7 8 Service Manual 7525 XXX Assembly 2 continued Scanner Part Units Units Description number mach FRU P 40X2602 40X5509 40X5510 40X2517 40X5523 40X5524 40X2681 40X5521 40X5522 40X2624 40X5525 40X5526 40X2689 40X5529 40X5530 40X2686 40X5505 40X5506 40X2724 40X5507 40X5508 40X2783 40X5531 40X5532 40X2784 40X5501 40X5502 40X2515 40X5503 40X5504 40X2723 40X5527 40X5528 40X2682 40X5488 40X5468 40X5469 40X5472 40X5471 40X5539 40X5535 40X1569 40X2252 p i j i i i i j i i j i i i bh sesch zk sch sch b sch mb sch wech sesch zk hb sesch mb mb mb sch mb mb bo mb bo mb mb mb sch sch sch mb X546 Finnish operator panel bezel Bezel op panel 4 1 Italian Bezel op panel 3 1 Italian X546 Italian operator panel bezel Bezel op panel 4 1 Russian Bezel op panel 3 1 Russian X546 Russian operator panel bezel Bezel op panel 4 1 Polish Bezel op panel 3 1 Polish X546 Polish operator panel bezel Bezel op panel 4 1 Czech Bezel op panel 3 1 Czech X546 Czech operator panel bezel Bezel op panel 4 1 Hungarian Bezel op panel 3 1 Hungarian X546 Hungar
241. ray and the integrated MP feeder count as two independent input sources The MF feeder is configured as cassette does not show up as Configure MP in the Paper Menu 1 8 Service Manual Duplex capability Y Supported Models Lexmark X543dn Lexmark X544n Lexmark X544dn Lexmark X544dw Lexmark X544dtn Lexmark X546dtn Media input size specifications Y Supported without size sensing K Not supported Input source mao www CA revere e e EC ES ESCH EES Universal 148 x 210mm to 216 x 356mm 5 8 x 8 3 in to 8 5 x 14 in 76 x 127mm to 216 x 356mm 3 x 5 in to 8 5 x 14 in 7525 XXX Duplex Type Automatic duplex ki 650 sheet Duo Drawer j Y O LO Ve us Leg O pur o O Se Ce n O n Optional 550 sheet drawer model C546dtn only MP feeder in the gt y es _J KN O LO N SIS SIS SIS SIS BROOKE Jpc cht esis AS Le Haidtsnidk K S K S x x x Y Y Y vw vw x x x Y General information 1 9 7525 XXX Y Supported without size sensing K Not supported Input source Optional 650 sheet 650 sheet Duo Drawer 250 sheet tray Duo Drawer Optional 550 sheet drawer model C546dtn only MP feeder in the 210mm x 279 4mm to 216mm x 356mm 8 27 in x 11 in to 8 5 in to 14 in 10 Envelope 105 x 241mm 4 12 x 9 5 in DL Envelope 110 x 220mm 4 3 x 8 7 in C5
242. refore the toner goes into the ITU cleaner which cannot process massive amounts of toner It is important to prevent extensive blank pages from being processed if they should have toner on them Diagnostic information 2 3 7525 XXX Unexpected page breaks occur e Increase the Print Timeout value on the operator panel Settings gt General Settings gt Timeouts gt Print Timeout Scan fax copy symptom table mn mm O o Go to 840 xx service check on page 2 63 Go to ADF Duplex service check on page 2 70 Go to ADF feed errors service check on page 2 69 Scanner makes buzzing noise on startup or Go to Flatbed home position service check on page 2 66 during a scan Document feeds but jams in ADF Go to ADF paper jam service check on page 2 68 Black streaks on scans Go to ADF streak service check on page 2 67 Blank page Go to Black or blank page copy service check on page 2 65 Black page No dial tone Go to Modem fax card service check on page 2 71 Machine dials a number but fails to make a The other fax machine may be turned off Ask the fax recipient to connection with another fax machine check their machine Incoming fax has blank spaces or poor 1 The sending fax machine may be faulty quality 2 The sending fax machine may have a dirty document glass 3 A noisy phone line can cause errors 4 Check the MFP print quality by making a copy 5 The print cartri
243. removals ADF cable 4 85 ADF input tray 4 84 ADF separator pad 4 87 ADF separator roll 4 88 AIO link 4 96 AIO release lever 4 95 AIO toner cover 4 97 auto compensator mechanism ACM standard tray 4 12 bezel cover 4 89 bin full flag 4 18 4 103 bin full sensor 4 15 controller board 4 18 covers AIO back cable cover 4 8 front cover assembly 4 2 front middle cover assembly 4 4 Lexmark confidential until announce left cover 4 4 rear shield 4 7 right cover 4 7 scanner left 4 92 scanner right 4 93 top cover 4 9 developer unit 4 42 duplex ADF 4 83 duplex ADF rear cover 4 82 duplex sensor 4 23 fax card 4 102 fax interface cable 4 102 flatbed 4 72 installing the new flatbed 4 78 flatbed pivot link 4 81 fuser 4 25 fuser drive motor assembly 4 28 fuser exit sensor 4 29 High voltage power supply 4 31 image transfer unit 4 35 imaging unit IU 4 40 4 57 left lower frame 4 45 left scanner cover 4 92 logo cover 4 101 low voltage power supply 4 43 main drive gear assembly with motors 4 53 op panel bezel 4 100 op panel cable 4 101 operator panel 4 98 output bin tray 4 103 photoconductor unit 4 57 pick tires integrated 250 sheet media tray 4 55 printhead 4 56 procedures 4 2 redrive unit 4 91 right lower frame 4 48 right scanner cover 4 93 toner cartridge contacts 4 59 toner density sensor L amp R 4 63 toner meter cycle card 4 61 tray present sensor 4 64 USB connector 4 67 waste toner bottle 4 67 waste toner bottle contact
244. rinter on Check the following connectors removal on page 4 9 page 4 18 JFAN1 Pin voltage Are the measured values correct Diagnostic information 2 31 7525 XXX Printhead service check Questions actions Turn the printer off and remove the rear shield Replace the printhead See Go to step 2 See Rear shield removal on page 4 7 Printhead removal on Check the cables connected at JMIRR1 and page 4 56 JPH1 on the controller board Check for damage Are the cables damaged Turn the printer on and verify the following Replace the printhead See Replace the controller values at JMIRR1 Printhead removal on board Replace the page 4 56 controller board See JMIRR1 Controller board removal on page 4 18 Are the values approximately correct 2 32 Service Manual 7525 XXX 950 xx NVRAM failure service check Warning Replace one of the following components and perform a POR before replacing a second component Never replace both of the components without performing a POR after installing each one or the printer will be rendered inoperable e Operator panel assembly e Controller board Warning Never install and remove components listed above as a method of troubleshooting components Once a component has been installed in a printer and the printer is powered on it cannot be used in another printer It must be returned to the manufacturer This error code indicates a
245. rive into the USB port located on the operator panel USB Menu Print from USB displays Note If Print from USB doesn t display by default use the lt Left or p Right buttons to navigate to the Print from USB command 2 Press y Select The flash drive s directory structure displays 3 Use the or p buttons to navigate to the fullnet fls also known as 1 fls firmware file Warning fullnet fls must be the first file to be updated failure to update this file first could damage the machine or render it inoperable 4 Press y Select Program Device Yes displays 5 Press y Select The printer will start the update process Various status and progress messages will display on the operator panel Warning DO NOT TURN THE MACHINE OFF until the update is complete When the update is completed the printer will automatically reboot and return to Ready If your flash drive is inserted into the USB port located on the operator panel USB Menu Print from USB displays Note If Print from USB doesn t display by default use the Left or p Right buttons to navigate to the Print from USB command Press y Select The flash drive s directory structure displays Use the a o buttons to navigate to the updeng fls also known as 2 fls firmware file Press y Select Program Device Yes displays Press y Select The printer will start the update process Various status and progress messages will
246. rning For models with a wireless antenna use supports to prevent the antenna from taking the weight of the printer Carefully tilt the printer so the rear shield rests on the table 4 12 Service Manual 1525 XXX 9 Remove the two springs D Repair information 4 13 7525 XXX 11 On the right side loosen the screw F with a screwdriver and hold the ACM in place as you use your fingers to remove the screw 12 Move the right side of the ACM out to free the shaft from the hole in the frame Note Observe the location of the shaft and hole for reinstallation 13 Remove the ACM Installation notes 1 Place the left side of the ACM in the printer Make sure the shaft on the left side aligns with the hole in the frame Turn the printer to the proper upright position Route the cable through the frame and through the cable channel making sure to clamp the cables into the two retainers on the left side Remove the rear shield and connect the cable Replace the rear shield NA WN 4 14 Service Manual 7525 XXX Bin full sensor 1 Remove the flatbed unit See Flatbed removal on page 4 72 2 Using a small flatblade screwdriver gently depress the tabs A which secure the sensor to the top cover assembly A 3 Pull the sensor away from the top cover assembly 4 Disconnect the sensor from the cable Repair information 4 15 7525 XXX Narrow media sensor flag removal Open the front cove
247. rt Color Pg Count the Prt Mono Pg Count or the Perm Page Count 1 Select PRINTER SETUP from DIAGNOSTICS and press Select y 2 Select PAGE COUNTS and press Select v 3 Select the page count you wish to view e Prt Color Pg Count e Prt Mono Pg Count e Perm Page Count 4 press Select A The value of the page count appears press Back el to return to PRINTER SETUP Serial Number The serial number can only be viewed lt cannot be changed To view or change the serial number 1 Select PRINTER SETUP from DIAGNOSTICS and press Select A 2 Select Serial number and press Select v press Back el to return to PRINTER SETUP Engine Setting 1 through 4 Warning Do not change these settings unless requested to do so by your next level of support Model Name The model name can only be viewed and cannot be changed Configuration ID The two configuration IDs are used to communicate information about certain areas of the printer that cannot be determined using hardware sensors The configuration IDs are originally set at the factory when the printer is manufactured However the servicer may need to reset Configuration ID 1 or Configuration ID 2 whenever the system board is replaced The IDs consist of eight digits The first seven digits in each ID are hexadecimal numbers while the last digit is a checksum of the preceding seven dig
248. rtificat als Estats Units aquesta impressora compleix els requisits de DHHS 21 CFR apartat J pels productes laser de classe 1 i segons ha estat certificat en altres llocs s un producte l ser de classe que compleix els requisits d IEC 60825 1 Els productes laser de classe no es consideren perillosos Aquesta impressora conte un l ser de classe IIIb 3b d arseniur de gal li nominalment de 5 mil liwats i funciona a la regi de longitud d ona de 770 795 nan metres El sistema l ser i la impressora han sigut concebuts de manera que mai hi hagi exposici a la radiaci laser per sobre d un nivell de classe durant una operaci normal durant les tasques de manteniment d usuari ni durant els serveis que satisfacin les condicions prescrites L R T A pD t TOTII y3 XETCTCADHHS 21 CERYTF xr 77 J OZIAI 1 ORB LHMKLEV P HHRCHSZCOLAAWS ATUETF EXRABDIIATHIEC g botz ZIO EE E EE NTOE F Z3RILIOL ek sde HE deM AFRO NTU TO CO FUYF lZ7FAMD 3b OL P AWRMETIEF CO LP BEOT7TO TISbt VA F OMRAC BH SL UDybhOAUUDLIEWMERAT ALP ECF COL Y Ze ZZ EU YZ SO 2a VPOA zz R g SImRLC BW TI AAR ZFATOVANVEEOL ik HIM SMS CEOBWKGRAHANTWES ER AX FT EN HL a Se ES LA WE 3 DHHS 21 CFR Subchapter 1 X D I 1 6 75 mm DI E TM HE E He X N A UE E FE TEC 825 HERE FET BOC ABURRE ME A TT EN SLA ah amp A or ZE IIb 3b BY BIL GRE REF ES Sb Ze wn EAO Fie Kw 770 795 nm zg BMI AS MITE P WRI A AR
249. rvice Standard Network or 979 xx Service Network Card x 982 xx Service lt device gt Comm Download emulation cyclic redundancy check CRC failure has occurred A checksum failure detected in the emulation header or emulation file Network error unrecognizable network port Unrecoverable software or error in network or network port Bad checksum while programming network port Flash parts failed while programming the network port Communications error detected by the specified device Note lt device gt can be one of the following e Duplex unit e Tray 2 e Tray 3 The following actions may be taken 1 Disable the Download Emulation 2 Program the download emulation into the code overlay SIMM again 3 If the problem is not resolved replace the code overlay SIMM and download emulation again Replace the standard network card or the card in the specified slot If unable to clear the error message check the following e f installed check network card for correct installation If correctly installed replace the network card If a network card is not installed replace the controller board Check the following e Make sure you have downloaded the code in binary mode not ASCII Reprogram the Network card If the problem persists and if installed check the network card for correct installation e f correctly installed replace the network card If a network card is not in
250. s Note Make sure the clamps on the legs extend onto the surface of the plate 4 24 Service Manual 1525 XXX Fuser assembly removal A Remove the right cover See Right cover removal on page 4 7 Remove the left cover See Left cover removal on page 4 4 Disconnect the two wire fuser cable A from the LVPS Position the fuser cable so that it can be pulled through from the front of the printer and guide the cable to the front Warning Be careful not to damage the cable by pulling too hard or cutting the cable insulation e O ne 5 Remove the screw B on the right side of the frame 6 Disconnect the two thermistor cables C from the fuser d N a av Fat E vi 4 Repair information 4 25 7525 XXX 7 Unhook the springs D from either side of the fuser 8 Detach the geared belt E from the drive pulley on the fuser exit roll shaft Note Do not remove the pulley or spacer from the shaft 9 Rotate the top of the fuser toward the front slide it to the left to align the fuser side frame with the flat areas of the shaft F and lift to remove the fuser Warning Be careful to not interfere with or damage the fuser exit sensor to the left of the fuser Si 4 26 Service Manual 7525 XXX Installation notes e Make sure the springs are resting on the top so they can be reached once the fuser is in place When reinstalling on the right make sure the gears mesh Be
251. s it damaged With the front cover open inspect the two switches Using a tool such as a spring hook push the metal arms to check the movement Is there any damage to the switches or the surrounding area Turn the printer off and remove the rear shield See Rear shield removal on page 4 7 Turn the printer on and verify the following values at JINT1 and JCVR1 JINT1 JCVR1 Pin Value pin Value efem Are the values approximately correct Close the front cover and the toner door Be sure the right cover is in place Turn the printer off and then disconnect the cables at JINT1 and JCVR1 Test continuity at the connector under the following conditions e With front cover and toner door closed Test pin 1 and pin 3 at JINT1 cable end and pin 1 and pin 2 at JCVR1 cable end e With one or both doors open Pin 2 and 3 at JINT1 cable end should indicate continuity but Pin 1 and 2 at JCVR1 should have no continuity Are the tests verified Sensor toner door and right doors are OK Go to step 2 Replace the right cover assembly See Right cover removal on page 4 7 Go to step 3 Go to step 4 Go to step 5 Replace the controller board See Controller board removal on page 4 18 Replace the top cover assembly See Top cover assembly removal on page 4 9 Replace the right cover assembly See Right cover removal on page 4 7 Go to step 6 Contact your next le
252. s on the ADF are Are the actuators ok broken replace the ADF unit Go to Duplex ADF removal on page 4 83 Check all the connections on the ADF Go to step A Properly connect all the relay card Are they properly connections connected Check the ADF cable to ensure it is Go to step 5 Properly connect the ADF cable properly connected to CN 15 on the to its connections ADF relay card and main controller board at JADF1 Is the ADF cable properly connected Check the ADF cable for continuity Go to step 6 Replace the ADF cable Go to Make sure pin22 has continuity Is ADF cable removal on there continuity on pin 22 page 4 85 Replace the ADF Go to Duplex ADF Problem solved Replace the controller board Go removal on page 4 83 Does this fix to Controller board removal the situation on page 4 18 2 70 Service Manual 7525 XXX Modem fax card service check Is the phone line properly connected to the Go to step 2 Go to step 3 modem card and the wall jack Properly connect the phone line to the Problem resolved Go to step 3 modem card and wall jack Did this fix the problem Test the phone line s ability to send and Go to step 5 Go to step 4 receive calls Did the phone line work properly Use the MFP on a properly functioning Problem resolved Go to step 5 phone jack Did this fix the problem Is the modem card ribbon cable properly Go to step 7 Go to step 6 connected to the s
253. se the top cover e Remove and re install the cartridge s Listen for the click to ensure the cartridge is installed properly e Turn the printer power off and then turn the printer power on If the message persists determine if the imaging kit counter is greater than 15 000 cycles It it is then replace the entire kit See Imaging unit IU removal on page 4 40 If the counter is below 250 000 cycles replace only the photoconductors 32 xx Replace Remove the specified cartridge replace with a supported cartridge and close the unsupported lt color gt front cover Cartridge 34 Short Paper press Select to clear the message and continue printing The printer does not automatically reprint the page that prompted the message Check tray length and width guides to ensure paper is properly fitted in the tray Make sure the print job is requesting the correct size of paper Adjust the Paper Size setting for the size paper you are using If MP Feeder Size is set to Universal make sure the paper is large enough for the formatted data Cancel the current job 35 RES Save Off This message displays when the printer lacks sufficient memory to enable Resource Deficient Memory Save This message usually indicates the user has allocated too much memory for one or more of the printer link buffers however modification of other printer settings which affect the amount of available memory may also create this condition If re
254. sed Parts Return Universal Serial Bus Volts Volts alternating current Volts direct current Voice over internet protocol Volt Ohmmeter Vacuum Transport Belt XML Paper Specification Yellow 7525 XXX 2 Diagnostic information Start CAUTION Unplug the power cord from the electrical outlet before you connect or disconnect any cable or electronic board or assembly for personal safety and to prevent damage to the printer Disconnect any connections between the printer and PCs peripherals Begin here to locate the service error code user status message user error message symptom table service checks and diagnostic aids in this chapter to determine the corrective action necessary to repair a malfunctioning printer They will lead you to solutions or service checks including use of various tests Does the POR stop Check the POR Power On Reset sequence on page 2 2 e Do you have a symptom rather than an error message Locate your symptom and take the appropriate action Printer symptom table on page 2 3 Scan fax copy symptom table on page 2 4 e If you have an error message or user message check the following Service error messages on page 2 15 User status and attendance messages on page 2 6 Paper Jam messages on page 2 13 Service checks on page 2 31 for individual error messages e Additional information can be found at the following locations
255. sensor removal Remove the media tray Remove the imaging unit See Imaging unit IU removal on page 4 40 Remove the rear screw A in the waste toner bottle sensor contact to allow access to the cable cover Note The waste toner bottle sensor contact does not need to be unplugged or removed Remove the four screws B from the cable cover and remove the cable cover eS B A 5 Turn the printer on the back 6 Remove the three screws C securing the lower right frame to the printer 7 Remove the screw D closer to the front of the printer Le 4 64 Service Manual 1525 XXX 8 Next to screw D lift the right lower frame pin E out of the hole in the printer frame 9 Swing the rear of the lower frame away from the printer to access the tray present sensor latches 10 Remove and secure the spring F from the right lower frame Note The spring easily gets lost 11 Disconnect the tray present sensor cable Repair information 4 65 7525 XXX 12 Remove the sensor retaining plate G and then pinch the latches together to remove the tray present sensor Installation notes 1 Clean the contact surface where you removed the sensor retaining plate or where you need to install the new one Install the sensor Note Make sure the clips on the posts latch to the frame Remove the backing from the new plate and place the plate on the surface between the sensor mounting posts Connec
256. ser 12 Enter the printers IP address in the Web browsers address bar 13 Press Enter The printers homepage opens 14 Click Settings The settings page opens 15 Click the Update Firmware link The update firmware page opens 16 Click the Browse button A file browser will open 17 Browse to updeng fls also known as 2 fls 18 Click Open 19 Click Submit Various status and progress messages will appear on the operator panel The printer will reboot The webpage will post File Transfer Complete The HTTP session will terminate Warning Do not turn the machine off until the update is complete When the firmware update is completed the printer will automatically reboot and return to a Ready state Diagnostic aids 3 55 7525 XXX Scanner firmware update 20 21 22 23 24 25 26 27 28 On a computer attached to the network open a Web browser Enter the printers IP address in the Web browsers address bar Press Enter The printers homepage opens Click Settings The settings page opens Click the Update Firmware link The update firmware page opens Click the Browse button A file browser will open Browse to scanner fls also known as 3 fls Click Open Click Submit Various status and progress messages will appear on the operator panel The printer will reboot The webpage will post File Transfer Complete The HTTP session will terminate Warning Do not turn the machine off until the update
257. sionais destes servi os devem estar avisados deste facto e tomar os cuidados necess rios CUIDADO Quando vir este s mbolo existe a poss vel presenca de uma potencial tens o perigosa na zona do produto em que est a trabalhar Antes de come ar desligue o produto da tomada el ctrica ou seja cuidadoso caso o produto tenha de estar ligado a corrente el ctrica para realizar a tarefa necess ria Safety information XIX 7525 XXX Informacio de Seguretat e La seguretat d aquest producte es basa en l avaluaci i aprovaci del disseny original i els components especifics El fabricant no es fa responsable de les questions de seguretat si s utilitzen peces de recanvi no autoritzades e La informacio pel manteniment d aquest producte esta orientada exclusivament a professionals i no esta destinada a ningu que no ho sigui e El risc de xoc electric i de danys personals pot augmentar durant el proces de desmuntatge i de servei d aquest producte El personal professional ha d estar ne assabentat i prendre les mesures convenients re ra gt q OF PRECAUCIO aquest simbol indica que el voltatge de la part de l equip amb la qual esteu treballant s perill s Abans de comen ar desendolleu l equip o extremeu les precaucions si per treballar amb l equip l heu de connectar s ear e e le Se Troa He EE a oe NEE ER ul s ECK E kee E o 2 as E Jr dl Er Thee eo le e Be E E At Ai El H 02 E H Moy AT Sol A oi AL Cf 10L
258. sive Update firmware or replace controller Invalid Firmware boot code board See Controller board removal on page 4 18 959 02 Service Failure to authenticate Signature Update firmware or replace controller Invalid Firmware Verification Code board See Controller board removal on page 4 18 959 03 Service Signature verification Code failure to Update firmware or replace controller Invalid Firmware authenticate a code partition board See Controller board removal on page 4 18 959 04 Service Jump to unverified address Update firmware or replace controller Invalid Firmware board See Controller board removal on page 4 18 959 05 Service Unknown Boot Failure Update firmware or replace controller Invalid Firmware board See Controller board removal on page 4 18 959 20 Service System hardware failure Replace controller board See Controller System Board board removal on page 4 18 959 21 Service System did not respond to command Replace controller board System Board request 959 22 Service Challenge Secret Failure ASIC SP mismatch System Board Replace controller board See Controller board removal on page 4 18 959 23 Service System self test failure during Replace controller board See Controller System Board initialization board removal on page 4 18 959 24 Service EEPROM Retention Error write failure Replace controller board See Controller System Board board removal o
259. sor 3 18 S1 3 18 S2 3 18 Standard Bin 3 18 Y TMC Sensor 3 18 Device Tests Flash Test 3 18 device tests 3 18 Duplex Tests Quick Test 3 15 Top Margin 3 16 Duplex tests left margin 3 15 Event Log Clear Log 3 24 exit diagnostics 3 30 Hardware Tests Button Test 3 13 CACHE Test 3 14 DRAM Test 3 13 Panel Test 3 13 image transfer unit ITU 3 20 Input Tray tests feed tests 3 17 sensor test 3 17 ITU Barcode 3 20 miscellaneous tests 3 10 motor detect 3 10 Print Tests input source tests 3 11 Prt Quality Pgs 3 11 print tests 3 11 Printer Setup configuration ID 3 19 l 2 Service Manual defaults 3 19 engine setting 1 through 4 3 19 model name 3 19 page counts 3 19 serial number 3 19 printer setup 3 19 REGISTRATION Bottom Margin 3 4 Left Margin 3 4 Right Margin 3 5 Top Margin 3 4 registration 3 4 Scaner Tests ASIC test 3 25 Scanner Tests sensor test 3 25 ADF cover closed sensor test 3 27 ADF paper present sensor test 3 26 FB Cover closing sensor test 3 27 home sensor test 3 27 sensor 1 test 3 28 sensor 2 test 3 29 Scanner tests feed test 3 25 TPS Setup Cal Ref Adj 3 22 Diagnostics Mode description 3 1 diagram menu 2 79 didital imaging specifications 1 16 dimensions 1 5 disable scanner 3 36 DRAM Test 3 13 duplex duplex sensor 2 36 models 1 9 Quick Test 3 15 Top Margin 3 16 duplex ADF rear cover removal 4 82 duplex ADF unit removal 4 83 duplex sensor removal 4 23 E emoval 4 4 Energy Conserve 3 33 error c
260. ss y See Quick test on page 3 6 The message Quick Test Printing appears on the display and the page prints Retain this page to determine the changes you need to make to the margin settings 3 Use 4 or gt to select the margin setting you need to change and press y 4 Use 4 to decrease or to increase the offset values and press y to confirm the value The message Submitting changes displays and the original margin setting screen appears The print registration ranges are Top margin 50 to 50 A positive change moves the image down the ZE E E page and increases the top margin A negative t a 600 doi Lies te 0 0133 change moves the image up and decreases cans atra pi scan rate 0 the top margin No compression or expansion inches or 0 339 mm occurs The default is 0 Bottom margin 25 to 25 A positive offset moves text down the page and Each morenen Cause narrows the bottom margin while a negative l D offset moves text up the page and narrows the E mm shift in the bottom margin The image is compressed or SERIES expanded The default is 0 Left margin 50 to 50 A positive change moves the image to the left Each i icon ado and a negative change moves the image to the pixels at 600 dpi 0 00666 q e right No compression or expansion occurs 0 1693 mm The default is O 3 4 Service Manual 7525 XXX A positive change moves the image to the left and
261. ss Stop Mm to cancel the test DRAM Test This test checks the validity of DRAM both standard and optional The test writes patterns of data to DRAM to verify that each bit in memory can be set and read correctly To run the DRAM Test 1 Select Hardware Tests in Diag Menu and press Select y 2 Select DRAM Test and press Select a The printer displays DRAM Test Testing b The printer initiates a POR of the printer and the following screen is displayed Resetting the Printer C After the POR the printer begins testing the memory DRAM Test 128M P HHHHH OF AAA P represents the number of times the memory test has passed and finished successfully Initially 000000 displays with the maximum pass count being 99 999 F represents the number of times the memory test has failed and finished with errors Initially 0000 displays with the maximum fail count being 99 999 3 Once all the memory is tested the test stops Diagnostic aids 3 13 7525 XXX To stop the test early turn off the printer CACHE Test The CACHE Test is used to verify the processor cache is functioning properly 1 Select Hardware Test in Diag Menu and press Select A1 2 Select CACHE Test and press Select a The printer displays CACHE Test Testing b The printer initiates a POR of the printer and the following screen is displayed Resetting the Printer C Upon com
262. st 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 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 To run the Flash Test 1 2 Select DEVICE TESTS from Diag Menu and press Select y Select Flash Test and press Select v Contents will be lost Continue appears To continue select Yes and press Select v To end the test select No and press Select y If you continue Flash Test Testing appears e If the test is successful Flash Test Passed appears Use Format Flash in the Utilities Menu to reformat the flash card e If the test is unsuccessful Flash Test Failed appears Replace the flash card press Back 5 to remove the message and return to the Device Tests menu 3 18 Service Manual 7525 XXX Printer Setup Defaults US Non US defaults changes whether the printer uses the US factory defaults or the non US factory defaults The settings affected include paper size envelope size PCL symbol set code pages and units of measure Warning Changing this setting resets the printer to factory defaults and data may be lost It cannot be undone Page Counts You can view but not change any of the three counts displayed under PAGE COUNTS To view the P
263. stalled replace the controller board Check the following e f installed check the network card for correct installation e f correctly installed replace the network card e f a network card is not installed replace the controller board Diagnostic information 2 25 7525 XXX Service error messages 1XX 8XX and 9xx continued 990 xx Service This error message indicates that an lt device gt equipment check condition has occurred in the specified device but the device is unable to identify the exact component failure Note lt device gt can be one of the following e Duplex option e Tray2 e Tray 3 2 26 Service Manual 7525 XXX Fax error log codes Fax error log codes No error occurred during fax No action needed transmission 200 Error occurred when transmitting Check line quality training Select a lower Max Speed value under Fax Send settings Adjust the transmit level 3XX Error occurred when receiving Check line quality image data Adjust Receive Threshold Select a lower Max Speed value under Fax Receive settings 4XX Error occurred when sending Check line quality image data Adjust Transmit Level Select a lower Max Speed value under Fax Receive settings 5XX Received unknown response from No action needed Issue is with the other device remote fax device 6XX Error occurred when receiving a frame e Check line quality e Adjust
264. storation of Resource Save is required after this message is received the customer should install additional memory or set each link buffer to Auto Once all link buffers are returned to Auto you should exit the menu to activate the link buffer changes Once the printer returns to the Ready state you can enable Resource Save and go back and modify the link buffers again Note the reduction of available memory to the link buffers wnen Resource Save has been enabled and compare it to the memory available when Resource Save is disabled e press Select y to disable Resource Save and continue printing To enable Resource Save after you get this message Make sure the link buffers are set to Auto then exit the menus to activate the link buffer changes When Ready is displayed enable Resource Save e Install additional memory 37 Insufficient Collation This message is displayed when the printer memory used to store pages is too full to Area collate the print job The following actions can be taken e press Select to print the portion of the job already stored and begin collating the rest of the job e press Menus to access the Busy Waiting Menu The following functions are available Cancel Job Note Menu Lockout does NOT prevent access to the Busy Waiting Menu Diagnostic information 2 9 7525 XXX User status and attendance messages continued User primary message E
265. sts go to Is the sensor cable properly connected step 7 Replace the controller board See Controller board removal on page 4 18 Turn the printer off and remove the rear shield See Rear shield removal on page 4 7 Turn the printer on and check the values at JFUSES1 Replace the duplex sensor See Duplex sensor removal on page 4 23 Pin Value e Ground Po esv Are the values approximately correct 2 36 Service Manual 7525 XXX Front door sensor or switches service check Enter Diagnostics Menu turn the printer off press and hold and x turn the printer on and then release the buttons when the installed memory and processor speed displays Perform the Base Sensor Test See Base Sensor Test on page 3 18 1 Select Base Sensor Test and press Select Lv 2 Select Front Door and press Select y 3 Open and close the front door and observe the display Does the display indicate Value Closed with the door closed and Value Opened with the door opened Open the front door and check the thin tall plastic web pivot plate at the top right of the printer With the other covers in place and closed this web interacts with switches in the door Open the toner cover and check the motion of the web Is the web loose damaged or missing Open the toner door and inspect the vertical web that pushes and rotates the pivot plate I
266. t and press o Use the or p to increase or decrease the settings value OOND PARA Note Each button press move the margin values one pixel in the respective direction 9 Press y to accept the value 10 Scroll to Top Edge and press y 11 Use the 4 or p to increase or decrease the settings value Note pressing q moves the margin up and pressing p moves the margin down 12 Press y to accept the value 13 To view and adjust the duplex ADF backside registration place the quick test pageface down up into the ADF scroll to the Copy Quick Test Page item and press y 14 After the quick test page copies scroll to ADF Backside Bref press y 15 Scroll to Horizontal Adjust and press y Diagnostic aids 3 35 7525 XXX 16 Use the qor p to increase or decrease the settings value Note Each button press moves the margin values one pixel in the respective direction 17 Press 18 Scroll to Top Edge and press y d to accept the value 19 Use the 4 or p to increase or decrease the settings value Note Pressing q moves the margin up and pressing p moves the margin down 20 Press y to accept the value To manually register the flatbed perform the following steps Press Press eae eee YS d In the Con
267. t diags config menu gt verify that the Go to step 9 Go to step 8 Enable Fax Receive setting is on Is the setting set to on Set Enable Fax Receive to On Problem resolved Go to step 9 Did this fix the problem Is Distinctive Ring enabled Go to step 11 Go to step 10 Turn on Distinctive ring Problem resolved Go to step 11 Did this fix the problem 11 Is the phone line analog Go to step 13 Go to step 12 12 IS the VOIP server configured to support Go to step13 Stop here This is an issue fax with the VOIP provider 13 Does the MFP have reception issues with Go to step 14 Go to step 15 only a certain remote device 4 Go to step 15 1 Verify communications with a different The issue is with the other remote device device Can the other device receive faxes 15 Go to the Administrator menu Enter the Fax Go to step 16 Go to step 17 settings Analog Fax Settings submenu Verify the Block No Name Fax user setting Is it enabled 16 Disable Block No Name Fax user setting Problem resolved Go to step 17 Did this fix the issue 2 74 Service Manual 7525 XXX Goto the Administrator menu Enterthe Fax Goto step18 Go to step 19 settings Analog Fax Settings submenu Verify the remote device number is not in the Banned Fax List user setting Is the remote device number in the banned fax list Remove the remote number from the Problem resolved Go to step
268. t is waiting for an End of job command a Form Feed command or additional data The following actions can be taken e Press Select v to print the contents of the buffer e Cancel the current print job Wait for the message to clear Waiting too many events Warning Potential Damage Do not turn the printer off while this message appears on the display Waste Toner Box The waste toner bottle is nearly full Press Select to clear the message and continue printing 30 xx lt color gt Toner The specified toner cartridge is missing Re install the missing toner cartridge to clear Cart Missing the message and then continue printing If the message recurs remove and re install the cartridge Listen for the click to ensure the cartridge is installed properly Close the front cover 2 8 Service Manual 7525 XXX User status and attendance messages continued User primary message Explanation 31 xx Defective lt color gt The specified cartridge is defective Try one of the following canngge e Open and close the top cover e Remove and re install the cartridge s Listen for the click to ensure the cartridge is installed properly e Turn the printer power off and turn the printer power on If the message persists replace the cartridge with a new one and close the front cover 31 xx Defective Imaging Defective imaging kit Try one or more of the following Kit e Open and clo
269. t of the Menu Settings Page Either OK or Replace appears To print a Menu Settings page 1 Press Menu f on the operator panel 2 Select Reports from the Admin Menu and press Select 3 Select Menu Settings and press Select v Replacement is recommended every 30 000 pages for the imaging unit e 4800C Q default full printer speed e 1200 dpi reduced printer speed is supported in PS and PCL only Connectivity network support VY Supported Pasian K Not supported X544n Lexmark X544dn Lexmark Lexmark Network protocol X543 X544dtn X544dw X546dtn Standard Ethernet 10 100 Base T Standard USB B Full speed device port USB A host ports In front low full speed This port only supports the following flash drives and file types Supported flash drives Lexar Jump Drive 2 0 Pro 256 512 MB 1G size or SanDisk Cruzer Mini 256 512 MB 1 G size Supported file _ types pdf gif jpeg jpg bmp p ng tiff tif ocx dcx 802 11n Wireless Network card Manufacturing installs the wireless card during the fabrication process A wireless card CANNOT be installed post manufacturing Scan and Scan and print Scan and print Scan and print USB direct drive print Select Select Select Select formats a ee e General information 1 3 7525 XxXX Operating modes EA Description Quiet Designed for customers where noise levels are a very important factor e
270. t the cable to the tray present sensor Replace the spring Je me ZS 4 66 Service Manual 1525 XXX USB connector removal ol Remove the rear shield See Rear shield removal on page 4 7 2 Disconnect the USB connector from the controller board 3 Remove the flatbed assembly See Flatbed removal on page 4 72 Note Do not remove the flatbed covers or any of the hinges The flatbed only needs to be removed from the print engine 4 Remove the operator panel from the flatbed assembly Operator panel removal on page 4 98 5 Remove the CCD ribbon cable cover A and route the USB cable out through the cable channel on the flatbed unit Waste toner bottle The waste toner bottle is a customer replaceable unit Open the front cover Lift the toner cover Remove the right cover assembly See Right cover removal on page 4 7 press the two tabs A to release the waste toner bottle and remove it gt E Repair information 4 67 7525 XXX Waste toner bottle contact block removal Open the front cover Remove the right cover assembly See Right cover removal on page 4 7 Remove the waste toner bottle See Waste toner bottle on page 4 67 Remove the screw A from the back of the waste toner bottle contact block tt E A 5 Remove the rear shield See Rear shield removal on page 4 7 6 Disconnect the waste toner bottle contact block cable from connector J
271. t to OFF RGB Brightness RGB Contrast RGB Saturation Set to O Color Balance Select Reset Defaults to zero out all colors Check the paper type texture and weight settings against what is loaded in the printer Once the printer has been restored to its default levels do the following 1 Inspect the imaging unit for damage including the developers and toner cartridges Replace if damaged 2 If paper other than 20lb plain letter A4 paper is being used load 20Ib plain letter A4 3 Print the Print Quality pages to see if the problem remains Look for variations in the print from what is expected To print the print Quality pages a b C Enter Diagnostics turn off the printer press and hold Left 4 and Select x turn on the printer and release when the installed memory and processor speed displays Select PRINT TESTS and press Select y Select Print Quality Pgs and press Select Ali The message Printing Quality Test Pages is displayed An incorrect printer driver for the installed software can cause problems Incorrect characters could print and the copy may not fit the page correctly Measure all voltages from the connector to the printer ground Service Manual 7525 XXX Print quality background Service tip Some background problems can be caused by rough papers non Lexmark toner cartridges or if the media texture is set to the rough setting Some slick or coate
272. ta to printhead Failure reading data from the printhead Printhead declared error Cyan printhead error The cyan printhead lost HSYNC The cyan printhead failed to complete servo The cyan printhead mirror motors failed to achieve lock The cyan printhead mirror motors lost PLL motor lock Failure reading NVRAM from the cyan printhead Perform a POR If the problem persists go to Printhead service check on page 2 57 Perform a POR If the problem persists go to Printhead service check on page 2 57 Perform a POR If the problem persists go to Printhead service check on page 2 57 Perform a POR If the problem persists go to Printhead service check on page 2 57 Perform a POR If the problem persists go to Printhead service check on page 2 57 Perform a POR If the problem persists go to Printhead service check on page 2 57 Perform a POR If the problem persists go to Printhead service check on page 2 57 Perform a POR If the problem persists go to Printhead service check on page 2 57 Perform a POR If the problem persists go to Printhead service check on page 2 57 Perform a POR If the problem persists go to Printhead service check on page 2 57 Perform a POR If the problem persists go to Printhead service check on page 2 57 Perform a POR If the problem persists go to Printhead service check on page 2
273. tema e a impressora laser foram concebidos de forma a nunca existir qualquer possiblidade de acesso humano a radiac o laser superior a um n vel de Classe durante a opera o normal a manuten o feita pelo utilizador ou condi es de assist ncia prescritas Laserinformatie De printer voldoet aan de eisen die gesteld worden aan een laserprodukt van klasse Voor de Verenigde Staten zijn deze eisen vastgelegd in DHHS 21 CFR Subchapter J voor andere landen in IEC 60825 1 Laserprodukten van klasse worden niet als ongevaarlijk aangemerkt De printer is voorzien van een laser van klasse lllb 3b dat wil zeggen een gallium arsenide laser van 5 milliwatt met een golflengte van 770 795 nanometer Het lasergedeelte en de printer zijn zo ontworpen dat bij normaal gebruik bij onderhoud of reparatie conform de voorschriften nooit blootstelling mogelijk is aan laserstraling boven een niveau zoals voorgeschreven is voor klasse 1 Lasermeddelelse Printeren er godkendt som et Klasse l laserprodukt i overenstemmelse med kravene i IEC 60825 1 Klasse I laserprodukter betragtes ikke som farlige Printeren indeholder internt en Klasse IIIB 3b laser der nominelt er en 5 milliwatt galliumarsenid laser som arbejder pa belgelaangdeomradet 770 795 nanometer Lasersystemet og printeren er udformet s ledes at mennesker aldrig udseettes for en laserstr ling over Klasse l niveau ved normal drift brugervedligeholdelse eller obligatoriske servicebeting
274. ter GER AE Repair information 4 97 7525 XXX Operator panel removal Warning When replacing any one of the following components e Operator panel assembly e Controller board Replace only one component at a time Replace the required component and perform a POR before replacing a second component listed above If this procedure is not followed the printer will be rendered inoperable Never replace both of the components listed above without a POR after installing each one or the printer will be rendered inoperable Warning Never install and remove components listed above as a method of troubleshooting components Once a component has been installed in a printer it cannot be used in another printer It must be returned to the manufacturer Remove the op panel bezel See Op panel bezel removal on page 4 100 Remove the op panel bezel cover See Bezel cover on page 4 89 Remove the left cover See Left cover removal on page 4 4 Disconnect the ground wire from the LVPS cage Remove the one screw A attaching the operator panel to the op panel mounting frame Note Support the operator panel with your free hand PAN 4 98 Service Manual 7525 XXX 6 Disconnect the operator panel cable B 7 Remove the two screws C attaching the USB connector to the operator panel Set the USB connector aside to attach to the new operator panel Note The USB is only used on certain X544 and X546 models 8
275. ter and change the camera mode Replace Black Imaging Replace the Black Imaging Unit Unit Replace Color Imaging Replace the Color Imaging Unit Unit Replace lt color gt Replace the toner cartridge of the indicated color The printer continues after the Cartridge toner door is closed Std Bin Full The following actions can be taken R paper from the standard exit bin to clear the message and continue rinting ahha ld to clear the message and continue printing Tray lt x gt Empty The following actions can be taken wad e Load the paper tray or other source with the correct paper type and size e Press Stop el and then press Select y to cancel the current job Load the paper tray or other source with the correct paper type and size Tray lt x gt Missing Insert the specified tray into the printer Unplug and Change Camera is not in a proper mode to use the PictBridge feature Unplug the camera Mode cable to the printer and change the camera mode Unsupported Mode Camera is not in a proper mode to use the Pict Bridge feature Unplug the camera cable to the printer and change the camera mode Unsupported USB Remove the unrecognized device from the USB port on the front of the printer Device Please Remove Unsupported USB Hub Remove the unrecognized USB hub device from the USB port on the front of the please remove printer Waiting The printer has received data to print bu
276. th the Exit Config menu item displayed press Select v to exit the Configuration Menu The printer performs a power on reset and returns to normal mode Diagnostic aids 3 37 7525 XXX SE Menu Note This is not the Fax SE menu To enter the Fax SE menu press 411 from the Ready screen Note This menu should be used as directed by second level support Print SE Menus General Copyright Displays copyright information Optra Forms mode On or off Code Revision Info Network Code Level Displays network code level Network Compile Info Displays compile information Printer Code Level Displays printer code information Printer Compile Info Displays compile information History Print History Mark History History Mode MAC Set Card Speed LAA Keep Alive NVRAM Dump NVRAM Re init NVRAM NPAP Print Alerts TCP IP netstat r arp a Allow SNMP Set MTU Meditech Mode Raw LPR Mode Gather Debug Enable Debug 3 38 Service Manual 7525 XXX Paper jams Avoiding jams The following hints can help you avoid jams Use only recommended paper or specialty media For more information see the Card Stock amp Label Guide available on the Lexmark Web site at www lexmark com publications Do not load too much paper Make sure the stack height does not exceed the indicated maximum height Do not load wrinkled creased damp or curled paper Flex fan and straighten paper before loading it Do not
277. the Submit button on the bottom of the page A dialogue asking you to save the file will appear Note The file generated by the MFP is not automatically transmitted to second level support It is placed on the computer desktop 8 Enter a name for the file and indicate where you want to save the file 9 press OK The file appears on the desktop 10 E mail the file to second level support 2 76 Service Manual 7525 XXX User operator panel menus and messages Understanding the operator panel The printer operator panel has a four line back lit grayscale display that can show both graphics and text The Mode selection job setup Back and Menu buttons are located to the left of the display the navigation buttons are located below the display and the start buttons stop button and numeric pad are located to the right of the display In addition there is a USB jack that enables printing of certain graphics formats as well as enabling Pict Bridge functionality Mode Menu Fax selection Stop Alphanumeric ontent opies Stop Cancel edial Pause L 2 ABC 3 DEF Photo Scan Email Or xX patne cale esolution 5 KL 6 MNo Fax os Duplex 2 Sided Options Select Start e Btu Qwxyz Ye Ss D lt y gt lt gt lt gt Ge 0 Shortcuts Job SEH setup Back o Pictbridge USB Navigation 8 white Start color Operator panel buttons press Select y to initiate action on a menu item d Navigation buttons press lt or p
278. the controller board See Controller board removal on page 4 18 Replace the operator panel cable See Op panel cable on page 4 101 Replace the Op panel USB cable page 4 18 USB service check 1 Is the USB cable properly connected to the Go to step 2 Properly connect the cable MFP and host PC at both ends 2 Try a different USB cable Does this fix the Issue fixed Go to step 3 issue 3 Connect a different device to the USB cable Replace the RIP system Did the host PC see the device board See Controller board removal on page 4 18 There is an issue with the host machine Diagnostic information 2 45 7525 XXX Networking service check Note Before starting this service check print out the network setup page This page is found under Menu Reports Network Settings Consult the network administrator to verify that the physical and wireless network settings displayed on the network settings page for the device are properly configured If a wireless network is used verify that the printer is in range of the host computer or wireless access point and there is no electronic interference 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 Questions actions Yes If the device is physically connected to the Go to step 3 Go to step 2 network
279. the front of the printer WS i L i ewww ESS AA Ss AO eee Repair information 4 49 7525 XXX 13 Swing the rear part away from the printer to access the spring and remove the spring F from the right lower frame 4 50 Service Manual 1525 XXX 15 Swing the rear part away from the printer to access the spring G and remove the spring G from the right lower frame UP Wass ty G 16 Disconnect the cable H from the tray present sensor 17 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 18 Remove the sensor retaining plate J and pinch the latches K together to remove the tray present sensor Repair information 4 51 7525 XXX 19 Remove the screw L and remove the spring bracket Note For non wireless models Remove the screw M and remove plate from your printer if it does not have a wireless antenna Installation notes 1 et Y Reinstall the spring bracket and the wireless antenna plate or the blank plate if this is not a wireless model Clean the contact surface where you removed the sensor retaining plates or where you need to install the new ones Install the sensors Remove the backing from the new plate and place the plates on the surfaces between the sensor mounting posts
280. the printer posts a paper jam message but no paper is found paper dust or paper particles may have fallen in one of the sensor eyes Use a can of compressed air to gently clean the sensor Duplexing models with duplex support only The MFPs with duplex support use a secondary paper path in the front cover and the 250 sheet paper tray to print on the second side of a sheet of paper The following steps summarize the duplexing process After the first side of the media is printed and the trailing edge of the paper clears the fuser exit sensor the fuser motor reverses The reversed motor pulls the media into the duplexer paper path In addition to the fuser motor reversing the pick motor also reverses The pick motor drives the duplex aligner rolls A which push the media down to the bottom turnaround in the paper tray and gate aligner B Note While the sheet is being transported through the front door and paper tray it is the only piece of media being processed by the print engine A user should not attempt to insert a piece of media into the manual paper feed while a duplex job is being processed This would invoke a paper jam error Diagnostic aids 3 67 7525 XXX When the trailing edge of the media clears the fuser the fuser engine rotates forward to prepare the fuser for the page travelling through the duplexer As the media reaches the gate aligner a sensor S1 is triggered indicating the presenc
281. the tension spring to make sure it is properly attached to the top cover C The following illustration shows the properly attached spring and belt B C Warning After performing any repair that involves detaching the belt from the re drive pulley on the fuser run approximately 30 test pages both simplex and duplex to ensure the belt is performing properly While the pages are running listen for any noises buzzing clicking or rattling that might indicate improper routing of the re drive belt Repair information 4 11 7525 XXX Autocompensator mechanism ACM standard tray removal 1 eS a Remove the toner bottles the waste toner container and the imaging unit IU See Imaging unit IU removal on page 4 40 and see Waste toner bottle on page 4 67 Remove the rear shield See Rear shield removal on page 4 7 Remove the left cover See Left cover removal on page 4 4 Remove the right cover See Right cover removal on page 4 7 Disconnect the autocompensator mechanism ACM cable connector JSP1 A from the controller board Unclip the cable B from the retainers C on the left side C ie 1 Zi H Bl j AS Ma IA Ag i LS PZA Y i y y F y Fou gt D Lg dh a ii p a of A E bk r wi P F E e y SC D EE ml A B C Reinstall the rear shield to protect the controller board Turn the printer so the bottom is facing you Wa
282. thetic papers thermal papers Rough edged rough or heavily textured surface papers or curled papers Recycled papers containing more than 25 post consumer waste that do not meet DIN 19 309 and weighing more than 80 g m Paper weighing less than 80 g m 21 lb Multiple part forms or documents General information 1 13 7525 XXX Selecting paper Using appropriate paper prevents jams and helps ensure trouble free printing To help avoid jams and poor print quality e Always use new undamaged paper e Before loading paper know the recommended print side of the paper This information is usually indicated on the paper package e Do not use paper that has been cut or trimmed by hand e Do not mix paper sizes types or weights in the same source mixing results in jams e Do not use coated papers unless they are specifically designed for electrophotographic printing Selecting preprinted forms and letterhead Use these guidelines when selecting preprinted forms and letterhead e Use grain long for 60 to 176 g m weight paper e Use only forms and letterhead printed using an offset lithographic or engraved printing process e Avoid papers with rough or heavily textured surfaces Use papers printed with heat resistant inks designed for use in xerographic copiers The ink must be able to withstand temperatures up to 200 C 392 F without melting or releasing hazardous emissions Use inks that are not affected by the resin in toner I
283. tions 3 40 L LCD operator panel 4 98 left scanner cover removal 4 92 lithium battery ii xvii logo cover removal 4 1 01 low volatage power supply removal 4 43 Low voltage power supply parts catalog 7 12 lower left and right frame covers parts catalog 7 10 lubrication specifications 6 1 M Main drive gear assembly w motors parts catalog 7 10 main drive gear assembly with motors removal 4 53 manually register a duplex ADF 3 35 manually register the flatbed 3 36 media guidelines 1 13 input size 1 9 input sources 1 8 input type 1 11 output 1 8 output size and type 1 11 recycled 1 14 unacceptable media 1 13 weights 1 12 media jams 3 39 memory 1 2 parts catalog 7 18 memu settings page 3 32 menu users map 2 79 menus diagram 2 79 Menu Settings Page 3 32 messages attendance 2 6 min copy memory 3 34 miscellaneous tests 3 10 models 1 1 modem fax card service check 2 71 motor detect test 3 10 moval 4 7 MP feeder parts catalog 7 16 N new flatbed installation 4 78 Index 1 3 7525 XXX O Op panel bezel removal 4 100 Op panel cable removal 4 101 operating modes 1 4 Operator panel removal 4 98 operator panel display is dim 2 45 service check 2 42 blank printer beeps 5 times and pauses 2 43 diamonds 5 beeps 2 44 diamonds no beeps 2 44 display blank 5 beeps 2 42 one or more buttons fail 2 42 operator panels parts catalog 7 6 options and features description 1 2 output bin tray removal 4 103
284. ts of Measure Portrait Width Portrait Height Feed Direction Reports Menu Settings Page Device Statistics Network Setup Page Shortcut List Fax Job Log Fax Call Log E mail Shortcuts Fax Shortcuts Profiles List Print Fonts Print Directory Print Defects Print Demo Demo Page PPDS Info Asset Report Network Ports Active NIC Network Menu PCL Smartswitch PS Smartswitch NPA Mode Network Buffer Mac Binary PS Network Setup Wireless Menu USB Menu PCL Smartswitch PS Smartswitch NPA Mode USB Buffer Mac Binary PS USB With ENA ENA Address ENA Netmask ENA Gateway ENA Gateway Settings General Settings Copy Settings Fax Settings Flash Drive Settings Print Settings Set Date Time Diagnostic information 2 79 7525 XXX 2 80 Service Manual 3 Diagnostic aids 7525 XXX This chapter explains the tests and procedures to identify printer failures and verify repairs have corrected the problem Menu key combinations There are different test menus that can be accessed during POR to identify problems with the printer Configuration Menu Diagnostics Mode 1 Turn off printer 2 ae and hold 41 gt Turn on the printer Release the buttons when 128mb 500MHZ 256mb 500 MHZ or 640mb 500 MHZ displays Turn off printer 2 press and hold y dy P Turn on the printer Release the buttons when 128mb 500MHZ 256mb 500 MHZ or 640mb 500 MHZ displays
285. uage card can be added Memory Y Supported Lexmark X543 Lexmark X544n Lexmark Lexmark X Not supported X544dn X544dtn X544dw X546dtn Standard DIMM sizes 128MB 256MB Optional DDR1 128MB 256MB and 512MB 256MB 512MB Maximum printer memory 640MB Flash memory 64 MB Option Slots single slot is available or either font or flash memory card Font card support 1 font card Optional user flash memory 64MB 64MB 64 MB card sizes ene USB A x Y ki ki allows direct USB printing using approved USB flash memory device x Pict Bridge Y Only on FAX W Only on FAX Only on FAX allows printing photos equipped equipped equipped SE EES machines machines machines Wireless standard 802 11 x Te Y b g n a Dual Inline Memory Module An optional memory card that can be plugged into an available memory slot The X546 slot is filled with a 128 mb DIMM The maximum usable DDRSDRAM is standard soldered plus 512MB 1 2 Service Manual 7525 XXX Print quality During the life of the printer components are subject to wear based on usage Printers continuously operating at or near the maximum duty cycle may require service for replacement of these components to ensure high quality printing and good performance throughout the life of the printer Replacement is recommended every 60 000 pages for the fuser and 60 000 pages for the ITU The fuser and ITU replacement should be determined by checking the last shee
286. uctor surface Service tips e 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 e Never touch the surface of the photoconductor with your bare hand The oil from your skin may cause a charge differential on the surface and toner will not stick properly The result would be repeating blotches of voids light print on a page Then the photoconductor will have to be replaced e The surface of the photoconductor is coated with an organic substance that makes it sensitive to light Be sure and cover the photoconductor when you are working on the printer so you don t burn it If exposed to light for too long it will cause light dark print quality problems and have to be replaced Diagnostic aids 3 59 7525 XXX Step 3 Develop Once the laser exposes the photoconductor the high voltage power supply sends charge to the developer roll C For each color the toner cartridge engages the photoconductor so it is in contact with the surface Because of the charge difference between the toner on the developer roller and the electrostatic image created by the laser the toner will attract to the photoconductor only where the laser exposed the surface This process would
287. uld be and if you can continue before you correct the hazard Check the following items Damaged missing or altered parts especially in the area of the On Off switch and the power supply e Damaged missing or altered covers especially in the area of the top cover and the power supply cover e Possible safety exposure from any non Lexmark attachments Scheduled maintenance Maintenance kit After 60 000 printed pages sides a maintenance kit may be required It is necessary to replace the fuser assembly ITU and duplex reference plate to maintain the print quality and reliability of the printer The parts are available as a maintenance kit with the following part numbers Maintenance kits Description Part number 115 V Maintenance kit 115 V fuser ITU duplex reference edge 40X2254 230 V Maintenance kit 230 V fuser ITU duplex reference edge 40X2255 100 V Maintenance kit 100 V fuser ITU duplex reference edge 40X2261 Lubrication specifications Lubricate only when parts are replaced or as needed not on a scheduled basis Use of lubricants other than those specified can cause premature failure Some unauthorized lubricants may chemically attack polycarbonate parts Use IBM no 10 oil P N 1280443 Approved equivalents Mobil DTE27 Shell Tellus 100 Fuchs Renolin MR30 IBM no 23 grease Approved equivalent Shell Darina 1 and grease P N 99A0394 to lubricate appropriate areas Use Nyogel type 774 to lubricate the Fuser Drive
288. umber mach FRU P ON OD FW DN PN 40X5470 40X5477 40X5478 40X5479 40X5872 40X5467 40X5492 40X5536 40X5487 40X5533 40X5481 40X5480 40X5473 40X5474 40X5475 40X5476 40X5491 40X5493 40X5494 40X1537 40X5495 40X5496 40X2513 40X5497 40X5498 40X2514 40X5499 40X5500 40X2516 40X5519 40X5520 40X2518 40X5511 40X5512 40X2519 40X5517 40X5518 40X2521 40X5515 40X5516 40X2520 40X5513 40X5514 ech ee wh sch sch _b bh ech sesch h wech sch sch sch sch Tray ADF input Cover ADF rear simplex Cover ADF rear duplex Cable ADF Bin full flag Asm Flatbed Asm redrive Lever AlO release Cover scanner right Cover bezel Cable Op panel Cable USB for thumbdrive 3 1 Op panel 4 1 op panel 3 1 op panel DBCS 4 1 op panel DBCS Cover Logo Bezel op panel 4 1 English Bezel op panel 3 1 English X546 English operator panel bezel Bezel op panel 4 1 French Bezel op panel 3 1 French X546 French operator panel bezel Bezel op panel 4 1 Spanish Bezel op panel 3 1 Spanish X546 Spanish operator panel bezel Bezel op panel 4 1 German Bezel op panel 3 1 German X546 German operator panel bezel Bezel op panel 4 1 Dutch Bezel op panel 3 1 Dutch X546 Dutch operator panel bezel Bezel op panel 4 1 Danish Bezel op panel 3 1 Danish X546 Danish operator panel bezel Bezel op panel 4 1 Swedish Bezel op panel 3 1 Swedish X546 Swedish ope
289. unctioning of the front door input and output sensors 1 2 Select Base Sensor Test from Diag Menu and press Select Select the sensor you want to test and press Select y The following test are available sensor vane Howtotest o Input Front Door Value opened Open and close front door The sensor should change Not closed state Standard Bin Bin full Toggle the bin full media flag attached to the redrive unit 1 S Media clear Remove the media tray Activate the input sensor flag The sensor should change state S2 Media clear Remove and re insert the media tray The sensor should change state Fuser exit sensor Media clear Open the front door Activate the fuser exit flag The sensor should change state C TMC Sensor Value opened Remove the cyan toner cartridge Shine a flashlight on Not closed the toner level sensor The sensor should change state M TMC Sensor Value opened Remove the magenta toner cartridge Shine a Not closed flashlight on the toner level sensor The sensor should change state Y TMC Sensor Value opened Remove the yellow toner cartridge Shine a flashlight Not closed on the toner level sensor The sensor should change state K TMC Sensor Value opened Remove the black toner cartridge Shine a flashlight Not closed on the toner level sensor The sensor should change state To exit the test press Back or Stop gg Device Tests Flash Te
290. undancy check Customer Replaceable Unit Customer Setup Clockwise Double byte character set Direct Current Dual Inline Memory Module Downloadable emulator Dynamic random access memory Digital multimeter Error correcting code Error correction mode Enhanced Data Out Electrical Erasable Programmable Read Only Memory External Network Adapter End of line Electrophotographic process Erasable programmable read only memory Electrostatic Discharge Flatbed Facedown Field replaceable unit Face up Gigabyte Ground Fault Interrupter Gigahertz Host Based Printing High capacity feeder High capacity Input Tray High Capacity Output Finisher High capacity feeder Hypertext markup language High Voltage High voltage power supply HVU Hz INTL ITC ITU LAN LASER LCD LCM LD LED LEF LES LSU LV LVPS MB MDC MFD MFP MH MIF MMR MPF MR MROM MS NAND NVM NVRAM OCF OCR OEM OHP OPC OPT PC PDF PICS PIN PIXEL PJL POR POST PPDS ppm PQET PRC PSC PSD PSO High voltage unit Hertz International Internal Tray Card Image Transfer Unit Black Key Local area network Light amplification by stimulated emission of radiation Liquid crystal display Liquid Crystal Module Laser Diode Light emitting diode Long edge feed Lexmark Embedded Solution applications Laser Scanning Unit Low Voltage Low voltage power supply Magenta Megabyte Motor Driver Control Multifunction Device Multifu
291. ure reading NVRAM from the magenta printhead The magenta laser showed bad in EMS testing Failure writing data to printhead Failure reading data from the printhead Printhead declared error Black printhead error The black printhead lost HSYNC Perform a POR If the problem persists go to Printhead service check on page 2 57 Perform a POR If the problem persists go to Printhead service check on page 2 57 Perform a POR If the problem persists go to Printhead service check on page 2 57 Perform a POR If the problem persists go to Printhead service check on page 2 57 Perform a POR If the problem persists go to Printhead service check on page 2 57 Perform a POR If the problem persists go to Printhead service check on page 2 57 Perform a POR If the problem persists go to Printhead service check on page 2 57 Perform a POR If the problem persists go to Printhead service check on page 2 57 Perform a POR If the problem persists go to Printhead service check on page 2 57 Perform a POR If the problem persists go to Printhead service check on page 2 57 Perform a POR If the problem persists go to Printhead service check on page 2 57 Perform a POR If the problem persists go to Printhead service check on page 2 57 Perform a POR If the problem persists go to Printhead service check on page 2 57
292. use paper that has been cut or trimmed by hand Do not mix paper sizes weights or types in the same stack Store the paper in an appropriate environment Do not remove trays while the printer is printing Wait for Load tray lt x gt or Ready to appear before removing a tray Do not load the manual feeder while the printer is printing Wait for Load Manual feeder with lt x gt to appear Push all trays in firmly after loading paper Make sure the guides in the trays are properly positioned and are not pressing too tightly against the paper Make sure all paper sizes and paper types are set correctly in the operator panel menu Make sure all printer cables are attached correctly Diagnostic aids 3 39 7525 XXX Understanding jam numbers and locations When a jam occurs a message indicating the jam location appears The following illustration and table list the paper jams that can occur and the location of each jam Open doors and covers and remove trays to access jam locations Standard 250 sheet tray and Pull tray 1 out and remove the jam manual feeder tray 1 Jam under the fuser Open the front door and remove the jam Jam in the fuser Open the front door and pull the fuser cover toward you Remove the jam Jam in the duplex Open the front door and remove the jam 650 sheet Duo Drawer tray Pull tray 2 out and remove the jam 2 MP feeder Jam in the multipurpose Pull tray 2 out and remove the jam feeder
293. uter operating system adjusts the RGB or CMYK combinations specified in the program through color management The resulting printed color may not be an exact match of the Color Samples pages 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 The likeness of the colors in the set are dependent on the value entered in the RGB or CMYK Increment box To access a detailed Color Samples set from the Embedded Web Server Open a Web browser In the address bar type the network printer IP address Click Configuration Click Color Samples Click Detailed Options to narrow the set to one color range When the Detailed Options page appears select a color conversion table Enter the RGB or CMYK color number Enter an Increment value from 1 255 Note The closer the value is to 1 the narrower the color sample range will appear Click Print to print the detailed Color Samples set a Se teg Diagnostic aids 3 73 7525 XXX 3 74 Service Manual 7525 XXX 4 Repair information Warning Read the following before handling electronic parts Handling ESD sensitive parts Many electronic products use parts that are known to be sensitive to electrostatic discharge ESD To prevent damage to ESD se
294. ve the AIO rear cable cover See AlO back cable cover removal on page 4 8 Remove the rear shield See Rear shield removal on page 4 7 Remove the left cover See Left cover removal on page 4 4 Remove the ADF unit See Duplex ADF removal on page 4 83 or Simplex ADF removal on page 4 84 Disconnect the CCD cable form JCCD1 on the controller board Remove the first toroid A from the CCD cable The toroid will be reused on the new flatbed unit oe ae Ye 7 Remove the second toroid A from the toroid holder and slide it off the CCD cable This toroid will also be used on the new flatbed unit 8 Remove the screw B that fastens the redrive ground wire and ADF ground wire to the frame p B 9 Disconnect JADF1 and route the cable through the top of the card cage 4 72 Service Manual 7525 XXX 10 Disconnect the USB cable from JUSB1 op panel cable from JOPP1 flatbed home sensor cable from JHS1 and flatbed motor cable from JFBM1 Route the cables through the right side of the card cage 11 Disconnect the operator panel ground wire C from the LVPS es AA 5 a y i e ES S Repair information 4 73 7525 XXX 13 Disconnect the screw D connecting the flatbed to the AIO link on the rear of the MFP 14 Carefully disconnect the AIO link from the flatbed 15 Remove the two screws E securing the flatbed hinge to the top cover LAS 16 Remove the two springs F
295. ve without a POR after installing each one or the printer will be rendered inoperable Warning Never install and remove components listed above as a method of troubleshooting components Once a component has been installed in a printer it cannot be used in another printer It must be returned to the manufacturer CAUTION POTENTIAL INJURY There is danger of explosion if a lithium battery is incorrectly replaced Replace it only with the same or an equivalent type of lithium battery Do not recharge disassemble or incinerate a lithium battery Discard used batteries according to the manufacturer s instructions and local regulations Remove the rear shield See Rear shield removal on page 4 7 Remove the fax card See Fax card removal on page 4 102 Remove the fax card standoff fax equipped models only from the controller board Disconnect all the cables from the controller board Remove the six screws A that are securing the controller board to the controller board cage 1 2 3 4 2 e A Se mes pr a kK L i db E Zb t H hi WU DK ot A e Az iE Eb uh BAR b d i 44 ei 6 Remove the board Installation notes Warning Do not start the machine into a Ready state to test it See Testing generic FRUs on page 4 1 Warning 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 HVP
296. vel of support Replace the front cover assembly See Front cover assembly removal on page 4 2 Diagnostic information 2 37 7525 XXX Fuser exit sensor service check Enter Diagnostics Menu turn the printer off Correct the sensor or Go to step 2 press and hold a and x turn the printer on replace it See on and then release the buttons when the page 4 28 installed memory and processor speed displays Perform the Base Sensor Test See Base Sensor Test on page 3 18 1 Select Base Sensor Test and press Select y 2 Select Fuser Exit Sensor and press Select x 3 Open and close the front door and inspect the fuser exit sensor located on the LVPS shield Is the sensor dislodged or damaged Rotate the flag paper diverter in and out of Sensor is good Go to step 3 the sensor Does the display indicate Media Clear and Media Present with the cycle Does the flag rotate freely but returns to block Go to step 4 Replace the fuser the sensor See Fuser assembly removal on page 4 25 Is the cable correctly connected to JBIN1 on Go to step 5 Reconnect the cable the controller board and to the sensor is the sensor properly connected Make sure the printer is turned off Disconnect Replace the fuser exit Replace the controller the cable at the sensor and at JBIN1 on the sensor See on board See Controller controller board Turn th
297. veloper unit removal the IU on page 4 42 Are all the toner cartridge contacts clean on both the Pin and IU Are all the spring loaded Pin in the HVPS free Go to step 7 Replace the HVPS See to move in and out with an equal amount of High voltage power spring force supply HVPS assembly removal on page 4 31 Turn the printer off and remove the rear shield Go to step 8 Replace the cable See Rear shield removal on page 4 7 Check the continuity between the spring loaded Pin and the JSC1 connector on the controller board Are all conductors continuous Replace the printhead See Printhead Problem resolved Replace the controller removal on page 4 56 board See Controller board removal on page 4 18 Did this fix the problem Diagnostic information 2 51 7525 XXX Print quality blurred or fuzzy print Run the automatic alignment The TPS sensor may be damaged To run Reset Color ABC 1 Enter the Diagnostics Menu Turn the printer off press and hold lt and y turn the printer on and release the buttons when installed memory and processor D F speed displays 2 Select TPS Setup from Diag Menu and press Select y 3 Select Reset Color Cal and press Select d L 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 th
298. wing voltages Me problem I not resolved replace the JOPP1 operator panel cable See Op panel cable on Pin Voltage page 4 101 5 V dc Ground 5 V dc 6 3 3 V de Ground Are the voltage values approximately correct Operator panel display blank five beeps Service tip The printer has detected a problem with the controller board the operator panel assembly cable part of the front cover assembly or the operator panel assembly if POST does not complete The printer emits five beeps and sticks in a continuous pattern until the printer is turned off Is the operator panel assembly cable properly Go to step 2 Reinstall the cable installed at controller board JOPP1 and at the operator panel assembly 2 42 Service Manual 7525 XXX Turn the printer off and remove the rear shield See Rear shield removal on page 4 7 Disconnect the operator panel assembly cable at JOPP1 on the controller board Turn on the printer and verify the following voltages JOPP1 Pin Voltage 5 V dc Ground 5 V dc 6 3 3 V de Ground Are the voltage values approximately correct Go to step 3 Replace the operator panel assembly See Operator panel removal on page 4 98 Replace the controller board See Controller board removal on page 4 18 Replace the operator panel cable See Op panel cable on page 4 101 Operator panel display blank printer beeps five times and pauses
299. x and 9xx error messages are stored in the event log To view the event log 1 Select EVENT LOG from Diag Menu and press Select 2 Select Display Log and press Select v lt lt Up to three error codes display at a time press q or p to view additional error codes press to view additional details press Back e to return to the EVENT LOG menu Print Log Additional diagnostic information is available when you print the event log from DIAGNOSTICS rather than CONFIG MENU The Event Log printed from DIAGNOSTICS includes Detailed printer information including code versions Time and date stamps Page counts for most errors Additional debug information in some cases Model and Event Log Serial number y Lexmark x54x s n 98P104V Printer information o lalarmat Panel display Ca when error occurred Page count Earliest error code Diagnostic aids 3 23 7525 XXX The printed event log can be faxed to your next level of support for verification or diagnosis To print the event log 1 Select EVENT LOG from DIAGNOSTICS and press Select 4 2 Select Print Log and press Select y press Back s5 to return to EVENT LOG Clear Log Use Clear Log to remove the current information in the Event Log This affects both the viewed log and the printed log information 1 Select Clea
300. xplanation 37 Insufficient memory This message is displayed when insufficient printer memory is available to perform for flash defragment Flash Memory Defragment operation operation This message appears prior to the actual start of the defragment operation press Select y to stop the defragment operation To perform the defragment operation you can e Delete fonts macros and other data in RAM e Install additional printer memory e press Menus to access the Busy Waiting Menu The following functions are available using the Busy Waiting Menu Cancel Job Reset Printer Note Menu Lockout does NOT prevent access to the Busy Waiting Menu 38 Memory Full This message is displayed when the printer is processing an incoming job and there is not enough memory available to continue processing the job The following actions can be taken e Determine how to make more memory available to your print job by Deleting fonts macros and other data in RAM Simplify your print job Install additional memory e press Select y to clear the message and continue printing The job may nat print correctly e press Menus to access the Busy Waiting Menu The following functions may be available Cancel Job 39 Complex Page This message is displayed when a page is too complex to print The following actions can be taken e press Select v to clear the message an
301. ystem board at JMOD2 and the modem card Properly connect the modem card cable to Problem resolved Go to step 7 the modem card and system board Did this fix the problem 7 Check the modem card ribbon cable for Go to step 8 Replace the modem card continuity Is there continuity cable Check the voltages from connector JMOD2 Replace the fax card See Replace the controller on the controller board Check Pin 4 and 5 Fax card removal on board See Controller for 3 3VDC Pin 7 for 5VDC 9 11 13 15 page 4 102 board removal on 17 and 19 are grounds Are the signals or page 4 18 voltages present Diagnostic information 2 71 7525 XXX Fax transmission service check Note Before performing this service check verify that the correct country code for the MFP is selected This setting must match the country in which the MFP is used to transmit and receive faxes If the setting is wrong the modem settings can be changed in the Fax SE menu See step 14 These settings should only be performed with guidance from your second level support 1 Is the phone line properly connected to the Go to step 2 Go to step 3 modem card and the wall jack 2 Properly connect the phone line to the Problem resolved Go to step 3 modem card and wall jack Did this fix the problem Test the phone line s ability to send and Go to step 5 Go to step 4 receive calls Did the phone line work properly Use the MFP on a properly funct

Lexmark X543, X544 and X546 7525-xxx Service Manual

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