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Lexmark X548 Series, Service Manual

The Lexmark X548 Series service manual is a comprehensive guide for maintaining and troubleshooting your printer. Easily download the manual for free from manualshive.com to access detailed instructions on setup, maintenance, and repair procedures. Ensure optimal performance and longevity for your Lexmark X548 printer with this essential resource.

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5-6

Service Manual

7525-63

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JCARTB1

1

CART1_HALL_U

2

NC_CARTB1_2

3

CART1_HALL_V

4

V_CART2_WIND_W

5

CART1_HALL_W

6

V_CART2_WIND_V

7

CART1_PG

8

V_CART2_WIND_U

9

Ground

10

+5V 

11

+5V 

12

Ground

13

V_CART1_WIND_U

14

CART2_PG

15

V_CART1_WIND_V

16

V_CART1_WIND_W

17

V_CART1_WIND_W

18

V_CART1_WIND_V

19

NC_JCARTB1_19

20

V_CART1_WIND_U

Connector

Pin no.

Signal

Summary of Contents for X548 Series

Page 1: ...ble of contents Start diagnostics Safety and notices Trademarks Index Lexmark and Lexmark with diamond design are trademarks of Lexmark International Inc registered in the United States and or other c...

Page 2: ...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 which it operate...

Page 3: ...size specifications 1 10 Media input type specifications 1 12 Media output size and type 1 12 Media guidelines 1 13 Paper characteristics 1 13 Unacceptable paper 1 14 Selecting paper 1 14 Selecting pr...

Page 4: ...32 Bin full sensor service check 2 33 Dead printer service check 2 34 Duplex manual feed sensor S1 service check 2 35 Front door sensor or switches service check 2 36 Fuser exit sensor service check...

Page 5: ...support 2 70 Diagnostic aids 3 1 User operator panel menus and messages 3 1 Understanding the operator panel 3 1 Operator panel buttons 3 1 Understanding the home screen 3 2 Other buttons that may app...

Page 6: ...enu Settings Page 3 25 Event Log 3 25 Display Log 3 25 Print Log 3 25 Clear Log 3 26 SCANNER TESTS 3 26 ASIC Test 3 26 Feed Test 3 26 Sensor Tests 3 26 ADF paper present sensor test 3 27 FB cover open...

Page 7: ...s and settings 3 44 Paper jams 3 45 Avoiding jams 3 45 Understanding jam numbers and locations 3 46 200 paper jam 3 47 201 paper jam 3 48 202 paper jam 3 49 230 paper jam 3 50 235 paper jam 3 50 241 p...

Page 8: ...Developer unit removal 4 47 Low voltage power supply LVPS assembly removal 4 48 Left lower frame and right lower frame removal 4 50 Left lower frame 4 50 Right lower frame 4 53 Main drive gear assemb...

Page 9: ...ar 5 2 Print engine interior view 5 3 Printer boards 5 4 RIP board 5 4 Connectors 5 5 HVPS 5 16 Connectors 5 17 LVPS 5 18 Connectors 5 19 Toner meter card 5 20 Connectors 5 20 Preventive maintenance 6...

Page 10: ...x Service Manual 7525 63x Go Back Previous Next...

Page 11: ...h betrachtet Der Drucker enth lt im Inneren einen Laser der Klasse IIIb 3b AlGaInP der sichtbare Strahlung im Wellenl ngenbereich von 650 bis 670 Nanometern abgibt Dieser befindet sich in einer Druckk...

Page 12: ...rante el funcionamiento normal mantenimiento del usuario o condici n de servicio prescrita Declara o sobre Laser Este produto foi certificado nos EUA por estar em conformidade com os requisitos do DHH...

Page 13: ...el ngde p 650 670 nanometer indkapslet i en ikke servicerbar printhovedsamling Lasersystemet og printeren er udviklet p en s dan m de at der ikke er en direkte laserstr ling der overskrider Klasse I n...

Page 14: ...inneholder en intern AlGaInP laser av klasse IIIb 3b som produserer synlig str ling i b lgelender p 650 670 nanometer i en ikke reparerbar skrivehodeenhet Lasersystemet og skriveren er utformet slik...

Page 15: ...Notices and safety information xv 7525 63x Go Back Previous Next...

Page 16: ...xvi Service Manual 7525 63x Go Back Previous Next...

Page 17: ...tenance qualifi Le d montage et l entretien de ce produit pouvant pr senter certains risques lectriques le personnel d entretien qualifi devra prendre toutes les pr cautions n cessaires ATTENTION Ce s...

Page 18: ...informaci n sobre el mantenimiento de este producto est dirigida exclusivamente al personal cualificado de mantenimiento Existe mayor riesgo de descarga el ctrica y de da os personales durante el des...

Page 19: ...d aquest producte est orientada exclusivament a professionals i no est destinada a ning que no ho sigui El risc de xoc el ctric i de danys personals pot augmentar durant el proc s de desmuntatge i de...

Page 20: ...ng and installing FRUs 5 Locations uses illustrations to identify the connector locations and test points on the printer 6 Preventive maintenance contains the lubrication specifications and recommenda...

Page 21: ...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...

Page 22: ...xxii Service Manual 7525 63x Go Back Previous Next...

Page 23: ...can also support a 550 sheet option while the 650 sheet duo drawer is attached Models The Lexmark X548 Series MFPs are available in the following models Options and features Certain options are availa...

Page 24: ...K or Replace appears To print a Menu Settings page from the home screen navigate to Reports Menu Settings Page Replacement is recommended every 30 000 pages for the imaging unit 4800 CQ default full p...

Page 25: ...SB 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 512MB 1GB siz...

Page 26: ...Print quality is maintained Power Saver is set to one minute Fuser standby is off The operator panel back light is off Power supply energy consumption is reduced Energy Paper Settings associated with...

Page 27: ...Depth Weight Lexmark X548de 463 mm 18 2 in 440 mm 17 3 in 597 mm 23 5 in 27 8 kg 61 3 lb Lexmark X548dte 597 mm 23 5 in 440 mm 17 3 in 597 mm 23 5 in 32 1 kg 70 7 lb 550 sheet duo drawer 133 mm 5 2 i...

Page 28: ...ce Manual 7525 63x Go Back Previous Next Clearances Description Clearances 1 Rear 102 mm 4 in 2 Right side 508 mm 20 in 3 Front 152 mm 6 in 4 Left side 76 mm 3 in 5 Top 254 mm 10 in 2 3 4 32 07 kg 70...

Page 29: ...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 Al...

Page 30: ...dB Quiet mode duplex printing color 48 dB Environment Specifications Operating Air temperature operating 16 32 C 60 90 F Air temperature power off 10 43 C 50 110 F Air relative humidity 8 80 RH Wet bu...

Page 31: ...inputs is 4 650 sheet duo drawera includes 100 sheet MP feeder 550 sheets or 100 sheets in MP feeder Multipurpose tray capacity 650 sheet duo drawer 100 sheets Optional third tray capacity 550 sheets...

Page 32: ...210 mm 5 83 x 8 3 in A6 105 x 148 mm 4 1 x 5 8 in JISb B5a 182 x 257 mm 7 2 x 10 1 in Letter 216 x 279 mm 8 5 x 11 in Legal 216 x 356 mm 8 5 x 14 in Executivea 184 x 267 mm 7 3 x 10 5 in Oficio Mexic...

Page 33: ...176 x 250 mm 3 9 x 6 3 in to 6 9 x 9 8 in a The MP feeder runs slower if A5 Statement B5 A6 Executive Statement Universal narrower than 210mm or envelopes are loaded b Japanese Industry Standard c Alt...

Page 34: ...lain paper Card stock Transparency Recycledb Glossy Paper backed labels Bond Envelopes Rough envelopes Letterhead Preprinted Colored Light Heavy Rough or cotton Custom type x b a For MP feeder and man...

Page 35: ...Light Paper 75 to 89 9 g m2 grain long 20 to 23 8 lb bond Plain Paper 90 to 104 9 g m2 grain long 23 9 to 27 8 lb bond Heavy Paper 105 to 176 g m2 grain long 27 9 to 47 lb bond 7 Card stock Specialty...

Page 36: ...printer fuser Preprinted papers that require a registration the precise location on the page greater than 2 3 mm 0 9 in such as optical character recognition OCR forms In some cases registration can b...

Page 37: ...the world using chamber tests for different temperature and humidity conditions Lexmark has found no reason to discourage the use of today s recycled office papers but generally the following property...

Page 38: ...Resolution and color depth Resolution 1200 dpi optical CDD 1200 dpi and 600 dpi Selectable through electronics Color depth 48 bit RGB output 16 bit channel Flatbed document specifications Document siz...

Page 39: ...600 x 600 dpi Duplex scan Duplex scan and copy is available on X548 series machines Scan file output formats TIFF JPEG PDF XPS Supported compressions PDF 1 bit JBIG2 CCIT G4 Flate 8 24 bit Flate JPEG...

Page 40: ...nal Level Dual RJ 11C Guaranteed North American and Europe PTT standard Input Level Range Ring Detection 16dBm 59dBm Complies with all regulatory requirements Receive 200 x 100 dpi 200 x 200 dpi 300 x...

Page 41: ...ous 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...

Page 42: ...Electrostatic Discharge FB Flatbed FRU Field Replaceable Unit GB Gigabyte HBP Host Based Printing HTML Hypertext markup language HVPS High voltage power supply Hz Hertz ITU Image Transfer Unit K Blac...

Page 43: ...al Printer Data Stream ppm Pages per minute RAM Random access memory RH Relative humidity SCC Scanner Control Card SEF Short edge feed TPS Toner Patch Sensing USB Universal Serial Bus V Volts V ac Vol...

Page 44: ...1 22 Service Manual 7525 63x Go Back Previous Next...

Page 45: ...d then go to User status and attendance messages on page 2 5 User attendance messages are indicated by a two or three digit error code that provides the user with information that explains a problem w...

Page 46: ...constant misfeeds or jams Remove and flex the paper in the tray Reload the paper and try printing Turn the paper over inside the tray Make sure the feeder is properly installed Make sure the paper is...

Page 47: ...with another fax machine The other fax machine may be turned off Ask the fax recipient to check their machine Incoming fax has blank spaces or poor quality The sending fax machine may be faulty The s...

Page 48: ...page 2 50 Insufficient fusing Go to Print quality insufficient fusing on page 2 50 Missing image at edge Go to Print quality missing image at edge on page 2 50 Mottle 2 5mm speckles Go to Print quali...

Page 49: ...ing Change paper source to custom string load orientation Change paper source to paper size Change paper source to paper size load orientation Change paper source to paper size paper type Change paper...

Page 50: ...h custom string Load src with size Load src with type size Load Manual Feeder with custom type name Try one or more of the following Load the specified paper in the manual feeder Touch Prompt each pag...

Page 51: ...e Save after receiving this message make sure the link buffers are set to Auto and then exit the menus to activate the link buffer changes When Ready appears enable Resource Save Install additional me...

Page 52: ...ne or more of the following Remove the specified tray Touch Continue to clear the message and continue printing without using the specified tray 61 Remove defective disk Try one or more of the followi...

Page 53: ...Order a replacement toner cartridge immediately 2 Remove the specified cartridge 3 Firmly shake the cartridge side to side and front to back several times to redistribute the toner 4 Reinsert the cart...

Page 54: ...touch More Information 2 Touch Continue to clear the message and continue printing 82 xx Waste toner bottle missing Reinsert the waste toner bottle into the printer 88 xx Color cartridge critically l...

Page 55: ...See 242 243 paper jam on page 3 52 243 xx Paper Jam Check area or 243 xx Paper Jam x Pages Jammed A single or multiple page media jam in the optional 550 sheet drawer tray 3 Multiple pages of media ar...

Page 56: ...e ADF cover is open while paper is fed through the ADF Remove the paper from the ADF and close the ADF cover If the error recurs go to ADF cover open service check on page 2 62 293 Replace all origina...

Page 57: ...nthead service check on page 2 54 106 11Service Yellow Printhead Failure writing data to printhead Perform a POR If the problem persists go to Printhead service check on page 2 54 106 12 Service Yello...

Page 58: ...o achieve lock Perform a POR If the problem persists go to Printhead service check on page 2 54 108 04 Service Magenta Printhead The magenta printhead mirror motors lost PLL motor lock Perform a POR I...

Page 59: ...Printhead Printhead declared error Perform a POR If the problem persists go to Printhead service check on page 2 54 122 xx Service Fuser Error Fuser error Go to Fuser service check on page 2 38 122 01...

Page 60: ...hange between interrupts Go to 90x xx error 902 xx 907 xx service check on page 2 31 141 05 Service Staging Motor Staging motor has encountered a stall timeout Go to 90x xx error 902 xx 907 xx service...

Page 61: ...drive service check on page 2 40 8xx xx service errors 840 01 Scanner disabled The scanner is disabled and can t be used Enter the configuration menu and re enable the scanner module Go to 840 xx err...

Page 62: ...es 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 60...

Page 63: ...at a modem should be present 848 01 Modem Config ID Mismatch A device has a modem installed but its Configuration ID indicates that a modem shouldn t be present 849 HD Config ID mismatch A device does...

Page 64: ...w voltage power supply did not detect zero crossing Replace the LVPS Go to Low voltage power supply LVPS assembly removal on page 4 48 940 xxService Cyan TMC Sensor The cyan cartridge toner meter cycl...

Page 65: ...ROM or NAND flash failed the Cyclic Redundancy Check CRC check or the NAND experienced an uncorrectible multi bit failure loc indicates the source of the failure and has one of the following values CR...

Page 66: ...on page 4 19 959 22 Service RIP board Challenge secret failure ASIC SP mismatch Replace RIP board See RIP board removal on page 4 19 959 23 Service RIP board System self test failure during initializa...

Page 67: ...network port If unable to clear the error message check the following If installed check the RIP board for correct installation If correctly installed replace the RIP board See RIP board removal on p...

Page 68: ...Level Select a lower Max Speed value under Fax Send settings 800 Received EOT unexpectedly from the modem in V 34 mode If error persists disable V 34 modulation scheme 802 Too many timeouts occurred...

Page 69: ...ted speed using V 34 modulation scheme Adjust Transmit Level Adjust to a lower modulation scheme 815 Fax transmission was interrupted due to power failure Troubleshoot MFP If the error persists see Mo...

Page 70: ...lly at 2400 bps in V 27 terminal modulation scheme Adjust Transmit Level Check line quality 889 Failed to connect at the minimum speed supported by the MFP Adjust Transmit Level Incompatible connectio...

Page 71: ...te fax device No action needed A02 Received request for unsupported image resolution from remote fax device No action needed A03 Received request for unsupported compression type from remote fax devic...

Page 72: ...p 2 Problem resolved 2 Write down the exact 900 xx error code displayed Turn the device off Clear the print queues Disconnect all communication cables and remove all memory options Remove all ISP and...

Page 73: ...o to step 10 9 Upgrade the firmware Contact your next level of support for the correct firmware level to use Restart the printer to operating mode Send the printer a print job Does the 900 xx error re...

Page 74: ...ur Go to step 24 Go to step 23 23 Run a job to test the option Does the 900 xx error reoccur Go to step 24 Go to step 26 24 Upgrade the firmware Contact your next level of support for the correct firm...

Page 75: ...em Driver used PCL PS Frequency of the occurrence of the error Step Questions actions Yes No 1 Turn the printer off and remove the rear shield See Rear shield removal on page 4 7 Check the cable conne...

Page 76: ...mechanism service check Note The input S2 sensor is part of the autocompensator mechanism ACM and is not available separately Step Questions actions Yes No 1 Have any updates been made to the firmware...

Page 77: ...rm the standard bin sensor base sensor test See BASE SENSOR TEST on page 3 20 Toggle the bin full flag attached to the rear shaft of the redrive unit Does the flag rotate freely and interrupt the sens...

Page 78: ...voltage Is the line voltage correct Go to step 2 Inform the customer 2 Is the AC line cord damaged Replace the line cord Go to step 3 3 Is the JLVPS1 cable correctly connected at JLVPS1 on the RIP bo...

Page 79: ...tructing the sensor Remove the obstruction and restart the test Go to step 4 4 Inspect the spring loaded shaft flag in the tray The flag portion of the shaft intercepts the sensor except when a sheet...

Page 80: ...itches in the door Open the toner cover and check the motion of the web Is the web loose damaged or missing Replace the right cover assembly See Right cover removal on page 4 7 Go to step 3 3 Open the...

Page 81: ...nter Diagnostics Menu 1 Turn off the printer 2 Press and hold 3 and 6 3 Turn on the printer 4 Release the buttons when the progress bar appears Perform the Base Sensor Test See BASE SENSOR TEST on pag...

Page 82: ...ear shield See Rear shield removal on page 4 7 Check the cable at JFUSES1 for proper connection to the RIP board the cable for pinch points and the cable or connector for any other damage Is the cable...

Page 83: ...the buttons when the progress bar appears Perform the Base Sensor Test See BASE SENSOR TEST on page 3 20 1 Navigate to BASE SENSOR TEST Input S2 2 Pull Tray 1 out and rotate the S2 sensor flag S2 is l...

Page 84: ...n the printer off and remove the rear shield See Rear shield removal on page 4 7 Check the cable at JCARTB1 for proper connection to the RIP board the cable for pinch points and the cable or connector...

Page 85: ...s properly connected Go to step 3 Go to step 2 2 Reconnect the cables POR the device into Diagnostics mode and perform the button test See Button Test on page 3 17 Do any of the buttons fail the test...

Page 86: ...User interface controller card cable removal on page 4 112 POR the device Does this fix the problem Problem resolved Go to step 5 5 Are the LEDs on the operator panel lit Go to step 6 Go to step 7 6...

Page 87: ...ace the RIP board See RIP board removal on page 4 19 Replace the USB cable See USB cable removal on page 4 112 Step Questions actions Yes No 1 Is the USB cable properly connected to the MFP and host P...

Page 88: ...e network is wireless got to step 3 Go to step 2 2 Connect the ethernet cable Did this fix the problem Problem resolved Go to step 3 3 Check the printer s online status under Printers and Faxes on the...

Page 89: ...ht 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 car...

Page 90: ...unter was not reset Has the imaging unit been recently replaced Reset the value To reset this value 1 In the Ready mode touch 2 Navigate to Supplies Menu Replace Supplies 3 Select the imaging unit to...

Page 91: ...he packing material 2 Print a document that requires all four colors with just a few characters to verify if one specific color is a problem For example print the Print Quality Test Pages 1 Enter the...

Page 92: ...idge contacts from the HVPS to the IU Are all the toner cartridge contacts clean on both the pin and IU Go to step 6 Clean the developer cartridge contacts See Developer unit removal on page 4 47 6 Ar...

Page 93: ...they are not bent corroded or damaged Replace the high voltage power supply as necessary See High voltage power supply HVPS with spring assembly removal on page 4 40 Print quality half color page A ph...

Page 94: ...e missing color black cyan magenta or yellow See Developer unit removal on page 4 47 Check the various rollers in the printer for debris Step Questions actions Yes No 1 Is the printer setup to use the...

Page 95: ...toconductor unit See Developer unit removal on page 4 47 Problem solved Replace the developer unit See Developer unit removal on page 4 47 Step Questions actions Yes No 1 Is there any loose or foreign...

Page 96: ...n page 4 47 2 Measure the distance from the original image to the same point on the residual image Is the distance 43 9 mm Replace the developer corresponding to the color of the image See Developer u...

Page 97: ...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 Replace the printhead See Printhead removal on page 4...

Page 98: ...hield removal on page 4 7 Check the cable at JMIRR1 for proper connection to the RIP board the printhead cable for pinch points and the cable or connector for any other damage Is the cable damaged Rep...

Page 99: ...st see BASE SENSOR TEST on page 3 20 Does the operator panel display a change of state Replace the toner cartridge Replace the toner meter cycle TMC card See Toner meter cycle TMC card removal on page...

Page 100: ...HVPS High voltage power supply HVPS with spring assembly removal on page 4 40 Replace the RIP board See RIP board removal on page 4 19 Step Questions actions Yes No 1 When the printer is in Ready stat...

Page 101: ...g used Go to step 2 Go to step 4 2 If two option trays are being used is the 550 sheet tray on the bottom Go to step 4 Go to step 3 3 Switch the order of the trays so the 500 sheet tray is on the bott...

Page 102: ...tray failed to appear go to step 10 9 Remove the 650 sheet tray from the printer attach the 550 sheet tray directly to the printer and print a page from the 550 sheet tray Did the page print Go to ste...

Page 103: ...onnections on the ADF relay card and RIP board POR the device into Configuration mode Go to Disable Scanner and select Enabled See Disable Scanner on page 3 39 POR the device into operating mode Try r...

Page 104: ...lved Contact your next level of support Step Questions actions Yes No 1 Print a menu page or a page from the host Is the page black See Print quality solid color page on page 2 53 Go to step 2 2 Is th...

Page 105: ...V ac Is voltage present Replace the flatbed unit See Flatbed removal on page 4 75 Replace the RIP board Go to RIP board removal on page 4 19 Step Questions actions Yes No 1 POR the printer Does the CC...

Page 106: ...to step 6 Go to step 5 5 Fix the actuator so it moves freely Did this fix the problem Problem resolved Go to step 6 6 Remove the ADF rear cover and inspect the ADF cover closed sensor for dirt and deb...

Page 107: ...Go to step 3 Set the paper guides so they contact the edges of the paper 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 Prope...

Page 108: ...e paper is skewing when it is fed into the ADF check the paper guide width Is it set correctly Go to step 3 Set the paper guides so they make contact with the edges of the paper 3 If paper is skewing...

Page 109: ...rs working properly Go to step 3 Clean the actuators If any actuators on the ADF are broken replace the ADF unit See Duplex ADF removal on page 4 87 3 Check all the connections on the ADF relay card A...

Page 110: ...oblem Problem resolved Go to step 5 5 Is the modem card ribbon cable properly connected to the RIP board at JMOD2 and the modem card Go to step 7 Go to step 6 6 Properly connect the modem card cable t...

Page 111: ...roperly functioning phone jack Does this fix the problem Problem resolved Go to step 5 5 Is the phone line being used by the MFP an analog line Go to step 8 Go to step 6 6 Is the line being used a VOI...

Page 112: ...from the default value Did this fix the problem Problem resolved Go to your second level of support See Escalating a fax issue to next level support on page 2 70 Step Questions actions Yes No 1 Is th...

Page 113: ...munications with a different remote device Can the other device receive faxes The issue is with the other device Go to step 15 15 Go to the Administrative menu Enter the Fax settings Analog Fax Settin...

Page 114: ...check list displays 19 Adjust the Receive Threshold setting in the SE menu press 411 to enter the SE menu enter Modem settings and select Receive Threshold Test by adjusting the received signal level...

Page 115: ...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 Che...

Page 116: ...2 72 Service Manual 7525 63x Go Back Previous Next...

Page 117: ...he button functions only within the Fax menu or with fax functions When outside of the Fax menu fax function or home screen pressing causes an error beep 4 Back In the Copy menu press to delete the ri...

Page 118: ...6 Home Press to return to the home screen 7 Submit Press to initiate the current job indicated on the display From the home screen press to start a copy job with the default settings If pressed while...

Page 119: ...marks URL into a tree view of folders and file links Note The tree view supports only bookmarks created from this function and not from any other application Held Jobs Display all current held jobs Ot...

Page 120: ...appears enabling you to scroll through the jobs Change Language Launch the Change Language pop up window that allows you to change the primary language of the printer Icon Button Function Supplies Men...

Page 121: ...acturing and servicing the printer Go to Diagnostics Menu Diag Menu on page 3 6 for more information Invalid Engine Code Mode 1 Turn off the printer 2 Press and hold 3 4 and 6 simultaneously 3 Turn on...

Page 122: ...anes See Alignment Menu on page 3 11 Magenta Yellow Factory Scanner See Factory Scanner on page 3 13 Factory Manual See Factory Manual on page 3 13 Scanner Calibration Copy Quick Test See Copy Quick T...

Page 123: ...on page 3 22 Engine Setting 1 See Engine Setting 1 through 4 on page 3 22 Engine Setting 2 Engine Setting 3 Engine Setting 4 Model Name See Model Name on page 3 22 Configuration ID See Configuration I...

Page 124: ...g on page 3 26 DEVELOPMENT MENU Do not use For development use only SCANNER TESTS ASIC Test See ASIC Test on page 3 26 Feed test See Feed Test on page 3 26 Sensor Tests See Sensor Tests on page 3 26 S...

Page 125: ...oves the image up and decreases the top margin No compression or expansion occurs Bottom margin 25 to 25 Each increment causes approximately 0 55 mm shift in the bottom margin The default value is 0 A...

Page 126: ...stration shows proper alignment versus skewed alignment Quick Test The Quick Test contains the following information Print registration settings Alignment diamonds at the left right top and bottom Hor...

Page 127: ...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 Navigate to Alignment Menu 2 Select a color Cyan Yellow or Magenta...

Page 128: ...of the Top Margin setting to enter the sum of the numbers and touch Submit Submitting changes appears and the display returns to the Alignment Menu Print the Quick Test again to verify if the observe...

Page 129: ...re the same 7 On the second page of the latest Quick Test pages printed proceed to Step 2 adjust the left right and bow settings Continue printing the Quick Test after each adjustment to verify the se...

Page 130: ...es These settings revert the selected scan source s IQT related black values to Nominal Black setting and its white values to Nominal White setting Note This operation should be performed only when th...

Page 131: ...uality and paper feed problems To run the Print Test Page 1 Navigate to PRINT TESTS 2 Select the media source to test 3 Select Single or Continuous If Single is selected a single page is printed If Co...

Page 132: ...Menu or the Diagnostics Menu To run the print quality pages from the Diag Menu 1 Navigate to PRINT TESTS Print Quality Pages 2 Printing Quality Test Pages appears and the pages print Note Once the tes...

Page 133: ...ates a POR and Resetting the Printer appears 4 After POR the printer begins testing the memory DRAM Test 512MB P F appears P represents the number of times the memory test has passed and finished succ...

Page 134: ...Test Page for the 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...

Page 135: ...the back aligns with the top margin of the front 3 Select Top Margin from DUPLEX TESTS 4 Touch or to adjust the margin setting Each increment shifts the duplex top margin by 1 100 of an inch The Top...

Page 136: ...tray MP Feeder Sensor Value How to test Front Door Value open Value closed Open and close front door The sensor should change state Standard Bin Bin empty Bin full Toggle the bin full media flag attac...

Page 137: ...CE TESTS Quick Disk Test 2 Quick Disk Test Testing DO NOT POWER OFF appears 3 When the test is complete Quick Disk Test Test Passed or Quick Disk Test Test Failed appears Disk Test Clean This test per...

Page 138: ...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 manufact...

Page 139: ...1 Navigate to PRINTER SETUP Reset Maintenance Counter Reset Maintenance Counter 2 Resetting Maintenance Counter appears Reset Fuser Cnt Resets the fuser count value to zero The Event Log records each...

Page 140: ...he TPS sensor is set at manufacturing If a sensor is replaced enter the 32 digit hexadecimal TPS value associated with the sensor To enter the value 1 Navigate to TPS Setup 2 Select Right or Left and...

Page 141: ...f entries exists you may scroll down to view the next set of entries To view the event log navigate to EVENT LOG Display Log Print Log The Event Log printed from DIAGNOSTICS includes Detailed printer...

Page 142: ...the paper size 3 Touch Submit Feed Test Running appears 4 Running Flatbed xxxx ADF xxxx appears while the feed test is executing 5 Press Stop to end the test Sensor Tests A series of sensor tests are...

Page 143: ...top cover 3 Press and hold the ADF paper present sensor actuator A at the top of the ADF unit 4 The value of ADF Paper should change from 0 to 1 if the sensor is working properly 5 Press to return to...

Page 144: ...properly 5 Press to return to SCANNER TESTS ADF cover open sensor test This test verifies the functionality of the ADF cover closed sensor To test this sensor perform the following steps 1 ADF Cover...

Page 145: ...ing steps 1 Scan 1st Sensor 0 appears 2 Lift the ADF top cover and close the ADF cover sensor by pressing down on the ADF sensor actuator A with a small flat blade screwdriver 3 Press the Sensor 1 act...

Page 146: ...Sensor 0 appears 2 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 3 Move the Sensor 2 actuator by inserting a...

Page 147: ...t this setting 1 Navigate to SCANNER TESTS ADF Magnification 2 Touch or to adjust the setting 3 Touch Submit to save the setting or touch Back to return to the Diagnostics Menu without saving any chan...

Page 148: ...Location on page 3 37 Automatic Color Adjust See Automatic Color Adjust on page 3 37 ADF Edge Erase See ADF Edge Erase on page 3 38 FB Edge Erase See FB Edge Erase on page 3 38 Scanner Manual Registra...

Page 149: ...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 print the pages 1 Navigate to Print Qu...

Page 150: ...white gap that is caused by incorrect registration To adjust this setting 1 Navigate to Color Trapping 2 Touch or to adjust the setting 3 Touch Submit to save the setting or touch Back to return to th...

Page 151: ...er memory RAM are deleted 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 Infra...

Page 152: ...er 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...

Page 153: ...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...

Page 154: ...uick Test to print a Quick Test page 2 To view the ADF s current registration Place the Quick Test page in the ADF with the image facing up and touch Copy Quick Test to view the frontside registration...

Page 155: ...e All Information on Disk Note Due to the lengthy amount of time required to wipe the entire hard disk a wipe should not be initiated unless it is absolutely unavoidable or unless the device can remai...

Page 156: ...to save the setting or touch Back to return to the Configuration Menu without saving any changes Require Standby This setting determines if the Standby Mode is On or Off The default is On To change th...

Page 157: ...this operation erases any strings that have been defined by the user for the default or alternate custom messages To clear custom status 1 Navigate to Clear Custom Status 2 Touch Clear Custom Status...

Page 158: ...Configuration Menu without saving any changes Automatically Display Error Screens To change this setting 1 Navigate to Automatically Display Error Screens 2 Touch or to change the setting 3 Touch Sub...

Page 159: ...information Optra Forms mode On or off CODE Network Code Level Displays network code level Network Compile Info Displays compile information Printer Code Level Displays printer code information Printe...

Page 160: ...his hasn t been done an attempt to back up the data should be performed before replacing the RIP Board To back up the eSF applications and settings 1 POR the device into invalid engine code mode See M...

Page 161: ...ing it Do not 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 print...

Page 162: ...e 3 48 3 202 In the fuser See 202 paper jam on page 3 49 4 230 In the duplex unit See 230 paper jam on page 3 50 5 235 In the duplex unit Note This jam number indicates that the paper being used for a...

Page 163: ...Next 200 paper jam 1 Pull out the standard 250 sheet tray Tray 1 2 Grasp the jammed paper on each side and gently pull it out Note Make sure all paper fragments are removed 3 Insert the tray 4 From t...

Page 164: ...Make sure all paper fragments are removed There may be a second sheet jammed if 200 xx Paper Jam and 202 xx Paper Jam appear 3 Close the front door 4 From the printer display touch Continue jam clear...

Page 165: ...jam 1 Raise the scanner assembly to the up position 2 Open the front cover 3 Grasp the green lever and pull the fuser cover CAUTION The inside of the printer might be hot To reduce the risk of injury...

Page 166: ...er 2 Grasp the jammed paper on each side and gently pull it out Note Make sure all paper fragments are removed 3 From the printer display touch Continue jam cleared 235 paper jam This jam occurs when...

Page 167: ...Next 241 paper jam 1 Pull out the standard 250 sheet tray Tray 1 2 Grasp the jammed paper on each side and gently pull it out Note Make sure all paper fragments are removed 3 Insert the tray 4 From t...

Page 168: ...the 550 sheet tray Tray 3 2 Grasp the jammed paper on each side and then gently pull it out Note Make sure all paper fragments are removed 3 Align the tray and insert it 4 From the printer display to...

Page 169: ...l original documents from the ADF input tray 2 Open the ADF cover Remove the jammed paper 3 Close the ADF cover 4 Open the flatbed cover Remove any jammed pages Note Make sure all paper fragments are...

Page 170: ...lace the ADF input tray 5 From the printer display touch Continue jam cleared Updating printer firmware The latest firmware can be found by going to http support lexmark com printerfirmware and inputt...

Page 171: ...oconductor PC unit 4 First transfer to the ITU and second transfer to the media 5 Fuse the toner to the media 6 Clean erase the photoconductor and the ITU In summary the printer s RIP board receives p...

Page 172: ...t for the laser beam Service tips 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 t...

Page 173: ...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 Never touch the surface of the photocond...

Page 174: ...e 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 Never touch the surface of the developer r...

Page 175: ...t surface to surface contact between the Photoconductors and the ITU belt Service tips Never touch the surface of the ITU belt with your bare hand The oil from your skin will cause a charge differenti...

Page 176: ...e charge Once the image on the transfer belt reaches the transfer roll the negatively charged toner clings to the media and the entire image is transferred from the transfer belt to the media Service...

Page 177: ...damaged they can cause toner to be pulled off the page or cause paper jams Toner that rubs off a printed page can be a sign of a malfunctioning fuser or an improper media setting Always check the pap...

Page 178: ...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 bla...

Page 179: ...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 prepare...

Page 180: ...o 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 printer s feed and t...

Page 181: ...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...

Page 182: ...duplex ADF The X548 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 moto...

Page 183: ...er 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 o...

Page 184: ...reate 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 fo...

Page 185: ...he 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 comb...

Page 186: ...nt on the value entered in the RGB or CMYK Increment box To access a detailed Color Samples set from the Embedded Web Server 1 Open a Web browser 2 In the address bar type the network printer IP addre...

Page 187: ...e 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 throug...

Page 188: ...l screws before final tightening Print engine removal procedures Notes Remove the waste toner container color toner cartridges imaging unit and media tray before removing other printer parts The imagi...

Page 189: ...t cover Note Support the door with one hand after removing the screw holding the restraining strap This is the longest of the eight screws Two flat headed Phillips screws are used in the door hinge 7...

Page 190: ...er to the lower front cover 3 Pull the front middle cover away from the front cover Left cover removal Note Some printers may have a filter installed on the fan grill Remove the filter before continui...

Page 191: ...Repair information 4 5 7525 63x Go Back Previous Next 4 Remove the three screws A on the rear side of the left cover A...

Page 192: ...and 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 the cover Instal...

Page 193: ...he flatbed assembly to the raised position 2 Open the front cover 3 Release the green latches securing the door 4 Lower the right cover and remove it from the hinges Rear shield removal The rear shiel...

Page 194: ...us Next AIO back cable cover removal Note Some printers may have a filter installed on the fan grill Remove the filter first before continuing with the removal procedure 1 Remove the two screws A secu...

Page 195: ...driver under the bottom of the cover and gently pry the cover upward Top cover assembly removal 1 Remove the flatbed assembly Go to Flatbed removal on page 4 75 2 Remove the AIO toner cover Go to AIO...

Page 196: ...4 10 Service Manual 7525 63x Go Back Previous Next 4 Remove the screw B from the top right side of the cover 5 Remove the four screws C on the right side of the top cover B C...

Page 197: ...ed for the new top cover 7 Detach the re drive belt F from the pulley on the fuser exit roll shaft 8 Disconnect the fan power cable from JFAN1 on the RIP board 9 Disconnect the bin full sensor cable f...

Page 198: ...ttached spring and belt 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...

Page 199: ...Remove the rear shield See Rear shield removal on page 4 7 3 Remove the left cover See Left cover removal on page 4 4 4 Remove the right cover See Right cover removal on page 4 7 5 Disconnect the ACM...

Page 200: ...4 14 Service Manual 7525 63x Go Back Previous Next 9 Remove the two springs D 10 Remove the two screws E on the bottom D...

Page 201: ...ocation 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 f...

Page 202: ...oval 1 Remove the flatbed unit See Flatbed removal on page 4 75 2 Using a small flat blade screwdriver gently depress the tabs A which secure the sensor to the top cover assembly 3 Pull the sensor awa...

Page 203: ...ous Next Narrow media sensor flag removal 1 Open the front cover 2 Remove the narrow media sensor flag 3 Remove the cable from the retainer Note Be sure to note the routing for reinstallation 4 Discon...

Page 204: ...Clean the contact surface where you removed the sensor retaining plate or where you need to install the new one 2 Guide the latches that hold the sensor in the bracket into place 3 Remove the backing...

Page 205: ...ponents 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 Note Back u...

Page 206: ...4 20 Service Manual 7525 63x Go Back Previous Next 5 Disconnect all the cables from the RIP board 6 Remove the six screws B securing the RIP board to the RIP board cage B...

Page 207: ...d properly The cable may have come loose from the HVPS 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 conne...

Page 208: ...Go Back Previous Next Tuck the printhead cable toroid C as shown below Failure to do so can damage the RIP board Note Pay attention to the jumper configuration D An improper configuration will cause t...

Page 209: ...al Note If the duplex reference edge is made of plastic then replace it If the duplex reference edge is made of metal then do not replace it 1 Open the front door 2 Remove the four short screws A in f...

Page 210: ...ervice Manual 7525 63x Go Back Previous Next 3 Lift the duplex aligner on the right side and disengage the gears C on the left 4 Remove the four screws D from the duplex reference guide and remove the...

Page 211: ...information 4 25 7525 63x Go Back Previous Next Installation notes 1 Depending on the kind of front cover follow the procedure that applies If the front cover has a slot a Place the tab in the slot Sl...

Page 212: ...4 26 Service Manual 7525 63x Go Back Previous Next b Rotate the tab into position and replace the three screws A A...

Page 213: ...Repair information 4 27 7525 63x Go Back Previous Next If the front cover does not have a slot a Place the tab against the cover b Replace the two screws B Tab B...

Page 214: ...bearing on the left 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 3 Align...

Page 215: ...Duplex sensor removal 1 Remove the waste toner bottle See Waste toner bottle removal on page 4 73 2 Remove the two screws A from the cable channel cover 3 Pull the corner of the cable channel cover B...

Page 216: ...lightly 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 surfa...

Page 217: ...Go Back Previous Next Fax card removal 1 Remove the rear shield See Rear shield removal on page 4 7 2 Disconnect the fax card cable A from the RIP board 3 Open the fax card cover and remove the three...

Page 218: ...ove the left cover See Left cover removal on page 4 4 3 Disconnect the two wire fuser cable A from the LVPS 4 Position the fuser cable so that it can be pulled through from the front of the printer an...

Page 219: ...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 towar...

Page 220: ...4 34 Service Manual 7525 63x Go Back Previous Next Warning Be careful not to interfere or damage the fuser exit sensor located to the left of the fuser F...

Page 221: ...e right make sure the gears mesh Be careful not to interfere with the exit sensor on the left side Reroute the cables back through their retainers After replacing a new fuser make sure to reset the Fu...

Page 222: ...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 the toroid B is removed from the cable be sure to reinstall the...

Page 223: ...ht cover removal on page 4 7 3 Remove the left cover See Left cover removal on page 4 4 4 Disconnect the two wire fuser cable A from the LVPS Note You do not have to extract the cable 5 Remove the scr...

Page 224: ...ve the cable routing 8 Unhook the springs D from both sides of the fuser 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...

Page 225: ...mation 4 39 7525 63x Go Back Previous Next Hard drive removal 1 Remove the rear shield See Rear shield removal on page 4 7 2 Disconnect the hard drive cable A from the RIP board 3 Pull the hard drive...

Page 226: ...ng assembly removal 1 Remove the left cover Note There should be a leaf spring A biasing the HVPS upward 2 Remove the rear shield See Rear shield removal on page 4 7 3 Remove the RIP board See RIP boa...

Page 227: ...4 41 7525 63x Go Back Previous Next 5 Remove the screw B securing the HVPS 6 Press down on the spring mount and carefully slide the HVPS out Release the pressure on the spring mount when the LVPS slid...

Page 228: ...ot to dislodge the cable from the HVPS When reinserting the HVPS make sure to slightly raise the board to avoid snagging the locating pin C and the two protruding screws D Damage may occur to the comp...

Page 229: ...bottle removal on page 4 73 5 Remove the imaging unit IU See Imaging unit IU removal on page 4 63 Note The ITU FRU includes a spring clamp kit If the printer does not have this kit installed perform t...

Page 230: ...4 44 Service Manual 7525 63x Go Back Previous Next 2 Remove the rubber pad C 3 Place the spring clamp onto the shaft D 4 Snap the new gear onto the shaft D The installation is the same as the old gear...

Page 231: ...inuing the removal with or without spring clamp kit 1 Disconnect the one spring A from the side frames leaving them attached to the ITU or spring clamp 2 Rotate the left spring B and pivot the cam awa...

Page 232: ...le pulling the ITU toward the front 4 Hold the release lever while removing the ITU Installation notes Write down the 16 digit numeric value of the new FRU before you begin to install it You may have...

Page 233: ...vigate to PRINTER SETUP ITU Barcode 3 Enter the 16 digit value 4 Touch Submit to save the changes 5 CHECK SUM DOES NOT MATCH appears if the value entered is incorrect Check and re enter the value Deve...

Page 234: ...revious Next Low voltage power supply LVPS assembly removal 1 Remove the left cover See Left cover removal on page 4 4 2 Disconnect the three cables A from the LVPS 3 Remove the six screws B and the g...

Page 235: ...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 re...

Page 236: ...move the screw A in front 2 Remove the waste toner bottle See Waste toner bottle removal on page 4 73 3 Remove the imaging unit See Imaging unit IU removal on page 4 63 4 Remove the low voltage power...

Page 237: ...s Next 7 At the rear of the printer remove the ground screw C and two screws D from the AC receptacle 8 Remove the three screws E securing the left lower frame 9 Remove the LVPS See Low voltage power...

Page 238: ...4 52 Service Manual 7525 63x Go Back Previous Next 10 Remove the screw F on top of the frame 11 Swing the left lower frame away from the printer and remove F...

Page 239: ...assembly See Right cover removal on page 4 7 3 Remove the waste toner bottle See Waste toner bottle removal on page 4 73 4 Remove the imaging unit See Imaging unit IU removal on page 4 63 5 Remove the...

Page 240: ...10 Remove the three screws C securing the lower right frame to the printer 11 Remove the screw D close to the front of the printer 12 Swing the rear part away from the printer to access the spring an...

Page 241: ...s Next 13 Lift the right lower frame pin F out of the hole in the printer frame 14 Swing the rear part away from the printer to access the spring G and remove it from the right lower frame 15 Disconne...

Page 242: ...plate J and press the latches K together to remove the tray present sensor 18 Remove the screw L and remove the spring bracket 19 Remove the screw M and remove the plate from your printer if it does...

Page 243: ...e posts extend onto the surface of the plate 5 Connect the cable to the tray present sensor and put the spring in place before installing the right lower frame Main drive gear assembly with motor remo...

Page 244: ...ner left side 5 Disconnect the cable from the fuser exit sensor 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 Pay at...

Page 245: ...5 63x Go Back Previous Next 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 11 Lift the main drive gear asse...

Page 246: ...his additional 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 1 Remove the media tray 2...

Page 247: ...o verify it turns properly in the direction shown Printhead removal 1 Remove the scanner assembly See Flatbed removal on page 4 75 2 Remove the top cover See Top cover assembly removal on page 4 9 3 D...

Page 248: ...evious Next 5 Remove the three screws B 6 Remove the printhead Installation note When the printhead is replaced perform the registration black planes and alignment color planes See REGISTRATION on pag...

Page 249: ...e developer units 1 Open the front cover 2 Lift the scanner unit by sliding the latch to the left 3 Remove the right cover assembly See Right cover removal on page 4 7 4 Remove the waste toner bottle...

Page 250: ...emoval on page 4 63 4 Remove the rear cover See Right cover removal on page 4 7 5 Remove the rear screw A in the waste toner bottle sensor contact to allow access to the cable cover Note The waste ton...

Page 251: ...x Go Back Previous Next 10 Disconnect the cable E from the RIP board at JSC1 11 Remove the cable from the retainer on the bottom of the printer 12 Extract the cable through the frame and remove the ca...

Page 252: ...ottle See Waste toner bottle removal on page 4 73 3 Remove the imaging unit IU See Imaging unit IU removal on page 4 63 4 Remove the rear shield See Rear shield removal on page 4 7 5 Disconnect and re...

Page 253: ...e 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 Remove the two machine screws A 2 Remove the two...

Page 254: ...4 43 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 RIP board If you are removin...

Page 255: ...ter the TPS value 7 Touch Submit to save the settings 8 Submitting changes displays If the value is incorrect Checksum does not match appears and the original screen appears to re enter the value If t...

Page 256: ...vious Next 7 Remove the screw D closer to the front of the printer 8 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...

Page 257: ...nnect the tray present sensor cable 12 Remove the sensor retaining plate G and then squeeze the latches together to remove the tray present sensor Installation notes 1 Clean the contact surface where...

Page 258: ...ear shield removal on page 4 7 2 Disconnect the USB connector from the RIP board 3 Remove the flatbed assembly See Flatbed removal on page 4 75 Note Do not remove the flatbed covers or any of the hing...

Page 259: ...toner bottle removal The waste toner bottle is a customer replaceable unit 1 Open the front cover 2 Lift the toner cover 3 Remove the right cover assembly See Right cover removal on page 4 7 4 Press t...

Page 260: ...oval on page 4 7 3 Remove the waste toner bottle See Waste toner bottle removal on page 4 73 4 Remove the screw A from the back of the waste toner bottle contact block 5 Remove the rear shield See Rea...

Page 261: ...e cover removal on page 4 8 2 Remove the rear shield See Rear shield removal on page 4 7 3 Remove the left cover See Left cover removal on page 4 4 4 Remove the ADF unit See Duplex ADF removal on page...

Page 262: ...ed unit 8 Remove the screw C that fastens the redrive ground cable and ADF ground cableground cable to the frame 9 Disconnect JADF1 and route the cable through the top of the card cage 10 Disconnect t...

Page 263: ...Repair information 4 77 7525 63x Go Back Previous Next 11 Disconnect the operator panel ground cable D from the LVPS 12 Thread the ground cable E under the top cover D E...

Page 264: ...e 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 G securing the flatbed hinge to the top cover 16 Remove the two springs...

Page 265: ...les 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 flatbed as...

Page 266: ...drive unit L See Redrive unit removal on page 4 93 23 Remove the cable cover plates and scanner homing plates M These will be used on the replacement flatbed unit Warning When replacing the rear cable...

Page 267: ...ecuring the flatbed link to the flatbed 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...

Page 268: ...ual 7525 63x Go Back Previous Next 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 t...

Page 269: ...line B and remove the paper backing from the adhesive strip located next to the folding guide line on the scanner 4 Fold the ribbon cable as shown Align the fold of the cable with the folding guide l...

Page 270: ...the flatbed and there should be no slack on the ribbon cable between the two folds 7 Replace the plastic front hinge from the old scanner 8 Replace the cable cover plates and scanner alignment guides...

Page 271: ...AIO link See AIO link removal on page 4 97 2 Remove the right scanner cover See Scanner right cover removal on page 4 94 3 Remove the AIO release lever See AIO release lever removal on page 4 96 4 Re...

Page 272: ...63x Go Back Previous Next Duplex ADF rear cover removal 1 While lifting the ADF use a flat blade screwdriver to pry open the three tabs A on the bottom of the ADF cover 2 Lift and remove the rear cove...

Page 273: ...page 4 86 Save the cover for use on the new ADF unit 2 Disconnect the ground cable A from the ADF assembly 3 Disconnect the ADF cable B from the ADF card located on the ADF assembly 4 Carefully pull...

Page 274: ...the new ADF unit perform the scanner calibration procedure and the scanner manual registration procedure See Scanner Calibration on page 3 14 and Scanner Manual Registration on page 3 38 ADF input tra...

Page 275: ...oval on page 4 4 3 Remove the AIO back cable cover See AIO back cable cover removal on page 4 8 4 Remove the rear shield See Rear shield removal on page 4 7 5 Disconnect the ground cable A from the AD...

Page 276: ...d 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 th...

Page 277: ...Back Previous Next ADF separator pad removal 1 Remove the ADF separator roll See ADF separator roll assembly removal on page 4 92 2 Press the two tabs on each side of the pad inward 3 Tilt the pad up...

Page 278: ...rvice Manual 7525 63x Go Back Previous Next ADF separator roll assembly removal 1 Lift the locking lever A 2 Slightly lift the separator roll assembly and pull it out of the mount B on the opposite si...

Page 279: ...mbly See Flatbed removal on page 4 75 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 sec...

Page 280: ...s A securing the left flatbed cover to the flatbed unit using a small flat blade screwdriver Scanner right cover removal 1 Remove the imaging unit in the print engine See Imaging unit IU removal on pa...

Page 281: ...Repair information 4 95 7525 63x Go Back Previous Next 4 While holding the ADF away from the flatbed use the other hand to lift and disengage the right scanner cover from the flatbed unit...

Page 282: ...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 fla...

Page 283: ...Previous Next AIO link removal 1 Lift the scanner to the up position Remove the screw A securing the AIO link to the AIO toner cover 2 Return the flatbed to the down position 3 Remove the screw B secu...

Page 284: ...the AIO toner cover to the scanner unit 3 Remove the screws B securing the AIO hinge to the MFP 4 Remove the hinge C Save this for the new AIO toner cover or top cover 5 Rotate the AIO toner cover so...

Page 285: ...9 7525 63x Go Back Previous Next 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 the redrive unit 3 Remo...

Page 286: ...anel bezel removal on page 4 104 2 Remove the operator panel frame cover See Operator panel frame cover removal on page 4 107 3 Remove the rear case with speaker See Rear case with speaker removal on...

Page 287: ...Repair information 4 101 7525 63x Go Back Previous Next 6 Disconnect the two cables B from the user interface controller card 7 Remove the LCD B...

Page 288: ...ver removal on page 4 8 2 Remove the rear shield See Rear shield removal on page 4 7 3 Remove the left cover See Left cover removal on page 4 4 4 Remove the ADF unit See Duplex ADF removal on page 4 8...

Page 289: ...r removal on page 4 107 3 Remove the rear case with speaker See Rear case with speaker removal on page 4 108 4 Remove the sleep button PCB See Sleep button PCB removal on page 4 110 5 Remove the sleep...

Page 290: ...4 104 Service Manual 7525 63x Go Back Previous Next Operator panel bezel removal 1 Open the front door 2 Open the top door...

Page 291: ...Back Previous Next 3 Remove the screw A from the joint linking the flatbed to the printer Warning Do not over extend the flatbed when lifting it after the screw A has been removed 4 Remove the three s...

Page 292: ...erator panel away from the printer then pry the operator panel bezel off the operator panel Warning During reinstallation be sure to properly engage the tabs of the operator panel bezel to their corre...

Page 293: ...erator panel frame cover removal 1 Remove the operator panel bezel See Operator panel bezel removal on page 4 104 2 Using a 1 0 Phillips screwdriver remove the three screws A from the rear side of the...

Page 294: ...the MFP Rear case with speaker removal The rear case with speaker is not a field replaceable unit FRU 1 Remove the operator panel bezel See Operator panel bezel removal on page 4 104 2 Remove the oper...

Page 295: ...ormation 4 109 7525 63x Go Back Previous Next 4 Pull the operator panel cover away from the rear case and disconnect the four cables B 5 Route the cables off the rear case 6 Remove the rear case with...

Page 296: ...ee Rear case with speaker removal on page 4 108 4 Remove the sleep button PCB See Sleep button PCB removal on page 4 110 5 Remove the sleep button Sleep button PCB removal 1 Remove the operator panel...

Page 297: ...Remove the operator panel bezel See Operator panel bezel removal on page 4 104 2 Remove the operator panel frame cover See Operator panel frame cover removal on page 4 107 3 Remove the rear case with...

Page 298: ...operator panel cover away from the rear case to access the USB cable 10 Route the USB cable off the rear case and remove User interface controller card cable removal 1 Remove the AIO rear cable cover...

Page 299: ...bezel removal on page 4 104 2 Remove the operator panel frame cover See Operator panel frame cover removal on page 4 107 3 Remove the rear case with speaker See Rear case with speaker removal on page...

Page 300: ...4 114 Service Manual 7525 63x Go Back Previous Next 6 Remove the user interface controller card...

Page 301: ...Top door latch 5 Right side cover 6 Standard 250 sheet tray Tray 1 7 Manual feeder 8 650 sheet duo drawer with integrated multipurpose feeder Tray 2 Note When used with the 550 sheet tray the 650 she...

Page 302: ...5 2 Service Manual 7525 63x Go Back Previous Next Rear Part name 1 Power 2 Line 3 Extension 4 Ethernet 5 USB 1 2 5 4 3...

Page 303: ...Locations 5 3 7525 63x Go Back Previous Next Print engine interior view...

Page 304: ...FAN1 JADF1 JFBM1 JCCD1 JPH1 JMIRR1 JCTM1 JSP1 JCARTB1 JTHM1 JTPS2 JHVPS1 JBIN1 JPJP1 JFUSES1 JTPS1 JTRAY1 JCVR1 JSC1 JINT1 JLVPS1 JWT1 1 1 JUIC1 JFPUSB1 JFP1 JMOD2 JOPT1 JCFAN1 JHS1 JSJ1 JETH1 JUSB1 J...

Page 305: ...C 7 I1B_ADF_C 8 Ground 9 DIRB_ADF_C 10 Ground 11 V_24_ADF 12 V_24_ADF 13 Ground 14 V_5_ADF 15 PAP_PRES2_2 16 VREF1_ADF_C 17 VREF2_ADF_C 18 PAP_PRES_C 19 ADF_CVR_C 20 FIRST_SCAN_C 21 FB_CVR_C 22 SOL1_E...

Page 306: ...2 3 CART1_HALL_V 4 V_CART2_WIND_W 5 CART1_HALL_W 6 V_CART2_WIND_V 7 CART1_PG 8 V_CART2_WIND_U 9 Ground 10 5V 11 5V 12 Ground 13 V_CART1_WIND_U 14 CART2_PG 15 V_CART1_WIND_V 16 V_CART1_WIND_W 17 V_CART...

Page 307: ...1 FBR_AFE_D 4 12 FBR_AFE_D 5 13 GND 14 FBR_AFE_D 6 15 FBR_AFE_D 7 16 GND 17 FB_AFE_VSMP_R 18 GND 19 FB_AFE_RSMP_R 20 GND 21 FB_AFE_CLK_R 22 GND 23 FB_CCD_CLAMP_R 24 GND 25 FB_CCD_RESET_R 26 GND 27 FB_...

Page 308: ...R 24V dc 2 COVER_OPEN cover open 0V dc closed 24V dc JFAN1 1 FAN_FG 2 Ground 3 V_FAN_P3 JFBM1 Flatbed Motor 1 FB_A 2 FB_A 3 FB_B 4 FB_B JFP1 1 I2CDATA 2 LED_DRV_YLW2 3 I2CCLK 4 Ground 5 PWR_BUTTON 6 3...

Page 309: ...s closed 4 V_FUSER_PHB 24V dc doors closed 5 FUSER_HR_THM AVCC 2 3 V dc 6 FUSER_HR_THM_RTN 7 5V_SW 8 Ground 9 S1_MPF_SNS 10 FUSER_BELT 11 FUSER_HR_THM_RTN 12 Ground JHD1 1 Ground 2 USBOUT 3 USBOUT 4 G...

Page 310: ..._OUT 7 CMY_SRVO_OUT 8 ITM_TX_PWM_OUT 9 CMY_TX_PWM_OUT 10 ITM_SRVO_OUT 11 K_SRVO_OUT 12 K_TX_PWM_OUT 13 24V 14 Ground 15 5V_HVPS_REF 16 Ground JINT1 1 5V Fused 2 Ground 3 VS_INT JLVPS1 1 5V 2 Ground 3...

Page 311: ...2 NC_JMOD2_2 3 POR_CHUD_R 4 3 3V 5 3 3V 6 NC_TONE_CUHD 7 5V 8 IRQ_CUHD 9 Ground 10 SDA_CUHD 11 Ground 12 SCL_CUHD 13 Ground 14 CLK_CUHD 15 Ground 16 SDO_CUHD 17 Ground 18 SDI_CUHD 19 Ground 20 CS_CUH...

Page 312: ...K 3 3 V dc 3 VDO_HSYNC0 5 V dc 4 VDO_LEN0 3 3 V dc 5 VDO_BOOST3 6 3 3V 7 VDO_BOOST1 8 5V_PH 5 V dc 9 VDO_BOOST2 Shade B 10 5V_PH 5 V dc 11 VDO_BOOST0 12 Ground 13 D_VDO_7 14 D_VDO_7 1 5 V dc 15 Ground...

Page 313: ...7 Ground 28 D_VDO_1 29 D_VDO_1 30 Ground 31 D_VDO_4 32 D_VDO_4 33 Ground 34 D_VDO_0 35 D_VDO_0 36 Ground 37 I2CCLK_PH 38 VDO_LADJ1 3 3 V dc 39 I2CDATA_PH 40 VDO_LADJ 3 3 V dc JPJP1 1 5V_SW 2 PAPER_JAM...

Page 314: ...d no wire 7 Ground 8 CATHODE 9 VOUTA 10 5V 11 VOUTB 12 ANODE 13 Ground no wire 14 ANODE 15 5V 16 CATHODE Ground JTHM1 1 TPS_THERM_SNS 1 5 V dc 2 TPS_SNS_RTN Ground JTPS1 1 ANODE 2 CATHODE 3 Ground Ano...

Page 315: ...DS 6 Y2P_LVDS 7 CLK_TX 8 CLK_TX 9 Ground 10 5 0 V dc 11 RXD232_N 12 TXD232_N 13 Y0M_LVDS 14 Y0P_LVDS 15 Ground 16 5 0 V dc 17 5 0 V dc 18 5 0 V dc JUSB1 Port G1 Ground 1 USB_5V_Sense 2 USB D 3 USB D 4...

Page 316: ...5 16 Service Manual 7525 63x Go Back Previous Next HVPS...

Page 317: ...wm 2 K Drpwm 3 C Drpwm 4 CMY Chrgpwm 5 Y Drpwm 6 K Chrgpwm 7 CMY Srvo_Out 8 I Txpwm 9 CMY Txpwm 10 I Srvo_Out 11 K Srvo_Out 12 K Txpwm 13 24V 14 24VRtn 15 VREF Buffered 16 24VRtn Contacts to machine 1...

Page 318: ...5 18 Service Manual 7525 63x Go Back Previous Next LVPS...

Page 319: ...tors LVPS board Connector Pin no Signal CN1 1 5 V 2 Ground 3 5 V 4 Ground 5 5 V 6 Ground 7 24 V 8 Ground 9 24 V 10 Ground 11 24 V 12 Ground 13 Relay drive 14 ZC out 15 Heat On 16 NC CN2 1 AC phase inp...

Page 320: ...63x Go Back Previous Next Toner meter card Connectors Toner meter card Connector Pin no Signal From JCTM1 connector on the RIP board 1 5 V_SW 2 Cart_Meter_C_IN 3 Cart_Meter_M_IN 4 Cart_Meter_Y_IN 5 C...

Page 321: ...e from any non Lexmark attachments Scheduled maintenance Customer replacable units CRUs The following parts also need to be checked for wear or damage and replaced if necessary Maintenance kit After 6...

Page 322: ...Cartridge Drive assemblies Cleaning the printer Cleaning the exterior of the printer 1 Make sure that the printer is turned off and unplugged from the wall outlet 2 Remove paper from the standard exit...

Page 323: ...eas of the scanner glass and both white underside areas 1 Slightly dampen a soft lint free cloth or paper towel with water 2 Open the scanner cover 3 Wipe the scanner glass until it is clean and dry 4...

Page 324: ...6 4 Service Manual 7525 63x Go Back Previous Next...

Page 325: ...ts packaged together and identified by the part number NS Not shown in the Asm Index column indicates that the part is procurable but is not pictured in the illustration PP Parts Packet in the parts d...

Page 326: ...7 2 Service Manual 7525 63x Go Back Previous Next Assembly 1 Covers 7 11 9 8 1 2 3 4 5 6 10...

Page 327: ...489 1 1 Cover AIO back cable 3 40X5482 1 1 Assembly Top cover 4 40X5537 1 1 Link AIO 5 40X5534 1 1 Cover AIO toner 6 40X5486 1 1 Cover Right AIO 7 40X5419 1 1 Tray asm 250 sheet 8 40X5168 2 2 Pick tir...

Page 328: ...7 4 Service Manual 7525 63x Go Back Previous Next Assembly 2 Scanner 2 1 4 3 5 6 8 10 11 12 7 13 9...

Page 329: ...0X5872 1 1 Bin full flag 5 40X8342 1 1 Asm Redrive 6 40X7529 1 1 Asm LED flatbed 7 40X5536 1 1 Lever AIO release 8 40X1569 1 1 Flatbed pivot link 9 40X5487 1 1 Cover Scanner right 10 40X5488 1 1 Cover...

Page 330: ...7 6 Service Manual 7525 63x Go Back Previous Next Assembly 3 Operator panel 1 2 3 4 7 8 5 6 9...

Page 331: ...523 1 1 Cover Operator panel bezel 2 40X6521 1 1 Display 7 inch LCD with ground cable 3 40X6519 1 1 Cover Operator panel with keypads sleep button and light pipe 4 40X6515 1 1 PCBA UICC 5 40X6516 1 1...

Page 332: ...7 8 Service Manual 7525 63x Go Back Previous Next Assembly 4 Paperpath 5 2 4 7 6 1 3 8 9 3 10...

Page 333: ...3 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 5 40X5803 1 1 Duplex reference edge 6 40X5403 1 1 Image transfer unit ITU...

Page 334: ...7 10 Service Manual 7525 63x Go Back Previous Next Assembly 5 Electronics 1 2 3 4A 4B 5 6 4C 4D 7 8...

Page 335: ...and others 7 40X0288 1 1 Power cord 2 5 m straight Argentina 7 40X0271 1 1 Power cord 2 5 m straight United Kingdom 7 40X0275 1 1 Power cord 2 5 m straight Israel 7 40X1772 1 1 Power cord 2 5 m straig...

Page 336: ...7 12 Service Manual 7525 63x Go Back Previous Next Assembly 6 Electronics 2...

Page 337: ...2 40X5414 2 1 Toner patch sensors left or right one in package 3 40X7046 1 1 Waste toner bottle contact block 4 40X5421 1 1 Imaging unit contact Pogo pin 5 40X5423 1 1 Cable packet used for A AC powe...

Page 338: ...7 14 Service Manual 7525 63x Go Back Previous Next Assembly 7 Media drawers and trays 1 3 2 4 2...

Page 339: ...heet duo drawer complete X548 includes a 100 sheet MPF 2 40X5168 2 2 Pick tire replacement CRU 3 40X2285 1 1 650 sheet duo drawer tray assembly X544n X544dn X544dw X540n X543dn includes a 100 sheet MP...

Page 340: ...kit fuser ITU duplex reference edge NS 40X5937 1 1 128MB DDR DRAM DIMM card assembly NS 40X5938 1 1 256MB DDR DRAM DIMM card assembly NS 40X5939 1 1 512MB DDR DRAM DIMM card assembly NS 40X1455 1 1 64...

Page 341: ...ck 2 31 950 xx NVRAM failure service check 2 32 9xx xx service errors 2 19 ADF service checks 2 62 autocompensator mechanism service check 2 32 bin full sensor service check 2 33 dead printer service...

Page 342: ...0 parts catalog 7 1 covers 7 3 electronics 7 11 7 13 media drawers and trays 7 15 operator panel 7 7 options 7 16 paperpath 7 9 scanner 7 5 pick tires integrated 250 sheet media tray removal 4 60 POR...

Page 343: ...2 56 service checks 900 xx system software error 2 28 90x xx error 2 31 925 01 fan error 2 31 925 01 fan error 2 31 950 xx NVRAM failure 2 32 ADF service checks 2 62 autocompensator mechanism 2 32 bin...

Page 344: ...I 4 Service Manual 7525 63x Go Back Previous Next...

Page 345: ...254 115 V Maintenance kit 7 9 7 16 40X2255 230 V Maintenance kit 7 9 7 16 40X2261 100 V Maintenance kit 7 9 7 16 40X2285 650 sheet duo drawer tray assembly 7 15 40X2512 550 sheet MPF latch cover 7 15...

Page 346: ...nese font card assembly 7 16 40X6514 PCBA RIP 7 11 40X6515 PCBA UICC 7 7 40X6516 Cable UICC 7 7 40X6517 Speaker 7 7 40X6518 EPROM PCBA 7 7 40X6519 Cover Operator panel with light pipe 7 7 40X6520 Cove...

Page 347: ...Part number index I 7 7525 63x Go Back Previous Next...

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