PRINT COPY
UP TO 25 PPM COLOR UP TO 25 PPM BLACK DUPLEX NETWORK

Lexmark X540 Series

Lexmark X543dn Lexmark X544 models

SCAN FAX AVAILABLE

Power up your workday with
Lexmark multifunction color!

Print Less. Save More.

Print less? This may seem like a surprising message for a company dedicated solely to printing. But when you consider that businesses spend, on average, up to 6% of their revenue on printing and that active print management can cut office print costs by up to 30%1, it makes a lot of sense. Lexmark products, solutions and services provide innovative ways to save you time, drive down costs and reduce your impact on the environment. We are committed to helping you print less and save more.
Source: InfoTrends/CapVentures, Network Document Solutions Forecast 2007-2012, Network Document Solutions Consulting Service, August 2008
The network-ready Lexmark X540 Series offers high-performance color and multifunction savings for cost-conscious small workgroups. Whats more, youre protected by Lexmarks Lifetime Pricing Guarantee. Lexmark guarantees, for as long as you own your MFP, not to increase the price* of toner cartridges for your Lexmark X540 MFP. Save even more when you enroll in Lexmark Rewards!
* U.S. dollar price only listed on www.lexmark.com. Other currency prices listed subject to currency fluctuation based on the U.S. dollar. This guarantee does not apply to dealer and/or distributor pricing. Lexmark reserves the right to discontinue selling these toner cartridges any time after it discontinues service support for this printer.
Easy to use, easy to share
Surprisingly compact for such a fully functioned solution, these devices are also incredibly quiet, easy to use and integrate effortlessly into your existing office environment. As quiet as 47 dBA while printing; reduce sound even more with Quiet Mode l User-friendly operator panel for easy access to all functions l PCL 6 and PostScript 3 emulations ensure compatibility with your application software l Fully network-ready for enhanced workgroup performance l Quick and convenient cartridge replacement
The power of multifunction
Built for serious office work, these new color MFPs equip you with all the productivity functions you need to maximize your business performance. Move easily between hardcopy and digital documents with advanced scanning, such as scan to desktop, scan to email or scan to shared server l Models available with duplex printing and duplex scanning l Duo Drawer combines a 100-sheet multipurpose feeder and 550-sheet tray in one unique option l Lexmark X544 models add Super G3 fax capability
Color that makes a difference!
Outstanding color adds impact to your important business documents. Lexmark puts its color expertise to work for you and gives you the tools to control color output effectively. Rich, vibrant, true 1200 x 1200 dpi color printing Lexmark High Yield Toner Cartridges to keep printing costs low l Includes new generation Lexmark toner l Consistent color balance with Pantone calibration l Color-control tools: coverage estimator and ColorSaver mode

Eco-responsible printing

Printing responsibly means everyone wins your business, your budget and the environment! Lexmarks new color MFPs are eco-designed and come with a range of features to help you print greener at every level. Models with built-in duplex offer excellent value and paper savings l Paper Saver lets you copy multiple pages per sheet l Eco-Mode reduces power consumption l Instant warm-up fuser saves energy while delivering first page quickly l Lexmark Cartridge Collection Program for leading-edge recycling

Powerful scanning features!
Duplex color scanning Saves time by scanning both sides of your document automatically
Scan to e-mail Eliminates the need for paper copies; quickly locates addresses stored in your company directory
Direct USB Front USB port for walk-up printing and scanning to memory device
Lexmark Scan Center software Scan options and scan-to destinations located on one easy-to-use window
Multi-format support Save your documents in common image formats (PDF, JPG, TIF) for viewing, sharing and use on the Web
A small office partner packed with features!

Lexmark Rewards

Green looks good on you!
Purchase a Lexmark X540 Series color laser MFP and you can save up to 20 percent of the total cost of supplies while you help save the planet. Its easy with Lexmark Rewards. Lexmark Rewards gives you free high-yield toner cartridges and imaging kits simply for using genuine Lexmark toner and returning your empty cartridges to Lexmark for recycling youll earn two rewards points just for signing up and an additional point for each cartridge return. For every 10 points earned Lexmark will send you a free high-yield toner cartridge, and when its time to replace your imaging kit well send you one of those free too. Learn more www.LexmarkRewards.com
Get exactly the performance you need

Lexmark X543dn

Network-ready, 3-in-1 compact color laser with paper-saving duplex printing Up to 21 ppm output in black and color l High-quality printing, copying and scanning l Built-in paper-saving duplex printing l Optional Duo Drawer expands input capacity and includes a multipurpose feeder l Ships with Lexmark High Yield Toner Cartridges l Recommended monthly volume: 500 to 1,500 pages

Lexmark X544 models

Reliable 4-in-1 color MFP, loaded with high-performance features Up to 25 ppm output in black and color Includes fax and high-quality duplex scanning l Direct USB port for walk-up printing and scanning to memory device l Lexmark Extra High Yield Toner Cartridges available l Recommended monthly volume: 800 to 3,000 pages
Configurations available: Lexmark X544n, Lexmark X544dn, Lexmark X544dtn, Lexmark X544dw

Product specifications

Printing Print Technology Print Speed (Letter, Black): Up to Print Speed (Letter, Color): Up to Print Resolution, Black Print Resolution, Color Memory, Standard Memory, Maximum Print Noise Level, Operating Noise Level, Idle Maximum Monthly Duty Cycle: Up to Recommended Monthly Page Volume Supplies Supplies Yield (*Average continuous black or continuous composite CMY declared cartridge yield up to this number of standard pages in accordance with ISO/IEC 19798.) Cartridge(s) Shipping with Product Copying Copy Speed (A4, Black): Up to Copy Speed (Letter, Black): Up to Copy Speed (Letter, Color): Up to Scanning ADF Scan Scanning Resolution Reduce / Enlarge Range Faxing Modem Speed Paper Handling Paper Handling Standard Paper Handling Optional Paper Input Capacity, Standard Paper Input Capacity, Maximum Paper Output Capacity, Standard Paper Output Capacity, Maximum ADF Paper Input Capacity : Up to Media Types Supported Media Sizes Supported Compatibility Network Protocol Support Printer Languages (Standard) Standard Ports 20 cpm 21 cpm 21 cpm Simplex 35000 pages per month 500 - 1500 pages 47 dBA 21 ppm 21 ppm

Lexmark X544n

Color Laser 25 ppm 25 ppm 1200 x 1200 dpi, 4800 Color Quality (1200 x 600 dpi) 1200 x 1200 dpi, 4800 Color Quality (1200 x 600 dpi) 128 MB 640 MB 48 dBA inaudible dBA 55000 pages per month 800 - 3000 pages 1,000*-page Color Toner Cartridges (CMY), 2,000*-page Color High Yield Toner Cartridges (CMY), 4,000*-page Color Extra High Yield Toner Cartridges (CMY), 2,500*-page Black High Yield Toner Cartridge, 6,000*-page Black Extra High Yield Toner Cartridge, 1,000*-page Black Toner Cartridge
1,000*-page Color Toner Cartridges (CMY), 2,000*-page Color High Yield Toner Cartridges (CMY), 2,500*-page Black High Yield Toner Cartridge, 1,000*-page Black Toner Cartridge
2,500*-page Black Return Program Toner Cartridge, 2,000*-page Color (CMY) Return Program Toner Cartridges 23 cpm 25 cpm 25 cpm RADF (reversing Duplex) 600 X 600 dpi 25 - 400 % 33.6 Kbps 150-Sheet Output Bin, Integrated Duplex, Single Sheet Manual Feed, 250Sheet Input Tray 150-Sheet Output Bin, Single Sheet Manual Feed, 250-Sheet Input Tray
550-Sheet Duo Drawer with 100-Sheet Feeder 250+1 pages 20 lb or 75 gsm bond 900 +1 pages 20 lb or 75 gsm bond 150 pages 20 lb or 75 gsm bond 150 pages 20 lb or 75 gsm bond 50 pages 20 lb or 75 gsm bond Card Stock, Paper Labels, Plain Paper, Transparencies, Refer to the Card Stock & Label Guide A4, A5, Executive, Folio, JIS-B5, Legal, Letter, Universal, Oficio TCP/IP IPv4, AppleTalk, TCP/IP IPv6, TCP, UDP PCL 5c Emulation, PCL 6 Emulation, Personal Printer Data Stream (PPDS), PCL 5c Emulation, PCL 6 Emulation, Personal Printer Data Stream (PPDS), PostScript 3 Emulation, PDF 1.6 PostScript 3 Emulation, PDF 1.6, Direct Image Ethernet 10/100BaseTX (RJ-45), USB 2.0 Specification Hi-Speed Certified Ethernet 10/100BaseTX (RJ-45), USB 2.0 Specification Hi-Speed Certified, PictBridge Certified Port, Front USB port Compatible with USB 2.0 Specification (Type A)

Microsoft Windows Operating Systems Supported
2000, XP, Server 2003, XP x64, Server 2003 running Terminal Services, 2000 Server running Terminal Services, Server 2003 x64, Server 2003 x64 running Terminal Services, Vista, Vista x64, Server 2008, Server 2008 x64, Server 2008 running Terminal Services, Server 2008 x64 running Terminal Services Mac OS X, Mac OS 9.x Color Copying, Color Printing, Network Scanning Color Copying, Color Faxing, Color Printing, Color Scanning, Network Scanning 1-Year Onsite Service, Next Business Day www.lexmark.com 18.23 x 17.32 x 21.14 in. 60 lb. Temperature: 16 to 32C (60 to 90F), Humidity: 8 to 80% Relative Humidity, Altitude: 0 - 3048 Meters (10,000 Feet)
Apple Macintosh Operating Systems Supported General Function Product Warranty Product Certifications Size (in. - H x W x D) Weight (lb.) Specified Operating Environment
Maximum Monthly Duty Cycle Maximum Monthly Duty Cycle is defined as the maximum number of pages a device could deliver in a month. This metric provides a comparison of robustness in relation to other Lexmark printers and MFPs. Recommended Monthly Page Volume Recommended Monthly Page Volume is a range of pages that helps customers evaluate Lexmarks product offerings based on the average number of pages customers plan to print on the device each month. Lexmark recommends that the number of pages per month be within the stated range for optimum device performance, based on factors including: supplies replacement intervals, paper loading intervals, speed, and typical customer usage. License/Agreement Terms Printers are sold subject to certain license/agreement conditions. See www.lexmark.com/printerlicense for details.
Trademarks Lexmark and Lexmark with the diamond design are trademarks of Lexmark International, Inc., registered in the United States and/or other countries. All other trademarks are the property of their respective owners. PCL is a registered trademark of Hewlett-Packard Company. AppleTalk, Mac and Macintosh are trademarks of Apple Computer, Inc., registered in the United States and other countries. MarkNet and MarkVision are trademarks of Lexmark International, Inc., registered in the United States and/or other countries. The USB-IF logos are trademarks of Universal Serial Bus Implementers Forum, Inc. ENERGY STAR is a U.S. registered mark. Microsoft, Windows, the Windows logo, Windows Vista, and the Windows Vista logo are trademarks or registered trademarks of Microsoft Corporation in the United States and/or other countries. Citrix, MetaFrame and MetaFrame XP are registered trademarks or trademarks of Citrix Systems, Inc. in the U.S. and other countries. Information in this document is subject to change without notice.

Ordering information Lexmark X543dn

150-Sheet Output Bin

Part # 3001385 Part # C540H1KG C540H1CG C540H1MG C540H1YG C540A1KG C540A1CG C540A1MG C540A1YG C540H2KG C540H2CG C540H2MG C540H2YG C540X75G C540X71G C540X74G Part # 12A5950 12A8240 Part # 3000551

250-Sheet Input Tray

Model Lexmark X543dn Laser Toner/Print Cartridge Black High Yield Return Program Toner Cartridge Cyan High Yield Return Program Toner Cartridge Magenta High Yield Return Program Toner Cartridge Yellow High Yield Return Program Toner Cartridge Black Return Program Toner Cartridge Cyan Return Program Toner Cartridge Magenta Return Program Toner Cartridge Yellow Return Program Toner Cartridge Black High Yield Toner Cartridge Cyan High Yield Toner Cartridge Magenta High Yield Toner Cartridge Yellow High Yield Toner Cartridge Waste Toner Bottle Black Imaging Kit Black and Color Imaging Kit Paper & Transparencies Glossy Laser Paper, Letter (200 sheets) Professional Color Laser Transparencies, Letter Paper Handling 550-Sheet Duo Drawer with 100-Sheet MPF Memory Options 128MB DDR1-DRAM 256MB DDR1-DRAM 512MB DDR1-DRAM 64MB Flash Card Japanese Font Card Korean Font Card Connectivity USB (2 Meter) Cable Lexmark N4050e 802.11g Wireless Print Server MarkNet N7020e Gigabit Ethernet Print Server Extended Warranties 2-Years Total Onsite Service, Next Business Day 3-Years Total Onsite Service, Next Business Day 1-Year Onsite Service Renewal, Next Business Day User Replaceable Parts ADF Separator Pad
40X5539 40X5470 40X5484 40X5168
X543 Scanner Cover Cushion ADF Paper Tray Output Bin Extension Pick Tire

Integrated Duplex

Single Sheet Manual Feed
550-Sheet Duo Drawer with 100-Sheet MPF
Part # 30G0828 30G0825 Part # 1021294 14T0145 14T0220 Part # 2350507 Part # 40X5472
Paper Handling Standard Paper Handling Optional
In the box Lexmark X543dn Multifunction Color Laser, up to 2,000*-page color High Yield Return Program Toner Cartridges (CMY), up to 2,500*-page black High Yield Return Program Toner Cartridge, software and documentation CD, power cord(s), RJ-11 phone cable or adapter (country dependent), setup guides (network and local attachment), Lexmark Rewards brochure, Lexmark Cartridge Collection Program information, Statement of Limited Waranty, operator panel language overlays Part # 3044503 Part # C544X1KG C544X1CG C544X1MG C544X1YG C540H1KG C540H1CG C540H1MG C540H1YG C540A1KG C540A1CG C540A1MG C540A1YG C544X2KG C544X2CG C544X2MG C544X2YG C540H2KG C540H2CG C540H2MG C540H2YG C540X75G C540X71G C540X74G Part # 12A5950 12A8240 Part # 3000551 Part # 30G0828 30G0825

Model Lexmark X544n Laser Toner/Print Cartridge Black Extra High Yield Return Program Toner Cartridge Cyan Extra High Yield Return Program Toner Cartridge Magenta Extra High Yield Return Program Toner Yellow Extra High Yield Return Program Toner Black High Yield Return Program Toner Cartridge Cyan High Yield Return Program Toner Cartridge Magenta High Yield Return Program Toner Cartridge Yellow High Yield Return Program Toner Cartridge Black Return Program Toner Cartridge Cyan Return Program Toner Cartridge Magenta Return Program Toner Cartridge Yellow Return Program Toner Cartridge Black Extra High Yield Toner Cartridge Cyan Extra High Yield Toner Cartridge Magenta Extra High Yield Toner Cartridge Yellow Extra High Yield Toner Cartridge Black High Yield Toner Cartridge Cyan High Yield Toner Cartridge Magenta High Yield Toner Cartridge Yellow High Yield Toner Cartridge Waste Toner Bottle Black Imaging Kit Black and Color Imaging Kit Paper & Transparencies Glossy Laser Paper, Letter (200 sheets) Professional Color Laser Transparencies, Letter Paper Handling 550-Sheet Duo Drawer with 100-Sheet MPF Memory Options 128MB DDR1-DRAM 256MB DDR1-DRAM 512MB DDR1-DRAM 64MB Flash Card Japanese Font Card Korean Font Card Connectivity USB (2 Meter) Cable
14T0145 14T0220 Part # 2350525 Part # 40X5472 40X5535 40X5470 40X5484 40X5168
Lexmark N4050e 802.11g Wireless Print Server MarkNet N7020e Gigabit Ethernet Print Server Extended Warranties 2-Years Total Onsite Service, Next Business Day 3-Years Total Onsite Service, Next Business Day 1-Year Onsite Service Renewal, Next Business Day User Replaceable Parts ADF Separator Pad X544 Scanner Cover Cushion ADF Paper Tray Output Bin Extension Pick Tire
250-Sheet Input Tray Single Sheet Manual Feed 550-Sheet Duo Drawer with 100-Sheet MPF

Part # 1021294

Models available Lexmark X544n: Network ready, Part #3044503 Lexmark X544dn: Network ready plus duplex, Part #3001389 Lexmark X544dtn: Network ready with duplex plus extra input drawer, Part #26C0300 Lexmark X544dw: Duplex with built-in wireless, Part #26C0400

In the box Lexmark X544n Multifunction Color Laser, up to 2,000*-page color High Yield Return Program Toner Cartridges (CMY), up to 2,500*-page black High Yield Return Program Toner Cartridge, software and documentation CD, power cord(s), RJ-11 phone cable or adapter (country dependent), setup guides (network and local attachment), Lexmark Rewards brochure, Lexmark Cartridge Collection Program information, operator panel language overlays, Statement of Limited Warranty
Lexmarks guarantee to you At Lexmark, were always working hard to ensure you achieve maximum productivity and minimum downtime. For greater level of peace of mind, you can opt for one of our Lexmark service offerings detailled on www.lexmark.com/services.
Environmental commitment Lexmark believes that the environment is a critical component of responsible business management and clearly demonstrates it by implementing the 4R strategy: Reduce, Recover, Reuse and Recycle. To learn more about these programs please visit www.lexmark.com/recycle.
Cost-saving and environmental features - nergy Star compliant E - uplex printing, Print and Hold (verify print), multi-up printing and support for recycled paper help reduce paper consumption. D - electable toner-saving modes help reduce the amount of toner used on a page. S - exmark Cartridge Collection Program and end-of-life product recycling help reduce waste. L
w w w. l e x m a r k. c o m

Repair information. 4-1

Handling ESD-sensitive parts. Testing generic FRUs. Removal procedures. Print engine removal procedures. Front cover assembly removal. Front middle cover removal. Left cover removal. Right cover removal. Rear shield removal. AIO back cable cover removal. 4-1 4-1 4-2 4-2 4-2 4-4 4-4 4-7 4-7 4-8
Top cover assembly removal. 4-9 Installation. 4-11 Autocompensator mechanism (ACM)standard tray removal.4-12 Bin full sensor. 4-15 Controller board removal. 4-16 Duplex sensor removal.4-17 Fuser assembly removal. 4-19 Fuser drive motor assembly removal. 4-22 Fuser exit sensor removal.4-23 High-voltage power supply (HVPS) assembly removal. 4-24 Image transfer unit (ITU). 4-26 Imaging unit (IU) removal. 4-28 Developer unit removal.4-30 Low-voltage power supply (LVPS) assembly. 4-31 Lower frame removal, right and left. 4-33 Left lower frame. 4-33 Right lower frame. 4-35 Main drive gear assembly with motor removal.4-39 Pick tires removalintegrated 250-sheet media tray. 4-41 Printhead removal. 4-42 Imaging unit contacts. 4-43 Toner meter cycle (TMC) card removal. 4-45 Toner patch sensor (TPS)left and right removal.4-47 Tray present sensor removal. 4-48 USB connector removal. 4-49 Waste toner bottle. 4-49 Wireless network antenna. 4-50 Wireless network card.4-52 Scanner component removal procedures. 4-53 Flatbed removal.4-53 Preparing and installing re new flatbed. 4-59 Duplex ADF rear cover. 4-62 Duplex ADF removal. 4-63 Simplex ADF rear cover. 4-64 Simplex ADF removal. 4-64 ADF input tray. 4-64 ADF cable. 4-65 ADF separator pad. 4-66 ADF separator roll assembly. 4-67 Bezel cover. 4-68 Redrive unit. 4-70 Cover scanner left. 4-71 Cover scanner right. 4-72 AIO release lever. 4-74 AIO link. 4-75 AIO toner cover. 4-76 Operator panel removal.4-77 Op panel bezel removal.4-79 Op panel cable. 4-80 Logo cover. 4-80 Fax card removal. 4-81 Fax interface cable. 4-81 Output bin tray. 4-82 Bin full flag removal. 4-82

Locations

Exterior views.5-1 Front.5-1 Rear. 5-2

viii Service Manual

Interior view. 5-3 Printer boards. 5-4 Controller Board. 5-4 Connectors. 5-5 HVPS. 5-15 Connectors. 5-16 LVPS. 5-17 Connectors. 5-18 Toner meter card. 5-19 Toner meter card connectors. 5-19 Wireless card. 5-20 Connectors. 5-20

1-12 Service Manual

Media guidelines

Paper characteristics

The following paper characteristics affect print quality and reliability. Consider these characteristics when evaluating new paper stock.
WeightThe printer can automatically feed paper weights from 60 to 176 g/m2 (16 to 47 lb bond) grain
long. Paper lighter than 75 g/m2 (20 lb) might not be stiff enough to feed properly, causing jams. For best performance, use 80 g/m2 (21 lb bond) grain long paper. For paper smaller than 182 x 257 mm (7.2 x 10.1 in.), we recommend 90 g/m2 or heavier paper. CurlCurl 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. SmoothnessPaper 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 contentThe 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 directionGrain 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/m2 (16 to 47 lb bond) paper, use grain long fibers. Fiber contentMost 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), synthetic 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/m2 Paper weighing less than 80 g/m2 (21 lb) Multiple-part forms or documents

PWM RAM RFID RH RIP ROM ROS RPM SCC SDRAM SEF SIMM SOL SOS SRAM TAR TPS TTM TVOC UAT UPR USB V V ac V dc VOIP VOM VTB XPS Y
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 Used 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

1-22 Service Manual

2. Diagnostic information
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 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 If you have an error message or user message, check the following: Service error messages on page 2-14 User status and attendance messages on page 2-6 Paper Jam messages on page 2-12 Service checks on page 2-32 for individual error messages Additional information can be found at the following locations: Operator panel and menus on page 2-2 POR (Power-On Reset) sequence on page 2-2 Print engine theory on page 3-46

Diagnostic information

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:

Remove original documents from the ADF.
The MFP senses that the flatbed cover is open. Jam at the ADF exit sensor.
A jam is detected at the ADF exit sensor.

Service error messages

Service error messages (1XX, 8XX and 9xx)
Error code 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 106.06 Service Yellow Printhead 106.07 Service Yellow Printhead 106.08 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 107.06 Service Cyan Printhead Description Yellow printhead error. Action Perform a POR. If the problem persists, go to Printhead service check on page 2-59. Perform a POR. If the problem persists, go to Printhead service check on page 2-59. Perform a POR. If the problem persists, go to Printhead service check on page 2-59. Perform a POR. If the problem persists, go to Printhead service check on page 2-59. Perform a POR. If the problem persists, go to Printhead service check on page 2-59. Perform a POR. If the problem persists, go to Printhead service check on page 2-59. Perform a POR. If the problem persists, go to Printhead service check on page 2-59. Perform a POR. If the problem persists, go to Printhead service check on page 2-59. Perform a POR. If the problem persists, go to Printhead service check on page 2-59. Perform a POR. If the problem persists, go to Printhead service check on page 2-59. Perform a POR. If the problem persists, go to Printhead service check on page 2-59. Perform a POR. If the problem persists, go to Printhead service check on page 2-59. Perform a POR. If the problem persists, go to Printhead service check on page 2-59 Perform a POR. If the problem persists, go to Printhead service check on page 2-59. Perform a POR. If the problem persists, go to Printhead service check on page 2-59. Perform a POR. If the problem persists, go to Printhead service check on page 2-59.

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. Failure reading NVRAM from the magenta printhead. The magenta printhead thermistor is open. The magenta printhead thermistor is shorted to ground. The magenta laser showed bad in EMS testing. Black printhead error.
The black printhead lost HSYNC.
The black printhead failed to complete servo. The black printhead mirror motors failed to achieve lock. The black printhead mirror motors lost PLL motor lock.
Error code 109.05 Service Black Printhead 109.06 Service Black Printhead 109.07 Service Black Printhead 109.08 Service Black Printhead 122.xx Service Fuser Error 122.01 Service Fuser Error 122.02 Service Fuser Error 122.03 Service Fuser Error 122.04 Service Fuser Error 122.05 Service Fuser Error 122.06 Service Fuser Error 122.07 Service Fuser Error 122.08 Service Fuser Error 122.09 Service Fuser Error 122.10 Service Fuser Error 122.11 Service Fuser Error 122.12 Service Fuser Error 122.13 Service Fuser Error 122.14 Service Fuser Error 122.15 Service Fuser Error Description Failure reading NVRAM from printhead. The black printhead thermistor is open. Action Perform a POR. If the problem persists, go to Printhead service check on page 2-59. Perform a POR. If the problem persists, go to Printhead service check on page 2-59. Perform a POR. If the problem persists, go to Printhead service check on page 2-59. Perform a POR. If the problem persists, go to Printhead service check on page 2-59. Go to Fuser service check on page 2-41. Go to Fuser service check on page 2-41. Go to Fuser service check on page 2-41. Go to Fuser service check on page 2-41. Go to Fuser service check on page 2-41. Go to Fuser service check on page 2-41. Go to Fuser service check on page 2-41. Go to Fuser service check on page 2-41. Go to Fuser service check on page 2-41. Go to Fuser service check on page 2-41. Go to Fuser service check on page 2-41. Go to Fuser service check on page 2-41. Go to Fuser service check on page 2-41. Go to Fuser service check on page 2-41. Go to Fuser service check on page 2-41. Go to Fuser service check on page 2-41.
The black printhead thermistor is shorted to ground. The black laser showed bad in EMS testing. Fuser error EWC errorAttempting to print with estimated power at or below minimum power. Fuser over temperature. Fuser open thermistor check failed. EWC ErrorDid not reach EWC start temperature in time. EWC ErrorDid not change temperature within expected time. EWC ErrorDid not reach EWC stop temperature in time. Timed out waiting for home sensor event. Wrong lamp bit is set in NVRAM. Fuser zero crossings out of range. Zero crossing detected. Fuser failed to warm up. Fuser under temperature error while in standby. Fuser under temperature error while printing. Fuser open thermistor check failed for second thermistor. Fuser shorted thermistor check failed for hot roll thermistor. Fuser started thermistor check failed for second thermistor

2-18 Service Manual

Error code 154.05 Service Yellow Cartridge Motor 154.06 Service Yellow Cartridge Motor 154.07 Service Yellow Cartridge Motor 8xx service errors 840.01 Scanner disabled 840.02 Scanner auto disabled The scanner is disabled and cant be used. The scanner is disabled and cant be used. Enter the configuration menu, and reenable the scanner module. Go to 840.xx service check on page 2-63 This message is posted when the MFP PORs. Enter the configuration menu, and re-enable the scanner module. Go to 840.xx service check on page 2-63 Image pipeline ASIC. Go to CCD service check on page 2-65. Also,Go to Flatbed home position service check on page 2-66. Communication failure. Go to CCD service check on page 2-65 Carriage mechanical failure.Go to Flatbed motor service check on page 2-65 ADF mechanical failure. Go to ADF paper jam service check on page 2-68 Lamp failure. Go to CCD service check on page 2-65 Go to CCD service check on page 2-65 Description Lost lock for motor. Action Go to Main drive gear assembly (EP drive) service check on page 2-43.
Go to Main drive gear assembly (EP drive) service check on page 2-43.

Image Pipeline 841

Scanner Failure Scanner Failure
843 Scanner Failure Scanner Failure Front scan module output level error Rear scan module output level error Front scan module lamp level too low 844.02

843.01 844.yy 844 844.01

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 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
Rear scan module lamp level too low 844.03

Scanner Failure 845.yy

Error code Description Front scan module cable failure or SCC card failure 845 Action 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 Rear scan module cable failure or SCC card failure 845.01 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 Cable / SCC Failure 845.02 Front scan module connector or cable failure Go to CCD service check on page 2-65 Cable / SCC Failure 845.03 Rear scan module connector or cable failure Go to CCD service check on page 2-65 Cable Failure 845.04 The connector cable is defective. Go to CCD service check on page 2-65. Front calibration strip unusable Rear calibration strip unusable Front calibration strip too far left 846.02 846.03 846.04 846.05 Front calibration strip too far right Front calibration strip has excessive skew Front calibration strip has excessive bow Front calibration strip has excessive dark area Front magnification exceeds limits 846.07 Modem Failure 847 Front excessive variability for Mono, Red, Green, or Blue. Go to CCD service check on page 2-65 Rear excessive variability for Mono, Red, Green, or Blue. Go to CCD service check on page 2-65 The Configuration ID bit that describes the devices modem doesnt match the actual modem installed in the device. The font calibration strip is placed to high or to low. Go to CCD service check on page 2-65 Go to CCD service check on page 2-65. Go to CCD service check on page 2-65

Error code 914.xx Service PC Pick Motor 917.xx Service Transfer Roll 920.xx Service Fuser Error 921.xx Service Fuser Error 922.xx Service Fuser Error 923.xx Service Fuser Error 924.xx Service Fuser Error 925.xx Service Fuser Error Description The DC pick has no encoder feedback. There is a problem with the transfer roll. The fuser is below temperature when printing. The fuser is below standby temperature when idle. The fuser failed to reach standby temperature. The fuser is too hot during printing or when the printer is idle. An open circuit in the connection to the fuser thermistor has been detected. Wrong fuser lamp is installed. The fuser type stored in the Cartridge ID doesnt match the actual fuser installed in the printer. The printer fan is 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. 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. Go to 931.xx935.xxPrinthead errors service check on page 2-34 Go to 931.xx935.xxPrinthead errors service check on page 2-34 Go to 931.xx935.xxPrinthead errors service check on page 2-34 Go to 931.xx935.xxPrinthead errors service check on page 2-34 Go to 936.xx, 937.xxTransport motor service check on page 2-34. Go to 936.xx, 937.xxTransport motor service check on page 2-34 Action Go to Autocompensator mechanism service check on page 2-35 Go to Go to Transfer roll service check on page 2-61. Go to 920.xx923.xxFuser temperature incorrect on page 2-32. Go to 920.xx923.xxFuser temperature incorrect on page 2-32 Go to 920.xx923.xxFuser temperature incorrect on page 2-32 Go to 920.xx923.xxFuser temperature incorrect on page 2-32 Go to 920.xx923.xxFuser temperature incorrect on page 2-32 Go to 920.xx923.xxFuser temperature incorrect on page 2-32
927.xx Service Fan Stalled 929.xx Service Toner Sensor
930.xx Service LVPS 931.xx Service Printhead Error 932.xx Service Printhead Error 933.xx Service Printhead Error 935.xx Service Printhead Error 936.xx Service Transport Motor 937.xx Service Transport Motor
Low voltage power supply did not detect zero crossing. There is no first HSYNC. Lost HSYNCs. Mirror motor is locked. No HSYNC received. Mirror motor is unable to reach operating speed. The transport motor had an initial lock failure. The transport motor lost lock.

Pull tray 1 out. Does the display indicate InputS1Media Present?
The sensor is functioning correctly.

Go to step 3.

Remove the tray, and inspect sensor. Is there something obstructing the sensor? Inspect the spring-loaded shaft/flag in the tray. The flag portion of the shaft intercepts the sensor, except when a sheet is being staged for duplexing. Does the shaft rotate freely and return to home position (flag at top of rotation)?
Remove the obstruction and restart the test. Go to step 5.

Go to step 4.

Replace the tray with a new one.
Is the flag on the shaft broken? Is the cable correctly connected to JFUSES1 on the controller board and to the sensor. Is the sensor cable properly connected?
Replace the tray. Go to step 7.
Go to step 6. Reconnect the cable. If the problem persists, go to step 7.
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: JFUSES1 Pin Value Ground +3.3 V dc
Replace the duplex sensor. See Duplex sensor removal on page 4-17.

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Front door sensor or switches service check
Step 1 Questions / actions Enter Diagnostics Menu (turn the printer off, press and hold and , turn the printer on, and then release the buttons when the installed memory and processor speed displays). Perform the Base Sensor Test. See Base Sensor Test on page 3-18. 1. Select Base Sensor Test, and press Select ( ). 2. Select Front Door, and press Select ( ). 3. Open and close the front door, and observe the display. Does the display indicate Value C losed with the door closed and Value Opened with the door opened? Yes Sensor, toner door, and right doors are OK. No Go to step 2.
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?
Replace the right cover assembly. SeeRight cover removal on page 4-7.
Open the toner door and inspect the vertical web that pushes and rotates the pivot plate. Is it damaged?
Replace the top cover assembly. See Top cover assembly removal on page 4-9. Replace the right cover assembly. SeeRight cover removal on page 4-7.
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?

Replace the fuser cable.

Check the connector JLVPS1 for proper connection to the controller board, the cable for pinch points, and the cable or connector for any other damage. Is the cable damaged?
Repair or replace the LVPS cable. See Low-voltage power supply (LVPS) assembly on page 4-31.
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?
Repair the cables. If the cables cannot be repaired, replaced the fuser. See Fuser assembly removal on page 4-19. Go to step 6.
Disconnect the cable at JFUSES1 on the controller board, and check the following voltages: JFUSES1 Pin 11 Voltage +3.3 V dc Ground Ground +2.7 V dc Ground
Are the voltages correct?
Replace the fuser. See Fuser assembly removal on page 4-19. Does the error clear?
Input sensor (S2) service check
The Input sensor (S2) is part of the ACM FRU. Step 1 Questions / actions Enter Diagnostics Menu (turn the printer off, press and hold and , turn the printer on, and then release the buttons when the installed memory and processor speed displays). Perform the Base Sensor Test. See Base Sensor Test on page 3-18. 1. Select Base Sensor Test, and press Select ( ). 2. Select S2, and press Select ( ). 3. Pull tray 1 out, and rotate the S2 sensor flag (S2 is located in front of the center autocompensator mechanism housing.) It should rotate freely and return to its original position. Is the input (S2) sensor flag damaged? Yes Replace the autocompensator mechanism. See Autocompensator mechanism (ACM)standard tray removal on page 4-12. No Go to step 2.
Watch the display while rotating the flag. Does the display indicate Media Clear and Media Present?
Turn the printer off, and remove the rear shield. See Rear shield removal on page 4-7. Is the JSP1 cable connector properly connected to the controller board?

Reseat the connector.

Turn the printer on, and check the voltage at JSP1 pin 15. Is the voltage approximately +5 V dc?
Replace the autocompensator mechanism. See Autocompensator mechanism (ACM)standard tray removal on page 4-12.

expected. To print the print Quality pages a. Enter Diagnostics (turn off the printer, press and hold Left ( ) and Select ( and release when the installed memory and processor speed displays). b. Select PRINT TESTS, and press Select ( ). c. Select Print Quality Pgs, and press Select ( ). The message Printing Quality Test Pages is displayed.

), turn on the printer

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.

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Print qualitybackground
Service tip: Some background problems can be caused by rough papers, non-Lexmark toner cartridges or if the media texture is set to the rough setting. Some slick or coated papers may also cause background problems. Some problems occur with printers that run a large amount of graphics in a humid environment.

Step 1

Questions / actions Read the current status of the imaging unit from the customer menus. To view the status of the photoconductor units: 1. In Ready mode, press Menus ( ). 2. Select Reports, and press Select ( ). 3. Select Device Statistics, and press Select ( ). It is possible a new imaging unit was installed, but the counter was not reset. Has the imaging unit been recently replaced?
Yes Reset the value. To reset this value: 1. In Ready mode, press Menus ( ). 2. Select Supplies Menu, and press Select ( ). 3. Select Replace Supply, and press Select ( ). 4. Select the imaging unit you want to change, and press Select ( ). 5. Select Yes, and press Select ( ). If this does not fix the problem, go to step 2. Replace the developer unit for the background color and retest. See Developer unit removal on page 4-30. Go to step 3.

No Go to step 2.

Is the background only one of the primary colors; yellow, cyan, magenta, or black?
Did replacing the developer unit correct the problem? Replace the photoconductor unit. Does this fix the problem? Check the high-voltage contact from the HVPS to the image transfer unit (ITU). Is a problem found?
Problem resolved. Problem resolved.
Go to step 4. Go to step 5.
Replace the failing part: Image transfer unit (ITU). See Image transfer unit (ITU) on page 4-26. High-voltage power supply (HVPS). See High-voltage power supply (HVPS) assembly removal on page 4-24. Problem resolved.
Reseat the cable in the JHVPS1 connector. Does this fix the problem? Replace the HVPS. See High-voltage power supply (HVPS) assembly removal on page 4-24. Does this fix the problem?

Go to step 8.

Questions / actions Clean the printhead. Does this fix the problem?

Yes Problem resolved.

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
Set Card Speed LAA Keep Alive

Dump NVRAM Re-init NVRAM

Print Alerts

TCP/IP

netstat -r arp -a Allow SNMP Set MTU Meditech Mode Raw LPR Mode Gather Debug Enable Debug

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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 & 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 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 <x> 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 <x> 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.
Understanding jam numbers and locations
1 @!. 2 ABC 4 GHI 5 JKL 7 PQRS 8 TUV 3 DEF 6 MNO 9 WXYZ 0
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. # 3 Error message 202 Jam message Standard 250-sheet tray and manual feeder (tray 1) Jam under the fuser Jam in the fuser Instructions Pull tray 1 out, and remove the jam. Open the front door, and remove the jam. Open the front door, and pull the fuser cover toward you. Remove the jam. 235 24x 250 29x Jam in the duplex Media not supported in the duplex 650-sheet Duo Drawer (tray 2) /MP feeder Jam in the multipurpose feeder Jams in the ADF unit Open the front door, and remove the jam. Load the tray with the correct paper size. Pull tray 2 out, and remove the jam. Pull tray 2 out, and remove the jam. Remove the jam from the top or bottom of the ADF unit. 3-43 3-43 3-43 3-43 3-44 Go to page 3-41 3-41 3-42

Warning: Be careful to not interfere with or damage the fuser exit sensor to the left of the fuser.

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Make sure the springs are resting on the top so they can be reached once the fuser is in place.
When reinstalling on the right, make sure the gears mesh. Be careful not to interfere with the exit sensor on the left side. Reroute the cables back through their retainers.
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. 4.
Note: If you remove the toroid (B) from the cable, be sure to return the toroid to the cable when you reinstall. Remove the two screws (C).
5. Remove the fuser drive motor assembly.

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Fuser exit sensor removal
Open the front cover. Remove the fuser assembly. See Fuser assembly removal on page 4-19. Remove the screw (A) securing the fuser exit sensor. Disconnect the cable (B) from the fuser exit sensor. Remove the lower end of the sensor with a flat blade screwdriver, and gently pull the sensor from the bracket.

6. Remove the sensor.

High-voltage power supply (HVPS) assembly removal
Note: This removal requires a magnetized, long-shank Phillips screwdriver at least 8 in. or 200 mm long.
Remove the top cover assembly. See Top cover assembly removal on page 4-9. Remove the rear shield. See Rear shield removal on page 4-7. Remove controller board. See Controller board removal on page 4-16. Remove the cable cover (A).
5. Disconnect the high-voltage power supply (HVPS) cable at the HVPS.

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6. Remove the screw (B). The screw is accessible from the top of the printer, and requires a long-shank
magnetized Phillips screwdriver. It is the only screw without a flanged head.
7. Remove the screw (C) securing the HVPS. 8. Carefully slide the HVPS out.
Installation notes: 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. Loosely replace screw (C), replace (tighten) screw (B) from step 6, and tighten screw (C).
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 2. 3. 4. 5. 6.
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 4-49. Remove the imaging unit (IU). See Imaging unit (IU) removal on page 4-28. Disconnect the one spring (A) from the side frames, leaving them attached to the ITU at the moment.