SHARP MX-3070N, MX-3570N, MX-4070N MX-3060N, MX-3560N, MX-4060N Installation Manual

Lexmark™ X543 - X544 series

• Table of contents

• Start diagnostics

• Safety and notices

7525xxx

•Trademarks

• Index

Lexmark and Lexmark with diamond design are
trademarks of Lexmark International, Inc., registered
in the United States and/or other countries.

7525xxx Lexmark confidential until annou nce

Edition: September 25, 2008
The following paragraph does not apply to an y country where such provisions are inconsistent with local la w:

LEXMARK INTERNATIONAL, INC. PROVIDES THIS PUBLICATION “AS IS” WITHOUT WARRANTY OF ANY KIND,
EITHER EXpress OR IMPLIED , INCLUDING, BUT NOT LIMITED TO , THE IMPLIED WARRANTIES OF
MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. Some states do not allow disclaimer of exp ress or
implied warr anties in certain transactions; therefore, this statement may not apply to you.

This publi cation could include technical inaccuraci es or typographical errors. Changes are periodically made to the
informati on herein; these changes will be incorporated in later editi ons. Improvements or changes in the products or the
programs descri bed m ay be made at any time .

Comments may be addressed to Lexmark International, Inc., Department D22A/032-2, 740 West New Circle Road,
Lexington, Kentucky 40550, U .S.A or e-mail at ServiceInfoAndTr [e-mail]. Lexmark ma y use or distribute any
of the inf ormati on you supply in any way it believes appropriate without incurring any obligation to you.

References in this pub li cation to products, programs, or services do not imply that the manufacturer intends to make these
available in all countries in which it operates. Any reference to a product, program, or service i s not i ntended to state or
imply that only tha t product , prog r am, or service may be used. Any func tional ly equi val ent pro duct , progr am, or service t hat
does not infringe any existing intellectual property right may be used instead. Evaluation and verification of operation in
conjunction with other products, programs, or service s, except those expressly designated by the manufacturer, are the
user’s responsibilit y.

Lexmark, Lexmark with diamond design, and M arkNet are trademarks of Lexm ark International, Inc., re gistered in the
United States and/or other countries.

Optra Forms is a trademark of Lexmark International, Inc.
Post Scri pt® is a registered tradem ark of Adobe Systems Incorporated.
PCL® is a registered trademark of the Hewlett-P ackard Company.
All other trademarks are the property of their respective owners.

© 2006 Lexmark International, Inc.

All rights reserved.

UNITED STA TES GOVERNMENT RIGHTS

This softwar e and any accompanying documentation provided under this agreemen t are commercial computer software
and documentation developed exclusively at private expense.

P/N 12G9825

Lexmark confidential until announce 7525xxx

Table of contents

Table of contents. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .iii

Notices and safety information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .xi

Laser notice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xi

Lithium warning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xvii

Safety information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xvii

Preface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .xxi

Conventions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xxi

General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

Options and features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1- 2

Memory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

Print quality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

Connectivity (networ k support) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

Operating modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

Data streams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5

Clearances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5

Power and electrical specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6

Acoustics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7

Environment specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7

Media handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8

Input and output sources . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8

Duplex capability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8

Media input size specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9

Media input type specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10

Media output size and type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11

Media guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13

Paper characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13

Unacceptable paper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13

Selecting paper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14

Selecting preprinted forms and letter head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14

Storing paper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14

Using recycled paper and other office papers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14

Digital imaging specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-16

General specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-16

ADF Scan speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-16

ADF Document handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-16

Resolution and color depth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-16

Flatbed document specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-16

Flatbed speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-16

Scanner operati ng environments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-16

Storage envir onm ents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-16

Tilt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-16

Scan and copy specific specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-17

Scan Resolutions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-17

Output resolutions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-17

Duplex scan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-17

Scan file output formats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-17

Supported compressions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-17

Supported scan destinations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-17

Multiple copies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-17

Reduce / Enlarge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-17

Table of contents iii

7525xxx Lexmark confidential until annou nce

Fax specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1 8

Phone network connectivity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1 8

Fax resolutions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-18

Miscellaneous FAX specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-18

Tools required for service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-19

Acronyms. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-20

Diagnostic information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1

POR (Power-On Reset) sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-2

Symptom tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-3

Printer symptom table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-3

Scan / fax / copy symptom table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 4

Print quality symptom table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-5

Error codes and messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-6

User status and attendance me ssages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-6

Paper Jam messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-12

Service error me ssages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-14

Fax error log codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-28

Service checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-32

Autocompensator mech anism service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-32

90x.xx error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-32

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-32

920.xx–923.xx— Fuser temperature incorrect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-32

925.01—Fan error service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-3 3

930.xx–935.xx— Printhead errors service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-34

936.xx, 937.xx—Transport motor service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-34

950.xx EPROM mismatch failure service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-35

Autocompensator mech anism service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-35

Bin full sensor service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-36

Dead printer service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-37

Duplex/manual feed sensor (S1) service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-38

Front door sensor or switches service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-39

Fuser exit sensor service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 -40

Fuser service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-41

Input sensor (S2) service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 -42

Main drive gear assembly (EP drive) service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-43

Operator panel service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-44

One or more operator panel buttons fail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-44

Operator panel di splay blank, five beeps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-44

Operator panel display blank, printer beeps five times and pauses . . . . . . . . . . . . . . . . . . . . . .2-45

Operator panel displays all diamonds, no beeps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-46

Operator panel displays all diamonds, five beeps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-46

Operator panel display is dim and unchanging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-47

Op panel USB cable service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2- 4 7

USB service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-47

Networking service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-48

Print quality service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-50

Print quality —bac kground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2- 5 1

Print quality—blank page . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-52

Print quality—blurred or fuzzy print . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-54

Print quality —half-color page . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 -54

Print quality —hor izontal banding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-54

Print quality—horizontal line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2- 5 5

Print quality—insufficient fusing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-55

Print quality —missing image at edge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-55

Print quality—mottle (2–5mm speckles) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-55

Print quality—narrow vertical line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-56

Print quality —r andom m arks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-56

iv S e rv ice Manu al

Lexmark confidential until announce 7525xxx

Print quality —r esidual image . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-57

Print quality—solid color page . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-58

Print quality—vertical banding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-58

Printhead servi ce check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-59

Toner meter cycle (TMC) card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-60

Toner sensors (Y, C, M, K) on TMC card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-60

Transfer roll service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-61

Tray 1 sensor service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-62

840.xx service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-63

Black or blank page copy service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2- 65

CCD service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-65

Flatbed motor servi ce check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-65

Flatbed home positio n service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-66

ADF cover open service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-67

ADF streak service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-67

ADF paper jam service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-68

ADF feed errors service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-69

ADF Duplex service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-69

Modem / fax card service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-70

Fax transmission service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-71

Fax reception service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-73

Escalating a fax issue to second-level support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-75

User operator panel, menus and mes sages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-76

Understanding the operator panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-76

Operator panel buttons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-76

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-77

Menu map . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-78

Diagnostic aids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

Diagnostics Menu (Diag Menu) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

Diagnostics menu stru cture . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

Available tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

Registration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

Skew . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5

Quick test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6

Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7

Factory Scanner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9

Factory Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9

Miscellaneous Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10

Motor Detect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10

Print Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11

Input source tes ts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11

Print quality test pages (Prt Quality Pgs) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11

Hardware Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13

Panel Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13

Button Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13

DRAM Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13

CACHE Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14

Duplex Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15

Quick Test (duplex) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15

Left Margin (duplex) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15

Top Margin (duplex ) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16

Sensor Test (duplex) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16

Input Tray tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17

Feed Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17

Sensor Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17

Base Sensor Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18

Device Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18

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7525xxx Lexmark confidential until annou nce

Flash Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-18

Printer Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-19

Defaults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-19

Page Counts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-19

Serial Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-19

Model Name . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-19

Configuration ID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-19

ITU Barcode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-20

Enable Edge to Edge Copy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-20

Reset Fuser Count . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-21

EP Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-21

EP Defaults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-21

Fuser Temp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-21

DC Charge Adjust, Deve Bias Adj, Transfer Adj . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-21

TPS Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-21

Right or Left TPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-21

Reset Color Cal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-22

Cal Ref Adj . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-22

Reports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-22

Main Settings Page . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-22

Event Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-23

Display Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-23

Print Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 - 2 3

Clear Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-24

Scanner Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-25

ASIC Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-25

Feed Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-25

Sensor Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-25

EXIT Diags . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-30

Configuration Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 - 3 1

Available tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-31

USB Scan to Local . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-31

Prt Quality Pages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-31

Color Trapping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-31

Reports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-32

Menu Settings Page . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3- 3 2

Event Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-32

Panel Menus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-32

PPDS Emulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-32

Demo Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-33

Factory defaults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-33

Energy Conserve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-33

Min Copy Memory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-34

Format Fax Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-34

Auto Color Adj . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-34

ADF Edge Erase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-34

FB Edge Erase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-35

Scanner Manual Registration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-3 5

To manually register a Duplex ADF, perform the following steps: . . . . . . . . . . . . . . . . . . . . . . .3-35

To manually regis ter the flatbed, perform the following steps: . . . . . . . . . . . . . . . . . . . . . . . . . .3-36

Disable Scanner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-36

Font Sharpening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-37

Pel Blurring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-37

Exit Config Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-37

SE Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-38

Print SE Menus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-38

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-38

Code Revision Info . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-38

History . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-38

vi Se rvi c e M anual

Lexmark confidential until announce 7525xxx

MAC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-38

NVRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 8

NPAP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-38

TCP/IP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-38

Paper jams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-39

Avoiding jams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-39

Understanding jam numbers and locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-40

200 paper jams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-41

201 paper jam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-41

202 paper jam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-42

230 paper jam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-43

235 paper jam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-43

24x paper jam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-43

250 paper jam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-43

29x ADF paper jam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-44

291.xx ADF paper jams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-44

Theory of operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-46

Print engine theory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-46

Electrophot ographic Process (EP Process) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-46

MFP electrophotographic process basics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-46

Step 1: Charge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-47

Step 2: Expose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-48

Step 3: Develop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-49

Step 4a: First transfer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-50

Step 4b: Second transfer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-51

Step 5: Fuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-52

Step 6: Clean/Erase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-53

Paper path, transport components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-55

Paper path Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-55

Transport components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-56

Duplexing (model s wit h duplex support only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-56

Scanner theory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-58

Duplex ADF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-58

Color theory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-60

What is RGB color? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-60

What is CMYK color? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-60

How is color specified in a document to be printed? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-60

How does the printer know what color to print? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-60

Should I use PostScript or PCL emulation? What setti ngs produce the best color? . . . . . . . . . 3-60

Why doesn't the printed color match the color I see on t he com puter screen? . . . . . . . . . . . . 3-60

The printed page appears tinted. Can I adjust the color? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-60

My color tra nsparenc ies seem dark when t hey are projec ted. I s ther e any thing I ca n do t o im prove t he

color? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-61

What is manual color correction? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-61

How can I match a particular color (such as a corporate logo)? . . . . . . . . . . . . . . . . . . . . . . . . 3-62

What are detailed Color Samples and how do I access them? . . . . . . . . . . . . . . . . . . . . . . . . . 3-62

Repair information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

Handling ESD-sensiti ve parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

Removal procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

Print engine removal procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

Front cover assembl y rem oval . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

Front middle cover removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4

Left cover removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4

Right cover removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7

Rear shield removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7

AIO back cable cover removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8

Top cover assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11

Table of co ntents vii

7525xxx Lexmark confidential until annou nce

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) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-25

Imaging unit (IU) removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-28

Developer unit removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-30

Low-voltage power supply (LVPS) assem bly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-31

Lower frame removal, right and left . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4- 3 3

Left lower frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-33

Right lower frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-35

Main drive gear assembly with motor removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-39

Pick tires removal—integrated 250-sheet med ia 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 remova l proc edures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-65

ADF separator roll assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-67

Bezel cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-68

Redrive unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-69

Cover scanner left . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-70

Cover scanner right . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-71

AIO release lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-73

AIO link . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-74

AIO toner cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-75

Operator panel removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-76

Op panel bezel removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-78

Op panel cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-79

Logo cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-79

Fax card removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-80

Fax interface cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-80

Output bin tray . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-81

Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

Exterior views . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1

Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1

Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-2

Interior view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-3

Printer boards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-4

Controller Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-4

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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

Preventive mainte nan ce. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

Safety inspection guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

Lubrication spec if ications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

Parts catalog . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

How to use this parts catalog . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

Assembly 1: Covers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2

Assembly 2: Scanner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4

Assembly 3: Paperpat h . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8

Assembly 4: Electronics 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10

Assembly 5: Electronics 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12

Assembly 6: Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-13

Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I-1

Part number index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I-7

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Notices and safety information

The foll owing laser notice label s m ay be affixed t o thi s pri n ter.

Laser no tice

The printer is certified in the U .S. to confo rm to the requirements of DHHS 21 CFR Subchapter J for Class I (1)
laser product s, and elsewhere is certified as a Class I laser product conforming to the requirements of IEC
60825-1.

Class I laser products are not considered to be hazardous. The printer contains internally a Class IIIb (3b) laser
that is nominally a 5 milliwatt galli um arsenide laser operati ng in the wavelength region of 770-795 nanometers.
The laser system and printer are designed so there is never an y hum an access to laser radiation above a Class
I level during normal operation, user maintenance, or prescribed service condition.

Laser

Der Drucker erfüllt gemäß amtlicher Bestätigu ng der USA die Anforderungen der Bestimmung DHHS
(Department of Health and Human Services) 21 CFR Teil J für Laserprodukte der Klasse I (1). In anderen
Ländern gilt der Drucker als Laserprodukt der Klasse I, der die Anforderungen der IEC (International
Electrotechnical Commission) 60825-1 gemäß amtlicher Bestäti gung erfüllt.

Laserprodukte der Klasse I gelten als unschädlich. Im Inneren des Druckers befindet sich ein Laser der Klasse
IIIb (3b), bei dem es sich um einen Galliumarsenlaser mit 5 Milliwatt handelt, der Wellen der Länge 770-795
Nanometer ausstrahlt. Das Lasersystem und der Drucker sind so konzipiert, daß im Normalbetrieb, bei der
Wartung durch den Benutzer oder bei ordnungsgemäßer Wartung durch den Kundendienst Laserbestrahlung,
die Klasse I überstei gen würde, Menschen k einesfalls erreicht.

Avis relatif à l’utilisation de laser

Pour les Etats-Unis : cette imprimante est certifi ée conforme aux provisions DHHS 21 CFR alinéa J concernant
les produits laser de Classe I (1). Pour les autres pa ys: cette imprimante répond aux normes IEC 60825-1
relatives aux produits laser de Classe I.

Les produits laser de Classe I sont considérés comm e des produits non dangereux. Cette imprimante est
équipée d’un l aser de Classe IIIb (3b) (arséniure de gall ium d’une puissance nomi nale de 5 milliwatts) émettant
sur des longueurs d’onde comprises entre 770 et 795 nanomètres. L’imprimante et son sys tème laser sont
conçus pour impossible, dans des conditions normales d’utilisation, d’entre tien par l’utilisateur ou de révision,
l’exposition à des rayonnements laser supérieurs à des ray onnements de Classe I .

Avvertenze sui prodotti laser

Questa stampant e è certificata negli St ati Uniti per essere conforme ai requisiti del DHHS 21 CFR Sottocapitolo
J per i prodotti las er di classe 1 ed è certificata negli altri Paesi come prodotto laser di classe 1 conf orme ai
requisiti del la norma CEI 60825-1.

I prodotti laser di class e non sono con sider ati pericol osi. La stampan te contiene al suo interno un l aser di classe
IIIb (3b) all’arseniuro di gallio dell a potenza di 5mW che opera sulla lu nghezza d’onda compresa tra 770 e 795
nanometri. Il sistema laser e la stampante sono stati progettati in modo tale che le persone a contatto con la
stampante, durante il normale funzionam ento, le operazioni di servizio o quelle di assis tenza tecnica, non
ricevano radiazioni laser superiori al livello della classe 1.

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Avisos sobre el láser

Se certifica que, en los EE.UU., esta impresora cumple los requisitos para los productos láser de Clase I (1)
establecidos en el subcapítulo J de la norma CFR 21 del DHHS (Departamento de Sanidad y Servicios) y, en
los demás países, reúne todas las condiciones expuestas en la norma IEC 60825-1 para productos láser de
Clase I (1).

Los productos láser de Clase I no se consideran pel igrosos. La impre sora contiene en su interior u n láser de
Clase IIIb (3b) de arseniuro de galio de funcionamiento nomin al a 5 miliv ati os en una longitud de onda de 770 a
795 nanómetros. El sistema láser y la impresora están diseñados de forma que ninguna persona pueda verse
afectada por ningún tipo de radiac ión láser superior al nivel de la Clase I durante su uso normal, el
mantenimiento realizado por el usuario o cualqui er otra situación de servic io técnico.

Declaração sobre Laser

A impressora está ce rtificada no s E. U .A. e m conf ormidade co m os r equi sito s da reg ulamenta ção DHHS 2 1 CFR
Subcapítulo J para a Cla sse I (1) de produt os laser. Em outros locais, está certificada como um produto lase r da
Classe I, em conf ormidade com os requisitos da norma IEC 60825-1.

Os produtos lase r da Classe I não sã o conside rados peri gos os. I nternamente , a impr esso ra cont ém um produ to
laser da Classe IIIb (3b), designado laser de arseneto de potássio , de 5 milliwatts ,operando numa faix a de
comprimento de onda entre 770 e 795 nanómetros. O sistema e a impressora laser f oram concebid os de forma
a nunca ex ist ir qualquer possiblidade de acesso humano a radiação laser superior a um nível de Classe I
durante a operação normal, a manutenção feita pelo utilizador ou condições de assistência prescritas.

Laserinformatie

De printer v oldoet aan de eis en die ges teld w orde n aan ee n laserprodukt v an klass e I. Voor de Ver enigde Stat en
zijn deze eisen vastgelegd in DHHS 21 CFR Subchapter J, voor andere landen in IEC 60825-1.

Laserprodukten van klasse I worden nie t al s ongevaarlij k aangemerkt. De printer is voor zien van een laser v an
klasse IIIb (3b), dat wil zeggen een gallium arsenide-laser van 5 milliwatt me t een g ol flengte van 770-795
nanometer . Het laser gedeelt e en de printer zij n zo ont worpen dat bij normaal gebru ik, bij onde rho ud of repar atie
conform de voorschriften, nooit blootstelling mogelijk is aan laserstraling boven een niveau zoals
voorgeschreven is voor klasse 1.

Lasermeddelelse

Printeren er godkendt som et Klasse I-laserprodukt, i overenstemmelse med kravene i IEC 60825-1.
Klasse I-laserprodukter betragtes ikke som farlige. Printeren indeholder internt en Klasse IIIB (3b)-laser, der

nominelt er en 5 milliwatt galliumarsenid laser, som arbejder på bølgelængdeområdet 770-795 nanometer.
Lasersystem et og printeren er udformet således, at mennesk er al drig udsættes for en laserstråling over Klasse
I-niveau ved normal drift, brugervedligeholdelse eller obligatoriske servicebetingelser.

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Laserilmoitus

Tämä tulostin on sertifioitu Yhdysvalloissa DHHS 21 CFR Subchapter J -standardin mukaiseksi luokan I (1) ­lasertuotteeksi j a m uualla IEC 60825-1 -standardi n m ukaiseksi luokan I lasertuot teeksi.

Luokan I lasertuottei ta ei pidet ä hai talli sina. Tulostimen sisäl lä on luo kan IIIb (3b ) laser, joka on nimellisteholt aan
5 mW:n galliumarsenidilaser ja toimii 770 - 795 nanometrin aallonpituuksilla. Laserjärjestelmä ja tulostin ovat
rakenteeltaan sellaisi a, että käyttäjä ei joudu alt tiiksi luokkaa 1 suuremm alle säteilylle normaalin käytön,
ylläpidon tai huollon aikana.

Huomautu s las er laittees ta

Tämä kirjoi tin on Yh dysv alloi ssa lu okan I ( 1) lase rlait teide n DHHS 21 CFR Subchapt er J -mää rityks en muk ainen
ja muualla luo kan I l aserl aitteiden IEC 60825-1 -määrityksen mukainen.

Luokan I las e r la itt e id e n e i ka ts o ta ol evan vaarallis ia käyttä jä lle . K irjoittim e s sa on si sä i ne n lu oka n IIIb (3 b ) 5
milliwatin galliumarsenidilaser, joka toimii aaltoal ueella 770 - 795 nanometriä. Laserj ärjestelmä ja kirjo it in on
suunnitelt u siten, että käyttäj ä ei al ti stu luokan I määrityksiä voimakkaammall e säteilylle kirjoittimen normaalin
toiminnan, käyttäjän tekemien huoltotoimien tai muiden huoltotoimien yhteydessä.

VARO! Av attaessa ja suojalukitus ohitettaessa ol et alttiina näkymätt öm älle lasersäteily ll e. Älä katso
säteeseen.

VARNING! Osynlig laserst rålning när denna del är öppnad och spär ren är urkopplad. Betrakta ej strålen.

Laser-notis

Denna skrivare är i USA certifierad att motsvara kr aven i DHHS 21 CFR, underparagr af J fö r la serprod ukter av
Klass I (1). I andra länder uppfyller skrivaren kraven för laserprodukter av Kl ass I enligt kraven i IEC 60825-1.

Laserprodukter i Klass I anses ej hälsovådliga. Skrivaren har en inbyggd laser av Klass IIIb (3b) som består av
en laserenhet av gallium-arsenid på 5 milliwatt som arbetar i våglängdsområdet 770-795 nanometer.
Lasersystem et och skrivaren är utformade så att det aldrig finns ris k för att någon person utsätts för
laserstrå lning över Klass I-ni vå vid normal användning, underhåll som utförs av användaren eller annan
föreskriv en serviceåtgärd.

Laser-melding

Skriveren er godkjent i USA etter kra vene i DHHS 21 CFR, underkapittel J, for klas se I ( 1) l aserprodukter, og er
i andre land godkjent som et Klasse I-laserprodukt i samsvar med kravene i IEC 60825-1.

Klasse I-la serprodukter er ikke å betrakte som farlige. Skriveren inneholder internt en klasse IIIb (3b)-laser, som
består av en gallium-arsenlaserenhet som avgir strål ing i bølgel engdeområdet 770-795 nanom eter.
Lasersystem et og skriveren er utformet slik at personer aldri utsettes f or laserstrå li ng ut ov er klasse I- nivå under
vanlig bruk , vedlikehold som utføres av brukeren, eller foreskre vne serviceoperasjoner.

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Avís sobre el Làser

Segons ha estat certificat al s Estats Units , aquesta impressor a complei x els req uisits de DHHS 21 CFR, apartat
J, pels productes làser de classe I (1), i segons ha estat certificat en altres llocs, és un producte làser de classe
I que compleix els requisits d’IEC 60825-1.

Els productes l àser de classe I no es consideren perillosos. Aquesta impr essora conté un làser de cl asse IIIb
(3b) d’arseniür de gal.li, nominalment de 5 mil.liwats, i funciona a la regió de longitud d’ona de 770-795
nanòmetres. El sistema làser i la impressora han sigut concebuts de manera que mai hi hagi exposició a la
radiació làser per sobre d’un nivell de classe I durant una operació normal, durant les tasques de manteniment
d’usuari ni durant els serveis que satisfacin les condicions prescrites.

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Lithium warn ing

CAUTION

This product conta ins a lithium bat tery. THERE IS A RISK OF EXPLOSION IF THE BATT ERY
IS REPLACED BY AN INCORRECT TYPE. Discard used batteries according to the battery
manufacturer’s instructions and local regulations.

Safety information

• The safety of this product is based on testi ng and approvals of t he orig inal design and specific

components . The manufacturer is not responsibl e for safety in the event of use of unauthorized
replacement parts .

• The maintenance information for this product has been prepared for use by a professional service person

and is not intended to be used by others.

• There may be an increased risk of electric shoc k and personal injury during disassem bly and servicing of

this product . Pro fessional service personnel should understand this and take necessa ry precaut ions.

• CAUTION: When you see th is symbol , ther e is a danger f rom hazard ous v olt age in the ar ea of the

product where y ou ar e working . Unplug the product bef ore you beg in, or use c autio n if t he produc t
must receive power in order to perform the task.

•This product contains mercury in the lamp (<5mg Hg). Disposal of mercury may be regulated due to

environmental consider ations. For disposal or recycling in formation, contact your local authorities
or the Electronic Industries Alliance: www.eiae.org.

Consignes de sécurité

• La sécurité de ce produit repose sur des tests et des

agréations portant sur sa conception d'origine et sur des com posants particuliers . Le fabricant n'assume
aucune respon sabilité concernant la sécurité en cas d'utilisation de pièces de rechange non agréé es.

• Les consignes d'entretien et de répar ati on de ce produit s'adressent uniquement à un personnel de

maintenance qualifié.

• Le démontage et l'entretien de ce produit pouvant présenter certains risques électriques, le personnel

d'entretien qualifié devra prendre toutes les précautions nécessaires.

• ATTENTION : Ce symbole indique la présence d'une tension dangereuse dans la partie du

produit sur laquelle vous travaillez. Débranchez le produit a vant de commencer ou f aites preuve
de vigilance si l' exécution de la t âche exige que le produi t reste sous tension.

Norme di sicurezza

• La sicurezza del prodotto si basa sui test e sull'approvazione del progetto originale e dei componenti

specifici. Il produttore non è responsabile per la sicurezza in caso di sostituzione non autorizzata delle
parti.

• Le informazioni riguardanti la manutenzione di questo prodotto sono indirizzate soltanto al personale di

assistenza autorizzato .

• Durante lo smontaggio e la manutenzione di questo prodotto,

il rischio di subire scosse elettriche e danni al la persona è più elev ato. Il personale di assistenza
autorizzato deve, quindi, adottare le precauzioni necessarie.

• ATTENZIONE: Questo simbolo indica la presenza ditensione pericolosa nell'area del prodotto.

Scollegare il pr odotto prima di iniziare o usare caut ela se il prodotto deve essere alimentato per
eseguire l'intervento.

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Sicherheitshinweise

• Die Sicherheit di eses Produkts basiert auf Tests und Zulassungen des ursprüngl ichen Modells und

bestimmter Baut eil e. Bei Verwendung nicht genehmigter Ersatztei le wird vom Hersteller kei ne
Verantwortung oder Haftung für die Sicherheit übernommen.

• Die Wartungsinformationen für dieses Produkt sind ausschließlich für die Verwendung durch einen

Wartungsfachmann bestimmt.

• Während des Auseinandernehmens und der Wartung des Geräts besteht ein zusät zliches Risiko eines

elektrischen Schlags und körperlicher Verletzung. Das zus tändige Fachpersonal sollte entsprechende
Vorsichtsmaßn ahm en treffen.

• ACHTUNG: Dieses Symbol weist auf eine gefährliche elektrische Spannung hin, die in diesem

Bereich des Produkts auftreten kann. Zie hen Sie vor den Arbeiten am Gerät den Netzstecker des
Geräts, bzw. arbeiten Sie mit großer Vorsicht, wenn das Produkt für die Ausführung der Arbei ten
an den Strom angeschlossen sein muß.

Pautas de Seguridad

• La seguridad de este prod ucto se basa en pruebas y aprobaciones del diseño original y componentes

específico s. El fabricante no es respo n sable de la seguridad en caso de uso de piezas de repuesto no
autorizadas.

• La información sobre el mantenimiento de este producto está dirigida exclusivamente al personal

cualificado de mantenimiento.

• Existe may o r riesg o de de scarga el éctrica y de dañ os person al es duran te e l desmont aj e y la r eparac ión de

la máquina. El personal cualificado debe ser consciente de este peligro y tomar las precauciones
necesarias.

• PRECAUCIÓN: este símbolo indica que el voltaje de la parte del equipo con la que está

trabajando es peligroso. Antes de empezar, desenchufe el equipo o tenga cuidado si, para
trabajar con él, debe conectarlo.

Informações de Segurança

• A segurança deste produto baseia-se em testes e aprovações do mode lo original e de componentes

específico s. O fabricante não é responsável pela segunrança, no caso de uso de peças de subst ituição
não autorizadas.

• As informações de segurança relativas a este produto dest inam-se a profissionais destes serviços e não

dev em ser utilizadas por outra s pessoas.

• Risco de choques eléct ricos e ferimentos graves durante a desmontagem e manutenç ão deste produto.

Os profissio nais destes serviços devem estar avis ados deste facto e tomar os cuidados necessários.

• CUIDADO: Quando vir este sí m bolo, existe a possível presença de uma potencial tensão

perigosa na zona do produto em que está a trabalhar. Antes de começar, desligue o produto da
tomada eléctrica ou s eja cui dado so caso o pro duto te nha d e estar liga do à corrent e eléc trica para
realizar a tarefa necessária.

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Inf ormació de Seguretat

• La seguretat d'aquest producte es basa en l'avaluació i apr ovació del dis seny original i els components

específics.
El fabricant no es fa responsable de les qüestions de
seguretat si s'u tilitzen peces de recanvi no autoritzades.

• La informació pel manteniment d’aquest pr oducte està orientada e xclusivament a pr ofessionals i no està

destinada
a ningú que no ho sigui.

• El risc de xoc elèctric i de danys personals pot augment ar dur ant el procés de desmuntatge i de servei

d’aquest producte. El personal professional ha d’estar-ne assabentat i prendre
les mesures con venients.

• PRECAUCIÓ: aquest símbol in dica que el voltatge de la part de l'equip amb la qual esteu

treballan t és perillós . Abans de començar, desendolleu l'equ ip o extremeu les precaucions si, per
treballar amb l'equip, l'heu de connectar.

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Preface

This manual contains maintenance procedures for service personnel. It is divided into t he following chapters:

1. General in fo rma tion contains a general description of t he prin ter and the maintenance appro ach used to

repair it. Speci al tools and test equipment, as well as general env ir onm ental and safety inst ructions, are
discussed.

2. Diagn o sti c information contains an error indicator table, symptom tables, and service checks used to

isolate failing field replaceable units (FRUs).

3. Diagn osti c aids contains tests and checks used to locate or repeat symptoms of printer problems.

4. Repair info rma tion provides instructions for making printer adjustments and removing and installing

FRUs.

5. Connecto r locations uses illustrations to identify the connector locations and test points on the printer.

6. Prev entive maintenance contains the lubrication specifications and recommendat ions to prevent

problems.

7. Parts catalog contains illus trations and part numbers for individual FRUs.

Appendix A contains service tips and information.
Appendix B contains representative print samples.

Conventions

Note: A note provides addition al i nformation.
Warning: A warning identifies something that might damage the product hardware or software.

There are several types of cauti on statements:

CAUTION

A caution identifies something that might cause a servicer harm.

CAUTION

This type of caution i ndicates there is a danger fro m haz ardous voltage in the area of the
product where you are working. Unplug the product before you begin, or use caution if th e
product must recei ve power in order to perform the task.

CAUTION

This type of caution indicates a hot surface.

CAUTION

This type of caution i ndicates a tipping hazard.

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1. General information

The Lexmark™ X54x series are color laser MFPs that combine print, scan, copy, and fax functions.
The X54x series are the ideal MFPs for presentations, business graphics, li ne art, and text. They use
laser diode electrophotographic technology to deliver remarkable quality print images and text. The
scan and copy functions work with A4, letter, and legal (ADF only) size paper. Photographic quality
images are possible with scan function. The FAX function delivers a wide range of functionality to the
office user. The MFPs can be used as shared network or desktop devices.

Models

The Lexmark X54x series MFPs are available in the following models:

Model Configurati on Machine type / model

X543dn Print, copy, simplex scan, network 7525-131
X543dn Print, copy, simplex scan , network. DBCS op panel 7525-133
X543dn Print, copy, simplex scan, network

X544n Print
X544n Print

2

, copy, duplex scan, network, fax [phone]

2

, copy, duplex scan, network 7525-352

1

7525-138

X544dn Print, copy, duplex scan, network, fax [phone]
X544dn Print, copy, duplex scan, network 7525-332
X544dn Print, copy, duplex scan, network, fax. DBCS op panel. 7525-337
X544dn Print, copy, duplex scan, network. DBCS op panel 7525-333
X544dw Print, copy, duplex scan, network
X544dw Print, copy, duplex scan, network
X544dw Print, copy, duplex scan, network
X544dw Print, copy, duplex scan, network
X544dtn Print, copy, duplex scan, network, fax. [phone] (bundled w/650-sheet

X544dtn Print, copy, duplex scan, network. 7525-332 (bundled w/650-sheet

X544dtn Print, copy, duplex scan, network, fax, DBCS op panel 7525-337 (bundled w/650-sheet

X544dtn Print, copy, duplex scan, network, DBCS op panel 752 5-333 (bundled w/650-sheet

1. Wireless network

2. Simplex printing only

1

, fax [phone]

1

1

, fax, DBCS op panel 7525-387

1

, DBCS op panel 7525-383

7525-382

optional tray)

optional tray)

optional tray)

optional tray)

General inf ormation 1-1

7525xxx Lexmark confidential until annou nce

Options and features

Certain options are available on selected printer models only.
Available opti ons include:

• 650-Sheet Duo Drawer—a 550-sheet dra wer with a 100-sheet multi purpose feeder (MP Feeder).

• Additional memory—One 128, 256, or 512MB memory card may be added.

• Flash memory card—One 64MB may be added.

• Font cards—One

Memory

✔—Supported
✘—Not supported

Memory

Optional slots One slot

a

Standard DIMM sizes
Optional (DDR2) 128MB, 256MB, and 512MB
Maximum printer memory
Flash memory 64 MB

Option Slots (single slot is available or eithe r font or flash memory card)

Font card support 1 font card
Optional user fla sh memory

card sizes

Connections

USB 2.0 High Speed
Ethernet 10/100 BaseTx
USB-A

(allows direct USB printing
using approved USB flash
memory device)

Pict Bridge
(allows printing photos
directly from a compa ti ble
camera)

128MB

b

Lexmark X543

640MB

0MB 64MB 64MB

✔✔

✔✔

✘✔

✘✔(Only on FAX

Lexmark X544n,

X544dn, X544dtn

equipped machines)

Lexmark X544dw

✔

✔

✔

✔(Only on FAX

equipped machines)

Wireless standar d 802.11
b/g/n

a

Dual Inline Memory Module. An opti onal memory card that can be plugged into an available memory slot .

b

The maximum usable DDRSDRAM is standard (soldered) plus 512MB.

1-2 Se rvi ce Manual

✘

✔ ✔

Lexmark confidential until announce 7525xxx

Print qua li ty

During the lif e of the printer, components are subject to wear based on us age . Printers con tinu ously oper at ing at
or near the maximum duty cycle may require service for replacement of these components to ensure high­quality printi ng and good performance throug hout the life of the printer. Replacement is recommended every
60,000 pages for the fuser and 60,000 pages for the ITU. Replacement is rec om m ended eve ry 30,000 pages for
the imaging unit.

• 4800C Q (default) full printer speed

• 1200 dpi (reduced printer speed) is supported in PS and PCL only

Connectivity (network support)

✔—Supported
✘—Not supported

Network protocol Lexmark X543

Lexmark X544 n,
X544dn,

X544dtn Lexmark X544dw
Standard Ethernet 10/100 Base T
Standard USB-B (Full speed) device port
USB-A host ports

(In front, low/full speed) This port only
supports the following flash drives and fil e
types:

Supported flash drives: Lexar Jump Drive

2.0 Pro (256/512 MB/1G size) or SanDisk
Cruzer Mini (256/512 MB/1 G siz e)

Supported file
types: .pdf, .gif, .jpeg, .jpg,.bmp, .png, .tiff,
.tif, .pcx, .dcx

802.11n Wireless Network card

Manufacturing installs the wireless card
during the fabricat ion process . A wireless card
CANNOT be install ed post-manufacturing.

USB direct drive

✔✔ ✔

✔✔ ✔

✘✔ ✔

✘✘ ✔

Scan and print

(Select f o rmats)

Scan an d pri nt

(Select for m ats)

Scan and print

(Select fo rmats)

General inf ormation 1-3

7525xxx Lexmark confidential until annou nce

Operating modes

Mode Description

Normal Factory default
Quiet Designed for customers where noise lev els are a very important

Eco-mode
(Energy and Energy + Paper

factor.

• Print quality is maint ained at factory default level.

• Speed is reduced.

Designed for customers where the environment is a key factor.
There are three options; Energy, Paper, and Ener gy+ Paper.

• Print quality is maint ained.

• Power Saver is set to one minute.

• Fuser standby is off.

• The operator panel back light is off.

• Power supply energy consumption is reduced.

• Duplex is on if Energy + Paper is selected (duplex models
only) (can be ov erwri tten by the driver.)

Data streams

✔—Supported
✘—Not supported

Data streams Lexmark X543
PCL 6 emulation
PostScript Level III emulation

Version 3011 of the Adobe definit ion
of PostScri pt 3 is supported.

PDF

Supports version 1.6

PPDS

By default, the PPDS interpreter is
inactive . A user can activate the dat a
stream by PJL or by the PPDS
Emulation set ting in the Configur ation
Menu

Pict Bridge
Directimage

Devices that support Directimage
support all of the following graphics
formats: TIFF, TIF, JPEG, JPG, GIF,
PNG, BMP, PCX, and DCX.

Host-Based Printing (HBP)/
Graphics Device Inte rface (GDI)

Version 3 (color) uses PCL XL.

✔✔ ✔

✔✔ ✔

✘✔✔

✘✔✔

✘✔✔

✘✔✔

✔✔ ✔

Lexmark X544n,
X544dn, X544dtn Lexmark X544dw

1-4 Se rvi ce Manual

Lexmark confidential until announce 7525xxx

Dimensions

Models Height Width Depth Weight

Lexmark X543 291 mm (11.5 in.) 424 mm (16.7 in.) 400 mm (15.7 in.) 21 kg (46.2 lbs)
Lexmark X544n, X544dn,

X544dtn, X544dw
650-sheet Duo Drawer 133 mm (5.2 in.) 424 mm (16.7 in. 416 mm (16.4 in.) 4 kg (8.7 lb)

422 mm (16.6 in.) 424 mm (16.7 in.) 416 mm (16.4 in.) 25 kg (54.9 lbs)

Clearances

Description Dimensions

All models

1 Rear 100 mm (3.9 in.)
2 Front 482.6 mm (19 in.)
3 Right side 100 mm (3.9 in.)
4 Left side 100 mm (3.9 in.)
5 Above 360 mm (14 in.)*

* Add 133 mm (5.2 in.) to the top if you want to add an optional

650-sheet Duo Drawer (Lexmark X54x models only) .

General inf ormation 1-5

7525xxx Lexmark confidential until annou nce

Power and electrical specifications

The following table specified nominal average power requirements for the base printer configurations. All power
levels are shown in Watts (W). Maximum curre nt i s given in Amperes (A).

Lexmark

Printing sta tes Lexmark 543dn

Average po w er w hile printing

Continuous copy 480 W 510 W 510 W
Continuous printing simplex 480 W 540 W 540 W
Continuous printing automatic duplex* 340 W 370 W n/a

Average po w er w hile idle

Power Saver 22 W 24 W

Stanby 45 W 50 W 50 W
Off 0 W

* Automatic duplex is not supported on the X544n.

X544dw, X544dn ,
and X544dtn

23 W (dn only)

Lexmark X544n

23 W

Low-voltage models

• 100 to 127 volts (V) ( 100 – 110 Japan) at 50 to 60 hertz (Hz) nominal

• 90 to 137 volts (90 – 110 Japan), extrem e

100 voltage models

• 100 Vac at 47 to 63 hertz (Hz) nominal

• 90 to 110 Vac, extreme

High-vol tage models

• 220 to 240 Vac at 50 to 60 hertz (Hz) nominal (not avai lable in all countries)

• 198 to 259 Vac, extreme

Notes:

• Using a 220 V ac to 110 V ac power converter with a low voltage printer is not recommended.

• Using an inverter to change DC to AC voltage (12 V to 120 V for example) is not recommended.

• All X54x MFP models will comply with the ENERGY STAR.

• All models ship with Power Sav er Mode = On.

• The default timeout to Power Saver = 60 minutes (220V).

• Power Saver can be adjusted to 1-240 minutes.

• Power Saver mode cannot be disabled from the operator panel.

--

1-6 Se rvi ce Manual

Lexmark confidential until announce 7525xxx

Acoustics

All acoustic measurements are made in accordance with ISO 7779-1999 and reported in conformance with
ISO9296:1988-04-15.

Operating mode

Printing (simplex m ono) 46 dBA 46 dBA
Printing (simplex color) 47 dBA 47 dBA
Printing (automatic

duplex mono)
Printing (automatic

duplex color )
Copy ADF (Mono) 50 dBA 49 dBA
Copy ADF (Color) 50 dBA 50 dBA
Scan ADF (Mono) 47 dBA 45 dBA
Scan ADF (Color) 46 dBA 45 dBA
Idle Inaudible Inaudible
Quiet Mode (simple x

mono)
Quiet Mode (simple x

duplex)

Environment specifications

1-Meter average sound
pressure at 4800 CQ

Lexmark
X543

50 dBA 50 dBA

50 dBA 51 dBA

45 dBA 45 dBA

45 dBA 45 dBA

Lexmark
X544

Environment Specifications
Operating

Air temperature—o perating 15.6 to 32.20° C (60 to 90.0° F)
Air temperature—p ower off 10.0 to 43.30° C (50 to 110.0° F)
Air relative humidity Relative Humidity 8 to 80%
Wet bulb temperature—operating 22.80° C (73.0° F) maximum
Web bulb temperature—power off 26.70° C (80.10° F) maximum
Altitude 0–3,048 meters (10,000 ft.)
Atmospheric pressure 74.6 kPa
Ambient operating environment* 15.6 to 32.2° C (60 to 90° F) and 8% to 80% RH

Ship / Storage

Cartridges -40 to 43.3° C (-40 to 110.0° F)
Printer with cartridges -40 to 43.3° C (-40 to 110.0° F)
Printer without cartridges -40 to 43.3° C (-40 to 110.0° F)
Air relative humidity Relative Humidity 8 to 80%
Altitude 10,300 meters (34,000 feet)
Web bulb temperature—power off 26.70° C (80.10° F) Maximum
* In some cases performanc e specifications (such as paper OCF, EP cartridge usage) are specif ied to be

measured at an ambient condi ti on.

General inf ormation 1-7

7525xxx Lexmark confidential until annou nce

Media handling

Input and output sources

Sheet numbers are assu ming 20 lb.
xerographic paper

Standard input sources

Standard input tray (250-sheet tray) 250 sheets 250 sheets 250 sheets
Manual feed slot (1-sheet) 1 sheet 1 sheet 1 sheet
Second tray capacity (650-sheet

Duo Drawer)
Multipurpose try capacity (65 0-

sheet Duo Drawer)

Optional input sources (maximum 1, total of all inputs is 4)

650-sheet Duo Drawer
(includes 100-sheet MP feeder)

Maximum total input capacity 901 901 901

Duplex

Type of duplex Integrated duplex Integrated duplex n/a

Standard output sources (no optional output sources are availab le)

Standard 100-sheet bin 100 100 100

a In the 650-sheet Duo Dra wer, the 550- sheet tray and the integrated MP feeder count as two independent

input sources. The MF feeder is configured as “cassette” does not show up as Configure MP in the Pape r
Menu.

a

Lexmark X543

550 sheets 550 sheets 550 sheets

100 sheets 100 sheets 100 sheets

550 sheets

(or 100 sheets in MP

feeder)

Lexmark X544dw,
X544dn, X544dtn

550 sheets

(or 100 sheets in MP

feeder)

Lexmark X544n

550 sheets

(or 100 sheets in MP

feeder)

Duplex capability

✔—Supported

Models

Lexmark X543dn
Lexmark X544n
Lexmark X544dn
Lexmark X544dw
Lexmark X544dtn

x

Duplex Type

Automatic duplex

✔

✔

✔

✔

1-8 Se rvi ce Manual

Lexmark confidential until announce 7525xxx

Media input size specifications

✔—Supported without size

sensing

✘—Not supported

(in the

a

Input source

A4 210 x 297mm

A5a 148 x 210mm
A6 ✘✘

JISb B5a 182 x 257mm

JISb B4 ✘✘✘✘✘
Letter 8.5 x 11 in.

Legal 8.5 x 14 in.
Executive 7.25 x 10.5 in.

Oficio (Me xi c o )

Foliod 8.5 x 13 in.
Statement 5.5 x 8.5 in. ✘✘

Universalc

148 x 210mm to

215.9 x 355.6mm
(5.83 x 8.27 in. to

8.5 x 14 in.)

d

250-sheet tray

Opti o n al 650-sheet

Duo Drawer

✔✔✔✔✔

✔✔✔✔

✔✔✔✔✔

✔✔✔✔✔

✔✔✔✔✔

✔✔✔✔

✔✔✔✔

✔✔✔✔

✔✔✔✔

MP feeder

✔

650-sheet Duo Draw er )

Manual slot

✔✘

✔✔

Duplex

✘

✘

✔

✔

✘

✘

76.2.x 127mm to

215.9 x 355.6mm
(3 x 5 in. to 8.5 x 14 in.)

210mm x 279.4mm to

215.9mm x 355.6mm
(8.27 in. x 11 in. to

8.5 in. to 14 in.)

7¾ Envelopea 98.4 x 190.5mm ✘✘

9 Envelopea ✘✘

10 Envelopea 104.8 x 241.3mm

(4.12 x 9.5 in.)

DL Envelopea 110 x 220mm

(4.33 x 8.66 in.)

C5 Envelopea 162 x 229mm

(6.38 x 9.01 in.)

✘

✔✔✔✔

✘✘

✘✘

✘✘✔✔✘

✘

✔✔

✔✔

✔✔

✔✔

✔✔

General inf ormation 1-9

✘

✔

✘

✘

✘

✘

7525xxx Lexmark confidential until annou nce

✔—Supported without size

sensing

✘—Not supported

(in the

a

Input source

B5 Envelopea ✘✘✔✔✘
Other envelopea

Length: 98.4–431. 8m m
(3.8–17 in.)
Width: 89–297mm (3.5–11.7 in.)

a

The MP feeder runs slower if A5, statement, B5, or envelope are loaded.

b

Japanese Industry Standard.

c

Although the user ma y select Univer sal paper size for these sources, not all tra y guides can be adju sted to
all Universal media sizes.

d

If a source supports size sensing and this featur es is activate d, th en neither Oficio or Folio appear in the
list of supported media siz es . These va lue s only appea r in a list of supported medi a siz es when t he sourc e
is non-size se nsing or the size sensing is deactivated .

Media input type specifications

✔—Supported
✘—Not supported

Input type

250-sheet tray

Opti o n al 650-sheet

Duo Drawer

✘✘

250-sheet tray

Optional

650-sheet

Duo Drawer

MP feeder

650-sheet Duo Draw er )

Manual slot

✔✔

a

MP feeder

(in 650-s h eet

Duo Drawer)

Manual feeder

Duplex

✘

Duplex

Plain paper ✔✔✔✔✔
Card stock ✔✔✔✔
Transparency ✔✔✔✔✘
Recycled
Glossy ✔✔✔✔✔
Heavy glossy
Paper -backed labels ✔✔✔✔
Bond ✔✔✔✔✔
Envelopes
Rough envelopes ✘✘✔✔✘
Letterhead ✔✔✔✔✔
Preprinted ✔✔✔✔✔

1-10 Service Manual

✘

b

✔✔✔✔✔

✘✘✘✘✘

✘✘✔✔✘

Lexmark confidential until announce 7525xxx

✔—Supported
✘—Not supported

Input type

Colored paper ✔✔✔✔✔
Light paper ✔✔✔✔✔
Heavy paper ✔✔✔✔✔
Rough or cotton ✔✔✔✔✔
Custom type <x>

a

For MP feeder and manual feeders the Default Sou rce Menu disp lays Manual Paper and Manua l Env. Select

Manual Env. for envelopes or when the type in Custom Type <x> is an envelope . For other types, use
Manual Paper.

b

The duplex uni t suppo rts this medi a type as lon g as the cus tomer has s el ected th e custom type f rom those
types the duple x unit supports.

b

Media output size and type

There is a single 100-sheet output bin available for this printer and no addition al output options.

a

250-sheet tray

✔✔✔✔✔

Optional

650-sheet

Duo Drawer

MP feeder

(in 650-sheet

Duo Drawer)

Manual feeder

Duplex

General information 1-11

7525xxx Lexmark confidential until annou nce

Weight ranges for each media type

Material Type Weight Select

2, 5, 7, 8

Paper

Specialty papers G loss Book 88 to 176 g/m

Card stock—uppe r
limit (grain long)

Card Stock—upper
limit (grain s h o rt)

Transparency
Labels—upper limit Paper 131 g/m
Envelopes
(Multipurpose

feeder or manual
slot only)

1

For 60 to 176 g/m2 paper, grain long fibers are recommended.

2

Paper less than 75 g/m2 (20 lb) must be printed with Paper Type set to Light Paper.

3

100% cotton content maximum weight is 24 lb bond.

4

28 lb bond envelopes are limited to 25% cotto n content.

5

The duplex unit supports paper weights between 60–105 g/m2 (16–28 pound) grain long bond. The duplex

unit does not support card stock, transparencies, envelopes, and labels.

6

Lexmark transparency part numbers 12A8240, and 12A8241 are supported from the standard tray, manual
slot and the multipurpose feeder.

7

Paper 90 to 104.9 g/ m2 (23.9 to 27.8 lb) must be printed with Paper Type set to Heavy Paper.

8

Paper 105 to 176 g/m2 (27.9 to 47 lb) must be printed with Paper Type set to Cardstock.

Xerographic or

business paper

60 to 74. 9 g/m2 grain long
(16 to 19.9 lb bond)

75 to 89.9 g/m

2, 5

2

grain long

(20 to 23.8 lb bond)

90. to 104.9 g/m

2

grain long

(23.9 to 27.8 lb bond)
105 to 176 g/m

(27.9 to 47 lb bond)

Gloss Cover 162 to 176 g/m
Index Bristol 120 g/m2 (67 lb)

1

Tag 120 g/m
Cover 135 g/m
Index Bristol 163 g/m2 (90 lb)

1

Tag 163 g/m
Cover 176 g/m

6

Laser print er 170 to 180 g/m2 (45 to 48 lb bond)

Sulfite, wood-free or

60 to 105 g/m

2

grain long

7

2

grain long (60 to 120 lb book)

2

grain long (60 to 65 lb cover)

2

(74 lb)

2

(50 lb)

2

(100 lb)

2

(65 lb)

2

(35 lb bond)

2

to 28 lb bond)
up to 100% cotton
bond

Light Paper

Plain Paper

Heavy Paper

Card stock

3, 4

1-12 Service Manual

Lexmark confidential until announce 7525xxx

Media guidelines

Paper characteristics

The foll owing paper characteristics affect pri nt quality and reliability. Consider these char acteristics when
ev aluating new paper stock.

• Weight—The printer can automatically feed paper weights from 60 to 176 g/m

long. Paper lighter than 75 g/m
performance, use 80 g/m
in.), we rec ommend 90 g/ m

2

(20 lb) might not be stiff enough to feed properly, causing jams. For best

2

(21 lb bond) gr ain long paper. For paper smaller than 182 x 257 mm (7.2 x 10.1

2

or heavier paper.

• Curl—Curl is the ten dency for pap er to curl at its e dges . Exces si ve curl can caus e paper f eedi ng prob lem s.

Curl can occur after the pap er passes through the printer, where it is e xposed to high temperatures.
Storing paper unwrapped in hot, humid, cold, or dry conditions, even in the trays , can contribute to paper
curling prior to printing and can cause feeding problems.

• Smoothness—Paper smoothness directly affects print quality. If paper is too rough, toner cannot fuse to it

properly. If paper is too smooth, it can cause paper feeding or print quality issues. Always use paper
between 100 and 300 Sheffield points; however, smoothness between 150 and 200 Sheffield point s
produces the best print quality.

• Moisture content—The amount of moisture in paper af fects both prin t qual ity and the abilit y of t he pri nter

to feed the paper correctly. Leave paper in its original wrapper until it is time to use it. This limits the
exposu re of paper to moisture changes that can degrade its performance. Condition pap er before printing
by storin g it in its original wrapper in the same environment as the printer for 24 to48 hours before printing.
Extend the time se veral days if the storage or transportation environm ent is very differen t from the pri nter
environment. Thick paper may also require a longer con ditioning period.

• Grain direction—Grain refers to the alignment of the paper fibers in a sheet of p aper. Grain is either grain

long, running the length of the paper, or grain short, running the widt h of the paper. For 60 t o 176 g/m
to 47 lb bond) paper, use grain long fibers.

• Fiber content—Most high-quality xerographic paper is made from 100% chemical ly treated pulped wood.

This content provides the paper with a high degr ee of stability resulti ng in fewer paper feeding probl em s
and better print quality. Paper containing fibers such as cotton possesses characteristics that can
negatively affect paper handling.

2

(16 to 47 lb bond) grain

2

(16

Unacce p tab l e p ap er

The foll owing paper types are not recomm ended for use with the printer:

• Preprinted papers wit h chem icals that may cont aminate 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 surf ace papers, or curled papers

• Recycled papers containing more than 25% post-consumer waste that do not mee t DIN 19 309, and

weigh ing m o r e t h an 80 g/ m

• Paper weighing less than 80 g/m

2

2

(21 lb)

• Multiple -p a rt forms or do c um en t s

General information 1-13

7525xxx Lexmark confidential until annou nce

Selecting paper

Using appropriate paper pre v ent s jams and helps ensur e troub le-f ree printing . To help avoid jams and poor print
quality:

• Always use new, undam aged paper .

• Before loading paper , know the recommended print side of the paper. This information is usually indicated

on the paper package.

• Do not use paper that has been cut or trimmed by hand.

• Do not mix paper sizes, types, or w eights in the same source; mi xing results in jams.

• Do not use coated papers unless they are specif ically designed for electrophotographic printing.

Selecting p r ep r i n t ed forms and let ter h ead

Use these guidelines when selecting preprinted forms and letterhead:

• Use grain long for 60 to 176 g/m

2

weight paper.

• Use only for m s and letterhead printed using an offset lithographic or engraved printing process.

• Av oid papers with rough or heavily textu red sur faces.

Use papers printed with heat -resistant inks designed for use in xerographic copiers. The ink must be abl e to
withstand tempe ratures up to 200°C (392°F) without melting or releasing hazardous emissions. Us e inks that
are not affected by the resin in toner. Inks that are oxidati on-set or oil-based generally m eet these requi rements;
latex inks might not. When in doubt, contact the paper supplier.

Preprinted papers such as letterhead must be able to withstand temperat ures up to 200°C (392°F) without
melting or releasing hazardous emissions.

Storing paper

Use these paper storage guidelines to help avoid jams and uneven print quality:

• For best results, store paper where th e temperature is 21°C (70°F) and the relative humidity is 40%. Most

label manufacturers recommen d printing in a temperature range of 18 to 24°C (65 to 75°F) with relative
humidity betw een 40 and 60%.

• Store paper in cartons when possi ble, on a pallet or shel f, rather than on the floor.

• Store individual packages on a flat surface.

• Do not store anyt hing on top of individual paper packages.

Using recycl ed p ap er and ot he r of fi ce papers

As an environmentally conscious company, Lexmark supports the use of recycled office paper produced
specifica ll y for use in laser (electr ophotographic) printers. In 1998, Lexmark presented to the US government a
study demonstrating that recycle d pa per produced by major mills i n the US fed as well as non-recycled paper.
Howe ver, no blanket statement can be made that all recycled paper will feed well. Lexmark consistently tests its
printers with recycled paper (20–100% post-consumer waste) and a variety of test paper from around the worl d,
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 follow ing property guidelines apply to
recycled paper.

• Low moisture cont ent (4–5%)

• Suitable smoothness (100–200 Sheffield units, or 140–350 Bendtsen units, European)

Note: Some much smoother papers (such as premium 24 lb laser papers, 50–90 Sheffield units) and

much rougher papers (such as premium cotton papers, 200– 300 Sheffield units) ha ve been engineered to
work very well in laser printers, despite surface texture. Before using these types of paper, consult your
paper supplier.

• Suitable sheet-to-sheet coefficient of friction (0.4–0.6)

• Sufficient bending resistance in the di rection of fee d

1-14 Service Manual

Lexmark confidential until announce 7525xxx

2

Recycled paper, paper of lower weight (<60 g/m

[16 lb bond]) and/or lower caliper (<3.8 mils [0. 1 m m]), and
paper that is cut grain-short for portrait (or short-edge) fed printers may have lower bending resistance than is
required for reliable paper feeding. Before using these types of paper for laser (electrophotographic) printing,
consult your paper supplier. Remember that these are general guidelines only and that paper meeting these
guidelines ma y stil l cause paper f ee ding pro b lems in an y l aser pri nter ( for e xamp le, if the p aper curls e xc essi vel y
under normal printing condi tions).

General information 1-15

7525xxx Lexmark confidential until annou nce

Digital imaging specifications

General specifications

ADF Scan sp eed

Simplex ADF - Up to 25 ppm
Duplex ADF - Up to 35 ppm (page sides)

ADF Document handling

ADF input capacity - 50 sheets.
ADF output capacity - 50 sheets.
ADF document width - 4.9’’ (125mm) to 8.5’’(216mm)
ADF document length - 5’’ (127mm) to 14.0”(356mm)

Resolution and color depth

Resolution - 1200 dpi opt ical

•

• CDD 1200 dpi, and 600 dpi. Selectable through electronics

• Color depth - 48 bit RGB output. 16 bit / channel

Flatbed document specifications

Document size- Up to A4 and letter

•

4.5’’ x 5.5’’ to 8.5’’x11’’ (SEF)

Flatbed speed

3 seconds to scan, 3 seconds to return.

Scanner operating environments

Temperature - 10C to 35C

•

• Humidity - 15% RH to 85% RH

Storage environ ments

Temperature - -20C to 43C

•

• Humidity - 5%RH to 95% RH

Tilt

This device should operate withi n the stated parameters when it is l evel withi n 10m m from fr ont to back and
10mm side to side.

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Scan and copy specific specifications

Scan Resolutions

Optical - 600 dpi (Local Twain only)

•

• Enhanced (vial Lexmark Scan Center) - 1200 X 1200 dpi, 2400 X 2400 dpi, 4800 X 4800 dpi, 9600 X 96 00

dpi, 19200 X 19200 dpi

Output resolutions

•

Mono - 600 X 600 dpi

• Color - 300 X 300 dpi

Dupl ex scan

Duplex and copy is available only on X544 series mach ines.

Scan file output formats

TIFF

•

• JPEG

• PDF

Supported compressions

•

PDF - (1 bit,- JBIG2 CCIT G4, Flate), (8/24 bit - Flate JPEG)

• TIFF - (1 bit - CCITT G4), (8/24 bit - Packbits, LZW)

• JPG - (8/ 24 bi t-JPG )

Supported scan destinations

•

Temporary profile from a user’s PC

• Scan to PC via network TWAIN

• Scan to PC using Web applet

• Scan to E-Mail

• Scan to USB (X544 models only)

• Lexmark Scan Center

Multiple copies

999 copies maximum

Reduce / Enlarge

-25% to 400%

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Fax specifications

Phone network connectivity

Phone networks types supported PSTN or analog PABX (RJ-11)
ITU COMPATIBILITY

Standard Resolution
Fine
Superfine
Ultrafine
Coding

Modem speed V.34 2,400-33,600 BPS,

Compression
Error correction ITU T.3 0

Line interface selection

Modular Plug
Out Band Signal Level

Input Level Range
Ring Detection

Group 3/E C M
8 x 3.85 pels/mm (200X100dpi) ( 204x98)
8 x 7.7 pels/mm (200X2 00dpi) (204x196)

11.8 x 11.8 pels/m m ( 30 0x 30 0 dp i) (20 4x391)

15.7 x 15.7 pels/mm (400x400 dpi) (408x391)
ITU T.4 and T.6(MH, MR, MMR, JPEG)

V.17 7,200-14,400 BPS,
V.27 2,400-4,800 BPS,
V.29 7,200-9,600 BPS

MH, MR, MMR, JPEG

Dual RJ-11C
Guaranteed North American and Europe PTT standard

-16dBm ~ -59dBm
Complies with all regulatory requirements

Fax resolutions

Receive 200x10 0 dp i, 20 0x 20 0 dpi, 300x 30 0 dp i,

Send 200x100dpi, 200x200 dpi, 300x300 dpi

400x400 dpi, 204x98 dpi, 204x196 dpi,
204x39 1 dp i, 40 8x 39 1 dpi

Miscellaneous FAX specifications

Fax memory 4 MB Flash (More than 320 pages based on ITU chart #1)

Speed dial Yes. 999 entri es
Transm is s ion Appr oxim a tel y 3 second s pe r pa g e
Color fax Yes
Fax from PC Yes. Supported using PostScript driver for both local and

Caller ID Yes
Junk FAX blocking Yes - based on caller ID and remote station ID
Tone/Pul se Tone: Default, Puls e: Yes
Fax forward Yes
Broadcasting Yes. 12 destinations
External ph on e int er fac e Yes
Manual mode Yes
Fax shortcuts Yes.
Fax content T ext, text/photo, photo
Fax perseveration Y es
Halftoning Yes

User sel ectable parameters are stored in NVRAM.

network attach modes.

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Tools required for service

Flat-bl ade screwdriver s, various sizes
#1 Phillips screwdriver, magnetic
#2 Phillips screwdriver, magnetic
#2 Phillips screwdriver, magnetic short-blade
7/32 inch (5.5 mm) open- end wrench

7.0 mm nut driver
Needlenose pli ers
Diagonal side cutters
Spring hook
Feeler gauges
Analog or digital multimeter
Par allel wrap plug 1319128
Flash light (optional)

General information 1-19

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Acronyms.

ac Alternating Current
ACM Autocompensator Mechan ism (or paper feed)
ADF A utomatic document f eeder
AFE Analog front end
AIO All-In-One
APS A utomatic Paper Size
ASIC Application Specific Integrated Circuit
BLDC Brushless DC Motor
BOR Black On ly Retra c t
BUD Belt up down
CCyan
CCD Charge-Couple Device
CCFL Cold Cathode Fluorescent Lamp
CCW Counter clockwise
CDB Command Descriptor Blocks
CMYK Cyan yellow magenta black
CPU Central processing unit
CRC Cyclic redundancy check
CRU Custom er Repl aceable Unit
CSU Customer Setup
CW Clockwise
DBCS Doub le byte character set
dc Direct Current
DIMM Du al Inline Memory Module
DLE Downloadable emulator
DRAM Dynamic random access memory
DVM Digital multimeter
ECC Error correcting code
ECM Error correction mode
EDO Enhanced Data Out
EEPROM Electrical Erasabl e Programmable Read-Only Memory
ENA External Network Adapter
EOL End of line
EP Electrophotographic proces s
EPROM Erasable prog rammable read-only memory
ESD Electrostatic Discharge
FB Flatbed
FD Facedown
FRU Field replaceable unit
FU F ace up
GB Gigabyte
GFI Ground Fault Interrupter
GHz Gigahertz
HBP Host Based Printing
HCF Hi gh-capacity feeder
HCIT High-capacity Input Tray
HCOF High-Capacity Output Finisher
HCPF High-capacity feeder
HTML Hypertext markup language
HV High Voltage
HVPS High vo lt age power supply

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HVU High voltage unit
Hz Hertz
INTL International
ITC I nternal Tray Card
ITU Image Transfer Unit
KBlack (Key)
LAN Local area network
LASER Light amplification by stimulated emission of radiation
LCD Liquid crystal display
LCM Liquid Crystal Module
LD Laser Diode
LED Light emitting diode
LEF Long edge feed
LES Lexmark Embedded Solution (applicati ons)
LSU Laser Scanning Unit
LV Low Voltage
LVPS Low voltage power supply
M Magenta
MB Megabyte
MDC Motor Driver Control
MFD Multifunction Device
MFP Multifunction Printe r
MH Message handling
MIF M otor in t e r fac e
mm Millimetre
MMR Modified modifi ed read
MPF Multipurpose fe eder
MR Modem ready
MROM Masked Read Only Memory
MS Microswitch
NAND NAND (usage: NAND gate)
NVM Nonvolatile Memory
NVRAM Nonvol atile Random Access Memory
OCF Operator correc table failure
OCR Oil coating roll
OEM Original Equipment Man ufacturer
OHP Overhead projector
OPC Optical photo conductor
OPT Optical Sensor
PC Photoconductor
PDF Portable Document Format
PICS Problem isolation charts
PIN Personal identification number
PIXEL Picture element
PJL Printer Job Language
POR P ower-on reset
POST Power-on self test
PPDS Personal Printer Data Stream
ppm Pages per min ute
PQET Print Quality Enhancement Technology
PRC Peoples' Republic of China
PSC Parallel Synchronous Communications
PSD Position Sensing Dev ice
PSO Participating Standards Organization

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PWM Puls e Width Modulation
RAM Random access memory
RFID Radio frequency identification
RH Relative humidity
RIP Raster image processor
ROM Read-only memory
ROS Read-only storage
RPM Revolutions Per Minute
SCC Scanner Control Card
SDRAM Synchronous Dynamic Random Access Memory
SEF Short edge feed
SIMM Single Inline Memory Module
SOL Solenoid
SOS Start of scan
SRAM Static random access memory
TAR Toner Add Roll
TPS Toner Pa tch Sensing
TTM Tandem Tray Module
TVOC Total Volatile Organic Compound
UAT Universally Adjustable Tray
UPR Used Parts Return
USB Universal Serial Bus
VVolts
V ac Volts alternating current
V dc Volts direct current
VOIP Voice ove r internet protocol
VOM Volt Ohmmeter
VTB Vacuum Transport Belt
XPS XML Paper Specification
YYellow

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2. Diagnostic information

Start

CAUTION

Unplug the power cord from the el ectrical outlet bef ore 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 neces sary to rep air a
malfunctioning printer. They will lead you to solutions or service checks , including use of vari ous tests.

• Does the POR stop? Check the “POR (P ower-On Reset) sequence” on page 2-2

• Do you hav e a sym ptom, rather than an error mes sage? 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 mess age, check the following:
– “Service error messages” on page 2-14
– “User status and attendance messages” on page 2-6
– “Paper Jam message s” 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

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POR (Power-On Reset) sequence

The foll owing is an example of the events that occ ur duri ng the POR sequence for the base machi ne with no
paper-handli ng options installed.

When you turn the printer on, it performs a Power-On Self Test. Check f or correct POST functioning of the base
printer by observing the following :

1. The LED turns on.

2. The main fan turns on.

3. The oper ator panel turns on.

4. A partial row of pix els appears.

5. The operator panel display clears.

6. Anothe r ro w of pi xels appears.

7. The operator panel display clears again.

8. The operator panel displays system information. For example:

*256MB 500Mhz

9. The fuse r lamp turns on. The fuser takes longe r to warm up from a cold start than a warm start.

10. The operator panel LED starts blin king.

The foll owing errors or messages may appear:

• Close Door or Insert Cartridge display if the upper front cover is open or the print cartridge is missing.

• Any cartridge errors, such as Defective Cartridge or Missing Cartridge.

11. Ready appears on the display.

12. The main drive motor turns on.

13. The EP drive assembly drives the developer shaft located i n the t oner cartridge.

14. The exit rollers tur n .

15. The printer calibrates.

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Sympto m tables

Printer symptom table

Symptom Action

Dead printer Go to “Dead printer service check” on page 2-37.
Operator panel—one or more buttons do

not work.
Operator panel—di splay is blank. Pri nter

sounds five beeps.
Operator panel—display is blank. Go to “Operator panel display blank, five beeps” on

Operator panel cont inuously displays all
diamonds and does not complet e POST.

Pages print blank after replaci ng the
controller board.

Tray linking does not work. • Check that the same size and type of paper are in each tray.

Unexpected page breaks occur • Increase the Print Timeout value on the operator panel

Multipurpose f eeder has c onstant misf ee ds
or jams.

Page that jammed does not reprint after
you clear the jam.

Pages print blank after replaci ng the
controller board.

Unexpected page breaks occur • Increase the Print Timeout value on the operator panel

Go to “One or more operator panel buttons fail” on

page 2-44.

Go to “Operator panel display blank, five beeps” on

page 2-44.

page 2-44.

Go to “Operator panel display blank, five beeps” on

page 2-44.

When replacing the cont rol ler board, verify the cable from the
high-voltage power supply is seat ed properly. The cable ma y
have come loose from the HVPS.

• Check the location of the paper guides.

• The multipurpose feeder does not automati cally sense the
paper size. You must set the size from the Paper Size/Type
menu.

• Print a menu settings page, compare the settings for each
tray, and adjust on the operator panel, if necessary.

(Settings–>General Settings–>Timeouts–>Print Timeout).

• Remove and fl ex the pa per in the tr a y. Reload the paper , and
try printing.

• Turn the paper over inside the tray.

• Make sure the feeder is properly install ed.

• M ake sure the paper is loaded correctly in the tray.

• Make sure the paper is not dam aged.

• Make sure the paper mee ts specifications . See “Media

input type specifications” on page 1-10.

• M ake sure the paper guides are positioned correctly for the
paper size loaded in the tray.

Jam Recovery may be set to Off. Change the setting to Auto or
On on the operator panel (Settings–>General settings–>Print
Recovery–>Jam Recovery.)

When replacing the cont rol ler board, verify the cable from the
high-voltage power supply is seat ed properly. The cable ma y
have come loose from the HVPS.

Warning: A blank page that should have toner on it could be an
indication that toner is appl ied to t he ITU belt but not tr ansf er red.
Therefore th e toner goes into the ITU cleaner which cannot
process massive amounts of toner. It is important to prevent
extensive blank pages from being processed if they should have
toner on them.

(Settings–>General Settings–>Timeouts–>Print Timeout.)

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Scan / fax / copy symptom table

Symptom Action

840.xx scanner error Go to “840.xx service c heck” on page 2-63.
ADF won’t duplex (Duplex ADF only) Go to “ADF Duplex service check” on page 2-69.
ADF skew Go to “ADF feed errors service check” on page 2-69.
Multiple pages feed into ADF
Documents wont feed into ADF
Scanner makes b uzzing noise on st artup or

during a scan.
Document feeds, but jams in ADF. Go to “ADF paper jam service check” on page 2-68.
Black streaks on scans G o to “ADF streak service check” on page 2-67.
Blank page Go to “Black or blank page copy service check” on
Black page
No dial tone Go to “Modem / fax card service check” on page 2-70.
Machine dials a number but fails to make a

connection with another fax machine.
Incoming fax has blank spaces or poor

quality.

Invali d fax partition, or fax parti ti on too
small.

Some words on an incoming fax are
stretched.

Faxes fail to transmit. Go to “Fax transmission service ch eck” on page 2-71.
Fax reception fails. Go to “Fax reception service check” on page 2-73.

Go to “Flatbe d home positi on service check” on page 2-66.

page 2-65.

The other f ax machi ne ma y be t urned o ff . Ask t he f ax r ecipi ent t o
check their machine.

1. The sending fax machine may be faulty.

2. The sending fax machine may ha ve a dirty document glass.

3. A noisy phone line can cau se err ors.

4. Check the MFP print quality by making a copy.

5. The print cartridge may be empty. Replace as necessary.
See “Format Fax Storage” on page 3-34.

The sending fax machine had a temporary jam.

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Print quality sym pto m tab le

Symptom Action

Background Go to “Print quality—background” on page 2-51.
Blank page Go to “Print quali ty—blank page” on page 2-52.
Blurred or fuzzy print Go to “Print quality—blurred or fuzzy print” on page 2-54.
Half-color page Go to “Print quality—half-color page” on page 2-54.
Horizontal banding Go to “Print quality—horizontal banding” on page 2-54.
Horizontal line Go to “Print quality—horizontal line” on page 2-55.
Insufficient fusing Go to “Print quality—insufficient fusing” on page 2-55.
Missing image at edge Go to “Print quality—m issing image at edge” on page 2-55.
Mottle (2–5mm speckles) G o to “Print quality—mottle (2–5mm speckles)” on

Narrow vertical lin e G o to “Print quality—narrow vertical line” on page 2-56.
Random marks Go to “Print quality—random marks” on page 2-56.
Residual image Go to “Print quality—residual image” on page 2-57.
Solid color page Go to “Print quality—solid color page” on page 2-58.
Vertical banding Go to “Print quality—vertical bandi ng” on page 2-58.
Color problems Go to “Color theory” on page 3-60.

page 2-55.

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Error codes and messages

User status and attendance messages

User status and attendance messages

User primary message Explanation

Calibrating The printer is performing a color adjustment.
Close Door Message clears when upper and lower doors are closed.
Insert Tray <x> This message is displayed when the printer requests the user t o insert tray x before i t

No Analog Phone Line

Memory Full, cannot
send faxes

Insert Duplex Page in
Tr ay < x>

Insta ll Tray <x> or
Cancel job

Load <source> <custom
string>

Load <source>
<custom type>

Load <source>
<size>

Load <source>
<type> <size>

Load Manual
<custom type>

can continue printin g the job . The pri nter needs to pick media from the missing tr a y or
the trays bel ow it.

Tray x=Tray 1, Tray 2
Note: This message displays when ref il ling the tra ys during a job. Before filling t ray a

tray, take the printer offl ine by pressing Stop , and wait for pages to stop feeding
into the output bin.

The following actions can be taken:

• Insert the requested tra y.

• Cancel the current job

An analog line is not detected as being plugged into the modem. If the device is in
Analog mode, this has a source of Fax. If the device is in F ax Server mode, and the
'Enable analog receive' Fax Server setting is set to 'On', this has a source of Fax
Receive. I f the device is in Fax Server mode and the 'Enable analog receive' Fax
Server setting is set to 'Off', then this IR is not generated.

After a start, there is no memory to do the fax job. Attempted f ax is cancelled.

Reload printed page in tray <x>. Cancel Job appears if the job can be cancelled.

Printer detects th at tr ay <x > is m issin g, where x is 1 or 2. Thi s mess age app ears if t he
job was begun, but the paper has not yet been retrieved. The tray is no longer
detected. Replace the i ndicated tray.

Printer does not detect media meeting the description <custo m st ring > in <source>,
where <source> is Tray 1, Tray 2, Multi-Page Feeder (MP feeder), or Envelope
Feeder.

• Load the input source wi th t he correct type and size media.

• Cancel the current job.

Printer does not detect media meeting the description <custom type> in <source>,
where <source> is Tray 1 or Tray 2.

• Load the input source wi th t he correct type and size media.

• Cancel the current job.

Printer does not detect medi a mee ti ng the size requested in the source indicated.

• Load the input source wi th t he correct type and size media.

• Cancel the current job.

Printer does not detect medi a mee ti ng the size or type requested i n the source
indicated.

• Load the input source wi th t he correct type and size media.

• Cancel the current job.

Printer does not detect media meeting the description <custom type> in the single
sheet feeder ( ma nual feeder).

The following actions can be taken:

• Load paper, and the job continues.

•press Select ( ), and choose an alternate source for media.

• Cancel the current job.

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User status and attendance messages (continued)

User primary message Explanation

Load Manual
<custom string>

Load Manual
<size>

Load Manual
<type> <size>

PJL ST Message Try one or more of the following:

Remove Paper ADF

Remove Paper
Standard Bin

Remo ve Pack agin g
Material

Unplug and Change
Mode

Replace Black Imagi ng
Unit

Replace Color Imaging
Unit

Replace <color>
Cartridge

Unsupported Mode Camera is not in a pro per mode to use the Pict Bridge feature. Unplug the camera

Unsupported USB
Device , Pl ease Remove

Unsupported USB Hub,
please remove

30.xx <color> Toner
Cart Missing

Printer does not detect media meeting the description <custo m st ring > in the single
sheet feeder ( ma nual feeder).

The following actions can be taken:

• Load paper and the job continues.

•press Select ( ), and choose an alternate source for media.

• Cancel the current job.

Printer does not detect media meeting the description <size> in the single sheet
feeder (manual feeder).

The following actions can be taken:

• Load paper and the job continues.

•press Select ( ), and choose an alternate source for media.

• Cancel the current job.

Printer does not dete ct med ia meeti ng the de script ion < type> and <size> in the single
sheet feeder ( ma nual feeder).

The following actions can be taken:

• Load paper and the job continues.

•press Select ( ), and choose an alternate source for media.

• Cancel the current job.

•press Select ( ) to clear the message, and continue printing.

• Wait for the message to clear.

This posts when there is paper detected in the ADF upon POR or when the cover is
closed (or any othe r situation that re-inits the scanner). Message clears when paper
is removed.

The standard output bin is full or nearly full. Remove the media from the bin.

Pack aging material is detected b y the printer. Remove the packaging material and
press Continue.

Camera is not in a proper mode to use the PictBridge feature. Unplug the camera
cable to the printer, and change the camer a mode.

Replace the Black Imaging Unit.

Replace the Color Imaging Unit.

Replace the toner cartridge of the indicated color. The printer continues after the
toner door is closed.

cable to the printer and change the camera mode.
Remove the unrecognized device from the USB port on the front of the printer.

Remove the unrecognized USB hub/device from the USB port on the front of the
printer.

The specified toner cartridge i s missi ng. Re- insta ll t he missi ng toner cartridge to cl ear
the message, and then continue printing. If the message recurs remove and re-inst all
the cartridge. Listen for the click to ensure the cartridge is installed properly. Close
the front cov er.

Diagnostic information 2-7

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User status and attendance messages (continued)

User primary message Explanation

31.xx Defe ctive <color>
cartridge

31.xx Defect ive Imagi ng
Kit.

32.xx Replace
unsupported <color>
Cartridge

34 Short Paper • press Select (

35 RES Save Off
Deficient Memory

37 Insufficient Coll ati on
Area

The specified cartridge is defective . Try one of the follo wing:

• Open and close the top cover .

• Rem ove and re-install the cartridge(s). Listen for the click to ensure the cartridge
is installed properly.

• Turn the printer power off and turn the printer power on.

If the message persists, replace the cartridge with a new one, and close the front
cover.

Defective imaging kit. Try one or more of the following:

• Open and close the top cover .

• Rem ove and re-install the cartridge(s). Listen for the click to ensure the cartridge
is installed properly.

• Turn the printer power off, and then turn the printer power on.

If the message persists, determine if the imaging kit counter is greater than 15,000
cycles. It it i s, then replace the entir e kit. See “Imaging unit (IU) re mo val” on

page 4-28. If the counter i s below 250,000 cycles , replace only the photoconductors.

Remove the spec if ied cartridge, replace with a supported cartridge, and cl ose the
front cover.

) to clear the message and continue printing.

The printer does not automati cally reprint the page that prompted the message.

• Check tray length and width guides to ensure paper is properly fitted in the tray.

• Make sure the print job is r equesting the correct siz e of paper.

• Adjust the Paper Size setting for the size paper you are using.
If MP Fe eder Size is s et to Univers al, make sure t he paper is lar ge enough f or the

formatted data.

• Cancel the current job.

This message displa ys when the printer lacks sufficient memory to enable Resource
Save. This message usually indicates the user has allocated too much memory for
one or more of the printer link buffers; however, modificat ion of other printer settings
which affect the amount of avail able memory may also create t his condition. If
restoration of Res ource Save is required after this message is recei v ed, the cu stome r
should install addi tional memory or set each link buffer to Aut o. Once all link buffers
are returned to Auto, you should exit the menu to activate the link buffer changes.
Once the printer returns to the Ready state, you can enable Resource Save and go
back and modify the link buffers again. Not e the reduction of available memory to the
link buffers when Resource Save has been enabled, and compare it to the memory
available when Resource Sav e is disabled.

•press

• I nstall additional memory.

This message is displayed when the printer memory used to store pages is too full to
collate the print job.

The following actions can be taken:

•press Select ( ) to print the portion of the job already stored , and begin col lati ng

•press Menus ( ) to access the Busy/Waiting Menu.

Note: Menu Loc kout does NOT prevent acc ess to the Busy/Wait ing Menu.

Select ( ) to di sable Resource Save and continue printing.

To enable Resource Save afte r you get this message:

- Make sure the link buffers are set to Auto, then exit the menus to activate the
link buff er changes.

- When Ready is displ ayed, enable Resource Save.

the rest of the job.

The follo w ing functions are available.

- Cancel Job

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User status and attendance messages (continued)

User primary message Explanation

37 Insufficient memory
for flash defragment
operation

38 Memory Full This message is displayed when the printer is pr ocessing an incoming job and there

39 Complex Page This message is display ed when a page is too complex to print.

50 PPDS Font Error This error only occurs when a printer i s formatting PPDS print data.

51 Defective Flash
Detected

52 Flash Full • press

This message is displayed when insufficient printer memory is ava il able to perf orm
Flash Memory Defragment operati on.

This message appears prior to the actual start of the defragment operation.
press

Select ( ) to stop the defragment operation.

To perf orm the defr agm ent operation, you can:

• Delete fonts, macros, and oth er dat a in RAM.

• Install additi onal printer memory.

•press Menus ( ) to access the Busy/Waiting Menu.
The follo wing functions are available using the Busy/Waiting M enu:

- Cancel Job

- Reset Printer

Note: Menu Loc kout does NOT prevent acc ess to the Busy/Wait ing Menu.

is not enough memory available to continue processing the job.
The following actions can be taken:

• Determine how to make more memory available to your print job by:

- Deleting fonts, macros and other data in RAM.

- Simplify your prin t job.

- Install additional memory

•press Select ( ) to clear the message and continue printing.
The job may not print correctly.

•press Menus ( ) to access the Busy/Waiting Menu.
The follo wing functions may be availab le:

- Cancel Job

The following actions can be taken:

•press

• Simplify the print jo b.

•press Menus ( ) to access the Busy/Waiting Menu.

Note: Menu Loc kout does NOT prevent acc ess to the Busy/Wait ing Menu.

The PPDS interpreter has detected a font error. When a specific font, which is not
installed, is requested based on a PPDS mode Set Font Global com ma nd, a Select
Code Page command, or a Comprehensive Font Selectio n com m and, and the printer
Best Fit setting is off. If Best Fit is on, the printer performs a best fit search to find a
similar font, and this error does not occur.

This error also displays when the printer recei ves invalid PPDS download font data.
The following actions can be taken while this message is displayed:

•press Select ( to clear the message and continue printing.

•press Menus ( to access the Busy/Waiting Menu.

press
You must install different flash memory before you can download any resources to

flash.

Select ( to clear the message and continue printing.

The job may not print correctly.

The follo wing functions may be availab le:

- Cancel Job

- Reset Printer

The job may not print correctly.

The follo wing functions may be availab le:

- Cancel Job

Select ( to clear the message and continue printing.

Select ( to clear the message and continue printing.

• Delete fonts, macros, and oth er data stored on the flash memory.

• Install a larger capacity flash memory card.

Diagnostic information 2-9

7525xxx Lexmark confidential until annou nce

User status and attendance messages (continued)

User primary message Explanation

53 Unformatted Flas h press

54 Standard Network
Software Error

54 Network <x>
Software Error

56 Standard USB
Port Disabled

58 Too many Flash
Options Installed

58 Too Many
Trays Installed

59 Incompatibl e
Tray <x>

82 Waste Toner Nearly
Full

82 Waste Toner Missing

88 <color> Toner Low The term <color> includes black, cyan, magenta, and yellow.

Select ( to clear the message and continue printing.

You must format the flash memory before you can store any resources on it. If the
error message remains, the flash memory may be defective and require replacing.

This message is displayed when the RIP software detects that a network port is
installed but cannot establish comm unications with it.

•press

• Program new firmware for the network interface.

• Turn the printer power off and then back on to reset the pri nter.

The printer disables all communications to the associated network interface. No data
may be received or sent from or to the associated interface. The user can program
new firmware in the network using the parallel port after this message clears.

•press

• Program new firmware for the network interface.

• Turn the printer power off and then back on to reset the pri nter.

This message m ay appear when data is sent to the printer across a USB port, but the
port is disabled.

Note: Once the erro r is displayed the f ir st time, reporting of further errors is
suppressed until the pri nter is reset or menus are enter ed.

The following actions can be taken:

•press

•press Menus ( to access the Busy/Waiting Menu.

Make sure the USB Buffer menu item is not set to Disabled. (press Menus to
access the Administrative Menus, select Network/Ports, USB Menu, and
USB Buffer.)

1.Turn off and unplug the printer.

2.Remove the excess f lash memory .

3.Plug in the printer, and turn it on.

1.Turn off and unplug the printer.

2.Remove the additional trays.

3.Plug in the printer, and turn it on.

1.Turn off and unplug the printer.

2.Remove the specified inc om patible tray.

3.Plug in the printer, and turn it on.

Try one or more of the following:

• Replace the waste toner bottle, and then press Select ( ) to clear the message

•press Select ( ) to clear the message and continue printing.

Order the waste toner bott le so it will be available when the replacement message is
displayed. Once the replacement me ssage is display ed, the printer will not continue
until the waste toner is replaced.

Waste tone r box must be present. Install the waste toner bot tle.

• Replace the specified toner cartridge.

• Replace the specified toner cartridge.

•press

Select ( to clear the message and continue printing.

The job may not print correctly.

Select ( to clear the message and continue printing.

The job may not print correctly.

Select ( to clear the message.

Any data receiv ed on the USB port is discarded.
The following functions ma y be available:

- Turn the printer powe r off and then back on to reset the printer.

- Reset Active Bin

- Check Supply Le vels

and continue printing. See Go to “Waste toner bottle” on page 4-49.

Select ( to clear the message and continu e print ing.

2-10 Service Manual

Lexmark confidential until announce 7525xxx

User status and attendance messages (continued)

User primary message Explanation

88 <color> Cartridge
Early Warning

88 Replace <color>
Cartridge

Scanner ADF cover
open

Scan job too long The scan job exceeds the maximum number of pages

Paper cleared Paper is cleared from ADF

The term <color> includes black, cyan, magenta, and yellow.

• Replace the toner cartridge and press
continue printing.

The term <color> includes black, cyan, magenta, and yellow.

• Replace the toner cartridge and press
continue printing.

The cover to the ADF is open.

• Close the ADF cove r . If thi s doesn’ t remedy th e probl em, Go to “ADF co ver open

service check” on page 2-67”.

• Break the scan job into multiple small jobs.

• Cancel the scan job.

• Cancel job

• Restart job - This can onl y be performed if job reco v ery is enab led and t he job c an
be restarted. A new job with the same parameters is started.

Select ( to clear the message and

Select ( to clear the message and

Diagnostic information 2-11

7525xxx Lexmark confidential until annou nce

Paper Jam messages

Paper jam messages (2xx)

Error code Description Action

2xx paper jams

200.xx Paper Jam
Check <area>

200.xx Paper Jam
<x> Pages Jammed

201.xx Paper Jam
Check <area>

201.xx Paper Jam
<x> Pages Jammed

202.xx Paper Jam
Check <area>

202.xx Paper Jam
<x> Pages Jammed

230.xx Paper Jam
Check <area>

230.xx Paper Jam
<x> Pages Jammed

A single page of media jam at th e input
sensor.

Multiple page s of media are j ammed at
the input sensor.

A single page of media is jammed
between the input and exit sensors.

Multiple page s of media are jammed
between the input and exit sensors.

A single page of media is jammed at
the exit sensors.

Multiple page s of media are j ammed at
the exit sensor

A single page of media is jammed at
the inner door.

Multiple page s of media are j ammed at
the inner door.

Remove t he tr ay1 u nit, open t he fro nt door,
and remove the print cartridge to access
the jam area. Remove the jammed page.
See “200 paper jams” on page 3-41.

Open the front door and remove the print
cartridge to access the jam area. Remove
all the jammed pages. See “200 paper

jams” on page 3-41.

Open the front door and remove the print
cartridge to access the jam area. Remove
the jammed page. See “201 paper jam”

on page 3-41.

Open the front door and remove the print
cartridge to access the jam area. Remove
all the jammed pages. See “201 paper

jam” on page 3-41.

Open the printer rear door to access the
jam area. Remove the jammed page. See

“202 paper jam” on page 3-42.

Open the printer rear door to access the
jam area. Remove all the jammed pages.
See “202 paper jam” on page 3-42.

Remove th e jammed page. See “230

paper jam” on page 3-43.

Remove al l t he jammed pages. See “230

paper jam” on page 3-43.

235 Paper Jam
Check Duplex

24x.xx Paper Jam
Check <area>

24x.xx Paper Jam
<x> Pages Jammed

250.xx Paper Jam
Check M a nu al
Feeder

250.xx Paper Jam
<x> Pages Jammed

290.02 Scanner ADF
Feed J am

290.10 Scanner
Static Jam

2-12 Service Manual

Paper jam in the duplex area. Remove all pages . See Go to “235 paper

A single or multipl e page media jam in
the 650-sheet Duo Dr awer (tray 2).

Multiple pages of media are jammed in
the 650-sheet Duo Dr awer (tray 2).

A single page of media is jammed in
the multipurpose feeder.

Multiple pages of media are jammed in
the multipurpose feeder.

The scanner ADF has fai led to feed a
page to the ADF interval sens or.

Scanner ADF detects pape r at the first
scanner sensor whi le t he ADF is i n an
idle state.

jam” on page 3-43.

See “24x paper jam” on page 3-43.

See “24x paper jam” on page 3-43.

Open tray 2 to access the jam area.
Remove th e jammed page. See “250

paper jam” on page 3-43.

Open tray 2 to access the jam area.
Remove al l t he jammed pages. See “250

paper jam” on page 3-43.

Remove the sheet of paper rom the ADF.
Retry the job. If the error recurs, Go to

“ADF paper jam service ch eck” on
page 2-68.

Remove all paper from the ADF. Retry the
job. If the error recurs, Go to “ADF paper

jam service check” on page 2-68.

Lexmark confidential until announce 7525xxx

Paper jam messages (2xx) (continued)

Error code Description Action

290.20 Scanner
Static Jam-Paper
Present

290.30-Scanner
Static Jam-Paper
Stop

291.00 Scanner Jam,
remove all originals
from the scanner

291.01 Scanner Jam,
remove all originals
from the scanner

292 Scanner jam,
remove all originals
from the scanner

293 Replace all
originals if res tarting
job

293.02 Flatbed cover
open

294.04 Scanner jam,
remove all originals
from the scanner

This message occu rs when paper is
detected in the ADF during a POR, or
when the MFP is starting up.

This message displays when paper is
inserted past the paper stop on the
ADF.

Scanner ADF detects pape r at the
second scanner sensor while the ADF
is in an idle stat e.

This message is posted if a jam is
detected at the fir st scanner sensor.

This message appears i f the ADF
cove r is open whil e paper is fed
through the ADF.

No paper sensed in the ADF. Ensure that the paper present actuator is

The MFP senses t hat the flatbed cover
is open.

Jam at the ADF exit sensor . Remove all paper fr om the ADF. I f the error

Remove original documents from the ADF.

Remove original documents from the ADF.

Remove t he paper from the ADF, and close
the ADF cover. If the error recurs, Go to

“ADF cover open service check” on
page 2-67.

in the correct position. See “ADF paper

jam service check” on page 2-68.

Close the flatbed cover. See “ADF cover

open service check” on page 2-67.

recurs, “ADF paper jam service check”

on page 2-68.

294.05 Scanner jam,
remove all originals
from the scanner

A jam is detected at the ADF ex it
sensor.

Diagnostic information 2-13

7525xxx Lexmark confidential until annou nce

Service error messa ges

Service error messages (1XX, 8XX and 9xx)

Error code Description Action

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

Yellow printhead error. Perform a PO R. If the problem persists, go

The yello w printhead lost HSYNC. Perform a POR. If the problem pers ists, go

The yello w p rinthead f ailed to com plete
servo.

The yellow printhead mirror motors
failed to achieve lock.

The yello w print head mi rror motors l ost
PLL motor lock.

Failure reading NVRAM from
printhead.

The yellow printhead thermistor is
open.

The yellow printhead thermistor is
shorted to ground.

to “Printhead service check” on

page 2-59.

to “Printhead service check” on

page 2-59.

Per form a POR. If the problem persis ts, go
to “Printhead service check” on

page 2-59.

Per form a POR. If the problem persis ts, go
to “Printhead service check” on

page 2-59.

Per form a POR. If the problem persis ts, go
to “Printhead service check” on

page 2-59.

Per form a POR. If the problem persis ts, go
to “Printhead service check” on

page 2-59.

Per form a POR. If the problem persis ts, go
to “Printhead service check” on

page 2-59.

Per form a POR. If the problem persis ts, go
to “Printhead service check” on

page 2-59.

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

The yellow laser showed bad in EMS
testing.

Cyan printhead error. Perform a POR. If the problem persists , go

The cyan printhead lost HSYNC. Perform a POR. If the problem pers ists, go

The cyan printhea d failed to complete
servo.

The cyan print head mirror motors f ailed
to achieve lock.

The cyan printhead mirror motors lost
PLL motor lock.

Failure reading NVRAM from the cyan
printhead.

The cyan printhea d thermis tor is open. Per form a POR. If the problem persists, go

Per form a POR. If the problem persis ts, go
to “Printhead service check” on

page 2-59.

to “Printhead service check” on

page 2-59.

to “Printhead service check” on

page 2-59.

Per form a POR. If the problem persis ts, go
to “Printhead service check” on

page 2-59.

Per form a POR. If the problem persis ts, go
to “Printhead service check” on

page 2-59

Per form a POR. If the problem persis ts, go
to “Printhead service check” on

page 2-59.

Per form a POR. If the problem persis ts, go
to “Printhead service check” on

page 2-59.

to “Printhead service check” on

page 2-59.

2-14 Service Manual

Lexmark confidential until announce 7525xxx

Service error messages (1XX, 8XX and 9xx) (continued)

Error code Description Action

107.07 Service
Cyan Printhead

107.08 Service
Cyan Printhead

108.xx Service
Magenta Printhead

108.01 Service
Magenta Printhead

108.02 Service
Magenta Printhead

108.03 Service
Magenta Printhead

108.04 Service
Magenta Printhead

108.05 Service
Magenta Printhead

The cyan printhead thermistor is
shorted to ground.

The cyan laser sho w ed bad in EMS
testing.

Magenta printhead error. Perform a POR. If the problem persists, go

The magenta printhead lost HSYNC. Perform a POR. If the problem persists, go

The magenta printhead failed to
complete servo.

The magenta printhead mirror motors
failed to achieve lock.

The magenta printhead mirror motors
lost PLL m o to r lock.

Failure reading NVRAM from the
magenta printhead.

Perform a POR. If t he problem persists, go
to “Printhead service check” on

page 2-59.

Perform a POR. If t he problem persists, go
to “Printhead service check” on

page 2-59.

to “Printhead service check” on

page 2-59.

to “Printhead service check” on

page 2-59.

Perform a POR. If t he problem persists, go
to “Printhead service check” on

page 2-59.

Perform a POR. If t he problem persists, go
to “Printhead service check” on

page 2-59.

Perform a POR. If t he problem persists, go
to “Printhead service check” on

page 2-59.

Perform a POR. If t he problem persists, go
to “Printhead service check” on

page 2-59.

108.06 Service
Magenta Printhead

108.07 Service
Magenta Printhead

108.08 Service
Magenta Printhead

109.

xx Servi ce

Black Printhead

109.01 Service
Black Printhead

109.02 Service
Black Printhead

109.03 Service
Black Printhead

109.04 Service
Black 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. Perform a POR. If the problem persists , go

The black pri nthead lost HSYNC. Perform a POR. If t he problem persists, go

The black pri nthead failed to com plete
servo.

The black pri nthead mirror motors
failed to achieve lock.

The black pri nthead mirror motors lost
PLL motor lock.

Perform a POR. If t he problem persists, go
to “Printhead service check” on

page 2-59.

Perform a POR. If t he problem persists, go
to “Printhead service check” on

page 2-59.

Perform a POR. If t he problem persists, go
to “Printhead service check” on

page 2-59.

to “Printhead service check” on

page 2-59.

to “Printhead service check” on

page 2-59.

Perform a POR. If t he problem persists, go
to “Printhead service check” on

page 2-59

Perform a POR. If t he problem persists, go
to “Printhead service check” on

page 2-59

Perform a POR. If t he problem persists, go
to “Printhead service check” on

page 2-59

Diagnostic information 2-15

7525xxx Lexmark confidential until annou nce

Service error messages (1XX, 8XX and 9xx) (continued)

Error code Description Action

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

Failure reading NVRAM from
printhead.

The black pri nthead thermistor is open. Perform a POR. If the problem persists, go

The black pri nthead thermistor is
shorted to ground.

The black laser showed bad in EMS
testing.

Fuser er ror Go to “Fuser service check” on

EWC err or—Attempting to pri n t with
estimated power at or below minimum
power.

Fuser over temperature. Go to “Fuser service check” on

Fuser open thermistor check faile d. Go to “Fuser service check” on

EWC Error—Did not reach EWC start
temperature in time.

Per form a POR. If the problem persis ts, go
to “Printhead service check” on

page 2-59.

to “Printhead service check” on

page 2-59.

Per form a POR. If the problem persis ts, go
to “Printhead service check” on

page 2-59.

Per form a POR. If the problem persis ts, go
to “Printhead service check” on

page 2-59.

page 2-41.

Go to “Fuser service chec k” on

page 2-41.

page 2-41.

page 2-41.

Go to “Fuser service chec k” on

page 2-41.

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

EWC Error—Did not change
temperature within expected time.

EWC Error—Did not reach EWC stop
temperature in time.

Timed out waiting for home sensor
event.

Wrong lamp bit is set in NVRAM. Go to “Fuser service check” on

Fuser zero cr ossings out of range. Zero
cros sing de tect ed .

Fuser failed to warm up. Go to “Fuser service chec k” on

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 thermist or check failed
for second thermistor

Go to “Fuser service chec k” on

page 2-41.

Go to “Fuser service chec k” on

page 2-41.

Go to “Fuser service chec k” on

page 2-41.

page 2-41.

Go to “Fuser service chec k” on

page 2-41.

page 2-41.

Go to “Fuser service chec k” on

page 2-41.

Go to “Fuser service chec k” on

page 2-41.

Go to “Fuser service chec k” on

page 2-41.

Go to “Fuser service chec k” on

page 2-41.

Go to “Fuser service chec k” on

page 2-41.

2-16 Service Manual

Lexmark confidential until announce 7525xxx

Service error messages (1XX, 8XX and 9xx) (continued)

Error code Description Action

122.16 Service
Fuser Error

141.xx Service
Staging Motor

141.01 Service
Staging Motor

141.02 Service
Staging Motor

141.03 Service
Staging Motor

141.04 Service
Staging Motor

141.05 Service
Staging Motor

150.xx Service
Black/ITU cartridge
Motor

150.01 Service
Black/ITU cartridge
Motor

150.02 Service
Black/ITU cartridge
Motor

EWC Error—Estimated power is at or
above maximum power.

Staging motor error. Go to “Autoco mpe nsator mechanism

Staging motor has e xceeded the ramp
up table.

Staging motor has e xceeded number
of encoders at min PWM.

Staging motor has e xceeded number
of encoders at max PWM.

Motor encoder count did not change
between inter rupts.

Staging motor has enc ountered a stall
timeout.

Black/I TU Cartridge Motor Go to “Main drive gear assembly (EP

Failed to achiev e lock for motor within
allotted time.

Timeout waiting for SAP BLDC motor
to reach val id FG speed.

Go to “Fuser service chec k” on

page 2-41.

service check” on page 2-32

Go to “Autocompensat or me chanism

service check” on page 2-32

Go to “Autocompensat or me chanism

service check” on page 2-32

Go to “Autocompensat or me chanism

service check” on page 2-32

Go to “Autocompensat or me chanism

service check” on page 2-32

Go to “Autocompensat or me chanism

service check” on page 2-32

drive) service ch eck” on page 2-43.

Go to “Main drive gear assembl y (EP

drive) service ch eck” on page 2-43.

Go to “Main drive gear assembl y (EP

drive) service ch eck” on page 2-43.

150.03 Service
Black/ITU cartridge
Motor

150.04 Service
Black/ITU cartridge
Motor

150.05 Service
Black/ITU cartridge
Motor

150.06 Service
Black/ITU cartridge
Motor

150.07 Service
Black/ITU cartridge
Motor

152.xx Service
Cyan Cartridge Motor

152.01 Service
Cyan Cartridge Motor

152.02 Service
Cyan Cartridge Motor

152.03 Service
Cyan Cartridge Motor

Timeout wait ing for
MP_NUM_INITIAL_SAP_HALLS.

Timeout waiting for SAP BLDC motor
FG.

Lost lock for motor. Go to “Main drive gear assemb ly (EP

Excessive SAP BLDC PWM. Go to “Main drive gear assemb ly (EP

Motor stalle d in tim e-based
commutation.

Failed to achiev e lock for motor within
allotted time.

Timeout waiting for SAP BLDC motor
to reach val id FG speed.

Timeout wait ing for
MP_NUM_INITIAL_SAP_HALLS.

Go to “Main drive gear assembl y (EP

drive) service ch eck” on page 2-43.

Go to “Main drive gear assembl y (EP

drive) service ch eck” on page 2-43.

drive) service ch eck” on page 2-43.

drive) service ch eck” on page 2-43.

Go to “Main drive gear assembl y (EP

drive) service ch eck” on page 2-43.

Go to “Main drive gear assembl y (EP

drive) service ch eck” on page 2-43.

Go to “Main drive gear assembl y (EP

drive) service ch eck” on page 2-43.

Go to “Main drive gear assembl y (EP

drive) service ch eck” on page 2-43.

Go to “Main drive gear assembl y (EP

drive) service ch eck” on page 2-43.

Diagnostic information 2-17

7525xxx Lexmark confidential until annou nce

Service error messages (1XX, 8XX and 9xx) (continued)

Error code Description Action

152.04 Service
Cyan Cartridge Motor

152.05 Service
Cyan Cartridge Motor

152.06 Service
Cyan Cartridge Motor

152.07 Service
Cyan Cartridge Motor

153.xx Service
Magenta Cartridge
Motor

153.01 Service
Magenta Cartridge
Motor

153.02 Service
Magenta Cartridge
Motor

153.03 Service
Magenta Cartridge
Motor

153.04 Service
Magenta Cartridge
Motor

Timeout waiting for SAP BLDC motor
FG.

Lost lock for motor. Go to “Main drive gear assemb ly (EP

Excessive SAP BLDC PWM. Go to “Main drive gear assemb ly (EP

Motor stall ed in tim e-based
commutation.

Failed to achiev e lock for motor within
allotted time.

Timeout waiting for SAP BLDC motor
to reach val id FG speed.

Timeout wait ing for
MP_NUM_INITIAL_SAP_HALLS.

Timeout waiting for SAP BLDC motor
FG.

Go to “Main drive gear assembl y (EP

drive) service ch eck” on page 2-43.

drive) service ch eck” on page 2-43.

drive) service ch eck” on page 2-43.

Go to “Main drive gear assembl y (EP

drive) service ch eck” on page 2-43.

Go to “Main drive gear assembl y (EP

drive) service ch eck” on page 2-43.

Go to “Main drive gear assembl y (EP

drive) service ch eck” on page 2-43.

Go to “Main drive gear assembl y (EP

drive) service ch eck” on page 2-43.

Go to “Main drive gear assembl y (EP

drive) service ch eck” on page 2-43.

Go to “Main drive gear assembl y (EP

drive) service ch eck” on page 2-43.

153.05 Service
Magenta Cartridge
Motor

153.06 Service
Magenta Cartridge
Motor

153.07 Service
Magenta Cartridge
Motor

154.

xx Serv ice
Yellow Cartridge
Motor

154.01 Service
Yellow Cartridge
Motor

154.02 Service
Yellow Cartridge
Motor

154.03 Service
Yellow Cartridge
Motor

154.04 Service
Yellow Cartridge
Motor

Lost lock for motor. Go to “Main drive gear assemb ly (EP

Excessive SAP BLDC PWM. Go to “Main drive gear assemb ly (EP

Motor stall ed in tim e-based
commutation.

Failed to achiev e lock for motor within
allotted time.

Timeout waiting for SAP BLDC motor
to reach val id FG speed.

Timeout wait ing for
MP_NUM_INITIAL_SAP_HALLS.

Timeout waiting for SAP BLDC motor
FG.

drive) service ch eck” on page 2-43.

drive) service ch eck” on page 2-43.

Go to “Main drive gear assembl y (EP

drive) service ch eck” on page 2-43.

Go to “Main drive gear assembl y (EP

drive) service ch eck” on page 2-43.

Go to “Main drive gear assembl y (EP

drive) service ch eck” on page 2-43.

Go to “Main drive gear assembl y (EP

drive) service ch eck” on page 2-43.

Go to “Main drive gear assembl y (EP

drive) service ch eck” on page 2-43.

Go to “Main drive gear assembl y (EP

drive) service ch eck” on page 2-43.

2-18 Service Manual

Lexmark confidential until announce 7525xxx

Service error messages (1XX, 8XX and 9xx) (continued)

Error code Description Action

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

841

842

Lost lock for motor. Go to “Main drive gear assemb ly (EP

Excessive SAP BLDC PWM. Go to “Main drive gear assemb ly (EP

Motor stalle d in tim e-based
commutation.

The scanner is disabled and can’t be
used.

The scanner is disabled and can’t be
used.

Image Pipeline Image pipeline ASIC. Go to “CCD service

Scanner Failure Communication failure. Go to “CCD

drive) service ch eck” on page 2-43.

drive) service ch eck” on page 2-43.

Enter the configuration menu, and re­enable the sc anner 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

check” on pa ge 2-65. Als o,Go to
“Flatbed home positi on service check”
on page 2-66.

service check” on page 2-65

843

843.01

844.yy

844

844.01

844.02

844.03

845.yy

Scanner Failure Carriage mechanical failure.Go to

“Flatbed motor service check” on
page 2-65

Scanner Failure ADF mechanical failu re. Go to “ADF

paper jam service c heck” on page 2-68

Scanner Failure Lamp failure. G o to “CCD service check ”

on page 2-65

Fr ont scan module output level error Go to “CCD service c heck” on

page 2-65

Rear scan module output level error

Fr ont scan module lamp level too low Front Mono channel, Front Co lor channels,

Fr ont Red channel, Fro nt Green channel,
and/or Front Blue channel is detected to
have low lamp level. Go to “CCD service

check” on pa ge 2-65

Rear scan module lamp level too low Rear Mono channel, Rear Color channels,

Rear Red channel, Rear Green channel,
and/or Rear Blue chan nel is detected to
have low lamp level. Go to “CCD service

check” on pa ge 2-65

Scanner Failure CCD failure

Go to “CCD service check” on

page 2-65

Diagnostic information 2-19

7525xxx Lexmark confidential until annou nce

Service error messages (1XX, 8XX and 9xx) (continued)

Error code Description Action

845

845.01

845.02

845.03

Front sc an module cable fail ure or SCC
card f ailure

Rear scan module cab l e f ailu re or SCC
card f ailure

Cable / SCC Failure Front scan module connector or cable

Cable / SCC Failure Rear scan module connector or cable

CCD channel fai lure. Check each
channel(mono , R, G, B) for identical values
indicating bad cable and/or SCC card.
Excessive noise test for the dark data
indicating some sort of CCD or analog
electronics issue on that channel or
channels.

Go to “CCD service check” on

page 2-65

CCD channel fai lure. 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

failure
Go to “CCD service check” on

page 2-65

failure
Go to “CCD service check” on

page 2-65

845.04

846

846.01

846.02

846.03

846.04

846.05

846.06

846.07

847

Cable Failure The connector cable is defective.

Go to “CCD service check” on

page 2-65.

Fr ont calibration strip unusable Go to “CCD service check” on

Rear calibr ati on strip unusable

Front calibration strip too far left The font calibration strip is placed to high

Front calibration strip too far right Go to “CCD service check” on

Fr ont calibration strip has excessive
skew

Fr ont calibration strip has excessive
bow

Fr ont calibration strip has excessive
dark area

Fr ont magnification exceeds limits Rear excessive v ari ability for Mono, Red,

Modem Failure The Configuration ID bit that describes the

page 2-65

or to low. Go to “CCD service check” on

page 2-65

page 2-65.

Front excessive variability for Mono, Red,
Green, or Blue. Go to “CCD service

check” on pa ge 2-65

Green, or Blue. Go to “CCD service

check” on pa ge 2-65

device’s modem doesn’t match the actual
modem installed in the device.

2-20 Service Manual

Lexmark confidential until announce 7525xxx

Service error messages (1XX, 8XX and 9xx) (continued)

Error code Description Action

847.01

847.02

848

848.01

849

849.01

Fax Storage The amount of flash storage available on

the device is too small. Note: The NAND
Flas h par tition can shri nk as bi t fail u r e s
cause blo cks to be invalidated. Go to

“Format Fax Storage” on page 3-34. If

the issue is not fi xed, repla ce the con tr oller
board. Go to “Controller board removal”

on page 4-16.

Fax Storage The devices’ fl ash partition is inva li d or

unav ailable. Go to “Form at Fax Storage”

on page 3-34. If the issue is not fixed,

replace the cont rol ler board. Go to

“Controll er board removal” on
page 4-16.

Modem/Config ID Mismatch A device doesn’t have a modem installed,

ev en though its Configurati on ID indicates
that a modem should be present.

Modem/Config ID Mismatch A device has a modem installed, but its

Configuration ID indicates that a modem
shouldn’t be pr esent.

HD/Config ID Mismatch A device doesn’t have a hard drive

installed, even though it s Configuration ID
indicates that a hard drive should be
present.

HD/Config ID Mismatch A device has a hard drive insta ll ed, but its

Configurat ion I D indic ates t hat a ha rd d rive
shouldn’t be pr esent.

9xx service errors

900.xx Service

RIP Software

902.xx Service

Engine Software

903.xx Service

Engine Software

904.xx Service

Engine Software

905.xx Service

Engine Software

906.xx Service

Engine Software

910.xx Service

DC Pick Motor

911.xx Service

DC Pick Motor

912.xx Service

DC Pick Motor

913.xx Service

DC Pick Motor

Unrecoverable RIP software error/
illegal tr ap.

A general engine so ftware error. Go to “90x.xx error” on page 2-32

A paperport link driver error. Go to “90x.xx error” on page 2-32

An interface violation by RIP. Go to “90x.xx error” on page 2-32

An interface violation by paperport
device.

A RIP interface driver error. Go to “90x.xx error” on page 2-32

The DC pick motor stalled. Go to “Autoco mpe nsator mechanism

The DC pick motor has excessiv e
PWM.

The DC pick motor is belo w speed. Go to “Autocompe nsator mechanism

The DC pick motor ov er speed. Go to “Autocompensator mechanism

Go to “90x.xx error” on page 2-32.

Go to “90x.xx error” on page 2-32

service check” on page 2-35.

Go to “Autocompensat or me chanism

service check” on page 2-35

service check” on page 2-35

service check” on page 2-35

Diagnostic information 2-21

7525xxx Lexmark confidential until annou nce

Service error messages (1XX, 8XX and 9xx) (continued)

Error code Description Action

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

927.xx Service
Fan Stal le d

929.xx Service
Toner Sensor

The DC pick has no encoder feedback. Go to “Autoco mpe nsator mechanism

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
doesn’t match th e actual fuser inst alle d
in the printer.

The printer fan is stalled.

The printer does n' t register a transition
on the toner sensor for a set period of
time. Either the printe r's toner senso r is
faulty or its print cartridge is defective.

service check” on page 2-35

Go to Go to “Transfer roll servi ce chec k”

on page 2-61.

Go to “920.xx–923.xx—Fuser

temperature incorrect” on page 2-32.

Go to “920.xx–923.xx—Fuser

temperature incorrect” on page 2-32

Go to “920.xx–923.xx—Fuser

temperature incorrect” on page 2-32

Go to “920.xx–923.xx—Fuser

temperature incorrect” on page 2-32

Go to “920.xx–923.xx—Fuser

temperature incorrect” on page 2-32

Go to “920.xx–923.xx—Fuser

temperature incorrect” on page 2-32

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 oper ation.

2.If the toner sensor is operat ing
correctly, then the problem is the print
cartridge.

930.xx

Ser vice

Printhead Error

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

2-22 Service Manual

The wrong printhead is installed. Go to “930.xx–935.xx—Pr inthead errors

There is no first HSYNC. Go to “930.xx–935.xx—Printhead error s

Lost HSYNCs. Go to “930.xx–935.xx—Printhead errors

Mirror motor is locke d. No HSYNC
received.

Mirror motor is unable to reach
operating speed.

The transport motor had an initial lock
failure.

The transport motor lost lock. Go to “936.xx, 937.xx—Transport motor

service check” on page 2-34.

service check” on page 2-34

service check” on page 2-34

Go to “930.xx–935.xx—Printhead errors

service check” on page 2-34

Go to “930.xx–935.xx—Printhead errors

service check” on page 2-34

Go to “936.xx, 937.xx—Transport motor

service check” on page 2-34.

service check” on page 2-34

Lexmark confidential until announce 7525xxx

Service error messages (1XX, 8XX and 9xx) (continued)

Error code Description Action

940.xx Service
LV Power Supply

940.00 Service
Cyan TMC Sensor

940.00 Service
Magenta TMC
Sensor

940.00 Service
Yellow T M C Se nsor

940.00 Service
Black TMC Sensor

948.xx Service
Engine Card

949.xx Service
Engine Card

950.xx Service
NVRAM Failure

A RIP to engine communi cati on fa ilur e.
The zero crossing signal used for fuser
control in the low-voltage (LV) power
supply has failed, or the wrong low­voltage power supply has been
installed.

The cyan cartridge toner meter cycle
(TMC) switch error.

The magenta cartridge toner meter
cycle (TMC) switch error.

The yellow cartridge toner meter cycle
(TMC) switch error.

The black cartridge toner meter cycle
(TMC) switch error.

The pel clock check failed. If this error message persists, replace the

Delay li ne calibration failure If this error message pers ists, replace the

There is a mis match between controll er
EEPROM and mirror.

• 950.00 through 950.29 codes:
mismatch between controller and
mirror

• 950.30 through 950.60 codes:
mismatch between secure and
controller

controlle r boar d. See “Controller board

removal” on page4-16.

controlle r boar d. See “Controller board

removal” on page4-16.

Go to “950.xx EPROM mismatch fai lure

service check” on page 2-35.

951.xx Service
NVRAM Failure

952.xx Service
NVRAM Failure

953.xx Service
NVRAM Failure

954.xx Service
NVRAM Failure

Mismatch betwe en controlle r EEPROM
and mirror.

• 951.00 through 951.29 codes:
mismatch between controller and
mirror

• 951.30 through 951.60: mismatch
between secu re and controller

A recoverable MVRAM Cyclic
Redundancy Check (CRC) error
occurred. "n" is the offset at which the
error occurred.

NVRAM chip failure with mirror.

The NVRAM chip failure with controller
part.

Performing a POR will clear this error.

Diagnostic information 2-23

7525xxx Lexmark confidential until annou nce

Service error messages (1XX, 8XX and 9xx) (continued)

Error code Description Action

955.xx Service
Code CRC <loc>

956.00 Service
System Board

956.01 Service
System Board

The Code ROM or NAND flash failed
the Cyclic Redunda ncy 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 :

• CRC Failure: The source is a
failing package indicated by Pn
where "n" is the package number.
This error could occur on a
controller with ROM or NAND flash
and could occur as a result of the
CRC check done when the
machine is powered on. The range
of package num bers is from 0 to

15.

• Error Correction Code (ECC)
Failure: The source is a failing
page indicated by Bn where "n" is
the page number . Thi s error occurs
only if a multi- bit failure is detected
during the ECC execution. Single
bit failures will be corrected
automatical ly and will not re sult in a
service error. The range of page
numbers is from 0 to 1023.

Controller board failure. Processor
failure.

Processor over temperature.

Replace conrtroll er bo ard. See“Controller

board removal” on page 4-16.

957.xx Service
System Board

958.xx Service
NAND Failure

959.01 Service
Invalid Firmware

959.02 Service
Invalid Firmware

959.03 Service
Invalid Firmware

959.04 Service
Invalid Firmware

959.05 Service
Invalid Firmware

959.20 Service
System Board

959.21 Service
System Board

Controller board failure. ASIC failure.

Printer has performed more than 100
“shift and refl ash” operations as a
result of ECC bit corrections.

Controller verification failure of pensive
boot code

Failure to authenticate Signature
Verification Code.

Signature v erification Code failure to
authenticat e a code partition.

Jump to unverified address. Update firmwar e or replace controller

Unknown Boot Failure. Update firmware or repl ace controller

Hardware control hardware failure. Replace controller board. See“Controller

Hardware control did not respond to
command request.

Update firmware or repl ace controller
board. See“Contr oller board removal”

on page 4-16.

Update firmware or repl ace controller
board. See“Contr oller board removal”

on page 4-16.

Update firmware or repl ace controller
board. See“Contr oller board removal”

on page 4-16.

board. See“Contr oller board removal”

on page 4-16.

board. See“Contr oller board removal”

on page 4-16.

board removal” on page 4-16.

Replace controller board.

2-24 Service Manual

Lexmark confidential until announce 7525xxx

Service error messages (1XX, 8XX and 9xx) (continued)

Error code Description Action

959.22 Service
System Board

959.23 Service
System Board

959.24 Service
System Board

959.25 Service
System Board

959.26 Service
System Board

959.27 Service
System Board

959.28 Service
System Board

960.xx Service
Memory Error

961.xx Service
Memory Failure

962.xx Service
Memory Failure

Challenge Secret Failure. ASIC/SP mismatch

Replace controller board. See“Controller

board removal” on page 4-16.

Hardware contr ol self test f ailur e during
initialization.

EEPROM Retenti on Error (write failure) Replace controller board. See“Controller

Insufficient device space during
hardware programming.

Incremental counter reset exceeds
maximum value.

Increment count failed due to
maximum value limit.

Invalid SP memory configuration. Replace controller board. See“Controller

RAM memory error: RAM soldered on
the board is bad.

RAM memory error: slot 1 RAM is bad. Check RAM. If RAM is ok, replace the

RAM memory error: slot 2 RAM is bad. Check RAM. If RAM is ok, replace the

Replace controller board. See“Controller

board removal” on page 4-16.

board removal” on page 4-16.

Replace controller board. See“Controller

board removal” on page 4-16.

Replace controller board. See“Controller

board removal” on page 4-16.

Replace controller board. See“Controller

board removal” on page 4-16.

board removal” on page 4-16.

Replace controller board. See“Controller

board removal” on page 4-16.

controller. See“Controller board

removal” on page4-16.

controller. See“Controller board

removal” on page4-16.

963.xx Service
Memory Error

964.xx Service
Emulation Error

975.xx Service
Standard Network

or

975.xx Service
Network Card x

976.xx Service
Standard Network

or

976.xx Service
Network Card x

RAM memory err

Download emulat ion cycli c redundancy
check (CRC) failure has occurred. A
checksu m failure detect ed in the
emulation header or emulation file.

Network error: unrec ognizab le net wo rk
port.

Unrecoverable soft w are or error in
network or network port.

The foll owing actions may be taken:

1.Disable the Download Emulation.

2.Program the download emulation into
the code overl ay SIMM again.

3.If the problem is not resolved replace
the code overl ay SIMM, and downlo ad
emulation agai n.

Replace the standa rd network card or the
card in the speci fi ed slot.

If unable t o clear the err or mess age, ch ec k
the following:

• If installed, check network card for
correct installation.

• If correctly installed, replace the
network card.

• If a network card is not installed,
replace the cont rol ler board.

Diagnostic information 2-25

7525xxx Lexmark confidential until annou nce

Service error messages (1XX, 8XX and 9xx) (continued)

Error code Description Action

978.xx Service
Standard Network

or

978.xx Service
Network Card x

979.xx Service
Standard Network

or

979.xx Service
Network Card x

980.xx Service
<device> Comm.

981.xx Service
<device> Comm.

Bad checksum while programming
network port.

Flash parts failed while programming
the network port

Engine is experiencing unreliab le
communicat ions with the specified
device.

Note: <device> can be one of the
following:

• Duplex unit.

•Tray 2.

Engine protocol violation detected by
the specified device.

Note: <device> can be one of the
following:

• Duplex unit.

•Tray 2.

Check the following:

• Make sure you have downloaded the
code in binary mode, not ASCII.

• Reprogram the Network card.

• If the problem persists, and if installed,
check the network card for correct
installation.

• If correctly installed, replace the
network card.

If a network card is not installed, replace
the controller board.

Check the following:

• If installed, check the network card for
correct installation.

• If correctly installed, replace the
network card.

• If a network card is not installed,
replace the cont rol ler board.

982.xx Service
<device> Comm.

983.xx Service
<device> Comm.

984.xx Service
<device> Comm.

2-26 Service Manual

Communications error detected by the
specified device.

Note: <device> can be one of the
following:

• Duplex unit.

•Tray 2.

Invalid command received by the
specified device.

Note: <device> can be one of the
following:

• Duplex unit.

•Tray 2.

Invalid comm an d parame ter re ce i ve d
by the specified device .

Note: <device> can be one of the
following:

• Duplex unit.

•Tray 2.

Lexmark confidential until announce 7525xxx

Service error messages (1XX, 8XX and 9xx) (continued)

Error code Description Action

990.xx Service
<device>

991.xx Service
<device> Card

This error message indicates that an
equipment check condition has
occurred in the specified devic e, but
the device is unable to identi fy the
exact component failure.

Note: <device> can be one of the
following:

• Duplex option.

•Tray2

The specified device has detected an
equipment check in its controller board.

Diagnostic information 2-27

7525xxx Lexmark confidential until annou nce

Fax error log codes

Fax error log codes

Error code Description Action

000

200 Error occurred when transmitting

3XX Error occurred when receiving

4XX Error occurred when sending

5XX Received unknown response from

6XX Error occurred when receiving a frame. • Check line quality.

7XX Error occurred when sending a frame. • Check line quality.

No err or occ u r red during fa x
transmission

training.

image data.

image data.

remote fax device .

No action needed

• Check line quality.

• Select a lower ‘Max Speed’.

• value under Fax Send sett ings

• Adjust the transmit level.

• Check line quality.

• Adjust ‘Receive Threshold’.

• Select a lower ‘Max Speed’ value
under F ax Receive settings.

• Check line quality.

• Adjust ‘Transmit Level’.

• Select a lower ‘Max Speed’ value
under F ax Receive settings.

No action needed. Issue is with the other
device.

• Adjust ‘Receive Threshold’.

• Adjust ‘Transmit Level’.

• Select a lower ‘Max Speed’ value
under F ax Send settings.

800 Received EOT unexpectedly from

the modem in V34 mode.

802 Too many timeouts occurred

during ECM reception.
803 Fax cancelled by user No action needed.
804 Unexpectedly received a disconnect

command from the remote end.

805 Remote f ax device failed to respond to

the DCS command.

808 T1 timeout occurred when trying to

establi sh a connection with a remote

fax device.
809 T2 Timeout occurred due to loss of

command/response synchronizat ion.

• If error persists d isab le V34 modulati on
scheme.

• If error persists disable ECM mode.

• Check line quality.

• Adjust T ransmit Level/Receiv e
Threshold values.

• Remote device could be requesting an
unsupported feature.

• Adjust T ransmit Level/Receiv e
Threshold values.

• Remote device could be
malfunctioning.

• Adjust T ransmit Level/Receiv e
Threshold values.

• Adjust T ransmit Level/Receiv e
Threshold values.

2-28 Service Manual

Lexmark confidential until announce 7525xxx

Fax error log codes (continued)

Error code Description Action

80A T5 Timeout occ urred when transm itting

image data to remote fax device.

80B Too many errors when transmitting in

ECM mode.

80C Remote device failed to respond to the

CTC command.

80D Received too many requests fr om

remote end to repeat the previous
command sent.

80E Function al l imitation- Remote fax

device does not support G3 receive
capability.

811 Failed to detect a f ax device at the

remote end.

812 No more data rates availa ble in V34

modulation scheme.

• Check line quality.

• Adjust ‘Transmit Level’.

• Select a lower ‘Max Speed’v al ue under
Fax Send settin gs.

• Check line quality.

• Adjust ‘Transmit Level’.

• Select a lower ‘Max Speed’v al ue under
Fax Send settin gs.

• Select a lower ‘Max Speed’ value
under F ax Send settings.

• Adjust ‘Transmit Level’.

• Check line quality.

• Adjust ‘Transmit Level’.

• Check if line conditions on remot e end
will facilitate a good connection.

No action needed. Issue with the remote
device.

• Verify MFD is answering to fax call and
not a voice cal l.

• Decrease value of ‘Rings To Answer’
setting.

• Adjust to a lower modulation scheme.

813 Timeout occ urred a ft er wai ting too lon g

to receive a good frame.

814 Tried too many ti mes at sel ec ted speed

using V34 modulation scheme.

815 Fax transmission was interrupted due

to power failure.

818 Fax transmission failed due to

insufficient memory to store scanned
image.

819 Fax transmission failed due to

insufficient memory to store received
image.

81A A timeout oc curred durin g transmis sion

of a page in ECM mode.

880 Failure to transmit training successfully

in V17, V29, V27 terminal modulati on
schemes.

881 Failure to transmit training successfully

in V33, V29, V27 terminal modulati on
schemes.

• Adjust “Receive Threshold”.

• Adjust ‘Transmit Level’.

• Adjust to a lower modulation scheme.

• Tro ub leshoot MFP if error persi st s. See

“Modem / fax car d service chec k” on
page 2-70.

Adjust ‘Memory Use’ setti ng to al locate
more memory for send jobs.

Adjust ‘Memory Use’ setti ng to al locate
more memory for receive jobs.

Select a lower ‘Max Speed’ value under
Fax Send settin gs.

• Select a lower “Max Speed” under Fax
Send settings.

• Adjust the “Transmit Level”.

• Check line quality.

• Select a lower “Max Speed” under Fax
Send settings.

• Adjust the “Transmit Level”.

• Check line quality.

Diagnostic information 2-29

7525xxx Lexmark confidential until annou nce

Fax error log codes (continued)

Error code Description Action

882 Failure to transmit training successfully

in V17, V29 terminal modulation
schemes.

883 Failure to transmit training successfully

in V17,V27 terminal modulat ion
schemes.

884 Failure to transmit training successfully

in V29, V27 terminal modulation
schemes.

885 Failure to transmit training successfully

in V17terminal modulati on scheme.

886 Failure to transmit training successfully

in V29 terminal modulati on schem e.

887 Failure to transmit training successfully

in V27 terminal modulati on schem e.

• Select a lower “Max Speed” under Fax
Send settings.

• Adjust the “Transmit Level”.

• Check line quality.

• Select a lower “Max Speed” under Fax
Send settings.

• Adjust the “Transmit Level”.

• Check line quality.

• Select a lower “Max Speed” under Fax
Send settings.

• Adjust the “Transmit Level”.

• Check line quality.

• Select a lower “Max Speed” under Fax
Send settings.

• Adjust the “Transmit Level”.

• Check line quality.

• Select a lower “Max Speed” under Fax
Send settings.

• Adjust the “Transmit Level”.

• Check line quality.

• Select a lower “Max Speed” under Fax
Send settings.

• Adjust the “Transmit Level”.

• Check line quality.

888 Failure to transmit training successfully

at 2400 bps i n V27 termina l modul ation
scheme.

889 Failed to connect at th e minimum

speed supported by the MFP.

88A Failed to connect using V.34

modulation scheme.

901 No f ax tones detected from remot e

end.

902 No dial tone det ected. • Check by enabling ‘Behind a PABX’

903 Busy tone detected. Check with remote end if successive

904 Hardware error detected. See “Modem / fax card service check”

905 A timeout occurred after dialing the

number and wai ti ng for a response.

• Adjust “Transmit Level”.

• Check line quality.

• Adjust “Transmit Level”.

• Incompatible connection.

• Check line quality.

• Adjust to a lower modulation scheme.

• Adjust T ransmit Level Receive
Threshold values.

• Verify destination phone number.

• Verify that the remote fax is authorized
to receive faxes.

setting.

• Check phone line.

• Check MFD modem hardware.

attempts fail.

on page 2-70.

Check with remote end if successive
attempts fail.

906 Fax cancelled by user. No action needed.

2-30 Service Manual

Lexmark confidential until announce 7525xxx

Fax error log codes (continued)

Error code Description Action

907 Modem detect ed a digital line

connection.

908 Phone line was disconnected Restor e phone line connection.
A00 Received request for unsupported

function from remote fax device.

A01 Received request for unsupported

image width from remot e fax device.

A02 Received request for unsupported

image resolution from remote fax
device.

A03 Received request for unsupported

compression type from rem o te fax
device.

A04 Received request for unsupported

image length from remote fax device.

F00 Unknown error occurred. No action needed.

Verify the MFP is connected to an analog
line. See“Fax transmission service

check” on pa ge 2-71.

No action needed.

No action needed.

No action needed.

No action needed.

No action needed.

Diagnostic information 2-31

7525xxx Lexmark confidential until annou nce

Service checks

Autocompensator mechanism service check

Step Questions / actio ns Yes No

1 Tur n the printer off, and then remove the rear

shield. See “Rear shield removal” on

page 4-7. Check the cable at JSP1 on the

controlle r board for proper connection.
Is the cable pr operl y connected?

Did the printer function correctly after

2

reconnecting the cables?
Turn the printer on, and then verify the

3

follo w ing approximat e values at JSP1:

JSP1

Pin Value Pin Value

2 +24 V dc 10 +5 V dc
4 +24 V dc 13 Ground
6 Ground 15 +5 V dc
7 Ground 16 Ground
8 Ground

Are the values approxim ately correct?

Go to step 3. Pr operl y connect the ca bles,

Problem resol ved. Go to step 3.

Replace the
autocompensator
mechanism. See

“Autocompensator
mechanism (A CM )—
standard tray remov al” on
page 4-12.

and POR the printer.
Go to step 2.

Replace the controller
board. See “Controller

board removal” on
page 4-16.

90x.xx error

Step Questions / actio ns Yes No

1 Turn the printer o ff , and rem ov e t he rear sh ield.

See “Rear shield remo val” on page 4-7.
Check the cable connections.

Are all the cable connections secure?

Replace the controller
board. See “Controller

board removal” on
page 4-16.

Securely make al l t he
connections. POR the
printer.

920.xx–923.xx—Fuser temperature incorrect

This service chec k covers fuser temperature errors, including 920.xx, 921.xx, 922.xx, and 923.xx.

Step Questions / actio ns Yes No

1 Check the clearance around the printer. See

“Clearances” on page 1-5.

Does the error clear?
Check the fuser connections on the fuser, at

2

JFUSES1 on the controller board, and the AC
connection at the LVPS.

Are the connectio ns correct?

2-32 Service Manual

Problem resol ved. Make sure the proper

Replace the fuser. See

“Fuser assembl y removal”
on page 4-19.

clearance is maintained.

Problem resol ved.

Lexmark confidential until announce 7525xxx

Step Questions / actio ns Yes No

Turn the printer on and check following v alues

3

on JFUSES1.

JFUSES1

Pin Value

5 +3.3 V dc
6 Ground
8 Ground

9 +3.3 V dc
10 +3.3 V dc
11 Ground

Are the values approxim ately correct?

Replace the fuser asse mbly.
See “Fuser asse mb ly

removal” on page 4-19.

Replace the controller
board. See “Controller

board removal” on
page 4-16.

925.01—Fan error service check

Step Questions / actio ns Yes No

1 Turn off the print er , an d remov e the rea r sh ield.

See “Rear shield remo val” on page 4-7.
Unplug the fan cable at JFAN1 and turn the
printer on. Check the following conn ectors:

JFAN1

Replace the top cover
(which includes the fan).
See “Top cover assembly

removal” on page 4-9.

Replace the controller
board. See “Controller

board removal” on
page 4-16.

Pin Voltage

1 +3.3 V dc

2 Ground

3 +24 V dc

Are the measured val ues correct?

Diagnostic information 2-33

7525xxx Lexmark confidential until annou nce

930.xx–935.xx—Printhead errors service check

Step Questions / actio ns Yes No

1 Turn the printer o ff , and rem ov e t he rear sh ield.

See “Rear shield remo val” on page 4-7.
Check the cables connected at JMIRR1 and
JPH1 on the controller board. Check for
damage.

Are the cables damaged?
Tur n the printer on, and verify the following

2

values at JMI R R 1:

JMIRR1

Pin Value

2 +3.3 V dc
4 Ground
5+24 V dc

Are the values approxim ately correct?

Replace the printhead. See

“Printhead removal” on
page 4-42.

Replace the printhead. See

“Printhead removal” on
page 4-42.

Go to step 2.

Replace the controller
board. Replace th e
controlle r boar d. See

“Controll er board
removal” on page4-16.

936.xx, 937.xx—Transport motor service check

Step Questions / actio ns Yes No

1 Turn the printer o ff , and rem ov e t he rear sh ield.

See “Rear shield remo val” on page 4-7.
Check the cable at JCARB1 for proper
connection to th e controller board

Is the cable pr operl y connected?

Reconnect the cable. Go to step 2.

Turn the printer on, and then measure the

2

values of the ca ble at JC A R B 1:

JCARB1

Pin Voltage

4 +24 V dc
6 +24 V dc
8 +24 V dc

9 Ground
12 Ground
13 +24 V dc
15 +24 V dc
17 +24 V dc

Are the measured voltages correct?

Replace the main driv e gea r
assembly. See “Main drive

gear assembly with motor
removal” on page 4-39.

Replace the controller
board. See “Controller

board removal” on
page 4-16.

2-34 Service Manual

Lexmark confidential until announce 7525xxx

950.xx EPROM mismatch failure service check

Warning: Replace one of the following components, and perform a POR before replacing a second

component. Never replace both of the components without performing a POR after installing each
one, or the printer will be rendered inoperable:

• Operator panel assembly

• Controller board

Warning: Never install and r emo ve components list ed above as a method of troubleshooting com ponents.

Once a component has be en install ed in a printer, and the printer is powered on, it cannot be
used in another printer. It must be returned to the manufacturer.

This error code indicates a mismatch betwee n the operator panel assembly and the controller board.

Step Questions / actio ns Yes No

1 Have an y updates been made to the fi rmware? Reload the firmware and try

Did reloading the firmware correct the

2

problem?

again.
Go to step 2.

Problem resolved. Replace the control ler board

Replace the con troller boa rd
with a new, and not
previously installed
controlle r boar d. See

“Controll er board
removal” on page4-16.

with a new, and not
previously installed
controlle r boar d. See

“Controll er board
removal” on page4-16.

Autocompensator mechanism service check

Step Questions / actio ns Yes No

1 Turn the printer o ff , and rem ov e t he rear sh ield.

See “Rear shield remo val” on page 4-7.
Check the cable at JSP1 on the controller
board for pr oper connection.

Is the cable pr operl y connected?

Did the printer function correctly after

2

reconnecting the cables?

Replace the
autocompensator
mechanism. See

“Autocompensator
mechanism (A CM )—
standard tray remov al” on
page 4-12.

Problem resol ved. Go to step 3.

Properly connect the cab les,
and POR the printer.

Go to step 2.

Disconnect the cab le at JSP1, and verify the

3

follo w ing approximate values:

JSP1

Pin Voltage Pin Voltage

2 +24 V dc 8 Ground
4 +24 V dc 10 +5 V dc
6 Ground 15 +5 V dc
7 Ground 16 Ground

Are the values approxim ately correct?

Replace the
autocompensator
mechanism. See

“Autocompensator
mechanism (A CM )—
standard tray remov al” on
page 4-12.

Replace the controller
board. See “Controller

board removal” on
page 4-16.

Diagnostic information 2-35

7525xxx Lexmark confidential until annou nce

Bin full sensor service check

Step Questions / actio ns Yes No

1 Is the input sensor dislodged or damaged? Repair or replac e the

Does the flag rotate freely and interrupt the

2

sensor beam when in normal position?
Turn the printer o ff , and remo v e t he rear sh ield.

3

See “Rear shield remo val” on page 4-7.
Disconnect t he cabl e a t JBI N1 on the control ler
board. Turn the printer on, and check the
voltage values below:

JBIN1

Pin Voltage

1 +5 V dc

2 +3.3 V dc

3 Ground

Are the voltage values correct?

autocompensator
mechanism. See

“Autocompensator
mechanism (A CM )—
standard tray remov al” on
page 4-12.

Go to step 3. Reposition or replace the

Problem resolved. Replace the controller

Go to step 2.

flag.

board. See “Controller

board removal” on
page 4-16.

2-36 Service Manual

Lexmark confidential until announce 7525xxx

Dead printer service check

A dead printer is a condition where the display is blank, the LED on the operato r panel is off, the fan does not
turn, no motors turn, and the fuser does not heat.

If a 650-sheet Duo Drawer is in stalled, remov e the option and check the base printer for correct operation. If the
base printer operates correctly, replace the 650-sheet Duo Dra wer.

Warning: Observe all necessary ESD precautions when removing and handling the controller board or any

installed op ti on cards or assemblies. See “Handling ESD-sensitive parts” on page4-1.

CAUTION

When you see thi s symbol, ther e is a d anger from haz ardous volt age in the a rea of the p roduct
where you are working. Unplug the product before you begin , or use caution if the product
must receive power in order to perform the task.

Remove any input paper handling opt ions from the printer.

Step Questions / actio ns Yes No

1 Check the AC li ne voltage.

Is the line vo lt age correct?
Is the AC line co rd damaged? Replace the line cord. Go to step 3.

2

Is the JLVPS1 cable correctly connected at

3

JLVPS1 on the controller board?
Tur n the printer off, and then on.

4

Does the problem persist?

Warning: Damage to the printer is possible.

5

Be careful to touch only one conductor at a
time. Rest the probe against the connector to
steady it.

With the printer on.v erify the f ollowi ng val ues at
JLVPS1:

JLVPS1 (exposed conductors)

Pin Value Pin Value

1 +5 V dc 7 +24 V dc
3 +5 V dc 9 +24 V dc
5 +5 V dc 11 +24 V dc

Are the values approxim ately correct?

Go to step 2. Inform the customer.

Go to step 5. Reconnect the JLVPS1

Go to step 5. Problem resolved.

Replace the controller
board. See “Controller

board removal” on
page 4-16.

cable, and g o to s t ep 4.

Replace the LVPS.
See“Low-voltage power

supply (LVPS) assembly”
on page 4-31.

Diagnostic information 2-37

7525xxx Lexmark confidential until annou nce

Duplex/manual feed sensor (S1) service check

Note: Before performing this service check, ensure that the printer is on a hard level surface.

Step Questions / actio ns Yes No

1 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 pro cessor speed
displays).

Perform the Base Sensor Test. See “Base

Sensor T est” on page 3-18.

1.Select Base Sensor Test, and press
Select ().

2.Select S1, and press Select ().

3.Install tra y 1.

Does the displa y indicate InputS1—Media
Clear…?

Pull tray 1 out.

2

Does the displa y indicate InputS1—Media
Present…?

Remove the tray, and inspect sensor.

3

Is there somethi ng obstructing the sensor?
Inspect the spring-l oaded shaft/flag in the tray.

4

The flag portion of the shaft intercepts the
sensor, except when a sheet i s being staged
for duplexing.

Does the shaft r otate freel y and ret urn to home
position (fla g at top of rotation)?

Is the flag on the shaft broken? Replace the tr ay. Go to step 6.

5

Go to step 2. Go to step 4.

The sensor is functioni ng
correctly.

Remove t he obst ructi on an d
restart the test.

Go to step 5. Replac e the t ray with a new

Go to step 3.

Go to step 4.

one.

Is the cable cor rectly connected to JFUSES1

6

on the controller board and to the sensor.
Is the sensor cable properly connected?

Turn the printer o ff , and remo v e t he rear sh ield.

7

See “Rear shield remo val” on page 4-7.
Turn the printer on, and check the values at
JFUSES1:

JFUSES1

Pin Value

8 Ground
9 +3.3 V dc

Are the values approxim ately correct?

Go to step 7. Reconnect the cable.

If the pr ob lem per sist s, go t o
step 7.

Replace the duplex sensor.
See “Duplex sensor

removal” on page 4-17.

Replace the controller
board. See “Controller

board removal” on
page 4-16.

2-38 Service Manual

Lexmark confidential until announce 7525xxx

Front door sensor or switches service check

Step Questions / actions Yes No

1 Enter Diagnostics Menu (turn the printer off, press

and hold and , turn the printer on, and then
release the but tons 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 displa y indicate Value C l ose d with the door
closed and Value Opened with the door opened?

Open the front door and che ck the thin, tall, plastic

2

web (pivot plate) at the top right of the printer. With
the other covers in place and closed, this web
interact s with switches in the door.

Open the toner cover and check the moti on of the
web. Is the web loose, damaged, or missing?

Open the toner d oor and i nspect the v ertical w eb that

3

pushes and rotates the pivot plate.
Is it damaged?

With the front cover open, inspect the two switches.

4

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 ar ea?

Sensor, toner door, and
right doors are OK.

Replace the right cover
assembl y. See“Right

cover removal” on
page 4-7.

Replace the top co ver
assembl y. See “Top

cover assembly
removal” on page 4-9.

Replace the right cover
assembl y. See“Right

cover removal” on
page 4-7.

Go to step 2.

Go to step 3.

Go to step 4.

Go to step 5.

Tur n the printer off, and remove the rear shield. See

5

“Rear shield removal” on page 4-7. T urn the

printer on, and veri fy the following values at JINT1
and JCVR1:

JINT1 JCVR1

Pin Value Pin Value

1 +5 V dc 1 +24 V dc

2 Ground
Are the values approxim ately correct?
Close the f ront cover and the toner door. Be sure the

6

right cove r is in pl ace. Turn the printer off , and then
disconnect the cables at JINT1 and JCVR1. Test
continuity at the connector under the following
conditions:

• With front cover and toner door closed:
Test pin 1 and pin 3 at JINT1 cable end and pin 1

and pin 2 at JCVR1 cable end.

• With one or both doors open:
Pin 2 and 3 at JINT1 cable end should indicate

continuity, but Pin 1 and 2 at JCVR1 should have
no continuity.

Are the tests verified?

Go to step 6. Replace the controller

Contact your next level
of support.

board. See “Controller

board removal” on
page 4-16.

Replace the front cover
assembly. See “Front

cover assembly
removal” on page 4-2.

Diagnostic information 2-39

7525xxx Lexmark confidential until annou nce

Fuser exit sensor service check

Step Questions / actio ns Yes No

1 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 pro cessor speed
displays).

Perform the Base Sensor Test. See “Base

Sensor T est” on page 3-18.

1.Select Base Sensor Test, and press
Select ().

2.Select Fuser Exit Sensor, and press
Select ().

3.Open and close the front door, and inspec t
the fuser ex it sensor located on the LVPS
shield.

Is the sensor dislodged or damaged?
Rotate the flag (paper diverter) in and out of

2

the sensor.
Does the displa y indicate Media Clear and

Media Pres ent with the cycle?
Does the flag rotate freely, but returns to b lock

3

the sensor?

Is the cable cor rectly connected to JBIN1 on

4

the controller board and to the sensor.
is the sensor properly connected?

Correct the sensor or
replace it. See “” on

page 4-22.

Sensor is good. Go to step 3.

Go to step 4. Replace the fuser .

Go to step 5. Reconnect the cable.

Go to step 2.

See“Fuser assembly

removal” on page4-19.

Make sure the print er is turned off. Disconnect

5

the cable at th e sensor and at JBIN1 on the
controlle r board. Turn the printer on and check
the voltag e values:

JBIN1

Pin Value

4 +5 V dc
5 +0 V dc (no media), +3.3 V dc (media)
6 Ground

Does the volta ge values correct?

Replace the fuser exit
sensor. See “” on

page 4-22.

Replace the controller
board. See “Controller

board removal” on
page 4-16.

2-40 Service Manual

Lexmark confidential until announce 7525xxx

Fuser service check

Step Questions / actio ns Yes No

1 Some low-voltage power suppl y FRUs have a

voltage selector switch. If it does, the switch
needs to be set to the correct voltage for your
area

Has the LVPS been changed?
Turn the printer o ff , and remo v e t he rear sh ield.

2

See “Rear shield remo val” on page 4-7.
Check the cable at JFUSES1 for proper
connection to t he controller board, the cab le for
pinch points , and the cable or connect or for
any other damage.

Is the cable damaged?
Check the connector JLVPS1 for proper

3

connection to t he controller board, the cab le for
pinch points , and the cable or connect or for
any other damage.

Is the cable damaged?

Check the s witch on the side
of the LVPS to verify the
correct voltage is set.

Replace the fuser cable. Go to step 3.

Repair or replace the LVPS
cable. See “Low-voltage

power supply (LVPS)
assembly” on page 4-31.

Go to step 2.

Go to step 4.

Check the power cable on the left side of the

4

fuser and the thermistor cables and
connections on the right side of the fuser.

Are the cables or connectors damaged?

Disconnect the cable at JFUSES1 on the

5

controlle r boar d, and check the following
voltages:

JFUSES1

Pin Voltage

5 +3.3 V dc
6 Ground

8 Ground
10 +2.7 V dc
11 Ground

Are the voltages correct?
Replace the fuser. See “Fuser assembly

6

removal” on page4-19.

Does the error clear?

Repair the cables. If the
cables cannot be repaired,
replaced the fuser. See

“Fuser assembl y removal”
on page 4-19.

Go to step 6. Replace the controller

Problem resol ved. Replace the controller

Go to step 5.

board. See “Controller

board removal” on
page 4-16.

board. See “Controller

board removal” on
page 4-16.

Diagnostic information 2-41

7525xxx Lexmark confidential until annou nce

Input sensor (S2) service check

The Input sensor (S2 ) is part of the AC M FRU.

Step Questions / actio ns Yes No

1 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 pro cessor speed
displays).

Perform the Base Sensor Test. See “Base

Sensor T est” on page 3-18.

1.Select Base Sensor Test, and press
Select ().

2.Select S2, and press Select ().

3.Pull tray 1 out, and rotat e the S2 sensor
flag (S2 is located in front of the center
autocompensator mechanism housing.) It
should rotat e freely and return to its original
position.

Is the input (S2) sensor flag damaged?
Watch the display while rotat ing the flag.

2

Does the displa y indicate Media Clear and
Media Pres ent?

Turn the printer o ff , and remo v e t he rear sh ield.

3

See “Rear shield remo val” on page 4-7.
Is the JSP1 cable connector properly

connected to the cont roller board?
Tur n the printer on, and check the voltage at

4

JSP1 pin 15.
Is the voltage approximately +5 V dc?

Replace the
autocompensator
mechanism. See

“Autocompensator
mechanism (A CM )—
standard tray remov al” on
page 4-12.

Problem resol ved. Go to step 3.

Go to step 4. Reseat the connector.

Replace the
autocompensator
mechanism. See

“Autocompensator
mechanism (A CM )—
standard tray remov al” on
page 4-12.

Go to step 2.

Replace the controller
board. See “Controller

board removal” on
page 4-16.

2-42 Service Manual

Lexmark confidential until announce 7525xxx

Main drive gear assembly (EP drive) service check

Step Questions / actio ns Yes No

1 Turn the printer o ff , and rem ov e t he rear sh ield.

See “Rear shield remo val” on page 4-7.
Check the cable at JCARTB1 for proper
connection to t he controller board, the cab le for
pinch points , and the cable or connect or for
any other damage.

Is the cable damaged?
Disconnect the cable at JCARTB1 on the

2

controller board, and verify the following
values.

JCARTB1

Pin Voltage

4 +24 V dc
6 +24 V dc
8 +24 V dc

9 Ground
12 Ground
13 +24 V dc
15 +24 V dc
17 +24 V dc

Are the voltages correct?
Replace the main drive assembly. See “Main

3

drive gear assembly with motor removal”
on page 4-39.

Does the error clear?

Replace the JCARTB1
cable.

Go to step 3. Repl ace the controller

Problem resol ved. Replace the controller

Go to step 2.

board. See “Controller

board removal” on
page 4-16.

board. See “Controller

board removal” on
page 4-16.

Diagnostic information 2-43

7525xxx Lexmark confidential until annou nce

Operator panel service check

Warning: Replace one of the following components, and perform a POR before replacing a second

component. Never replace both of the components without performing a POR after installing each
one, or the printer wil l be ren dered inoperabl e:

• Operator panel assembly

• Controller board

Warning: Never install and r em ove components list ed above as a method of troubleshooting com ponents.

Once a component has be en install ed in a printer, and the printer is powered on, it cannot be
used in another printer. It must be returned to the manufacturer.

One or more operator panel buttons fail

Step Questions / actio ns Yes No

1 Run the Button Test. See “Button Test” on

page 3-13 in Diagnostics Menu.

Did any of the buttons fail the test?

Turn the printer o ff , and remo v e t he rear sh ield.

2

“Rear shield removal” on page 4-7.

Disconnect the operator panel assembly cable
at JOPP1 on the controller board. Turn on the
printer, and verify the fol lowing voltages:

JOPP1

Pin Voltage

2 +5 V dc
4 Ground
5 +5 V dc
6 +3.3 V dc
7 Ground

Are the voltage values approximately correct?

Replace the operator panel
assembly. See “Operator

panel removal” on
page 4-76.

Replace the operator panel.
See “Operator panel

removal” on page 4-76.

If the problem is not
resolved, replace the
operator panel cable. See

“Op panel cable” on
page 4-79

Go to step 2.

Replace the controller
board. See “Controller

board removal” on
page 4-16.

Operator panel display blank, five beeps

Service tip: The printer has det ected a problem with the controller board, the operator panel assembly cable
(part of the front cover assem bly), or the operator panel as sem bly if POST does not complete. The pri nter emits
five beeps, and sticks in a continuous pattern until the printer is turned off.

Step Questions / actio ns Yes No

1 Is the operator panel assembly cable properly

installed at controller board JOPP1 and at the
operator panel assem bly?

Go to step 2. Reinst all the cable .

2-44 Service Manual

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Step Questions / actio ns Yes No

Turn the printer o ff , and remo v e t he rear sh ield.

2

See “Rear shield remo val” on page 4-7.
Disconnect the operator panel assembly cable
at JOPP1 on the controller board. Turn on the
printer, and verify the fol lowing voltages:

JOPP1

Pin Voltage

2 +5 V dc
4 Ground
5 +5 V dc
6 +3.3 V dc
7 Ground

Are the voltage values approximately correct?
Check continuity of the operator panel

3

asse m bly cabl e.
Is there continuity?

Go to step 3. Replace the controller

Replace the operator panel
assembly. See “Operator

panel removal” on
page 4-76.

board. See “Controller

board removal” on
page 4-16.

Replace the operator panel
cable. See “Op panel

cable” on page 4-79

Operator panel display blank, printer beeps five times and pauses

Step Questions / actio ns Yes No

1 Turn off the print er , an d remov e the rea r sh ield.

See “Rear shield remo val” on page 4-7.
Disconnect the cable at JOPP1 on the
controlle r board. Veri fy the following values:

Go to step 2. Replace the controller

board. See “Controller

board removal” on
page 4-16.

JOPP1

Pin Voltage

10 V dc
2 +5 V dc
30 V dc
4 Ground
5 +5 V dc
6 +3.3 V dc
7 Ground

Are all these values approximately correct?
Check f or conti nu ity in th e oper ator panel cab le

2

connector.
Do all the conductors i ndicate continuity ?

Replace the operator panel.
See “Operator panel

removal” on page 4-76.

Replace the operator panel
cable. See “Op panel

cable” on page 4-79

Diagnostic information 2-45

7525xxx Lexmark confidential until annou nce

Operator panel displays all diamonds, no beeps

Step Questions / actio ns Yes No

1 Turn off the print er , an d remov e the rea r sh ield.

See “Rear shield remo val” on page 4-7.
Disconnect the cable at JOPP1 on the
controlle r board. Veri fy the following values:

JOPP1

Pin Voltage

10 V dc
2 +5 V dc
30 V dc
4 Ground
5 +5 V dc
6 +3.3 V dc

7 Ground
Are all these values approximately correct?
Check f or conti nu ity in th e oper ator panel cab le

2

connector.
Do all the conductors i ndicate continuity ?

Go to step 2. Replace the controller

Replace the operator panel.
See “Operator panel

removal” on page 4-76.

board. See “Controller

board removal” on
page 4-16.

Replace the operator panel
cable. See “Op panel

cable” on page 4-79

Operator panel displays all diamonds, five beeps

Step Questions / actio ns Yes No

1 Turn off the print er , an d remov e the rea r sh ield.

See “Rear shield remo val” on page 4-7.
Disconnect the cable at JOPP1 on the
controlle r board. Veri fy the following values:

JOPP1

Pin Voltage

10 V dc

2 +5 V dc

30 V dc

4 Ground

5 +5 V dc

6 +3.3 V dc

7 Ground
Are all these values approximately correct?
Check f or conti nu ity in th e oper ator panel cab le

2

connector.
Do all the conductors i ndicate continuity ?

Go to step 2. Replace the controller

Replace the operator panel.
See “Operator panel

removal” on page 4-76.

board. See “Controller

board removal” on
page 4-16.

Replace the operator panel
cable. See “Op panel

cable” on page 4-79

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Operator panel display is dim and unchanging

Step Questions / actio ns Yes No

1 Turn off the print er , an d remov e the rea r sh ield.

See “Rear shield remo val” on page 4-7.
Disconnect the cable at JOPP1 on the
controlle r board. Veri fy the following values:

JOPP1

Pin Voltage

10 V dc
2 +5 V dc
30 V dc
4 Ground
5 +5 V dc
6 +3.3 V dc

7 Ground
Are all these values approximately correct?
Check f or conti nu ity in th e oper ator panel cab le

2

connector.
Do all the conductors i ndicate continuity ?

Go to step 2. Replace the controller

Replace the operator panel.
See “Operator panel

removal” on page 4-76.

board. See “Controller

board removal” on
page 4-16.

Replace the operator panel
cable. See “Op panel

cable” on page 4-79.

Op panel USB cable service check

Step Questions / actions Yes No

1 Check the op panel USB cable f or continu ity.

Is there continui ty?

Replace the control ler
board. See “Controller

board remo val” on
page 4-16

Replace the Op panel USB
cable.

USB s ervice check

Step Questions / actions Yes No

1 Is the USB cable properl y connected to the

MFP and host PC?

2 Try a d i fferen t US B cabl e. D oes th is fix t he

issue?

3 Connect a dif f erent de vice to the USB cab le .

Did the host PC see the device?

Go to step 2. Properly connect the cable

at both ends.

Issue fix ed. Go to step 3.

Replace the RIP/syst em
board.See “Controller

board remo val” on
page 4-16.

There is an issue with the
host machine.

Diagnostic information 2-47

7525xxx Lexmark confidential until annou nce

Networking service check

Note: Before starting this service check, print out the network setup page. This page is found under Menu ­Reports - Network Settings. Consult the network administrator to verify that the physical and wireless network
settings displayed on the network settings page for the device are properly configured. If a wireless network is
used, verify that the printer is in range of the host computer or wireless access point, and there is no electronic
interference. Have the network administr ator verify that the device is using the correct SSID, and wireless
security protocols. For more net work troubleshooting information, cons ult the Lexmark Network Setup Gu ide.

Step Questions / actio ns Yes No

1 If the devi ce is physicall y connected to the

network, verify that the ethernet cable is
properly connect ed on both ends.

Is the cable pr operl y connected?
Connect the ethernet cable.

2

Did this fix the problem?
Check the p rinter ’ s onli ne stat us under Print ers

3

and Faxes on the host computer. Delete all
print jobs in the print queue.

Is the printer online and in a Ready state.
Change the printer stat us to online.

4

Did this fix the issue?
Does the IP address displayed on the network

5

settings page match the IP address in the port
of the drivers using the printer?

Does the LAN use DHCP?

6

Note: A printer should use a st atic IP

addr e ss on a n et work .

Are the first two seg men ts if the IP address

7

169.254?
POR the printer.

8

Is the probl em resol ved

Go to step 3.
If the n e twork is wireless,

got to step 3.

Problem resol ved Go to step 3.

Go to step 5. Go to step 4.

Problem resol ved. Go to step 5.

Go to step 10. Go to step 6.

Go to step 7. Go to step 9.

Go to step 8. Go to step 9

Problem resol ved Go to step 10.

Go to step 2.

Reset the address on the printer to match the

9

IP address on the driv er.
Did this resolve the issue?

Have the network admin verify that the prin ter

10

and PC’s IP address have identical subnet
addresses.

Are the subnet addres ses the same?
Using the subnet addr ess supplied by the

11

network admin, assign a unique IP address to
the printer.

Note: The printer IP address shoul d match
the IP address on the printer driver.

Did this fix the problem?
Is the devic e physically connected (ethernet

12

cable) to the network?

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Problem fixed. Go to step 10.

Go to step 12. Go to step 11.

Problem resol ved. Go to step 12.

Go to step 13. Go to step15.

Lexmark confidential until announce 7525xxx

Step Questions / actio ns Yes No

Try using a different ethernet cable.

13

Did this remedy the sit uation?
Have the network administrator check the

14

network drop f or act ivity.
Is the drop functioning properly?

Is the printer on the same wirele ss network as

15

the other devices?
Assign the correct wireless network to the

16

printer.
Did this fix the problem?

Are the other de vices on the wireless network

17

communicating properly?
Verify that the wireless card is properly seated

18

on the controller board.
Is the wireless card seated correctly?

Properly reseat the wireless card.

19

Did this fix the problem?
Is the antenna damaged? Go to step 22. Go to step 21.

20

Replace the antenna.

21

Did this fix the problem?

Problem resol ved Go to step 14.

Replace the controller
board . Go to “Controller

board removal” on
page 4-16

Go to step 17. Go to step 16.

Problem resol ved Go to step 17.

Go to step 18. Contact the network

Go to step 20. Go to step 19.

Problem resol ved. Go to step 20.

Problem resol ved Go to step 22.

Contact the netw ork
administrator.

administrator.

Verify that the antenna is properly connected

22

to the wire le s s ca r d .
Is it connected correctly?

Properly connect the ant enna.

23

Did this fix the problem?
Check pin 6 for +3.3V, and Pin 5 for +5V. on

24

connector JUSBW1 of t he cont roll er boar d. Pi n
1 and 4 are GND.

Are the voltages and GNDs correct?

Go to step 24. Go to step 23.

Problem resol ved Go to step 24.

Replace the wireless card.
Go to “Wireless network

card” on page 4-52

Replace the controller
board. Go to “Controller

board removal” on
page 4-16

Diagnostic information 2-49

7525xxx Lexmark confidential until annou nce

Print quality servic e chec k

Note: This symptom m ay require replacement of one or more CRUs (Customer Replaceable Units) designated
as supplies or maintenance i tems, which are t he responsibility of the customer. With the customer' s permission,
you may need to install a developer (toner) cartridge or photo conductor unit.

Service tip

Before tr oubleshooting any print quality problems, do the following:

1. Print a menu sett ings page, and check the life status of all supplies. Any suppl ies that are low should be

replaced.
To print a menu settings page:

a. press Menu ( ) on the operator panel.
b. Select Reports from the Admin Menu, and press Select ().
c. Select Menu Settings, and press Select ().

Note: Be sure and keep the original menu page to restore the customer's custom settings if needed.

2. On the menu page, make sure the following is set to the default level:
– Colo r Co rre c tion: Set to Aut o.
– Print Resolution: Set to 1200 dpi (pri nt qual ity problems should be checked at different resolut ion

settings).

– Toner Darkness: Set to 4 (default).
– Color Saver: Set to OFF.
– RGB Brightness, RGB Contrast, RGB Saturation : Set to 0.
– Color Balance: Select Reset Defaults to zero out all colors.
– Check the paper type, texture and weight settings against what is loaded in the printer .

Once the printer has been restored to its default levels, do the following:

1. Inspe ct the imaging unit for dama ge, including the developers and toner cartridges. Replace if damaged.

2. If paper other than 20lb plain letter /A4 paper is being used, load 20lb plai n letter/A4.

3. Print the Print Qual ity pages to see if the problem remains. Look for variations in the print from what is

expected.
To print the print Quality pages

a. Enter Diagnostics (turn off the printer, press and hold Left ( ) and Select ( ), turn on the pr in te r

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.

An incorrect printer d rive r f or the i nst alled softw are can c ause prob lems . Incorrect cha ract ers could print , a nd the
copy may not fit the page correc tl y.

Measure all voltages from the connector to the printer ground.

2-50 Service Manual

Lexmark confidential until announce 7525xxx

Print quality—background

Service tip: Some background problems can be caused by rough papers, non-Lexmark
toner cartridges or if the media t exture is set to the rough setting.

Some slick or coat ed papers may also cau se background problems. Some problems
occur with printers that run a large amount of graphics in a humid environment.

Step Questions / actio ns Yes No

1 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 th e co unter wa s not reset.

Has the imaging unit been recently replaced?

Is the backgr ound only one of the primary

2

colors; yellow, cyan, magenta, or black?

Did replacing the developer unit correct the

3

problem?
Replace the photoconductor unit.

4

Does this fix the prob lem?
Check the high- vol tage cont act fr om the HVPS

5

to the image transfer unit (ITU).
Is a problem found?

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 st ep2.

Replace the developer unit
for th e bac kground col or and
retest. See “De veloper unit

removal” on page 4-30.

Go to step 3.
Problem resol ved. Go to step 4.

Problem resol ved. Go to step 5.

Replace the failing part:

• Image transfer unit
(ITU). See “Image

transfer unit (ITU)” on
page 4-25.

• High-voltage power
supply (HVPS). See

“Hig h - vo l t age pow er
supply (HVPS)
assembly removal” on
page 4-24.

Go to step 2.

Go to step 4.

Go to step 6.

Reseat the cable in the JHVPS1 connector.

6

Does this fix the prob lem?
Replace the HVPS . See “Hi gh-v olta ge power

7

supply (HVPS) assembly removal” on
page 4-24.

Does this fix the prob lem?

Problem resol ved. Go to step 7.

Problem resol ved. Go to step 8.

Diagnostic information 2-51

7525xxx Lexmark confidential until annou nce

Step Questions / actio ns Yes No

Clean the printhead.

8

Does this fix the prob lem?

Problem resol ved. Replace the printhead. See

“Pri nthead removal” on
page 4-42.

Print quality—blank page

Step Questions / actio ns Yes No

1 Is all the packing material for the imaging unit

in question removed?
Print a document that requi res all four colors

2

with just a few characters to verify if one
specific color is a problem. For example, print
the Print Quality Test Pages:

1.Enter Diagnostic mode. (Turn the printer
off, pre ss and hold Left ( ) and
Select ( ), turn the printer on, and then
release the but tons when the installed
memory and processor speed displays.)

2.Select PRINT TESTS, and press
Select ().

3.Select Prt Qual Pgs, and press
Select ().

Is only one color missing?

Go to step 2. Remo ve the packing

Replace the developer unit
for the missin g color.

material.
Go to step 3.

Replace the imaging unit. See “Imaging unit

3

(IU) removal” on page 4-28.

Does this fix the prob lem?

2-52 Service Manual

Problem resol ved. Go to step 4.

Lexmark confidential until announce 7525xxx

Step Questions / actio ns Yes No

Enter the Diagnostics Menu (turn the printer

4

off, pre ss and hold and , turn the printer
on, and release the b uttons when installed
memory and processor speed displays), and
run the appropriate cartridge drive m otor test
for the missing color:

1.Select MISC TESTS in the Diag Men u, and
press Select ().

2.Select Motor Detect.
Remove Cartr idge. press Select appears.

Note: Do not press Select yet.

3.Remove all toner cartridges and the
imaging unit.

4.Close the front cover.
If you press Select before closing the front

cover, a message appears: Close Cover.
press Select.

5.press Select ().
Motor Detection In Progress… appears. The

motor detecti on process takes about 10
seconds, and stops automatically.

Detect Complete. Rebooting… appears, and
the printer performs a POR (Power On
Reset).

Did the motor run?
Remove the developer unit. See “Developer

5

unit removal” on page 4-30. Check the

dev eloper cartridge contacts from the HVPS to
the IU.

Are all the toner cartridge contacts clean on
both the Pin and IU?

Go to step 5. Replace the Main driv e gea r

assembly. See “Main drive

gear assembl y with motor
removal” on page4-39.

Go to step 6. Clean t he developer

cartridge contacts. See

“Developer unit removal”
on page 4-30.

Are all the spring-loaded Pin in the HVPS free

6

to move in and out wi th an equal amount of
spring force?

Turn the printer o ff , and r emo ve t he rear sh ield.

7

See “Rear shield remo val” on page 4-7.
Check the conti nuity between the spring­loaded Pin and the JSC1 connector on the
controlle r board.

Are all conducto rs continuous?
Replace the printhead. See “Printhead

8

removal” on page4-42.

Did this fix the problem?

Go to step 7. Replac e the HVPS. See

“High-voltage power
supply (HVPS) assembl y
removal” on page4-24.

Go to step 8. Replace the cable.

Problem resol ved. Replace the controller

board. See “Controller

board removal” on
page 4-16.

Diagnostic information 2-53

7525xxx Lexmark confidential until annou nce

Print quality—blurred or fuzzy print

Run the automatic alignment. The TPS sensor may be damaged. To run Reset Color
Cal:

1. Enter the Diagnostics Menu. (Turn the printer off, press and hold and , turn

the printer on, and release the buttons when installed memory and processor
speed displays.

2. Select TPS Setup from Diag Menu, and press Select ().

3. Select Reset Color Cal, and press Select ().

Resetting appears. Wh en the reset i s complete , the screen is automatically returned
to TPS Setup.

Blurred or fuzzy print is usually caused by a problem in the main drive gear assembly or in the image transfer
unit (ITU). Check the main drive gear assembly and ITU for correct operation.

Blurred print can a lso be caus ed b y incor rect feeding from one of the input paper sour ces, medi a tra y s, or duple x
paper path.

Check the high-voltage spring cont acts to ensure they are not bent, corroded, or damaged. Repl ace the high­voltage power supply as necessary. See “High-voltage power supply (HVPS) assembly removal” on

page 4-24.

Print quality—half-color page

A photoconductor unit is not properly seated. Reset th e specific photoconductor unit.

Print quality—horizontal banding

Print the Print Defect Page:

1. At the Ready prompt, press Menu ().

2. Select Reports, and press Select ().

3. Select Print Defects, and press Select ().

Step Questions / actio ns Yes No

1 Measure the distan ce between repeating

bands.
Is the distance between bands either 34.6 or

94.2 mm?

Does the distance measure 95 mm or

2

108 mm?

Does the distance measure 37.7, 55, or

3

78.5 mm?

Replace the pho toconductor
unit. Remove the imaging
unit and remove the original
dev eloper units, and then
put them back into the new
photoconductor unit, and
reinstall the imaging unit.
See “Imaging unit (IU)

removal” on page 4-28.

Replace the fuser. See

“Fuser assembl y removal”
on page 4-19.

Replace the ITU. See

“Image transfe r unit (ITU)”
on page 4-25.

Go to step 2.

Go to step 3.

Go to step 4.

Does the distance measure 43.9 mm or 45.5? Replace the developers that

4

2-54 Service Manual

match the missing color
(black, cyan, magenta, or
yellow). See “Developer

unit removal ” on
page 4-30.

Check the various rollers in
the printer for debris.

Lexmark confidential until announce 7525xxx

Print quality—horizontal line

Either the photoconductor unit or one of the developer units that make up t he imaging unit is defective. Remo ve
and inspect the imaging unit. Replace the damaged part of the imaging unit. See “Imaging unit (IU) removal”

on page 4-28.

Print quality—insufficient fusing

Step Questions / actio ns Yes No

1 Is the printer setup t o use the correct media? Go to step 2. Change the settings to

Check the fuser connections on the left and

2

right side of the printer.
Are the cables and connection correct?

Is the fuser properly installed? Go to step 4. Install the fus er properly.

3

Replace the fuser. See “Fuser assembly

4

removal” on page4-19.

Does this fix the prob lem?

Go to step 3. Properly reconnect or

Problem resol ved. Replace the LVPS. see

indicate the correct media.

replace the cables.

“Low-voltage power
supply (LVPS) assembly”
on page 4-31.

Print qual i ty—missing imag e at edge

Remove and r eseat the following:

• Toner cartridge

• Imaging unit

• Developer units.

Print qual i ty—mottle (2–5mm speckles)

Keep running pri nts thr ough, and the prob le m normally clear s up. If the pro blem per sists ,
replace the developer cartridge .

Diagnostic information 2-55

7525xxx Lexmark confidential until annou nce

Print quality—narrow vertical line

ABCDE
ABCDE
ABCDE

Step Questions / actio ns Yes No

1 Replace the photoconductor unit. See

“Imaging unit (IU) removal” on page 4-28.

Problem solved. Replace the developer unit.

See “Developer unit

removal” on page4-30

Print quality—random marks

Service tip: The primary cause of random ma rks is due to lo ose m aterial moving around insi de the printer and
attaching to the phot oconductor unit, de veloper roll, or transf er bel t.

Step Questions / actio ns Yes No

1 Is there any loo se or foreign material on t he

imaging unit?

Is there any loo se or foreign material on the

2

developer roll?
Is there any loo se or foreign material on the

3

transfer belt?

Inspect the imaging unit by
looking at the individual
dev elopers and
photoconductor s. Clean or
replace the f aulty unit. See

“Imaging unit (IU)
removal” on page 4-28.

Replace the developer unit. Go to step 3.

Replace the image transfer
unit. See “Image transfer

unit (ITU)” on page 4-25.

Go to step 2.

Contact your next level of
support.

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