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6. Disconnect the operator panel cable (B).

7. Remove the two screws (C) attaching the USB connector to the operator panel.

Set the USB connector aside to attach to the new operator panel.

Note: The USB is only used on certain X544 and X546 models.

8. Remove the ground wire from the op panel.

Main Page

Default Chapter3
- Table of Contents3
Notices and Safety Information11
Table of Contents11
- Laser Notice11
- Aviso sobre O Laser12
- Lithium Warning17
- Safety Information17
Preface20
- Change History20
- Conventions21
- Navigation Buttons21
General Information23
- Models23
- Options and Features24
- Media Handling30
- Digital Imaging Specifications38
Fax Specifications40
- Phone Network Connectivity40
- Fax Resolutions40
- Miscellaneous FAX Specifications40
- Next40
Tools Required for Service41
Acronyms42
Diagnostic Information45
Start45
POR (Power-On Reset) Sequence46
Symptom Tables47
- Printer Symptom Table47
- Scan / Fax / Copy Symptom Table48
- Print Quality Symptom Table49
Error Codes and Messages50
- User Status and Attendance Messages50
- Paper Jam Messages57
- Service Error Messages59
- Fax Error Log Codes71
Service Checks75
- 900.XX-System Software Error75
- 90X.XX Error (902.XX-907.XX)77
- 925.01-Fan Error Service Check78
- Printhead Service Check79
- 950.XX NVRAM Failure Service Check80
- Autocompensator Mechanism Service Check80
- Bin Full Sensor Service Check81
- Dead Printer Service Check82
- Duplex/Manual Feed Sensor (S1) Service Check83
- Front Door Sensor or Switches Service Check84
- Fuser Exit Sensor Service Check85
- Fuser Service Check86
- Input Sensor (S2) Service Check87
- Main Drive Gear Assembly (EP Drive) Service Check88
- Operator Panel Service Check89
  - One or more Operator Panel Buttons Fail89
  - Operator Panel Display Blank, Five Beeps89
  - Operator Panel Display Blank, Printer Beeps Five Times and Pauses90
  - Operator Panel Displays All Diamonds, no Beeps91
  - Operator Panel Displays All Diamonds, Five Beeps91
  - Operator Panel Display Is DIM and Unchanging92
- Op Panel USB Cable Service Check92
- USB Service Check92
- Networking Service Check93
- Print Quality Service Check95
  - Print Quality-Background96
  - Print Quality-Blank Page97
  - Print Quality-Blurred or Fuzzy Print99
  - Print Quality-Half-Color Page99
  - Print Quality-Horizontal Banding99
  - Print Quality-Horizontal Line100
  - Print Quality-Insufficient Fusing100
  - Print Quality-Missing Image at Edge100
  - Print Quality-Mottle (2-5Mm Speckles)100
  - Print Quality-Narrow Vertical Line101
  - Print Quality-Random Marks101
    - Print Quality-Residual Image102
    - Print Quality-Solid Color Page103
    - Print Quality-Vertical Banding103
  - Printhead Service Check104
  - Toner Meter Cycle (TMC) Card105
  - Toner Sensors (Y, C, M, K) on TMC Card105
  - Transfer Roll Service Check106
  - Tray (X) Sensor Service Check107
  - Option Trays 2 and 3 Service Check108
  - 840.XX Service Check110
    - Go Back110
  - Black or Blank Page Copy Service Check112
  - CCD Service Check112
  - Flatbed Motor Service Check112
  - Flatbed Home Position Service Check113
  - ADF Cover Open Service Check114
  - ADF Streak Service Check114
  - ADF Paper Jam Service Check115
  - ADF Feed Errors Service Check116
  - ADF Duplex Service Check117
  - Modem / Fax Card Service Check118
  - Fax Transmission Service Check119
  - Fax Reception Service Check121
  - Escalating a Fax Issue to Second-Level Support123
- User Operator Panel, Menus and Messages124
  - Understanding the Operator Panel124
  - Operator Panel Buttons124
  - Menu Map126
Diagnostic Aids127
- Menu Key Combinations127
- Diagnostics Menu (Diag Menu)128
- Device Tests144
  - Flash Test144
- Printer Setup145
- EP Setup147
- TPS Setup148
- Reports148
  - Main Settings Page148
- Event Log149
- Scanner Tests151
- EXIT Diags156
Configuration Menu157
- Available Tests157
- USB Scan to Local157
- Prt Quality Pages157
- Color Trapping157
- Reports158
  - Menu Settings Page158
  - Event Log158
- Panel Menus158
- PPDS Emulation158
- Demo Mode159
- Factory Defaults159
- Energy Conserve159
- Min Copy Memory160
- Format Fax Storage160
- Auto Color Adj160
- ADF Edge Erase160
- FB Edge Erase161
- Scanner Manual Registration161
  - To Manually Register a Duplex ADF, Perform the Following Steps161
  - To Manually Register the Flatbed, Perform the Following Steps162
- Disable Scanner162
- Font Sharpening163
- Pel Blurring163
- Exit Config Menu163
SE Menu164
- Print SE Menus164
- General164
- Code Revision Info164
- Paper Jams165
  - Avoiding Jams165
  - Understanding Jam Numbers and Locations166
- Updating Printer Firmware172
  - There Are Three Options to Update Firmware on Your Printer. the Instructions for All Three Options Are Listed below172
    - Using the Host Computer to Update the Firmware over USB172
    - Updating the Firmware Using a USB Thumb Drive179
  - Updating the Firmware Using a Networked Computer180
    - Using FTP180
    - Using the Printer's Internal Web Server181
- Theory of Operation183
Repair Information201
- Handling ESD-Sensitive Parts201
- Testing Generic Frus201
Removal Procedures202
Print Engine Removal Procedures202
- Front Cover Assembly Removal202
- Front Middle Cover Removal204
- Left Cover Removal204
- Right Cover Removal207
- Rear Shield Removal207
- AIO Back Cable Cover Removal208
- Top Cover Assembly Removal209
  - Installation211
  - Go Back211
- Autocompensator Mechanism (ACM)-Standard Tray Removal212
- Bin Full Sensor215
- Narrow Media Sensor Flag Removal216
- Controller Board Removal218
- Duplex Reference Edge Removal220
- Duplex Sensor Removal226
- Fuser Assembly Removal228
- Fuser Drive Motor Assembly Removal231
- Fuser Exit Sensor Removal232
- High-Voltage Power Supply (HVPS) Assembly Removal234
  - High-Voltage Power Supply (HVPS) with or Without Spring235
  - High-Voltage Power Supply (HVPS) Without Spring236
  - High-Voltage Power Supply (HVPS) with Spring237
- Image Transfer Unit (ITU)240
- Imaging Unit (IU) Removal245
- Developer Unit Removal247
- Low-Voltage Power Supply (LVPS) Assembly248
- Lower Frame Removal, Right and Left250
  - Left Lower Frame250
  - Right Lower Frame253
- Main Drive Gear Assembly with Motor Removal258
- Pick Tires Removal-Integrated 250-Sheet Media Tray260
- Printhead Removal261
- Imaging Unit (IU) Removal262
- Toner Cartridge Contacts264
- Toner Meter Cycle (TMC) Card Removal266
- Toner Density Sensor (TPS)-Left and Right Removal268
- Tray Present Sensor Removal269
- USB Connector Removal272
- Waste Toner Bottle272
- Waste Toner Bottle Contact Block Removal273
- Wireless Network Antenna274
- Wireless Network Card276
Scanner Component Removal Procedures277
- Flatbed Removal277
  - Preparing and Installing the New Flatbed283
- Flatbed Pivot Link Removal286
- Duplex ADF Rear Cover287
- Duplex ADF Removal288
- Simplex ADF Rear Cover289
- Simplex ADF Removal289
- ADF Input Tray289
- ADF Cable Removal290
- ADF Separator Pad292
- ADF Separator Roll Assembly293
- Bezel Cover294
- Redrive Unit296
- Cover Scanner Left297
- Cover Scanner Right298
Locations309
- Exterior Views309
Preventive Maintenance329
- Safety Inspection Guide329
- Scheduled Maintenance329
  - Maintenance Kit329
- Lubrication Specifications329
Parts Catalog331
- How to Use this Parts Catalog331
- Assembly 1: Covers334
- Assembly 2: Scanner336
- Assembly 3: Paperpath340
- Assembly 4: Electronics 1342
- Assembly 5: Electronics 2344
- Assembly 6: Media Drawers and Trays346
- Assembly 7: Options348
Index349
Part Number Index359

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