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Lexmark C 540n, Service Manual

The Lexmark C 540n is a versatile color laser printer ideal for small businesses and home offices. Ensure optimal performance by downloading the free Service Manual from manualshive.com. This comprehensive manual provides step-by-step instructions for maintenance and troubleshooting to keep your printer running smoothly. Download it now for hassle-free operation.

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Table of contents

v

  

5025-2xx, 4xx

Hardware Tests

 

 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11

Panel Test  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  3-11
Button Test  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  3-12
DRAM Test  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  3-12

Duplex Tests

 

 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  3-13

Quick Test (duplex)  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  3-13
Top Margin (duplex)   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  3-14
Left Margin (duplex)   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  3-14

Input Tray Tests

 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15

Feed Tests   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  3-15
Sensor Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  3-15

Base Sensor Test

 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  3-16

Miscellaneous tests

 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  3-17

Motor Detect  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  3-17

Device Tests

 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  3-17

Flash Test  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  3-17

Printer Setup

 

 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  3-18

Defaults  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  3-18
Page counts   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  3-18
Serial Number  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  3-18
Engine Setting 1 through 4  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  3-18
Model Name  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  3-18
Configuration ID   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  3-19
ITU Barcode   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  3-19
Reset Fuser Cnt   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  3-20

EP Setup

 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  3-20

EP Defaults  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  3-20
Fuser Temperature  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  3-20
DC Charge Adjust, Dev Bias Adj, Transfer Adjust   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  3-20

TPS Setup

 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  3-21

Right or Left TPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  3-21
Cal Ref Adj   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  3-21
Reset Color Cal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  3-21

Reports

 

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

Menu Settings Page  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  3-22

Event Log

 

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

Display Log  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  3-22
Print Log  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  3-22
Clear Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  3-23

EXIT Diags

 

 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  3-23

Configuration menu (Config Menu)

 

 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  3-24

Available tests

 

 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  3-24

Prt Quality Pgs

 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  3-24

Color Trapping

 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  3-24

Reports

 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  3-25

Menu Settings Page  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  3-25
Event Log   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  3-25

Panel Menus

 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  3-25

PPDS Emulation

 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25

Demo Mode

 

 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  3-25

Factory Defaults

 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-26

Energy Conserve

 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  3-26

Auto Color Adj

 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  3-27

Font Sharpening

 

 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  3-27

Exit Config

 

 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  3-27

Summary of Contents for C 540n

Page 1: ...546dtn 5025 2xx 4xx Table of contents Start diagnostics Safety and notices Trademarks Index Lexmark and Lexmark with diamond design are trademarks of Lexmark International Inc registered in the United...

Page 2: ...available in all countries in which it operates Any reference to a product program or service is not intended to state or imply that only that product program or service may be used Any functionally e...

Page 3: ...x capability 1 9 Media output size and type 1 9 Media input size specifications 1 9 Media input type specifications 1 11 Media guidelines 1 12 Paper characteristics 1 12 Unacceptable paper 1 13 Select...

Page 4: ...quality blank page 2 42 Print quality blurred or fuzzy print 2 43 Print quality half color page 2 43 Print quality horizontal banding 2 44 Print quality horizontal line 2 44 Print quality insufficien...

Page 5: ...Configuration ID 3 19 ITU Barcode 3 19 Reset Fuser Cnt 3 20 EP Setup 3 20 EP Defaults 3 20 Fuser Temperature 3 20 DC Charge Adjust Dev Bias Adj Transfer Adjust 3 20 TPS Setup 3 21 Right or Left TPS 3...

Page 6: ...e 3 43 Step 6 Clean erase 3 44 Paper path transport components 3 46 Paper path Information 3 46 Transport components 3 47 Duplex process 3 48 Color theory 3 49 Repair information 4 1 Handling ESD sens...

Page 7: ...l 4 76 Waste toner bottle removal 4 77 Waste toner bottle contact block removal 4 78 Wireless network antenna removal 4 79 Wireless network card 4 81 Connector locations 5 1 Locations 5 1 Connectors 5...

Page 8: ...viii Service Manual 5025 2xx 4xx...

Page 9: ...oder bei ordnungsgem er Wartung durch den Kundendienst Laserbestrahlung die Klasse I bersteigen w rde Menschen keinesfalls erreicht Avis relatif l utilisation de laser Pour les Etats Unis cette imprim...

Page 10: ...to de pot ssio de 5 milliwatts operando numa faixa de comprimento de onda entre 645 e 670 nan metros O sistema e a impressora laser foram concebidos de forma a nunca existir qualquer possiblidade de a...

Page 11: ...ohitettaessa olet alttiina n kym tt m lle lasers teilylle l katso s teeseen VARNING Osynlig laserstr lning n r denna del r ppnad och sp rren r urkopplad Betrakta ej str len Laser notis Denna skrivare...

Page 12: ...s d IEC 60825 1 Els productes l ser de classe I no es consideren perillosos Aquesta impressora cont un l ser de classe IIIb 3b d arseni r de gal li nominalment de 5 mil liwats i funciona a la regi de...

Page 13: ...Notices and safety information xiii 10 2 2009 5025 2xx 4xx...

Page 14: ...xiv Service Manual 5025 2xx 4xx 10 2 2009...

Page 15: ...Les consignes d entretien et de r paration de ce produit s adressent uniquement un personnel de maintenance qualifi Le d montage et l entretien de ce produit pouvant pr senter certains risques lectriq...

Page 16: ...rmaci n sobre el mantenimiento de este producto est dirigida exclusivamente al personal cualificado de mantenimiento Existe mayor riesgo de descarga el ctrica y de da os personales durante el desmonta...

Page 17: ...quest producte est orientada exclusivament a professionals i no est destinada a ning que no ho sigui El risc de xoc el ctric i de danys personals pot augmentar durant el proc s de desmuntatge i de ser...

Page 18: ...g printer adjustments and removing and installing FRUs 5 Connector locations uses illustrations to identify the connector locations and test points on the printer 6 Preventive maintenance contains the...

Page 19: ...x printing Models Configurations Model name Machine type model Description Lexmark C540n 5025 210 Ethernet network Lexmark C543dn 5025 230 Ethernet network duplex Lexmark C544n 5025 410 Ethernet netwo...

Page 20: ...sizes 128MB 256MB and 512MB 256MB 512MB Maximum printer memoryb 640MB Option Slots single slot is available or either font or flash memory card Font card support N A 1 font card Optional user flash me...

Page 21: ...k protocol Lexmark C540n C543dn Lexmark C544n C544dn C544dn wireless Lexmark C546dtn Standard Ethernet 10 100 Base T Standard USB B Full speed device port USB A host ports In front low full speed This...

Page 22: ...minute Fuser standby is off The operator panel back light is off Power supply energy consumption is reduced Energy Paper All of the above Data streams Lexmark C540n C543dn Lexmark C544n C544dn C544dwn...

Page 23: ...sheet Duo Drawer 422 mm 16 6 in 424mm 16 7 in 416 mm 16 4 in 25 kg 55 lb 650 sheet Duo Drawer 133 mm 5 2 in 424 mm 16 7 in 416 mm 16 4 in 4 kg 8 7 lb 550 sheet Duo Drawer only C526dtn 133 mm 5 2 in 42...

Page 24: ...while idle Power Saver 18 W 18 W 18 W Ready 34 W 36 W 36 W Off 0 W 0 W 0 W Automatic duplex is not supported on the C540n and C544n Typical electricity consumption2 Model Mode Power supply voltage kwh...

Page 25: ...A 50 dBA N A 51 dBA 51 dBA Idle Inaudible Inaudible Inaudible Inaudible Inaudible Quiet Mode simplex 46 dBA 46 dBA 46 dBA 46 dBA 46 dBA Environment Specifications Operating Air temperature operating...

Page 26: ...ximum 1 total of all inputs is 4 650 sheet Duo Drawerab includes 100 sheet MP feeder 550 sheets or 100 sheets in MP feeder 550 sheets or 100 sheets in MP feeder 0 0 Multipurpose try capacity 650 sheet...

Page 27: ...ark C544n Lexmark C544dn Lexmark C544dw Lexmark C546dtn Input source 250 sheet tray Optional 650 sheet Duo Drawer Optional 550 sheet drawer model C546dtn only MP feeder a in the 650 sheet Duo Drawer M...

Page 28: ...nvelopea Other envelopea Length 98 432mm 3 8 17 in Width 89 297mm 3 5 11 7 in a The MP feeder runs slower if A5 Statement B5 A6 Executive Statement Universal narrower than 210mm or envelopes are loade...

Page 29: ...ls Bond Envelopes Rough envelopes Letterhead Preprinted Colored paper Light paper Heavy paper Rough or cotton Custom type x b a For MP feeder and manual feeders the Default Source Menu displays Manual...

Page 30: ...Heavy Paper 105 to 176 g m2 grain long 28 to 47 lb bond 7 Card stock Specialty papers Gloss Book 88 to 176 g m2 grain long 60 to 120 lb book Gloss Cover 162 to 176 g m2 grain long 60 to 65 lb cover C...

Page 31: ...emically treated papers used to make copies without carbon paper also known as carbonless papers carbonless copy paper CCP or no carbon required NCR paper Preprinted papers with chemicals that may con...

Page 32: ...paper will feed well Lexmark consistently tests its printers with recycled paper 20 100 post consumer waste and a variety of test paper from around the world using chamber tests for different temperat...

Page 33: ...s screwdriver magnetic short blade Long shank Phillips screwdriver at least 8 in or 200 mm long preferably magnetized 7 32 inch 5 5 mm open end wrench 7 0 mm nut driver Needlenose pliers Diagonal side...

Page 34: ...imulated Emission of Radiation LCD Liquid Crystal Display LED Light Emitting Diode LVPS Low Voltage Power Supply M Magenta MPF Multipurpose Feeder also MP feeder NVRAM Nonvolatile Random Access Memory...

Page 35: ...r symptom table on page 2 3 Print quality symptom table on page 2 4 Do you have an error message or persistent user message check the following Service error messages on page 2 13 User status and cust...

Page 36: ...ars 6 Another row of pixels appears 7 The operator panel display clears again 8 The operator panel displays system information For example 9 The fuser turns on The fuser takes longer to warm up from a...

Page 37: ...the paper guides The multipurpose feeder does not automatically sense the paper size You must set the size from the Paper Size Paper Type menu Print a menu settings page and compare the settings for...

Page 38: ...icient fusing on page 2 45 Light print on solids See Media guidelines on page 1 12 Missing image at edge Go to Print quality missing image at edge on page 2 45 Mottle 2 5mm speckles Go to Print qualit...

Page 39: ...and continue printing Insert Tray x This message is displayed when the printer requests the user to insert tray x before it can continue printing the job The printer needs to pick media from the miss...

Page 40: ...der load a sheet of paper and then press Select to clear the message and continue printing Press Select to clear the message and continue printing The printer manually overrides the manual request and...

Page 41: ...nge the camera mode Unsupported USB device please remove Remove the unrecognized device from the USB port on the front of the printer Unsupported USB hub please remove Remove the unrecognized USB hub...

Page 42: ...k buffers however modification of other printer settings which affect the amount of available memory may also create this condition If restoration of Resource Save is required after this message is re...

Page 43: ...et Font Global command a Select Code Page command or a Comprehensive Font Selection command and the printer Best Fit setting is off If Best Fit is on the printer performs a best fit search to find a s...

Page 44: ...inistrative Menus 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 58 Too many Flash options instal...

Page 45: ...exit sensor Multiple pages of media are jammed at the exit sensor Open the front door to access the jam area Remove the jammed page or pages See 202 paper jam on page 3 34 230 xx Paper Jam Check area...

Page 46: ...he door and remove all the jammed pages See 242 paper jam in the 650 sheet Duo Drawer on page 3 35 250 xx Paper Jam Check Manual Feeder or 250 xx Paper Jam x Pages Jammed A single page of media is jam...

Page 47: ...ervice check on page 2 49 106 11 Service Yellow Printhead Failure writing data to the printhead Perform a POR If the problem persists go to Printhead service check on page 2 49 106 12 Service Yellow P...

Page 48: ...erform a POR If the problem persists go to Printhead service check on page 2 49 108 04 Service Magenta Printhead The magenta printhead mirror motors lost motor lock Perform a POR If the problem persis...

Page 49: ...lack Printhead Printhead declared error Perform a POR If the problem persists go to Printhead service check on page 2 49 122 xx Service Fuser Error Fuser error Go to Fuser service check on page 2 28 1...

Page 50: ...per pick motor drive assembly service check on page 2 39 141 04 Service Staging Motor Motor encoder count did not change between interrupts Go to Paper pick motor drive assembly service check on page...

Page 51: ...in time based commutation Go to Main drive gear assembly EP drive service check on page 2 30 900 xx Service RIP Software Unrecoverable RIP software error illegal trap Go to 90x xx error on page 2 22...

Page 52: ...2 50 943 0x Service Black TMC Sensor The black cartridge toner meter cycle TMC switch error 01 Recoverable 02 Nonrecoverable Go Toner meter sensors Y C M K on TMC card on page 2 50 950 xx Service NVR...

Page 53: ...Processor over temperature 957 xx Service System Board Controller board failure ASIC failure 958 xx Service NAND Failure Printer has performed more than 100 shift and reflash operations as a result o...

Page 54: ...lid SP memory configuration Replace the controller board See Controller board removal on page 4 20 960 xx Service Memory Error RAM memory error RAM soldered on the board is bad Replace the controller...

Page 55: ...on If correctly installed replace the network card If a network card is not installed replace the controller board See Controller board removal on page 4 20 979 xx Service Standard Network or 979 xx S...

Page 56: ...See Controller board removal on page 4 20 Securely make all the connections POR the printer Step Questions actions Yes No 1 Turn the printer off and remove the rear shield See Top cover assembly remov...

Page 57: ...installed controller board See Controller board removal on page 4 20 2 Did reloading the firmware correct the problem Problem resolved Replace the controller board with a new and not previously instal...

Page 58: ...2 Inform the customer 2 Is the AC power cord damaged Replace the line cord Go to step 3 3 Is the LVPS cable correctly connected at JLVPS1 on the controller board Go to step 5 Reconnect the cable at JL...

Page 59: ...mething obstructing the sensor Remove the obstruction and restart the test Go to step 5 5 Inspect the spring loaded shaft flag in the tray The flag portion of the shaft intercepts the sensor except wh...

Page 60: ...e door Open the toner cover and check the motion of the web Is the web loose damaged or missing Replace the right cover assembly See Right cover assembly removal on page 4 12 Go to step 3 3 Open the t...

Page 61: ...on and then release the buttons when the installed memory and processor speed displays Perform the Base Sensor Test See Base Sensor Test on page 3 16 1 Select Base Sensor Test and press Select 2 Sele...

Page 62: ...on page 4 13 Check the cable at JFUSES1 for proper connection to the controller board the cable for pinch points and the cable or connector for any other damage Is the cable damaged Replace the fuser...

Page 63: ...ect Base Sensor Test and press Select 2 Select S2 and press Select 3 Pull tray 1 out and rotate the S2 sensor flag S2 is located in front of the center paper pick motor drive assembly housing It shoul...

Page 64: ...at JCARTB1 for proper connection to the controller board the cable for pinch points and the cable or connector for any other damage Is the cable damaged Replace the JCARTB1 cable Go to step 2 2 Verif...

Page 65: ...nder Printers and Faxes on the host computer Delete all print jobs in the print queue Is the printer online and in a Ready state Go to step 5 Go to step 4 4 Change the printer status to online Did thi...

Page 66: ...that the wireless card is properly seated on the controller board Is the wireless card seated correctly Go to step 20 Go to step 19 19 Properly reseat the wireless card Did this fix the problem Proble...

Page 67: ...eed displays Perform the Panel Test See Panel Test on page 3 11 The Panel Test should show alternating display of all pixels on and all pixels off Press Stop to end the test Did the test show errors o...

Page 68: ...ntroller board JOPP1 and at the operator panel assembly Go to step 2 Reinstall the cable 2 Turn the printer off and remove the rear shield See Top cover assembly removal on page 4 13 Turn the printer...

Page 69: ...ace the controller board See Controller board removal on page 4 20 2 Turn the printer off and check for continuity in the operator panel cable Note Remove the three screws holding the operator panel a...

Page 70: ...controller board See Controller board removal on page 4 20 2 Check for continuity in the operator panel cable connector Note Remove the three screws holding the operator panel and place it facedown on...

Page 71: ...oller board See Controller board removal on page 4 20 2 Check for continuity in the operator panel cable connector Note Remove the three screws holding the operator panel and place it facedown on top...

Page 72: ...el cable connector Note Remove the three screws holding the operator panel and place it facedown on top of the printer The cable connector pins will be exposed and easier to contact Do all the conduct...

Page 73: ...stom settings if needed 2 On the menu page make sure the following is set to the default level Color Correction Set to Auto Print Resolution Set to 600 dpi print quality problems should be checked at...

Page 74: ...ain letter A4 3 Print the Print Quality pages to see if the problem remains Look for variations in the print from what is expected To print the print Quality pages a Enter Diagnostics turn the printer...

Page 75: ...the imaging unit and press Select 5 Select Yes and press Select If this does not fix the problem go to step 2 Go to step 2 2 Is the background only one of the primary colors yellow cyan magenta or bla...

Page 76: ...Go to step 3 3 Replace the imaging unit See Imaging unit IU removal on page 4 45 Does this fix the problem Problem resolved Go to step 4 4 Run the Motor Detect Test 1 Remove the imaging unit and the...

Page 77: ...ly HVPS assembly removal on page 4 35 Print quality half color page The imaging unit and developer units may not properly seated Reseat the imaging unit If that does not work remove the imaging unit a...

Page 78: ...distance between bands either 34 6 or 94 2 mm Replace the photoconductor unit Remove the imaging unit and remove the original developer units and then put them back into the new photoconductor unit a...

Page 79: ...actions Yes No 1 Is the printer setup to use the correct media Go to step 2 Change the settings to indicate the correct media 2 Check the fuser connections on the left and right side of the printer Ar...

Page 80: ...unit See Developer unit removal on page 4 21 Step Questions actions Yes No 1 Is there any loose or foreign material on the imaging unit Inspect the imaging unit by looking at the individual developer...

Page 81: ...ce 43 9 mm Replace the developer corresponding to the color of the image See Developer unit removal on page 4 21 Replace the imaging unit or the photoconductor unit See Imaging unit IU removal on page...

Page 82: ...when you replace the imaging unit This will block the laser from discharging the photoconductors Print a Quality Test Page Does the page have a white vertical band Replace the printhead See Printhead...

Page 83: ...connection to the controller board the printhead cable for pinch points and the cable or connector for any other damage Is the cable damaged Replace the printhead See Printhead removal on page 4 65 Go...

Page 84: ...out the Base Sensor Test see Base Sensor Test on page 3 16 Does the operator panel display a change of state Replace the toner cartridge Replace the toner meter cycle TMC card See Toner meter cycle TM...

Page 85: ...ar shield See Top cover assembly removal on page 4 13 Turn the printer on and check the cable at JHVPS1 connector on the controller board without disconnecting it Verify the following voltage values A...

Page 86: ...or Is the sensor dislodged Replace the option tray present sensor If the 650 sheet tray is affected replace the 650 sheet drawer assembly If the 550 sheet assembly is affected replace the entire 550 s...

Page 87: ...order of the trays so the 500 sheet tray is on the bottom and print a page from both trays Did the pages print from both trays Problem resolved Go to step 4 4 Inspect the paperfeed pick tires on the...

Page 88: ...page print Go to step 11 Replace the 650 sheet tray 11 1 Turn off the printer 2 Remove the rear shield see Top cover assembly removal on page 4 13 3 Disconnect the cable at JOPT1 on the controller boa...

Page 89: ...Stops all printer activity A list of options is offered once Stopped appears on the display Navigation buttons Press or to scroll through menu lists Use the Select button in the center to initiate ac...

Page 90: ...Binary PS Network Setup Reports Network Card TCP IP IPv6 Wireless AppleTalk SE Menu USB Menu PCL Smartswitch PS Smartswitch NPA Mode USB Buffer Mac Binary PS USB With ENA ENA Address ENA Netmask ENA G...

Page 91: ...ocessor speed displays The Configuration menu group contains a set of menus settings and operations which are infrequently required by a user Generally the options made available in this menu group ar...

Page 92: ...Skew See Skew on page 3 5 Quick Test See Quick Test on page 3 5 Alignment Menu color alignment Cyan See Alignment on page 3 7 Yellow Magenta Factory Scanner A summary page for all the color alignment...

Page 93: ...Setting 1 through 4 on page 3 18 Engine Setting 2 Engine Setting 3 Engine Setting 4 Model Name See Model Name on page 3 18 Config ID Configuration ID See Configuration ID on page 3 19 ITU Barcode See...

Page 94: ...Log See Clear Log on page 3 23 Exit Diags This selection exits the Diagnostics Menu The printer performs a POR and returns to normal mode Description Value Direction of change Top margin 50 to 50 Eac...

Page 95: ...B Processor Speed xxxMHz Serial Number xxxxxxx CalStat xxxx CalSet x xx x xx x xx x xx x xx Engine ID xx FSpeed xxx Printer Rev isi on Levels Loader xx xx xxxx x Kernel xxx xx xxxx x Base xx xx xxxx x...

Page 96: ...and code level To print the Quick Test page Note Print the Quick Test Page on letter or A4 paper 1 Select Registration from Diag Menu and press Select 2 Select Quick Test Page and press Select The mes...

Page 97: ...s and requires that the best line in each set of lines must be selected To get started 1 Select Alignment Menu from the Diag Menu and press Select 2 Select a color Cyan Yellow or Magenta and press Sel...

Page 98: ...the current value for the Top Margin 6 Use or to enter the sum of the numbers and press Select Submitting changes appears Print the Quick Test again to verify the observed value is the same as the cur...

Page 99: ...k Test to see if the observed values and the current values are the same 8 On the second page of the latest Quick Test you printed proceed to Step 2 adjust the left right and bow settings Continue pri...

Page 100: ...PRINT TESTS from the Diag Menu and press Select 2 Select the media source Tray 1 Tray 2 Manual Feeder or Multi Purpose Feeder and press Select 3 Select Single or Continuous and press Select If Single...

Page 101: ...e print quality pages from the Diagnostics Menu 1 Select PRINT TESTS and press Select 2 Select Prt Qual Pgs and press Select The message Printing Quality Test Pages is displayed Note Once the test is...

Page 102: ...memory can be set and read correctly To run the DRAM Test 1 Select Hardware Tests in Diag Menu and press Select 2 Select DRAM Test and press Select a The printer displays b The printer initiates a POR...

Page 103: ...t DUPLEX TESTS from Diag Menu and press Select 2 Select Quick Test and press Select 3 Select Single or Continuous and press Select The single Duplex Quick test prints the Quick Test on front and back...

Page 104: ...alue 8 Print the Quick Test duplex again steps 1 4 to verify the adjustment Repeat if necessary Left Margin duplex This setting shifts the image on the back of the duplex sheet to the left or right to...

Page 105: ...are fed continuously until Stop is pressed Sensor Test This test is used to verify that the sensors are working correctly for an individual input tray 1 Select INPUT TRAY TESTS from Diag Menu and pres...

Page 106: ...he paper tray The sensor should change state S2 Media clear or Media present Remove the media tray Activate the input S2 sensor flag The sensor should change state Fuser exit sensr Media clear or Medi...

Page 107: ...matically Detect Complete Rebooting appears and the printer performs a POR Power On Reset If the motor ran the test was passed If the motor did not run the test failed Device Tests Flash Test This men...

Page 108: ...but not change any of the three counts To view the Prt Color Pg Count the Prt Mono Pg Count or the Perm Page Count 1 Select Printer Setup from Diag Menu and press Select 2 Select the page count you wi...

Page 109: ...r or digit press to decrease or to increase the underlined value and press Select to move to the next character or digit To move to the next character or digit without changing the current value press...

Page 110: ...ag Menu and press Select 2 Select EP Defaults and press Select 3 Select Restore to reset the values to the factory settings and select Do Not Restore To cancel and return to the menus press Back Fuser...

Page 111: ...appears e Continue entering and pausing 4 After the 32nd number is entered and becomes solid the number is automatically entered If the number is incorrect Checksum does not match appears and the orig...

Page 112: ...o there may be repetitions All 2xx and 9xx error messages are stored in the Event Log To view the event log 1 Select Event Log from Diag Menu and press Select 2 Select Display Log and press Select As...

Page 113: ...e Clear Log to remove the current information in the Event Log This affects both the viewed log and the printed log information 1 Select Event Log from Diag Menu and press Select 2 Select Clear Log an...

Page 114: ...hen small black text or fine black lines are being printed the printer checks to see if they are being printed on top of a colored background If so rather than remove the color from beneath the black...

Page 115: ...fig Menu and press Select 2 Select Print Log and press Select to begin printing the log Panel Menus Lets the system support person enable or disable the operator panel menus Selecting On the default a...

Page 116: ...t 5 Enter the Diagnostic Menu select Reports Menu Settings Page and press Select See Menu Settings Page on page 3 22 6 Turn the printer off or select Exit Diags 7 Enter Configuration Menu select Repor...

Page 117: ...the maximum number of pages printed will be reset For example if the user replaces an empty toner cartridge the next time the printer is started it will sense the new cartridge and perform the automat...

Page 118: ...file is displayed press Select Program Device Yes displays 5 Press Select The printer will start the update process Various status and progress messages will appear Warning Do not turn the printer off...

Page 119: ...SB Note This procedure uses the program USB Flash USButil is a command line USB flash utility that can also be used to update firmware from a host computer via USB To use any USB flashing utility the...

Page 120: ...Service Manual 5025 2xx 4xx 3 Select the printer from the list of printers installed on the computer 4 Press Start 5 Repeat these steps for every file you are updating on the printer Lexmark C54x ser...

Page 121: ...not use paper that has been cut or trimmed by hand Do not mix paper sizes weights or types in the same stack Store the paper in an appropriate environment Do not remove trays while the printer is pri...

Page 122: ...m under the fuser Open the front door and remove the jam 3 33 202 Jam in the fuser Open the front door and pull the fuser cover toward you Remove the jam 3 34 230 Jam in the duplex Open the front door...

Page 123: ...ove the jam Note Make sure all paper fragments are removed 3 Insert the tray 4 Press Select 201 paper jam 1 Grasp the front door at the side handholds and then pull it toward you to open it 2 Remove t...

Page 124: ...handholds and then pull it toward you to open it 2 Grasp the green lever and pull the fuser cover toward you 3 Hold the fuser cover down and then remove the jammed paper The fuser cover closes when r...

Page 125: ...e size of paper used 4 Check the pick tires for foreign material or wear Replace if necessary See Pick tires removal on page 4 64 5 Close the primary tray 6 Press Select to continue printing 242 paper...

Page 126: ...sed 4 Check the pick tires for foreign material or wear Replace if necessary See Pick tires removal on page 4 64 5 Close the primary tray 6 Press Select to continue printing Note Make sure all paper f...

Page 127: ...U and then to the media 5 Fuse the toner to the media 6 Clean erase the photoconductor and the ITU In summary the printer s controller board receives print data and the command to print The controller...

Page 128: ...surface of the charge roll is damaged such as a nick or pit it will cause the charge to be uneven on the photoconductor This will cause a repeating mark on the printed page Check the repeating marks...

Page 129: ...lens gets contaminated with toner or other debris it will cause white or light vertical streaks on the page Cleaning the lens solves the problem Never touch the surface of the photoconductor with your...

Page 130: ...ar to using glue to write on a can and then rolling it over glitter The glitter sticks to the glue but won t stick to the rest of the can Service tips Never touch the surface of the developer roller w...

Page 131: ...ce to surface contact between the photoconductors and the ITU belt Service tips Never touch the surface of the ITU belt with your bare hand The oil from your skin will cause a charge differential on t...

Page 132: ...e on the transfer belt reaches the transfer roll the negatively charged toner clings to the media and the entire image is transferred from the transfer belt to the media Service tips If the transfer r...

Page 133: ...Service tips If the fuser rolls are damaged they can cause toner to be pulled off the page or cause paper jams Toner that rubs off a printed page can be a sign of a malfunctioning fuser or an imprope...

Page 134: ...er cleans the photoconductors Transfer unit clean Once the toner image on the transfer belt has been transferred to the page the transfer belt rotates around and is cleaned by the cleaning blade G Thi...

Page 135: ...belt from the photoconductors a cleaning blade H scrapes the left over toner from the surface of each photoconductor This is the clean erase process Now the photoconductor surface is prepared to begi...

Page 136: ...fail and cause paper jams or other feed and transport problems These components should be examined for damage or wear and replaced if necessary Paper path Information This printer has a simple C shap...

Page 137: ...to the ITU where the image is transferred to the page The transfer roller moves the media to the fuser where heat and pressure are applied to the page The fuser rollers push the media toward the exit...

Page 138: ...dia being processed by the print engine A user should not attempt to insert a piece of media into the manual paper feed while a duplex job is being processed This would invoke a jam error When the tra...

Page 139: ...example it is possible to apply one type of color conversion table to text while applying a different color conversion table to photographic images Should I use PostScript or PCL emulation printer sof...

Page 140: ...generate preferred colors for the majority of documents To manually apply a different color conversion table 1 Press Menus to open the Admin menus 2 Select Settings and press Select 3 Select Quality...

Page 141: ...being printed text graphics or images and how the color of the object is specified in the software program RGB or CMYK combinations When the printer Color Correction setting is set to Off the color is...

Page 142: ...3 52 Service Manual 5025 2xx 4xx...

Page 143: ...lectricity in your body to the machine Hold the ESD sensitive part by its edge connector shroud cover do not touch its pins If you are removing a pluggable module use the correct tool Do not place the...

Page 144: ...echanical movement Front cover assembly removal See the front cover assembly on page 7 3 for the part number 1 Open the front cover 2 Remove the operator panel See Operator panel logo plate on page 4...

Page 145: ...front door open sensor cables from the controller board C 9 Pull the cables through the opening in the rear 10 Position the printer with the front cover overlapping the front edge of the table 11 Rem...

Page 146: ...4 4 Service Manual 5025 2xx 4xx 12 Lower the front cover to align the flats on the hinges and remove the front cover Note Not all models have all three cables shown See the chart below...

Page 147: ...5025 210 Operator panel cable E Front door switch cable F Note The USB port cable G is not included 40X5420 Lexmark C543dn 5025 230 Operator panel cable E Front door switch cable F USB port cable G n...

Page 148: ...bly on page 7 3 for the part number 1 Remove the media tray 2 Position the printer with the left side hanging over the edge of the table 3 On the rear remove the metal screw A the short plastic screw...

Page 149: ...5025 2xx 4xx 5 Unlatch the front bottom corner tab E and lower the front while disengaging from the top cover Installation note When replacing the left cover flex the cover slightly to engage the tab...

Page 150: ...plates including on page 7 3 for the part number 1 Remove the operator panel logo plate See Operator panel logo plate on page 4 9 2 Lift the bottom edge of the bezel A and remove the bezel 3 Lift the...

Page 151: ...See operator panel bezel and name plates on page 7 3 for the part number This is part of the operator panel bezel and name plate FRU 1 Open the front cover 2 With a flat bladed screwdriver unlatch th...

Page 152: ...y Controller board Warning Never install and remove components listed above as a method of troubleshooting components Once a component has been installed in a printer and the printer is powered on it...

Page 153: ...r information 4 11 5025 2xx 4xx 5 Detach the operator panel cable C from the panel Rear shield removal The rear shield is not a field replaceable unit FRU 1 Remove the six screws A 2 Remove the rear s...

Page 154: ...ice Manual 5025 2xx 4xx Right cover assembly removal See Right cover assembly on page 7 3 for the part number 1 Open the toner supply door 2 Open the front cover 3 Release the latches A and lift off t...

Page 155: ...mbly See Right cover assembly removal on page 4 12 2 Remove the waste toner bottle See Waste toner bottle removal on page 4 77 3 Remove the imaging unit See Imaging unit IU removal on page 4 45 4 Remo...

Page 156: ...4 14 Service Manual 5025 2xx 4xx 7 Remove the machine screws C and remove the ground cable from the cover 8 Lift and slide the paper stop to expose the screw D and remove the screw...

Page 157: ...Repair information 4 15 5025 2xx 4xx 9 Remove the two top screws E near the front 10 Remove the remaining four screws F 11 Remove the fuser screw G...

Page 158: ...e right fuser spring J from the fuser 14 Disengage the bin full narrow media sensor cable K from the retainer 15 Gently rotate the fuser away from the top cover and let it rest Note If fuser needs to...

Page 159: ...rmation 4 17 5025 2xx 4xx 16 Push in on the cover above the locating pins L while lifting to disengage the cover Carefully lift the cover while keeping it horizontal Note Guide the fan connector throu...

Page 160: ...nt cover 2 Remove the cable from the retainer Note Be sure to note the routing for re installation 3 Disconnect the cable from the bin full narrow media sensor 4 If there is a sensor retaining plate A...

Page 161: ...e latches together until they latch to the metal frame 4 Remove the backing from the new plate and place the plate on the surface between the sensor mounting legs 5 Reconnect the cable and reroute the...

Page 162: ...troller board Warning Never install and remove components listed above as a method of troubleshooting components Once one of these components has been installed in a printer and the printer is powered...

Page 163: ...PS A blank page that should have toner on it could be an indication that toner is applied to the ITU belt but not transferred Therefore the toner goes into the ITU cleaner which cannot process massive...

Page 164: ...e Duplex reference edge on page 7 5 for the part number 1 Open the front door 2 Remove the four short screws A in front and the four longer screws B in the back of the duplex aligner 3 Lift the duplex...

Page 165: ...rom the duplex reference guide and remove the guide Installation notes 1 Align the duplex reference guide so the tabs A are inserted into the slots and the top of the reference guide fits under the do...

Page 166: ...the bearing on the left is aligned with the slot C facing down towards the front door Note Improperly aligned bearings or seated shafts may cause vibration and noise in the front door 4 Align the dupl...

Page 167: ...See photo sensors on page 7 7 for the part number 1 Remove the waste toner bottle See Waste toner bottle removal on page 4 77 2 Remove the two screws A from the cable cover 3 Pull corner of cable cov...

Page 168: ...e duplex sensor Note Close the front cover and slightly lift the front of the printer to get better access Installation notes 1 Clean the contact surface where you removed the sensor retaining plate o...

Page 169: ...d bin full narrow media sensor flag are in the same FRU and should be replaced together 1 Open the front cover 2 Press upward on the tab A to unsnap the bin full narrow media sensor flag and remove th...

Page 170: ...4 28 Service Manual 5025 2xx 4xx 4 With one hand gently pull the exit deflector towards the rear and with the other hand press to unsnap the tabs C...

Page 171: ...page 4 6 3 Disconnect the two wire fuser cable A from the LVPS 4 Position the fuser cable so that it can be pulled through from the front of the printer and guide the cable through to the front Warni...

Page 172: ...9 Unhook the springs D from both sides of the fuser Note This pulley E is not used and may not be present on the failed fuser It does not need to be removed in Lexmark C54x printers 10 Rotate the top...

Page 173: ...de make sure the gears mesh Reroute the cables back through their retainers A B When you replace a new fuser be sure to reset the Fuser Page Count 1 Enter Diagnostics Menu turn the printer off press a...

Page 174: ...en the front cover 2 Remove the right cover assembly See Right cover assembly removal on page 4 12 3 Disconnect the cable A from the fuser drive motor assembly Note If you remove the toroid B from the...

Page 175: ...ge 4 6 4 Disconnect the two wire fuser cable A from the LVPS Note You do not have to extract the cable 5 Remove the screw and grounding washer B on the right side of the frame Note Be careful not to l...

Page 176: ...serve the cable routing 9 Unhook the springs D from both sides of the fuser 10 Rotate the fuser toward the front of the printer until the screw E can be accessed and removed 11 Disconnect the cable G...

Page 177: ...7 for the part number Before you begin determine which removal instruction you need to follow 1 Remove the left cover 2 Is there a leaf spring A biasing the HVPS upward Go to High voltage power suppl...

Page 178: ...long shank Phillips screwdriver at least 8 in or 200 mm long 1 Remove the top cover assembly See Top cover assembly removal on page 4 13 2 Remove the rear shield See Rear shield removal on page 4 11 3...

Page 179: ...n notes Warning Connect the high voltage power supply HVPS cable to the high voltage power supply before sliding the board into the printer Pull the HVPS cable through the access hole and plug into th...

Page 180: ...High voltage power supply HVPS with spring 1 Remove the rear shield See Top cover assembly removal on page 4 13 2 Remove the cable cover A 3 Disconnect the high voltage power supply HVPS cable at the...

Page 181: ...nect the high voltage power supply HVPS cable to the high voltage power supply before sliding the board into the printer Pull the HVPS cable through the access hole and plug into the controller board...

Page 182: ...ee Right cover assembly removal on page 4 12 3 Remove the waste toner bottle See Waste toner bottle removal on page 4 77 4 Remove the imaging unit IU See Imaging unit IU removal on page 4 45 Note The...

Page 183: ...gear A straight out to unsnap it and then discard it A new gear is included in the spring clamp kit and must be used with the new spring clamp 2 Remove the rubber pad C 3 Place the spring clamp onto t...

Page 184: ...with or without the spring clamp kit 1 Disconnect the two springs A B from the side frames leaving the right one A attached to the ITU or ITU spring clamp 2 Rotate the left spring B and the cam away...

Page 185: ...oward the front 4 Hold the release lever as you pull out the ITU for the first four inches 100 mm but a quick firm pull should overcome the latch at this point Installation notes Write down the 16 dig...

Page 186: ...lease the buttons when the installed memory and processor speed displays 2 Select PRINTER SETUP from Diag Menu and press Select 3 Select ITU Barcode and press Select 4 To enter the 16 digit numeric va...

Page 187: ...ginal developer units in the new photoconductor and re install the imaging unit When you replace the imaging kit you are replacing both the photoconductor and the developer units 1 Open the front cove...

Page 188: ...ll the two latches until the imaging unit meets resistance 8 Press and hold the handles B on the right and left sides and pull the imaging unit straight out Note Do not wrap your fingers around the im...

Page 189: ...supply LVPS assembly removal See Low voltage power supply universal power supply on page 7 7 for the part number 1 Remove the left cover See Left cover assembly removal on page 4 6 2 Disconnect the th...

Page 190: ...ector switch C be sure to set the switch to the correct setting for your voltage requirements before installing the low voltage power supply The switch can be set for either 115 V or 230 V Failure to...

Page 191: ...left lower frames are in the same FRU Left lower frame 1 Remove the media tray and remove the screw A in front 2 Open the front cover 3 Remove the waste toner bottle See Waste toner bottle removal on...

Page 192: ...4 50 Service Manual 5025 2xx 4xx 6 Remove the two top screws B near the front holding the top cover to the LVPS shield 7 Remove the two screws C...

Page 193: ...D 9 Lift the front left corner of the top cover and pull the LVPS cage E out There are two posts at the bottom of the cage on the left side that need to be disengaged Note Be careful with the fuser e...

Page 194: ...hing the tabs together and pushing the connector into the printer 12 At the rear of the printer remove the two screws G from the AC receptacle and the ground screw H 13 Remove the two screws J holding...

Page 195: ...Repair information 4 53 5025 2xx 4xx 15 Remove the three screws K securing the left lower frame 16 Remove the screw L above the frame...

Page 196: ...4 54 Service Manual 5025 2xx 4xx 17 Swing the left lower frame away from the printer and remove...

Page 197: ...etaining plates 1 Open the front cover 2 Remove the right cover assembly See Right cover assembly removal on page 4 12 3 Remove the waste toner bottle See Waste toner bottle removal on page 4 77 4 Rem...

Page 198: ...rew C and leave the plate and antenna attached to the wireless card 9 Remove the duplex sensor See Duplex sensor removal on page 4 25 10 Remove the three screws D securing the lower right frame to the...

Page 199: ...ew E lift the right lower frame pin F out of the hole in the printer frame 13 Swing the rear part away from the printer to access the spring G and remove the spring G from the right lower frame 14 Dis...

Page 200: ...odels Remove the screw M and remove plate from your printer if it does not have a wireless antenna Installation notes 1 Reinstall the spring bracket and the wireless antenna plate or the blank plate 2...

Page 201: ...See Left cover assembly removal on page 4 6 2 Remove the LVPS shield See Left lower frame on page 4 49 for instructions on removing the LVPS shield 3 Remove the screws A on the top cover 4 Disconnect...

Page 202: ...4xx 6 Remove the two screws E from the rear 7 Remove the two screws F from below the main drive gear assembly 8 Remove the two screws G on the right of the main drive gear assembly 9 Lift the main dr...

Page 203: ...t cover assembly removal on page 4 6 3 Remove the rear shield See Rear shield removal on page 4 11 4 Disconnect the paper pick motor drive assembly cable connector A fromJSP1 on the controller board 5...

Page 204: ...ght side loosen the screw E with a screwdriver and hold the ACM in place as you use your fingers to remove the screw 9 Move the right side of the ACM out to free the shaft from the hole in the frame N...

Page 205: ...e aligns with the hole in the frame 2 Install the two springs 3 Reinstall the three screws holding the ACM to the printer 4 Turn the printer to the proper upright position 5 Reroute the cable making s...

Page 206: ...replace the paper pick tires in pairs The tires come in a package of two 1 Remove the media tray 2 Place the printer so the front edge extends over the edge of the table or desk 3 Lower the paper pic...

Page 207: ...inthead on page 7 5 for the part number 1 Remove the top cover See Top cover assembly removal on page 4 13 2 Disconnect the cables from the controller board Note Be very careful disconnecting handling...

Page 208: ...d is replaced perform the registration black planes and alignment color planes See Registration on page 3 4 and Alignment on page 3 7 Be sure to replace the toroid on the cable when you reinstall the...

Page 209: ...it IU removal on page 4 45 4 Remove the rear shield See Top cover assembly removal on page 4 13 5 Remove the rear screw A in the waste toner bottle sensor contact to allow access to the cable cover No...

Page 210: ...d at JSC1 11 Remove the cable from the retainer on the bottom of the printer 12 Extract the cable through the frame and remove the cable with the spring contacts Note To remove the cable be sure to un...

Page 211: ...install a new TDS on the left side Reinstall the thermistor on the new TDS 1 Remove the ITU See Image transfer unit ITU removal on page 4 40 2 Remove the rear shield See Top cover assembly removal on...

Page 212: ...1 16 or TPS Left 1 16 appears above a blinking 0 in the left position 4 To enter a character or digit a Press to decrease or to increase the blinking value b Pause for several seconds without pressin...

Page 213: ...embly See Right cover assembly removal on page 4 12 3 Remove the waste toner bottle See Waste toner bottle removal on page 4 77 4 Remove the imaging unit IU See Imaging unit IU removal on page 4 45 5...

Page 214: ...top cover will have to be loosened so the right edge of the top cover can be lifted to get the toner meter cycle card back into position 1 Remove the two machine screws A 2 Push in on the cover above...

Page 215: ...r screw A in the waste toner bottle sensor contact to allow access to the cable cover Note The waste toner bottle sensor contact does not need to be unplugged or removed 4 Remove the four screws B fro...

Page 216: ...in E out of the hole in the printer frame 9 Swing the rear of the lower frame away from the printer to access the tray present sensor latches 10 Remove and secure the spring F from the right lower fra...

Page 217: ...Clean the contact surface where you removed the sensor retaining plate or where you need to install the new one 2 Install the sensor Note Make sure the clips on the posts latch to the frame 3 Remove t...

Page 218: ...mbly See Right cover assembly removal on page 4 12 3 Remove the waste toner bottle See Waste toner bottle removal on page 4 77 4 Remove the rear shield See Top cover assembly removal on page 4 13 5 Re...

Page 219: ...t side Waste toner bottle removal The waste toner bottle is not a FRU 1 Open the front cover 2 Lift the toner cover by sliding the latch to the left 3 Remove the right cover assembly See Right cover a...

Page 220: ...embly See Right cover assembly removal on page 4 12 3 Remove the waste toner bottle See Waste toner bottle removal on page 4 77 4 Remove the screw A from the back of the waste toner bottle contact blo...

Page 221: ...art number 1 Remove the rear shield See Top cover assembly removal on page 4 13 2 Lift to disconnect the wireless card A from the controller board 3 Carefully disconnect the antenna cable B from the w...

Page 222: ...e through the hole in the bracket 6 If the bushing is damaged remove it by pressing the tabs on each side Note Take note of the orientation of the bushing When reinstalling place the cover upright ben...

Page 223: ...twork card assembly C544dw only on page 7 7 for the part number 1 Remove the rear shield See Top cover assembly removal on page 4 13 2 Lift to remove the wireless card A from the controller board 3 Ca...

Page 224: ...4 82 Service Manual 5025 2xx 4xx...

Page 225: ...Connector locations 5 1 5025 2xx 4xx 5 Connector locations Locations...

Page 226: ...oller ITU PC unit part of imaging unit Developers Y C M K Y M K C Controller board Toner cartridges Y C M K Printhead Output bin Exit rolls duplex entry Operator panel Bin full narrow media sensor Fro...

Page 227: ...Connector locations 5 3 5025 2xx 4xx Connectors...

Page 228: ...ller board diagram JNET1 1 JUSB1 J1 1 JCTM1 JWIN1 1 JUSBW1 1 1 JWT1 JUSBH1 1 JSC1 1 JTPS1 JOPP1 JTRAY1 1 1 1 1 JINT1 JCVR1 JFUSES1 JBIN1 1 JHVPS1 JMIRR1 1 JFAN1 JCARTB1 JSP1 JMOT1 JLVPS1 JOPT1 JTPS2 J...

Page 229: ...artridges Black drive motor rear motor even pin numbers 2 20 CMY color drive motor odd pin numbers 1 19 1 CART1_HALL_U 2 NC_CARTB1_2 3 CART1_HALL_V 4 V_CART2_WING_W 24 V dc 5 CART1_HALL_W 6 V_CART2_WI...

Page 230: ...R_BUR_THM_RTN ground 12 Ground no wire JHVPS1 Developer transfer HVPS 1 M_DEV_PWM_OUT 2 K_DEV_PWM_OUT 3 C_DEV_PWM_OUT 4 CMY_CHG PWM_OUT 5 Y_DEV_PWM_OUT 6 K_CHG_PWM_OUT 7 CMY_SRVO_OUT 3 3 V dc 8 ITM_TX...

Page 231: ...ound JMIRR1 Mirror motor connector 1 MM_REFR 2 MM_LOCK 3 3 V dc 3 MM_START 4 Ground 5 24 V dc JOPP1 Operator panel connector 1 I2C_DATA 2 V_PANEL 5 V 5 V dc 3 I2C_CLK 4 Ground 5 OP_IRQ_N 4 5 V dc 6 3...

Page 232: ...O_LEN0 3 3 V dc 5 VDO_BOOST3 6 3 3 V dc 7 VDO_BOOST1 8 5V_PH 5 V dc 9 VDO_BOOST2 Shade B 10 5_PH 5 V dc 11 VDO_BOOST0 12 Ground 13 D_VDO_7 14 D_VDO_7 1 5 V dc 15 Ground 16 D_VDO_3 1 5 V dc 17 D_VDO_3...

Page 233: ...O_4 33 Ground 34 D_VDO_0 35 D_VDO_0 36 Ground 37 I2CCLK_PH 38 VDO_LADJ1 3 3 V dc 39 I2CDATA_PH 40 VDO_LADJ0 3 3 V dc JSC1 SC cartridge 1 3 3 V dc 2 DATA_SC 3 3 V dc 3 SCK_SC 4 Ground Controller board...

Page 234: ...ANODE 15 5 V dc 16 Ground JTHM1 TPS therm connector 1 TPS_THERM_SNS 1 5 V dc 2 TPS_SNS_RTN ground JTPS1 TPS1 connector 2 ANODE 1 CATHODE 3 Ground no wire 4 5V_SW 5 Ground JTPS2 TPS2 connector 1 ANODE...

Page 235: ...und 5 5 V dc 6 3 3 V dc JWT1 Waste toner detection 1 SENSE 2 VREF 3 1 5 V dc 4 Ground no wire Controller board connectors continued Note SW indicates voltage is switched on during a print cycle otherw...

Page 236: ...5 12 Service Manual 5025 2xx 4xx High voltage power supply HVPS diagram...

Page 237: ...Connector locations 5 13 5025 2xx 4xx Low voltage power supply LVPS diagram...

Page 238: ...5 14 Service Manual 5025 2xx 4xx Toner meter cycle TMC card Wireless network card...

Page 239: ...s Use of lubricants other than those specified can cause premature failure Some unauthorized lubricants may chemically attack polycarbonate parts Use IBM no 10 oil P N 1280443 Approved equivalents Mob...

Page 240: ...6 2 Service Manual 5025 2xx 4xx...

Page 241: ...that the part is procurable but is not pictured in the illustration PP Parts Packet in the parts description column indicates the part is contained in a parts packet Model information used in the part...

Page 242: ...7 2 Service Manual 5025 2xx 4xx Assembly 1 Covers 4 3 1 10 6 5 8 7 2 9...

Page 243: ...ck tires 6 40X5430 1 1 Front cover assembly including duplex and USB port cable C543dn C544dn C544n C546dtn 6 40X5420 1 1 Front cover assembly excluding duplex and USB port cable C540n 7 40X5431 1 1 O...

Page 244: ...7 4 Service Manual 5025 2xx 4xx Assembly 2 Frames 5 2 4 7 6 1 3 8 9 3 10...

Page 245: ...ITU Front Hold Down 1 Front Cover Latch Spring 2 M3 x 6 panhead 2 M3 x 6 Shoulder 1 M3 5 X 5 flathead Plastite 1 METAL ROLN M3 5 8L 2 PLAST ROLN 2 9 8L 2 PLAST ROLN 3 5 6L 4 5 40X2263 Duplex referenc...

Page 246: ...7 6 Service Manual 5025 2xx 4xx Assembly 3 Electronics 2 4 6A 5 1 6B 7 8 6C 3 9...

Page 247: ...0X5413 1 1 Fuser exit sensor 9 40X1766 1 1 Power cord 2 5M straight USA Canada Bolivia Peru shown 9 40X0288 1 1 Power cord 2 5M straight Argentina 9 40X0301 1 1 Power cord 2 5M straight Australia 9 40...

Page 248: ...7 8 Service Manual 5025 2xx 4xx Assembly 4 Cables...

Page 249: ...contact block 4 40X5421 4 4 Toner cartridge contacts Pogo pin 5 40X5423 1 1 Cable packet used for A Fuser exit narrow media to controller board B Fuser motor thermistor and duplex sensor to controller...

Page 250: ...7 10 Service Manual 5025 2xx 4xx Assembly 5 Media drawers and trays 1 3 2 4 2...

Page 251: ...34 drawer assembly see illustration and table below 3 40X2285 1 1 650 sheet Duo Drawer tray assembly C546dtn includes 100 sheet MPF using four wear strips Note Use only with P N 40X2284 drawer assembl...

Page 252: ...t fuser ITU duplex reference edge NS 40X5937 1 1 128MB DDR DRAM DIMM card assembly NS 40X5938 1 1 256MB DDR DRAM DIMM card assembly NS 40X5939 1 1 512MB DDR DRAM DIMM card assembly NS 40X1455 1 1 64MB...

Page 253: ...1 5 CMYK color 3 49 code updating 3 28 color conversion tables 3 50 color correction manual 3 50 color samples 3 51 color theory 3 49 Color Trapping 3 24 configuration ID 3 19 configuration menu acces...

Page 254: ...ings 3 2 TPS Setup Cal Ref Adj 3 21 Left 3 21 Reset Color Cal 3 21 Right 3 21 diagram menu 2 56 DRAM Test 3 12 duplex duplex reference edge removal 4 22 duplex sensor 2 25 4 25 Left Margin 3 14 models...

Page 255: ...e 4 59 MP feeder parts catalog 7 10 N name plate parts catalog 7 2 removal 4 8 O operating modes 1 4 operator panel buttons 2 55 overview 2 55 parts catalog 7 2 removal 4 10 service check 2 33 display...

Page 256: ...me 4 49 low voltage power supply LVPS 4 47 main drive gear assembly 4 59 narrow media sensor flag 4 27 paper pick motor drive assembly 4 61 photoconductor unit 4 45 pick tires 250 sheet media tray 4 6...

Page 257: ...s print quality test pages 3 11 3 24 Quick Test 3 5 Quick Test duplex 3 13 theory color theory 3 49 duplex process 3 48 EP process 3 37 paper path 3 46 transport components 3 46 toner cartridge contac...

Page 258: ...I 6 Service Manual 5025 2xx 4xx...

Page 259: ...V Maintenance kit 6 1 7 12 40X2255 230 V Maintenance kit 6 1 7 12 40X2261 100 V Maintenance kit 6 1 7 12 40X2263 Duplex reference edge 7 5 40X2268 Controller board C546dn only 7 7 40X2284 Optional 650...

Page 260: ...e plates 7 3 40X5433 Exit deflector and bin full narrow media sensor flag 7 5 40X5434 Optional 650 sheet Duo Drawer complete C544n C544dn C544dw C540n C543dn 7 11 40X5435 650 sheet Duo Drawer tray onl...

Page 261: ...lines The line that best matches the defects on the print job indicates which particular part may be causing the defect For example the distance between these two marks represents a repeating defect t...

Page 262: ......

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