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Lexmark C540n, C543dn, C544n, and C546dtn 5025 Service Manual

Contents

1. 4 44 Service Manual 5025 2xx 4xx Imaging unit IU removal The imaging unit is customer replaceable unit and is not a FRU Note The imaging unit contains e Photoconductor unit e Developer units To remove only the photoconductor remove the entire imaging unit remove the developer units place the original 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 Open the front cover Lift the toner cover by sliding the latch to the left Remove the right cover assembly See Right cover assembly removal on page 4 12 Remove the waste toner bottle See Waste toner bottle removal on page 4 77 Remove the toner cartridges Lift the two latches A to unlock the imaging unit STAN Repair information 4 45 5025 2xx 4xx 7 Pull 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 imaging unit Avoid touching the bottom 4 46 Service Manual 5025 2xx 4xx Low voltage power 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. 7 12 512MB DDR DRAM DIMM card assembly 7 12 Korean font card assembly 7 7 7 12 Simplified Chinese font card assembly 7 12 Traditional Chinese font card assembly 7 12 Japanese font card assembly 25 63 eo eee en eee ete ese ee ee eee eS ees 7 12 Waste toner bottle contact block o 7 9 l 8 Service Manual Print defects guide Page 1 of 1 Match a set of repeating defects on a print job to the marks on one of the vertical 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 Replace the jaa we marks represents a repeating defect that photoconductor occurs every 34 6 mm 1 4 in which means 94 2 mm 95 mm the photoconductor unit may need to be 3 71 in 3 74 in replaced Replace the Note If the defect appears on the printed ITU side of a single sided print job replace the 78 5 mm toner cartridge before replacing the fuser 3 1 in Replace the ITU 55 mm 2 2 in Replace the developer 43 9 mm Replace the 1 7 in ITU Replace the 37 7 mm photoconductor 1 5 in 34 6 mm 1 4 in C54x C54xn E E E n Printhead i
3. 7 7 Controller board C540n C543dn 2 errr rere reer errr renee 7 7 Optional 550 sheet drawer complete C546dtn only 7 11 Paper pick motor drive assembly rrr rrr rrr rr rr rrr errr eee 7 5 Power cord 2 5M straight USA Canada Bolivia Peru 7 7 Power cord 2 5M straight Switzerland 7 7 Power cord 2 5M straight South Africa gt 7 7 Power cord 2 5M straight Taiwan 7 7 Power cord 2 59M straight Kor a lt lt lt 2 20 2 a ee cee see See ees 7 7 115 V Maintenance kit 6 1 7 12 230 V Maintenance kit 6 1 7 12 100 V Maintenance kit 2s e ree ere te er ree ere teeter eee 6 1 7 12 DUDIEXTCICIGNCeCOGG Sa oe tenets tae o eee de A ene eae a e 7 5 Controller board C546dn only eee 7 7 Optional 650 sheet Duo Drawer complete C546dtn only 7 11 650 sheet Duo Drawer tray assembly C546dtn only 7 11 SOU SNGCLIMIPEJAICh COVE A ee eee ee ee eee ees 7 11 Name plate C546din lt 2 38 eens eee enn ene ee ee eee 7 3 Power cord 2 5M straignt Paraguay
4. 7 7 7 Power cord 1 8M straight Brazil 7 7 Wireless network card assembly C544dw only 7 7 PICK tires A 7 3 7 11 Antenna for wireless card C544dw only 7 7 image transier nit MU assembly e 2 ta a ii e e 7 5 Toner meter cycle card assembly mea a a ee RR RR Re el eR 7 7 High voltage power supply enan e E e rrr rrr rrr rrr a a Ea 7 7 USO assembly TIS V AAAA a O AS AA a leis 7 5 FUSE ASSeMDN 230 sta a ee a 7 5 USB assembly 1001 0 e A A 7 5 Low voltage power supply universal power supply 7 7 Printhead A a a 7 5 Main drive gear assembly with motors 7 7 5 FUSEEOCXIIGCNSOl ers s aa ata eee a A A O eee eee eee eee eae ae 7 7 Toner density Sensors leitor NOM 3 8 22 1202152221520 rte 7 9 F ser drive motor assembly anses A A 7 5 PUIOMECOVE assembly se es er Dan SRA A a 7 3 ECIVGOVElrASSeMDIy Sasa reat pra a a o o A erate 7 3 WPCC VEE assembly 2 52 22292 o a A a a 7 3 2o sheet Way aSSseniDly tas ob A A A eee eee es 7 3 Front cover assembly excluding duplex and USB port cable C540n 7 3 Part number index l 7 5025 2xx 4xx 40X5421 40X5422 40X5423 40X5424 40X5425 40X5426 40X5429 40X5430 40X5431 40X5432 40X5433 40X5434
5. Engine Setting 1 through 4 Warning Do not change these settings unless requested to do so by your next level of support Model Name The model name can only be viewed and cannot be changed 3 18 Service Manual 5025 2xx 4xx Configuration ID The two configuration IDs are used to communicate information about certain areas of the printer that cannot be determined using hardware sensors The configuration IDs are originally set at the factory when the printer is manufactured However the servicer may need to reset Configuration ID 1 or Configuration ID 2 whenever the system board is replaced The IDs consist of eight digits The first seven digits in each ID are hexadecimal numbers while the last digit is a checksum of the preceding seven digits Each ID can contain a combination of the digits 0 through 9 and A through F Note When the printer detects a Configuration ID that is not defined or invalid the following occurs e The default standard model Configuration ID is used instead e Configuration ID is the only function available in the Diagnostics Menu e Unless the menu is in the Diagnostics Menu Check Config ID displays To set the configuration ID 1 Select Printer Setup from Diag Menu and press Select 2 Select Configuration ID and press Select The current value for Configuration ID 1 is displayed 3 Enter the Configuration ID 1 e Change the left character or digit first e To change the
6. G 14 Disconnect the cable H from the tray present sensor Repair information 4 57 5025 2xx 4xx 15 16 17 Swing the rear of the lower frame away from the printer and remove the right lower frame Note There are parts in the right lower frame that are not included in the frame The following instructions show how to remove them Remove the sensor retaining plate J and pinch the latches K together to remove the tray present sensor Remove the screw L and remove the spring bracket Note For non wireless models Remove the screw M and remove plate from your printer if it does not have a wireless antenna Installation notes 1 2 3 4 Reinstall the spring bracket and the wireless antenna plate or the blank plate Clean the contact surface where you removed the sensor retaining plates or where you need to install the new ones Install the sensors Remove the backing from the new plate and place the plates A on the surfaces between the sensor mounting posts Note Make sure the clips on the posts latch to the metal frame 9 A Connect the cable to the tray present sensor and place the spring in place before installing the right lower frame 4 58 Service Manual 5025 2xx 4xx Main drive gear assembly removal A 1 Remove the left cover See Left cover assembly removal on page 4 6 2 Remove the LVPS shield See Left lower frame on page 4 49 for instruct
7. Open the front cover Remove the right cover assembly See Right cover assembly removal on page 4 12 Remove the waste toner bottle See Waste toner bottle removal on page 4 77 Remove the imaging unit See Imaging unit IU removal on page 4 45 Remove the rear 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 Remove the four screws B securing the cable cover Note The cable cover is part of the right lower frame FRU SS PEA 1 eu Er Y A pa a pee e T E all al y j ik wi l i ee i ME ki jl qe 6 N i de 4 arr Ne a me i a i Bee E i x 7 Carefully place the printer on its left side Repair information 4 55 5025 2xx 4xx 8 For wireless models Remove the screw C and leave the plate and antenna attached to the wireless card C 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 printer 11 Remove the screw E closer to the front of the printer 4 56 Service Manual 5025 2xx 4xx 12 Next to screw 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
8. Universal 148 x 210mm to Y x 216 x 356mm 5 8 x 8 3 in to 8 5 x 14 in 76 x 127mm to Y x 216 x 356mm 3 x 5 in to 8 5 x 14 in 210mm x 279 4mm to 216mm x 356mm 8 27 in x 11 in to 8 5 in to 14 in 734 Envelope 98 x 191mm 9 Envelope 10 Envelope 105 x 241mm 4 12 x 9 5 in DL Envelope 110 x 220mm 4 3 x 8 7 in C5 Envelope 162 x 229mm 6 4 x 9 in B5 Envelope Other envelope Length 98 432mm 3 8 17 in Width 89 297mm 3 5 11 7 in EEEO gt gt E SERENE E a The MP feeder runs slower if A5 Statement B5 A6 Executive Statement Universal narrower than 210mm or envelopes are loaded Japanese Industry Standard Although the user may select Universal paper size for these sources not all tray guides can be adjusted to all Universal media sizes 1 10 Service Manual 5025 2xx 4xx Media input type specifications Supported X Not supported Input type 250 sheet tray Optional 650 sheet Duo Drawer Optional 550 sheet drawer model C546dtn only MP feeder in 650 sheet Duo Drawer Plain paper Card stock Transparency Recycled Glossy Paper backed labels Bond Envelopes Rough envelopes Letterhead Preprinted Colored paper Light paper Heavy paper Rough or cotton Custom type lt x gt a Lo 2 c E AM AA Eat E A E AA IE GAAL IA E A ee e Ea O EIA E A AE LAIA AAA E ee SA IA O se ee
9. 5 or Stop ma Skew One printhead houses the four color planes The black plane is aligned to the printer and the other color planes are internally aligned to black Electronic alignment fine tunes the alignment of the color planes to the black plane once the printhead is installed See Alignment on page 3 7 for instructions on setting printhead alignment This must be performed before color skew adjustment is attempted The following illustration shows proper alignment versus skewed alignment Straight Skewed Quick Test The Quick Test contains the following information e Print registration settings e Alignment diamonds at the left right top and bottom e Horizontal lines to check for skew Diagnostic aids 3 5 5025 2xx 4xx e General printer information including current page count installed memory serial number and code level ZA lermart CEIT Duck Fest Device loformation MARGIN SETTINGS Prove eras arado 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 v 2 Select Quick Test Page
10. Do you have a symptom rather than an error message Locate your symptom and take the appropriate action Printer symptom table on page 2 3 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 customer attendance messages on page 2 5 Paper Jam messages on page 2 11 Paper jams on page 3 31 Service checks on page 2 22 for individual error messages Additional information can be found at the following locations User operator panel and Administration menus on page 2 55 Theory of operation on page 3 37 Diagnostic information 2 1 5025 2xx 4xx POR Power On Reset sequence The following is an example of the events that occur during the POR sequence for the base machine with no paper handling options installed When you turn the printer on it performs a Power On Self Test Check for correct POST functioning of the base printer by observing the following The LED turns on The main fan turns on The operator panel turns on A partial row of pixels appears The operator panel display clears Another row of pixels appears The operator panel display clears again The operator panel displays system information For example 128MB 500Mhz 9 The fuser turns on The fuser takes longer to warm up from a cold start than a warm start 10
11. Replace the HVPS See High voltage power Problem resolved Go to step 8 supply HVPS assembly removal on page 4 35 Does this fix the problem Clean the printhead Problem resolved Replace the printhead See Printhead removal on 1 In Ready mode press Menus 2 Select Reports and press Select y 3 Select Device Statistics and press Select y It is possible a new imaging unit was installed but the counter was not reset 7 Does this fix the problem page 4 65 Diagnostic information 2 41 5025 2xx 4xx Print quality blank page Step Questions actions No Is all the packing material for the imaging unit Go to step 2 Remove the packing in question removed material Print a document that requires all four colors Replace the developer unit Go to step 3 with just a few characters to verify if one for the missing color specific color is a problem For example print the Print Quality Test Pages 1 Enter Diagnostic mode Turn the printer off press and hold Left 4 and Select y turn the printer on and then release the buttons when the installed memory and processor speed displays 2 Select PRINT TESTS and press Select y 3 Select Prt Qual Pgs and press Select y Is only one color missing Replace the imaging unit See Imaging unit Problem resolv
12. to cancel printing Printer does not detect media meeting the size requested in the source indicated e Load the input source with the correct type and size media e Press Stop MM and then press Select to cancel printing Diagnostic information 2 5 5025 2xx 4xx Bee primary Explanation message Load lt source gt Printer does not detect media meeting the size or type requested in the source lt type gt lt size gt indicated e Load the input source with the correct type and size media e Press Stop gg and then press Select y to cancel printing Load single sheet Printer does not detect media meeting the description lt custom type name gt in the feeder with single sheet feeder SC USO Penang The following actions can be taken e Load paper press Select v and the job continues e Press Select to override the source and an alternate source for media is selected Press Stop MM and then press Select yj to cancel printing Define a name for each custom type Custom 1 6 using the MarkVision utility When the printer is prompting for one of the custom types which has been named then only the custom name is displayed Load single sheet Printer does not detect media meeting the description lt custom string gt in the single feeder with sheet feeder CUM sting The following actions can be taken e Load paper an
13. 1 Grasp the front door at the side handholds and pull it toward you to open it 2 Remove the jam 3 Close the front door 4 Press Select y to continue printing 235 paper jam Load the tray with the correct paper size supported for duplex Insert the tray Close the front door Press Select y to continue printing Pen gt 241 paper jam in primary tray Remove the primary tray Remove the jam Check the tray adjustments for the size of paper used Check the pick tires for foreign material or wear Replace if necessary See Pick tires removal on page 4 64 Close the primary tray Press Select x to continue printing oo PONS 242 paper jam in the 650 sheet Duo Drawer 1 Remove the 650 sheet duo tray tray 2 2 Remove the jam Note Make sure all paper fragments are removed Check the tray adjustments for the size of paper used Check the pick tires for foreign material or wear Replace if necessary See Pick tires removal on page 4 64 Close the primary tray Press Select to continue printing Note Make sure all paper fragments are removed Align the tray and insert it Press Select yj to continue SIA Py p Diagnostic aids 3 35 5025 2xx 4xx 243 paper jam in the 550 sheet drawer Remove the 550 sheet tray tray 3 Remove the jam Note Make sure all paper fragments are rem
14. Go to Main drive gear assembly EP drive service check on page 2 30 Go to Main drive gear assembly EP drive service check on page 2 30 Go to Main drive gear assembly EP drive service check on page 2 30 Go to Main drive gear assembly EP drive service check on page 2 30 Go to Main drive gear assembly EP drive service check on page 2 30 Go to Main drive gear assembly EP drive service check on page 2 30 Go to Main drive gear assembly EP drive service check on page 2 30 5025 2xx 4xx Service error messages 1xx 9xx continued E E IS Go to Main drive gear assembly EP 150 07 Service Motor stalled in time based Black ITU cartridge commutation Motor drive service check on page 2 30 152 xx Service Go to Main drive gear assembly EP CMY Cartridge Motor drive service check on page 2 30 152 01 Service Failed to achieve lock for motor within Go to Main drive gear assembly EP CMY Cartridge Motor allotted time drive service check on page 2 30 152 02 Service Timeout waiting for SAP BLDC motor Go to Main drive gear assembly EP CMY Cartridge Motor to reach valid FG speed drive service check on page 2 30 152 03 Service Timeout waiting for Go to Main drive gear assembly EP CMY Cartridge Motor MP_NUM_INITIAL_SAP_HALLS drive service check on page 2 30 152 04 Service Timeout waiting for SAP BLDC motor Go to Main
15. 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 A 4 38 Service Manual 5025 2xx 4xx 4 Remove the screw C securing the HVPS C 5 Press down on the spring mount and carefully slide the HVPS out Release the pressure on the spring mount when the LVPS slides out about 25mm Installation notes CAUTION After disconnecting the high voltage power cable from the controller board always check that the HVPS connection was not loosened Make this check anytime you are working near the HVPS cable Warning Connect the high voltage power supply HVPS cable to the high voltage power supply before sliding the board into the printer Pull the HVPS cable through the access hole and plug into the controller board Be careful not to dislodge the cable from the HVPS Repair information 4 39 5025 2xx 4xx Image transfer unit ITU removal See Image transfer unit ITU assembly on page 7 5 for the part number 1 Write down the number of the new ITU before installing it You will need the 16 digit numeric value from the barcode after the installation and it is easier to see at this point 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 Remove the imaging unit IU See
16. Print Log on page 3 22 Clear Log see Clear Log on page 3 23 This selection exits the Diagnostics Menu The printer performs a POR and returns to normal mode Registration Print registration makes sure the black printing plane is properly aligned on the page This is one of the steps in aligning a new printhead See Alignment on page 3 7 It is also the first step in aligning the duplex registration See Quick Test duplex on page 3 13 To set print registration 1 Select Registration from the Diag Menu and press Select y 2 Use q or p to select Print Quick Test and press Y See Quick Test on page 3 5 for additional information The message Printing appears on the display and the page prints Retain this page to determine the changes you need to make to the margin settings 3 Press Select y to enter the Registration 4 Use q or p to select the margin setting you need to change and press Select v 9 Use q to decrease or p to increase the offset values and press Select v to confirm the value The message Submitting changes displays and the original margin setting screen appears The print registration ranges are Top margin 50 to 50 A positive change moves the image down the Each increment corresponds to 8 page and increases the top margin A negative change moves the image up and decreases scans a
17. e Press Select x to clear the message and continue printing e Order the waste toner bottle so it will be available when the replacement message is displayed Once the replacement message is displayed the printer will not continue until the waste toner is replaced 2 10 Service Manual 5025 2xx 4xx al Explanation message 88 xx lt color gt The term lt color gt includes black cyan magenta and yellow Replace the toner Cartridge is low cartridge and then close the toner door to clear the message and continue printing 88 Replace lt color gt The term lt color gt includes black cyan magenta and yellow Replace the toner Cartridge cartridge and then close the toner door to continue printing Paper Jam messages Paper jam messages 2xx O e 200 xx Paper Jam Check lt area gt or 200 xx Paper Jam lt x gt Pages Jammed 201 xx Paper Jam Check lt area gt or 201 xx Paper Jam lt x gt Pages Jammed 202 xx Paper Jam Check lt area gt or 202 xx Paper Jam lt x gt Pages Jammed 230 xx Paper Jam Check lt area gt or 230 xx Paper Jam lt x gt Pages Jammed 235 xx Paper Jam Check Duplex 241 xx Paper Jam Check lt area gt or 241 xx Paper Jam lt x gt Pages Jammed 242 xx Paper Jam Check lt area gt or 242 xx Paper Jam lt x gt Pages Jammed A single page of media jam at the input S2 sensor Multiple pages of media are jammed at the input sensor A single pag
18. 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 r i USA certifierad att motsvara kraven i DHHS 21 CFR underparagraf J f r laserprodukter av Klass 1 andra l nder uppfyller skrivaren kraven f r laserprodukter av Klass enligt kraven i IEC 60825 1 Laserprodukter i Klass anses ej h lsov dliga Skrivaren har en inbyggd laser av Klass lllb 3b som best r av en laserenhet av gallium arsenid p 5 milliwatt som arbetar i v gl ngdsomr det 645 670 nanometer Lasersystemet och skrivaren r utformade s att det aldrig finns risk f r att n gon person uts tts f r laserstr lning ver Klass l niv vid normal anv ndning underh ll som utf rs av anv ndaren eller annan f reskriven service tg rd Laser melding Skriveren er godkjent i USA etter kravene i DHHS 21 CFR underkapittel J for klasse 1 laserprodukter og er i andre land godkjent som et Klasse l laserprodukt i samsvar med kravene i IEC 60825 1 Klasse l laserprodukter er ikke betrakte som farlige Skriveren inneholder internt en klasse IIIb 3b laser som best r av en gallium arsenlaserenhet som avgir str ling i b lgelengdeomr det 645 670 nanometer Lasersystemet og skriveren er utformet slik at personer aldri utsettes for laserstr ling ut over klasse l niv under vanlig bruk vedlikehold som utf res av brukeren eller foreskrevne serviceop
19. on page 4 9 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 conductors indicate continuity Check the operator panel USB cable for Replace the controller continuity board See Controller board removal on Is there continuity page 4 20 2 38 Service Manual Replace the controller board See Controller board removal on page 4 20 Replace the front cover assembly See Front cover assembly removal on page 4 2 Replace the USB port connector USB port connector removal on page 4 76 5025 2xx 4xx Paper pick motor drive assembly service check Note The input S2 sensor is part of the paper pick motor drive assembly and is not available separately Turn the printer off and then remove the rear Go to step 3 Properly connect the cables shield See Top cover assembly removal and POR the printer on page 4 13 Check the cable at JSP1 on the Coto sion controller board for proper connection EMO RIEL Is the cable properly connected Did the printer function correctly after Problem resolved Go to step 3 reconnecting the cables Turn the printer on and then verify the Replace the paper pick Replace the controller following approximate values at JSP1 motor drive assembly See board See Controller Paper pick motor drive board removal on JSP1 assembly removal page 4 20 standar
20. 2 Disconnect the three cables A from the LVPS A 3 Remove the seven screws B Repair information 4 47 5025 2xx 4xx 4 Remove the LVPS If you receive a new low voltage power supply with a voltage selector 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 do so could result in damage to the power supply Note If there is no switch the LVPS automatically senses the line voltage Warning 4 48 Service Manual 5025 2xx 4xx Lower frame removal right and left See Lower left frame and lower right frame with cable cover on page 7 5 for the part number The right and left lower frames are in the same FRU Left lower frame 1 Remove the media tray and remove the screw A in front A Open the front cover Remove the waste toner bottle See Waste toner bottle removal on page 4 77 Remove the imaging unit See Imaging unit IU removal on page 4 45 Remove the low voltage power supply See Low voltage power supply LVPS assembly removal on page 4 47 are Repair information 4 49 5025 2xx 4xx 6 Remove the two top screws B near the front holding the top cover to the LVPS shield KA ay ay Ez Ez E Ey b 1 7 Remove the two screws C 4 50 Service Manual 5025 2xx 4xx 8
21. 4xx Operator panel displays all diamonds five beeps Turn the printer off and remove the rear Go to step 2 Replace the controller shield See Top cover assembly removal board See Controller on page 4 13 board removal on page 4 20 Turn the printer on and verify the following values at JOPP1 Pin Value aove 2 sve s ove Ea EN 6 Are all these values approximately correct Check for continuity in the operator panel Replace the operator panel Replace the front cover cable connector See Operator panel logo assembly See Front plate on page 4 9 cover assembly removal Note Remove the three screws holding the on page 4 2 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 conductors indicate continuity Diagnostic information 2 37 5025 2xx 4xx Operator panel display is dim and unchanging Turn the printer off and remove the rear Go to step 2 shield See Top cover assembly removal on page 4 13 Turn the printer on and verify the following values at JOPP1 on the controller board JOPP1 Value a Joves e feve 3 0 V dc 4 Ground NN 5 V de 6 3 3 V de Ground Are all these values approximately correct Check for continuity in the operator panel Replace the operator panel cable connector See Operator panel logo Note Remove the three screws holding the plate
22. Are all these values approximately correct Turn the printer off and check for continuity in Replace the operator panel Replace the front cover the operator panel cable See Operator panel logo assembly See Front plate on page 4 9 cover assembly removal Note Remove the three screws holding the on page 4 2 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 conductors indicate continuity Diagnostic information 2 35 5025 2xx 4xx Operator panel displays all diamonds no beeps Turn the printer off and remove the rear Go to step 2 Replace the controller shield See Top cover assembly removal board See Controller on page 4 13 board removal on Disconnect the cable at JOPP1 on the page 4 20 controller board Verify the following values Pin Value aove 2 sve s avd a Ground s eve Ps rasva Are all these values approximately correct Check for continuity in the operator panel Replace the operator panel Replace the front cover cable connector See Operator panel logo assembly See Front Note Remove the three screws holding the plate on page 4 9 cover assembly removal operator panel and place it facedown on top of On pagers the printer The cable connector pins will be exposed and easier to contact Do all the conductors indicate continuity 2 36 Service Manual 5025 2xx
23. Electrostatic Discharge Field Replaceable Unit Gigabyte High Voltage Power Supply Image Transfer Unit Imaging Unit Japanese Industry Standard Black Light Amplification by Stimulated Emission of Radiation Liquid Crystal Display Light Emitting Diode Low Voltage Power Supply Magenta Multipurpose Feeder also MP feeder Nonvolatile Random Access Memory Photoconductor Picture elements same as pel Power On Reset Power On Self Test Pulse Width Modulation Raster Imaging Processor Read Only Memory Synchronous Dual Random Access Memory Single Inline Memory Module Toner Density Sensor see Toner Patch Sensor Toner Patch Sensor also referred to as Toner Density Sensor Volts alternating current Volts direct current Yellow 5025 2xx 4xx 2 Diagnostic information Start CAUTION Unplug power cord from the electrical outlet before you connect or disconnect any cable or electronic board or assembly for personal safety and to prevent damage to the printer Disconnect any connections between the printer and PCs peripherals Begin here to locate the service error code user status message user error message symptom table service checks and diagnostic aids in this chapter to determine the corrective action necessary to repair a malfunctioning printer They will lead you to solutions or service checks including use of various tests Does the POR stop Check the POR Power On Reset sequence on page 2 2
24. High voltage power supply HVPS with spring 0 cc eee ees 4 38 vi Service Manual 5025 2xx 4xx Image transfer unit ITU removal 0ocococcoc es 4 40 imaging UE UU TIBIO VAL 4 rai pas a A A A A A RA A 4 45 Low voltage power supply LVPS assembly removal 00 cc eee eee ee ees 4 47 Lower frame removal right and left rar ARENA eee Rhee ee Hees 4 49 Be PRG servira tir ri ire 4 49 sio o A o 4 55 Main drive gear assembly removal ooooooooooooonnnn 4 59 Paper pick motor drive assembly removal standard tray oooooooooommmo 4 61 PICK NGS TOOL score ari AA AA ood es 4 64 Pree IRMA cr nc oo o e A RR ER RIA RRA AAA 4 65 TOROS cariridge contacts mcr ARA A da AA RARA IRA 4 67 Toner density sensor TDS removal left or right Sensor coooccccooonno oo 4 69 Toner meter cycle TMC card removal 0 ooooooooconr es 4 71 Tray present sensor removal vicio RR ROS RRA Re ee Ke Ode 4 73 USB port connector removal socked ce deh ri A RAR de ee RP ROS 4 76 Waste toner bottle remOVal s1 ccscccseeee sete rr rr AAA 4 77 Waste toner bottle contact block removal 000 cece eee 4 78 Wireless network antenna removal 0000s eee 4 79 WII S IO INOCENCIA ERAS 4 81 Connector locati0NS ooooooccccooococor e teen een nen es 5 1 Lo 2eveiearenn ees eae sae A Guess euRedaeaas 5 1 A 465 0 recor ov E 5 3 Controler UGA GAGs errar seer ares oS e ened
25. If it is then replace the entire kit See Imaging unit IU removal on page 4 45 If the counter is below 250 000 cycles replace only the photoconductors 32 xx Replace Remove the specified cartridge replace with a supported cartridge and close the Unsupported lt color gt front cover Cartridge 34 Short paper Press Select to clear the message and continue printing The printer does not automatically 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 requesting the correct size of paper Adjust the Paper Size setting for the size paper you are using If MP Feeder Size is set to Universal make sure the paper is large enough for the formatted data Press Stop M and then press Select yj to cancel printing 35 Insufficient This message displays when the printer lacks sufficient memory to enable Resource memory to support Save This message usually indicates the user has allocated too much memory for Resource Save one or more of the printer link buffers however modification of other printer settings feature which affect the amount of available memory may also create this condition If restoration of Resource Save is required after this message is received the customer should install additional memory or set each link buffer to Auto Once all link buffers are returned to Auto you should exi
26. Media handling on page 1 8 Make 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 gt General settings gt Print Recovery gt Jam Recovery Check the narrow media sensor cable is correctly connected at the sensor and the cable is correctly connected to JBIN1 on the controller board Diagnostic information 2 3 5025 2xx 4xx Print quality symptom table Symptom Background Blank page Blurred or fuzzy print Color matching problems Half color page Horizontal banding Horizontal line Insufficient fusing Light print on solids Missing image at edge Mottle 2 5mm speckles Go to Print quality background on page 2 41 Go to Print quality blank page on page 2 42 Go to Print quality blurred or fuzzy print on page 2 43 See Color theory on page 3 49 Go to Print quality half color page on page 2 43 Go to Print quality horizontal banding on page 2 44 Go to Print quality horizontal line on page 2 44 Go to Print quality insufficient fusing on page 2 45 See Media guidelines on page 1 12 Go to Print quality missing image at edge on page 2 45 Go to Print quality mottle 2 5mm speckles on page 2 45 Narrow vertical line Go to Print quality narrow vertical line on page 2 46 Go
27. The operator panel LED starts blinking 11 The following errors or messages may appear e Close Door or Insert Cartridge displays if the upper front cover is open or the print cartridge is missing e Any cartridge errors such as Defective Cartridge or Missing Cartridge 12 Ready appears on the display 13 The main drive motor turns on 14 The EP drive assembly drives the developer shaft located in the toner cartridge 15 The printer calibrates Sea Se NS 2 2 Service Manual Symptom tables Printer symptom table 5025 2xx 4xx Dead printer Go to Dead printer service check on page 2 24 Operator panel one or more buttons do Go to One or more operator panel buttons fail on not work page 2 33 Operator panel display is blank Go to Operator panel display blank five beeps on page 2 34 Operator panel continuously displays all Go to Operator panel displays all diamonds no beeps on diamonds and does not complete POST page 2 36 Operator panel display is dim and Go to Operator panel display is dim and unchanging on unchanging page 2 38 Pages print blank after replacing the controller board Tray linking does not work Unexpected page breaks occur Multipurpose feeder has constant misfeeds or jams Page that jammed does not reprint after you clear the jam Printing speed reduced for more than 10 pages May happen after a service call When replacing the controller board ver
28. Z 0 a Current New Current New Cyan Cyan Cyan Cyan T value T value Z value Z value STEP 1 Adjust the Top T margin and Skew Z then confirm before going to Step 2 sts Press the up or down buttons until a check appears at the setting in need of adjusiment ak a od Press Select Then use the lt and gt buttons to enter the new value Press Select to save EA NOTE If the alignment values cannot be determined by using the fine adjustment i scales then use the coarse adjustment scales at the top of the page STEP 2 Go to the next page to adjust he Left L margin Right R margin and Bow P STEP 3 Reprint these pages to confirm final settings Go To Step 2 Diagnostic aids 3 7 5025 2xx 4xx 4 Select Top Margin and press Select v 5 Select the best choice for fine or coarse adjustment in Step 1 first page and add it to the current value for the Top Margin Top T Coarse Adjustment If the alignment is not close enough to use the fine adjustment get close to the ideal value by using the coarse adjustment marks Select the block that is most filled by the color on the left or approximate if 80 60 40 20 O 20 40 60 80 none of the blocks are completely filled and enter it for the new value Reprint the quick test page and then use the fine adjustment 0 Top T x Fine Adjustment 20 18 First locate the line of the color that you 4 are aligning that lines up best wi
29. a J concernant les produits laser de Classe 1 Pour les autres pays cette imprimante r pond aux normes IEC 60825 1 relatives aux produits laser de Classe l Les produits laser de Classe sont consid r s comme des produits non dangereux Cette imprimante est quip e d un laser de Classe Illb 3b ars niure de gallium d une puissance nominale de 5 milliwatts mettant sur des longueurs d onde comprises entre 645 et 670 nanom tres L imprimante et son syst me laser sont con us pour impossible dans des conditions normales d utilisation d entretien par l utilisateur ou de r vision Pexposition a des rayonnements laser sup rieurs des rayonnements de Classe Avvertenze sui prodotti laser Questa stampante certificata negli Stati Uniti per essere conforme ai requisiti del DHHS 21 CFR Sottocapitolo J per i prodotti laser di classe 1 ed certificata negli altri Paesi come prodotto laser di classe 1 conforme ai requisiti della norma CEI 60825 1 prodotti laser di classe non sono considerati pericolosi La stampante contiene al suo interno un laser di classe Illb 3b all arseniuro di gallio della potenza di 5mW che opera sulla lunghezza d onda compresa tra 645 e 670 nanometri Il sistema laser e la stampante sono stati progettati in modo tale che le persone a contatto con la stampante durante il normale funzionamento le operazioni di servizio o quelle di assistenza tecnica non ricevano radiazioni laser superiori al livello de
30. board See Controller host machine Did the host PC see the device board removal on page 4 20 2 54 Service Manual 5025 2xx 4xx User operator panel and Administration menus Printer operator panel The printer operator panel has a two line back lit grayscale text display The Back Menu and Stop buttons are located to the left of the display and the navigation buttons are located below the display Menu Indicator light USB Direct interface Stop Cancel Back Select button Navigation Navigation button button Operator panel buttons PA A AAA Press Select v to initiate action on a menu item Indicator light Indicates the printer status Status indicates Stop Cancel Stops all printer activity A list of options is offered once Stopped appears on the display Navigation buttons Press lt q or p to scroll through menu lists Use the Select button in the center to initiate action on a menu item Returns the display to the previous screen Opens the menu index USB Direct interface Note The USB connector is available on some models Diagnostic information 2 55 5025 2xx 4xx Menu map This menu map identifies menus available to customers The diagram shows the menus on the operator panel and items available under each menu Some menu items or values are displayed only if a specific option or feature is installed on your printer
31. e If the number is incorrect Checksum does not match appears and the original screen appears to reenter the value e If the number is correct Saving changes to NVRAM appears ao 4 70 Service Manual 5025 2xx 4xx Toner meter cycle TMC card removal See Toner meter cycle card assembly on page 7 7 for the part number UI Remove the rear shield See Top cover assembly removal on page 4 13 Remove the right cover assembly See Right cover assembly removal on page 4 12 Remove the waste toner bottle See Waste toner bottle removal on page 4 77 Remove the imaging unit IU See Imaging unit IU removal on page 4 45 Disconnect the TMC cable from JCTM1 connector A and push the toner meter cycle card cable through the frame opening Note Observe the routing for reinstallation Neopia m Repair information 4 71 5025 2xx 4xx Installation notes e Be sure the cable runs through the retainer e The toner meter cycle card is a tight fit Insert the bottom edge inside the frame and then push down on the top edge to clear the top cover e In some cases the top cover will have to be loosened so the right edge of the top cover can be lifted to get the toner meter cycle card back into position 1 Remove the two machine screws A A Push in on the cover above the locating pins C while lifting to disenga
32. flex the cover slightly to engage the tab E near the power switch Repair information 4 7 5025 2xx 4xx Operator panel bezel and name plate removal See Operator panel bezel and name 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 A 3 Lift the name plate B Note The name plate may or may not contain depending upon the model an opening for the USB port 4 8 Service Manual 5025 2xx 4xx Operator panel logo plate 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 the two latches A on the inside cover 3 Remove the logo plate B Repair information 4 9 5025 2xx 4xx Operator panel removal See Operator panel and display assembly on page 7 3 for the part number 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 may be rendered inoperable e Operator panel assembly e Controller board Warning Never install and remove components listed above as a method of troubleshooting components Once a component has been in
33. lt o Q Sensor 19po9U3 pue JOJO N gt O S E Power cord Aea euondo C3 Charge Roll K_CR I K_DEV I Developer Roll oh oh Developer Roll Y_DEV CMY_CR M_DEV C_DEV ew c Developer Roll CYM Transfer Roll Main Transfer Roll K Transfer Roll Main Transfer Roll ITU
34. output Vivid CMYK Increases the color saturation of the US CMYK color correction setting Off No color correction is implemented 3 50 Service Manual 5025 2xx 4xx How can match a particular color such as a corporate logo From the printer Quality menu nine types of Color Samples sets are available These are also available from the Color Samples page of the Embedded Web Server Selecting any sample set generates a multiple page printout consisting of hundreds of colored boxes Either a CMYK or RGB combination is located on each box depending on the table selected The observed color of each box is obtained by passing the CMYK or RGB combination labeled on the box through the selected color conversion table To print Color samples from the printer Press Menu to open the Admin menus Select Settings and press Select x Select Quality and press Select y Select Color Samples and press Select y Select the Color Conversion table to print and press Select y IAS By examining Color Samples sets a user can identify the box whose color is the closest to the desired color The color combination labeled on the box can then be used for modifying the color of the object in a software program For more information see the software program Help topics Manual color correction may be necessary to utilize the selected color conversion table for the p
35. put 2 29 Q quick test duplex 3 13 single page 3 5 R removals bin full narrow media sensor 4 18 bin full narrow media sensor flag 4 27 controller board 4 20 covers front cover assembly 4 2 left cover assembly 4 6 operator panel 4 10 operator panel bezel 4 8 operator panel name plate 4 8 rear shield 4 11 right cover 4 12 top cover assembly 4 13 developer unit 4 21 duplex reference edge 4 22 duplex sensor 4 25 exit deflector 4 27 fuser assembly 4 29 fuser drive motor assembly 4 32 fuser exit sensor 4 33 getting started 4 2 high voltage power supply HVPS 4 35 image transfer unit ITU 4 40 imaging unit IU 4 45 left lower frame 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 l 4 Service Manual pick tires 250 sheet media tray 4 64 printhead 4 65 right lower frame 4 55 toner cartridge contacts 4 67 toner density sensor TDS left and right 4 69 toner meter cycle TMC card 4 71 tray present sensor 4 73 USB port connector 4 76 waste toner bottle 4 77 waste toner bottle contact 4 78 wireless network antenna 4 79 wireless network card 4 81 reports event log 3 22 3 25 menu settings page 3 22 3 25 Print Qual Pages 3 11 Print Quality Pages 3 24 Quick Test 3 5 Quick Test duplex 3 13 Reset Fuser Cnt 3 20 RGB color 3 49 S S1 sensor 2 25 4 73 safety information XV safety inspection guide 6
36. toner door and right doors are OK Go to step 2 Go to step 3 Go to step 4 Replace the right cover assembly See Right cover assembly removal on page 4 12 Replace the top cover assembly See Top cover assembly removal on page 4 13 Replace the right cover assembly See Right cover assembly removal on page 4 12 Replace the controller board See Controller board removal on page 4 20 Go to step 6 5025 2xx 4xx Close the front cover and the toner door Be Contact your next level of Replace the front cover sure the right cover is in place Turn the printer support assembly See Front off and then disconnect the cables at JINT 1 cover assembly removal and JCVR1 Test continuity at the connector on page 4 2 under the following conditions e 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 e With one or both doors open Pin 2 and 3 at JINT1 cable end should indicate continuity but pins 1 and 2 at JCVR1 should have no continuity Are the tests verified Fuser exit sensor service check Step Questions actions Enter Diagnostics Menu turn the printer off press and hold 4 and yj turn the printer on and then release the buttons when the installed memory and processor speed displays Perform the Base Sensor Test See Base Sensor Test on page 3 16 1 Select Base Sensor Te
37. towards the front door Note Improperly aligned bearings or seated shafts may cause vibration and noise in the front door 4 Align the duplex aligner guide so the gears D mesh on the left mm 5 Replace the eight screws in the duplex aligner 6 Close the front door 4 24 Service Manual 5025 2xx 4xx Duplex sensor removal 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 A 3 Pull corner of cable cover B away from the right side to access the sensor posts C Repair information 4 25 5025 2xx 4xx 4 If there is a plate on the side the latches of the sensor connected remove the old adhesive plate D p N A wa Y a A D 5 Unlatch the sensor by pushing on the latches 6 Remove the sensor and disconnect the cable E from the 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 or where you need to install the new one 2 Install the new sensor Note Make sure the clamps on the legs latch to the metal frame 3 Remove the backing from the new plate and place the plate on the surface between the sensor mounting legs 4 26 Service Manual 5025 2xx 4xx Ex
38. 04 Service Jump to unverified address Update firmware or replace the controller Invalid Firmware board See Controller board removal on page 4 20 959 05 Service Unknown Boot Failure Update firmware or replace the controller Invalid Firmware board See Controller board removal on page 4 20 959 20 Service System hardware failure Replace the controller board See System Board Controller board removal on page 4 20 Diagnostic information 2 19 5025 2xx 4xx Service error messages 1xx 9xx continued EN CO CI 959 21 Service System did not respond to command Replace the controller board See System Board request Controller board removal on page 4 20 959 22 Service Challenge Secret Failure ASIC SP mismatch System Board 959 23 Service System self test failure during Replace the controller board See System Board initialization Controller board removal on page 4 20 959 24 Service EEPROM Retention Error write Replace the controller board See System Board failure Controller board removal on page 4 20 959 25 Service Insufficient device space during Replace the controller board See System Board hardware programming Controller board removal on page 4 20 959 26 Service Incremental counter reset exceeds Replace the controller board See System Board maximum value Controller board removal on page 4 20 959 27 Service Increment count failed due to Replace the con
39. 1 5 V de 5V safety interlock connector VS_INT 5 V dc door closed 0 V dc open 5 6 Service Manual 5025 2xx 4xx Controller board connectors continued Note SW indicates voltage is switched on during a print cycle otherwise voltages are taken with printer at Ready state door closed and cables plugged in JLVPS1 Low voltage power supply JMIRR1 Mirror motor connector JOPP1 Operator panel connector IC ICI IC fom EN ECN 2 mekse E fee pate Connector locations 5 7 5025 2xx 4xx Controller board connectors continued Note SW indicates voltage is switched on during a print cycle otherwise voltages are taken with printer at Ready state door closed and cables plugged in JOPT1 Optional Tray s Ground CCA TXD_PP 7 Ground JPH1 Printhead flat cable connector a Wooten 99 de e feve CN E o rs Wo 800872 Shade CN ESC ICI 13 D VDO 7 14 0 0 VDO BOOSTO 2 5 5 8 Service Manual 5025 2xx 4xx Controller board connectors continued Note SW indicates voltage is switched on during a print cycle otherwise voltages are taken with printer at Ready state door closed and cables plugged in CC ON s Connector locations 5 9 5025 2xx 4xx Controller board connectors continued Note SW indicates voltage is switched on during a print cycle otherwise voltages are taken with printer at Ready state door closed and cables plugged i
40. 3 17 5025 2xx 4xx Printer Setup Defaults US Non US defaults changes whether the printer uses the US factory defaults or the non US factory defaults The settings affected include paper size envelope size PCL symbol set code pages and units of measure Warning Changing this setting resets the printer to factory defaults and data may be lost It cannot be undone To change the Defaults 1 Select Printer Setup from Diag Menu and press Select y 2 Select Defaults and press Select y 3 Select U S default or Non U S and press Select y Press Back 5 to return to Printer Setup Page counts You can view 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 y 2 Select the page count you wish to view e Prt Color Pg Count e Prt Mono Pg Count e Perm Page Count 3 Press Select The value of the page count displays Press Back 5 to return to Printer Setup Serial Number The serial number can only be viewed but cannot changed To view the serial number 1 Select Printer Setup from Diag Menu and press Select 2 Select Serial number and press Select v The Serial Number is displayed Press Back 5 to return to Printer Setup
41. 40X0287 40X0288 40X0301 40X0303 40X0395 40X1368 40X1455 40X1525 40X1526 40X1538 40X1557 40X1766 40X1772 40X1773 40X1791 40X1792 40X2254 40X2255 40X2261 40X2263 40X2268 40X2284 40X2285 40X2512 40X2867 40X3141 40X4596 40X5036 40X5168 40X5319 40X5403 40X5404 40X5405 40X5406 40X5407 40X5408 40X5409 40X5411 40X5412 40X5413 40X5414 40X5415 40X5416 40X5417 40X5418 40X5419 40X5420 Page FOWencora 2 ONMSidignl vdpal mesetan eaae Serene ae eR AAA AR eee 7 7 Power cord 2 5M straighnt United Kingdom 7 7 Power cord 2 5M straight Chile Uruguay 7 7 Power cord 2 5M straight Israel errr eee 7 7 Power cord 2 5M straight Denmark 7 7 Power cord 2 5M straight Traditional Italy 7 7 Power cord 2 5M straight Argentina 7 7 Power cord 2 5M stralght Australla lt lt lt lt 7 7 Power cord 2 5M straight PRC 7 7 Field relocation package assembly 2 eaaa 7 12 USB cable packaged AMI 6 152 sos sota a E AE 7 12 64MB Flash card assembly lt lt 95 625 A ee eee 7 12 Controller board C544n C544dn Cd44dw
42. 40X5435 40X5436 40X5441 40X5937 40X5938 40X5939 40X5969 40X5970 40X5971 40X5972 40X7046 Tonercartridge contacts ir OGO PIM lt 522 seres ae al Sh Gt ee e 7 9 Lower left frame and lower right frame with cable cover 7 5 Cable packet rere eee ee ee eee ee 7 9 screw packet eee 7 5 USB port and cable e 7 9 Photo sensor and retainer 2 ere rrr rr rr rr rr rr eee 7 7 ITU paper path thermistor 2 2 rere rrr er re re eee c eee 7 9 Front cover assembly including duplex and USB port cable C543dn C544dn C544n C546dtn 7 3 Operator panel and display assembly 7 3 Operator panel bezel and name plates 7 3 Exit deflector and bin full narrow media sensor flag 7 5 Optional 650 sheet Duo Drawer complete C544n C544dn C544dw C540n C543dn 7 11 650 sheet Duo Drawer tray only C544n C544dn C544dw C540n C543dn 7 11 Operator panel DBCS and display assembly 7 3 Dust cover rer rr rr rr rt rr rt re er re ere eee cere 7 3 128MB DDR DRAM DIMM card assembly 7 12 256MB DDR DRAM DIMM card assembly
43. 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 trailing edge of the media clears the fuser the fuser engine rotates forward to prepare the fuser for the page traveling through the duplex unit As the media reaches the gate aligner a sensor S1 is triggered indicating the presence of the leading edge When the S1 sensor is triggered the paper continues to the S2 sensor S2 When the S2 signal is detected the speed of the pick motor is adjusted to accommodate the speed of the transfer belt ensuring the proper registration of the image on the media The paper travels to the ITU C and the second image is transferred to the reverse side of the media Once the image is transferred the media travels to the fuser D the fuser exit rolls E and the output bin TE al ir rr VO Y II 3 48 Service Manual 5025 2xx 4xx Color theory What is RGB color Red green and blue light can be added together in various amounts to produce a large range of colors observed in nature For example red and green can be combined to create yellow Televisions and computer monitors create colors in this manner RGB color is a method of describing colors by indicating the amount of red green or blue needed to produce a certain color What is CMYK color Cyan magenta yellow and black
44. Enter Diagnostics Menu turn the printer off press and hold and yj turn the printer on and then release the buttons when the installed memory and processor speed 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 on the display Perform the Button Test See Button Test on page 3 12 in Diagnostics Menu Did any of the buttons fail the test Remove the rear shield Top cover assembly removal on page 4 13 Turn the printer on and verify the following values at JOPP1 Pin Value 2 5vde a Ground Ps sve e reavao Are the values approximately correct Replace the operator panel assembly See Operator panel logo plate on page 4 9 Replace the operator panel assembly See Operator panel logo plate on page 4 9 Replace the operator panel See Operator panel logo plate on page 4 9 If this does not fix the problem replace the front cover assembly which contains the operator panel cables See Front cover assembly removal on page 4 2 Go to step 2 Go to step 3 Replace the controller board See Controller board removal on page 4 20 Diagnostic information 2 33 5025 2xx 4xx Operator panel display blank five beeps Service tip The printer has detected a problem with th
45. FR TA UE A E Mio ARENAL VE AY ERA BER ANT PE TT AP m AED fa RS IRA A n EH FRAT SEE Ho AmE EEN EXA ERA AAA A EMBA RIX RARA T FRE E FT Fe N Wicd SBAA SI WHER CER m Dx E FY FB FL ARE Wa LEFT RRES m AY FAA tko WEET DIA FEDER BUT ESA ADA Ho Safety information XVII 5025 2xx 4xx 10 2 2009 Preface This manual contains maintenance procedures for service personnel It is divided into the following chapters 1 General information contains a general description of the printer and the maintenance approach used to repair it Special tools and test equipment as well as general environmental and safety instructions are discussed Diagnostic information contains an error indicator table symptom tables and service checks used to isolate failing field replaceable units FRUs Diagnostic aids contains tests and checks used to locate or repeat symptoms of printer problems Repair information provides instructions for making printer adjustments and removing and installing FRUs Connector locations uses illustrations to identify the connector locations and test points on the printer Preventive maintenance contains the lubrication specifications and recommendations to prevent problems Parts catalog contains illustrations and part numbers for individual FRUs gt oO ee D Conventions xviii Note A note provides additional information Warning A warning identifies something that might damag
46. Imaging unit IU removal on page 4 45 Note The ITU FRU includes a spring clamp kit If the printer does not have this kit installed perform the following steps to prepare for the later installation Continue below with Removal of ITU without the spring clamp kit on page 4 41 If the spring clamp kit is not installed skip to Continuing the removal with or without the spring clamp kit on page 4 42 4 40 Service Manual 5025 2xx 4xx Removal of ITU without the spring clamp kit 1 Pull the 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 yy 2 Remove the rubber pad C 3 Place the spring clamp onto the shaft D 4 Snap the new gear onto the shaft D The installation is the same as the old gear Repair information 4 41 5025 2xx 4xx Continuing the removal 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 A 2 Rotate the left spring B and the cam away from the ITU so the spring is held out of the ITU path A pa f ce J ONO 4 42 Service Manual 5025 2xx 4xx 3 Rotate the release lever C in a counterclockwise direction with a springhook or needlenose pliers to decouple the ITU while pulling the ITU toward the front gt ed 4 Hold the release leve
47. Media present Fuser exit sensr Media clear or Open the front cover Activate the fuser exit flag The l sensor should change state Media present C TMC Sensor Opened Remove the cyan toner cartridge Shine a flashlight on Closed the toner level sensor The sensor should change state M TMC Sensor Opened Remove the magenta toner cartridge Shine a Closed flashlight on the toner level sensor The sensor should change state Y TMC Sensor Opened Remove the yellow toner cartridge Shine a flashlight Closed on the toner level sensor The sensor should change state K TMC Sensor Opened Remove the black toner cartridge Shine a flashlight Closed on the toner level sensor The sensor should change state To exit the test press Back or Stop E 3 16 Service Manual 5025 2xx 4xx Miscellaneous tests Motor Detect This test initiates an automatic motor detection process that should be performed whenever the controller board is replaced To run Motor Detect eo PONS Remove the imaging unit and the waste toner bottle See Imaging unit IU removal on page 4 45 Reinstall the right cover assembly Close the front cover Enter Diagnostics menu Turn the printer off press and hold Left 4 and Select v turn the printer on and release the buttons when the installed memory and processor speed displays Select MISC TESTS in the Diag Menu and press Select y Select Motor De
48. NAND flash and could occur as a result of the CRC check done when the machine is powered on The range of package numbers 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 This error occurs only if a multi bit failure is detected during the ECC execution Single bit failures will be corrected automatically and will not result in a service error The range of page numbers is from 0 to 1023 956 00 Service Controller board failure Processor Replace the controller board See System Board failure Controller board removal on 956 01 Service Processor over temperature System Board 957 xx Service Controller board failure ASIC failure System Board 958 xx Service Printer has performed more than 100 NAND Failure shift and reflash operations as a result of ECC bit corrections 959 01 Service Controller verification failure of system Update firmware or replace the controller Invalid Firmware boot code board See Controller board removal on page 4 20 959 02 Service Failure to authenticate Signature Update firmware or replace the controller Invalid Firmware Verification Code board See Controller board removal on page 4 20 959 03 Service Signature verification Code failure to Update firmware or replace the controller Invalid Firmware authenticate a code partition board See Controller board removal on page 4 20 959
49. Other menu items may only be effective for a particular printer language You can select these values at any time but they affect printer function only when you have the optional equipment feature on your model or the specified printer language Supplies Menu Cyan Cartridge Magenta Cartridge Yellow Cartridge Black Cartridge Imaging Kit Waste Toner Box 2 56 Service Manual Paper Menu Default Source Size Type Paper Texture Paper Weight Paper Loading Custom Types Universal Setup Units of Measure Portrait Width Portrait Height Feed Direction Reports Menu Settings Page Device Statistics Network Setup Page Profiles List Print Fonts Print Directory Print Defects Print Demo Demo Page PPDS Info Asset Report Network Ports Active NIC Network Menu PCL Smartswitch PS Smartswitch NPA Mode Network Buffer Mac 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 Gateway ENA Gateway Settings General Settings Display Language Eco Mode Quiet Mode Run Initial Setup Alarms Timeouts Print Recovery Factory Defaults Setup Menu Printer Language Print Area Download Target Resource Save Finishing Menu Sides Duplex Duplex Binding Copies Blank Pages Collate Separator Sheets Separator Source N up Pages Side N up Ordering Orientation N up Bor
50. amount of High voltage power spring force supply HVPS assembly removal on page 4 35 Turn the printer off and remove the rear Go to step 8 Replace the cable shield See Top cover assembly removal on page 4 13 Check the continuity between the spring loaded pins and the JSC1 connector on the controller board Are all conductors continuous Replace the printhead See Printhead Problem resolved Replace the controller removal on page 4 65 board See Controller Did this fix the problem Seye we 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 4 and y 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 y 3 Select Reset Color Cal and press Select Resetting appears When the reset is 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 also be caused by incorrect feeding from one of the input paper sources media trays or duplex paper path Check the high voltage spring contacts to ensure they are
51. any buttons The blinking value becomes solid If the value is incorrect use Back 5 to go back and reenter the number C Continue until the last value is reached d When the last of the 16 values is entered and becomes solid TPS Right 17 32 or TPS Left 1 32 appears e Continue entering and pausing 4 After the 32nd number is entered and becomes solid the number is automatically entered e If the number is incorrect Checksum does not match appears and the original screen appears to reenter the value e If the number is correct Saving changes to NVRAM appears Cal Ref Adj Used with Reset Color Cal which resets to a default value Cal Ref Adj allows you to fine tune the TPS function To set the Cal Ref Adj Select TPS Setup from Diag Menu and press Select y Select Cal Ref Adj and press Select v Select CMY or Black and press Select v Press to decrease or p to increase the value The values can be 8 to 8 and the default value is 0 AEDH To cancel and return to the menus press Back gt Reset Color Cal This setting allows the device to adjust the alignment of the color planes using pre programmed default values To reset the programmed value 1 Select TPS Setup from Diag Menu and press Select y 2 Select Reset Color Cal and press Select y Resetting appears When the reset is complete the screen is aut
52. appears only when the printer model does not support Automatic Power Saver or has deactivated Automatic Power Saver Energy Conserve affects only the values that are displayed in the Power Saver menu Select Off in Energy Conserve to allow Power Saver in the customer menu to display Disable as an option If Disable is selected in the customer Power Saver the printer deactivates the Power Saver feature Select On the default in Energy Conserve to prevent Disable from appearing as an option in the Power Saver setting and preventing the customer from turning off Power Saver 3 26 Service Manual 5025 2xx 4xx Auto Color Adj Sets the suggested number of pages which the printer should print between consecutive calibrations Selections are Off and the values between 100 and 1000 in increments of 50 The default is 500 pages If the printer exceeds the set value while printing a job it completes the current job and any other jobs received while printing the current job before it initiates a calibration The printer does not cancel or suspend an active job in order to perform a calibration If a user is using the menus including the Configuration Menu and the Diagnostics Menu an automatic color adjust calibration does not occur When an event other than page count triggers this calibration the count that monitors the maximum number of pages printed will be reset For example if the user replaces an empty toner cartridge the next time the print
53. assembly Staging Motor service check on page 2 39 141 01 Service Staging motor has exceeded the ramp Go to Paper pick motor drive assembly Staging Motor up table service check on page 2 39 141 02 Service Staging motor has exceeded number Go to Paper pick motor drive assembly Staging Motor of encoders at minimum PWM service check on page 2 39 141 03 Service Staging motor has exceeded number Go to Paper pick motor drive assembly Staging Motor of encoders at maximum PWM service check on page 2 39 141 04 Service Motor encoder count did not change Go to Paper pick motor drive assembly Staging Motor between interrupts service check on page 2 39 141 05 Service Staging motor has encountered a stall Goto Paper pick motor drive assembly timeout service check on page 2 39 Staging Motor 150 xx Service Black ITU cartridge Motor 150 01 Service Black ITU cartridge Motor 150 02 Service Black ITU cartridge Motor 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 2 16 Service Manual Black ITU Cartridge Motor Failed to achieve lock for motor within allotted time Timeout waiting for SAP BLDC motor to reach valid FG speed Timeout waiting for MP_NUM_INITIAL_SAP_HALLS Timeout waiting for SAP BLDC motor FG Lost lock for motor Excessive SAP BLDC PWM
54. customer problems with paper curl on low grade papers and problems with letterheads on some types of media To adjust the fuser temperature To restore EP Defaults 1 Select EP Setup from Diag Menu and press Select y 2 Select Fuser Temp and press Select v 3 Select Normal High or Low The default is Normal To return to the menus press Back 5 DC Charge Adjust Dev Bias Adj Transfer Adjust Each of these three settings enables you to adjust the high voltage levels controlling the electrophotographic process You will use these settings to compensate for unusual operating circumstances such as high humidity The printer uses the value of these settings together with other settings to calculate printing speed and media selection 3 20 Service Manual 5025 2xx 4xx TPS Setup Right or Left TPS The value of the toner density sensor also called toner patch sensor or TPS is set at manufacturing lf a sensor is replaced enter the 32 digit hexadecimal toner density value TPS value from the bar code next to the sensor To enter the value 1 Select TPS Setup from Diag Menu and press Select y 2 Select Right or Left and press Select TPS Right 1 16 or TPS Left 1 16 appears above a blinking O in the left position 3 To enter a character or digit a Press to decrease or pto increase the blinking value b Pause for several seconds without pressing
55. determined The timing of the pick is such that the media reaches the point where the transfer belt and transfer roll meet The paper passes between the transfer belt and transfer roll when the image on the belt reaches the second transfer area The high voltage power supply sends voltage to the transfer roll to create a positive charge Once the image on the transfer belt reaches the transfer roll the negatively charged toner clings to the media and the entire image is transferred from the transfer belt to the media Service tips e lf the transfer roll has nicks pits or flat spots on it the surface doesn t come into contact with the media and transfer unit properly This will cause voids or lights spots on the page or repeating voids light areas because the toner can t be fully transferred due to the charge difference in the areas of damage e lf the transfer roll does not engage the transfer unit or does not have voltage coming from the high voltage power supply the toner will not fully transfer from the transfer unit the entire page will be very light or blank Any toner that does transfer will be due to a contact transfer instead of a charge transfer Check the transfer roll clutch and the high voltage power supply contacts to the transfer roll 3 42 Service Manual 5025 2xx 4xx Step 5 Fuse Once the image has been fully
56. drive gear assembly EP CMY Cartridge Motor FG drive service check on page 2 30 152 05 Service Lost lock for motor Go to Main drive gear assembly EP CMY Cartridge Motor drive service check on page 2 30 152 06 Service Excessive SAP BLDC PWM Go to Main drive gear assembly EP CMY Cartridge Motor drive service check on page 2 30 152 07 Service Motor stalled in time based Go to Main drive gear assembly EP CMY Cartridge Motor commutation drive service check on page 2 30 900 xx Service Unrecoverable RIP software error Go to 90x xx error on page 2 22 RIP Software illegal trap 902 xx Service A general engine software error Go to 90x xx error on page 2 22 Engine Software 903 xx Service A general engine software error Go to 90x xx error on page 2 22 Engine Software 904 xx Service A general engine software error Go to 90x xx error on page 2 22 Engine Software 905 xx Service A general engine software error Go to 90x xx error on page 2 22 Engine Software 906 xx Service A general engine software error Go to 90x xx error on page 2 22 Engine Software 907 xx Service A general engine software error Go to 90x xx error on page 2 22 Engine Software 908 01 Service Board level was not obtained Go to 90x xx error on page 2 22 Engine Software 908 02 Service Timeout waiting for bullet serial data to Go to 90x xx error on page 2 22 Engine Software be update
57. fUSINg cerraran rre eee ERs tee eas 2 45 Print quality missing image at edge escindida 2 45 Print quality mottle 2 5mm speckles nananana naaa 2 45 Prin gualiy nanrow verlical INE 64 4068 rar A a i eee 2 46 Prim GU a SOCIO MIS sess sisrate or RARAS AAA A 2 46 Pon A ESOO MIMO ig bg 6 0 55h 54h OSs OS brs did di daa 2 47 Frnt guality s lid COM pag iria hanes ikter iiaea eae eden ARA AA 2 48 Print gualty verncal banding AAA E A 2 48 PINOS Service CECR 665 carer eee cewek eae AREA RARA RARE A 2 49 Toner meter cycle TMC Card oooooocooc es 2 50 Toner meter sensors Y C M K on TMC card 2 cece es 2 50 Transfer roll service check 6 6i2nd oni ds ees bbe hs deb OS Odeo ek de bn ens 2 51 Tray OC Sensor Service check rr AAA AA ADA AAA AA 2 51 Trays 2 and 3 optional service Check 0 0 e eee es 2 53 io AA 2 54 User operator panel and Administration MenuS o oococoococn es 2 55 PTI OOOO DOMO sarria rta ABRA REA AAA PARA 2 55 Operator panel DUNONS 6425066 EA AAA CARA AAA AAA ARAS 2 55 MANU ee ee ee ee eee ee ee 2 56 Diagnostic BINS is och woah oc pavenenerspsdde dere ad er satan xnsee sees 3 1 ACCSESINO Servic MEN S AAA AAA ee ek See eR aE SEH PRE EO OS 3 1 Diagnostics Menu Diag Menu isissicirr rnicorairincrricin beset rre 3 2 Biagnoslics Menu SIIC ero ERAN 3 2 AVANDIA di AAA AAA 3 2 NOIA cc RE ARANA dae eee 3 4 CI arriero A E PE EP ao oes ta eens 3 5 Ok chek ee vine oo ous Hk
58. for use with the printer e Chemically treated papers used to make copies without carbon paper also known as carbonless papers carbonless copy paper CCP or no carbon required NCR paper e Preprinted papers with chemicals that may contaminate the printer e Preprinted papers that can be affected by the temperature in the printer fuser e Preprinted papers that require a registration the precise print location on the page greater than 2 3 mm 0 9 in such as optical character recognition OCR forms In some cases registration can be adjusted with a software application to successfully print on these forms e Coated papers erasable bond synthetic papers thermal papers e Rough edged rough or heavily textured surface papers or curled papers e Recycled papers that fail EN12281 2002 European e Paper weighing less than 60 g m 16 Ib e Multiple part forms or documents Selecting paper Using appropriate paper prevents jams and helps ensure trouble free printing To help avoid jams and poor print quality e Always use new undamaged paper e Before loading paper know the recommended print side of the paper This information is usually indicated on the paper package e Do not use paper that has been cut or trimmed by hand e Do not mix paper sizes types or weights in the same source mixing results in jams e Do not use coated papers unless they are specifically designed for electrophotographic printing Selecting prepr
59. from JFUSES1 connector B on the controller board Note Observe the routing of the cable s for reinstallation A Right B ALeft 4 Remove the two screws C securing each sensor a Right sensor C Left sensor Repair information 4 69 5025 2xx 4xx Installation notes e Before beginning the installation of the new left or right toner density sensor note the 32 digit TPS value printed on the barcode on the new FRU e After installation perform the TPS Setup Enter the factory preset alignment number 1 Enter the Diagnostics Menu a Turn the printer off b Press and hold 4 and N 4 gt C Turn the printer on d Release the buttons when the installed memory and processor speed displays 2 Select TPS SETUP from Diag Menu and press Select y 3 Select Right or Left and press Select y TPS Right 1 16 or TPS Left 1 16 appears above a blinking O in the left position 4 To enter a character or digit a Press lt to decrease or to increase the blinking value b Pause for several seconds without pressing any buttons The blinking value becomes solid If the value is incorrect use Back 5 to go back and reenter the number Continue until the last value is reached When the last of the 16 values is entered and becomes solid PS Right 17 32 or TPS Left 17 32 appears e Continue entering and pausing 5 After the 32nd number is entered and becomes solid the number is automatically entered
60. ihe VED SOI ok io hh s 5G 555 6 S545 HONS 4 OOHRS EHO H Es BH Se EG oboe 44 3 28 Using the host computer to update the firmware over USB 00 00 eee 3 29 Pa POr Cl ee ee ee ee ee AAA 3 31 A A 3 31 Understanding jam numbers and locations o ooooocooooo 3 32 EOI DADO I rara rra AR AA AAA AA ADA 3 33 nn 3 33 BOR o a En T EE E E E Fee ES Ste Dede FO Od 040 E 4858 da oe eas 3 34 Be A OE 8 28 4 oe OS 3 35 e A 3 35 oe paper am n pimay Vay sarria rinitis Anda Ara 3 35 242 paper jam in the 650 sheet Duo Drawer 0 0 ee 3 35 243 paper jam in the 550 sheet drawer 0 cece eee eens 3 36 OA AA A 3 36 TACO OF OPETAN earn Ene on eee ee nei Oe Oe AAA AE AA 3 37 PrIRL ONGING MEO 26 00 0c006 0600855552886 a AAA PTE ORS 3 37 Electrophotographic process EP process 0 0 ee eee eee 3 37 Electirophotographic process DASICS oo crosorsrsrranorr nar 3 37 e A A EE E 3 38 A MA ee ie 45 be ee ae ee ae ee ones 3 39 IO ION escasas iert EGE ta in do Di Ee lt 5 3 40 SICA US WIR serrana rear ER 3 41 Step 4b Second transfer cei iwc oc dob been pri indaa bonds deus 3 42 Pe lee soonest wanes eens PE q ee hae P EAE E eines aes 3 43 a a MASSA 3 44 Paper pain transport COMPONENTES lt lt dees nie RARA RARA 3 46 PIP re 584 Se Go pirita dic 3 46 Fansport CON ool arar rc eee bee ere eee bee a bas heed eek ee 3 47 ee hk ek see he be oe ee eee oa 2b ee Geese 3 48 SOHO A EENES ATENE EEEREN EEEE rAr ENNE EEUE
61. is saving power while it waits for the next print job e Send a job to print e Press Select y to warm the printer to normal operating temperature Afterwards Ready appears Programming Code The printer is receiving a file that is a code update Wait for the message to clear Warning Potential Damage Do not turn the printer off while this message appears on the display Programming Flash Fonts and macros are being written to flash Wait for the message to clear The printer is ready to print Reload printed paged e Press Select y to clear the message and continue processing the second side in Tray lt x gt of the sheet e Press Stop MM and then press Select to cancel printing 2 6 Service Manual User primary message Remote Management Active Remove paper from standard output bin Remove packaging material Replace lt color gt cartridge Std Bin Full Tray lt x gt Empty Tray lt x gt Low Tray lt x gt Missing Unplug and Change ode Unsupported USB device please remove Unsupported USB hub please remove Waiting Waiting too many events Waste Toner Box 30 lt color gt Toner Cart Missing 31 xx Defective lt color gt Cartridge 5025 2xx 4xx Explanation The printer is offline while it configures settings Wait for the message to clear The following actions can be ta
62. meter sensors Y C M K on Black TMC Sensor TMC switch error TMC card on page 2 50 01 Recoverable 02 Nonrecoverable 950 xx Service There is a mismatch between controller Go to 950 xx NVRAM Failure service NVRAM Failure EEPROM and mirror check on page 2 23 e 950 00 through 950 29 codes mismatch between controller and mirror e 950 30 through 950 60 codes mismatch between secure and controller 951 xx Service Mismatch between controller EEPROM NVRAM Failure and mirror e 951 00 through 951 29 codes mismatch between controller and mirror e 951 30 through 951 60 mismatch between secure and controller 952 xx Service A recoverable MVRAM Cyclic Performing a POR will clear this error NVRAM Failure n Redundancy Check CRC error occurred n is the offset at which the error occurred 953 xx Service NVRAM chip failure with mirror NVRAM Failure 954 xx Service The NVRAM chip failure with controller NVRAM Failure part 2 18 Service Manual 5025 2xx 4xx Service error messages 1xx 9xx continued 955 xx Service The Code ROM or NAND flash failed Code CRC lt loc gt the Cyclic Redundancy Check CRC check or the NAND experienced an uncorrectable multi bit failure lt oc gt indicates the source of the failure and has one of the following values e CRC Failure The source is a failing package indicated by Pn where nis the package number This error could occur on a controller with ROM or
63. normal mode Prt Quality Pgs The Print Quality Pages can be printed from both the Configuration Menu and the Diagnostics Menu The Configuration Menu is limited in information compared to the pages printed from the Diagnostics Menu To help isolate print quality problems print the Print Quality Test Pages The pages are formatted The Printing Quality Test Pages message appears then the pages print The message remains on the operator panel until all the pages print Press Select x to print the pages The Print Quality Test Pages contain several pages The first page which is printed in English text only contains a mixture of text and graphics The information includes values of the Quality Menu settings in Settings and printer and toner cartridge configuration information The remaining pages contain only graphics For samples of the pages see Print quality test pages Prt Qual Pgs on page 3 11 Color Trapping Uses an algorithm to compensate for mechanical incorrect registration in the printer When 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 content the printer leaves the color around the edge of the text or line The hole in the colored region is reduced in size which prevents the characteristic white gap that is caused by incorrect registration Values in
64. not bent corroded or damaged Replace the high voltage power supply as necessary See High voltage power supply 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 and reseat each of the developer units Diagnostic information 2 43 5025 2xx 4xx Print quality horizontal banding Print the Print Defect Page 1 Atthe Ready prompt press Menu gt 2 Select Reports and press Select y 3 Select Print Defects and press Select y Questions actions Measure the distance between repeating bands Is the distance between bands either 34 6 or 94 2 mm Does the distance measure 95 mm or 108 mm Does the distance measure 37 7 55 or 78 5 mm Does the distance measure 43 9 mm or 45 5 Print quality horizontal line Replace the photoconductor unit Remove the imaging unit and remove the original developer units and then put them back into the new photoconductor unit and reinstall the imaging unit See Imaging unit IU removal on page 4 45 Replace the fuser See Fuser assembly removal on page 4 29 Replace the ITU See Image transfer unit ITU removal on page 4 40 Replace the developers that match the missing color black cyan magenta or yellow See Developer unit re
65. oe oe ee en Bias 3 5 o ged ddee s ENARA Es eee ee OEE a RO ow e He bbe e ee 3 7 PUN Vee a ie eat ee eae iia de RRA HOE ee es Oe ee eee 3 10 WOT SOIC TESIS a i oko ba bie oe oh oes RARA ERIE 495 44455 be OSES 3 10 Print Quality test paves Prr Qual Pus 22652562656 dr aaa da 3 11 Service Manual 5025 2xx 4xx PW NOES rra aa aaa N 3 11 E A A ee ee eee ee 3 11 sos thw oe Re ee eee eae AA eae ESAS AAA 3 12 Dao B gcueagaehescasnedss ones EE EE es nenSeaey E T E E see eee areses 3 12 DUDES TOSS siria AAA ARA es 596255856 A 3 13 AN MA o ES 3 13 ld AR OG E a a a he od 3 14 Pis o a2 canoes conan eae E shader ney be A ye ede eee eee EEY 3 14 DUL a od ee re ee ee ere eee ee 3 15 A A ee Pee S 3 15 nn 3 15 Dase Denso TOS eroinin eiA EENAA AAA DAA RARAS 3 16 Miscellaneous 10515 cra ARA A AAA ANR 3 17 gs A eS RR A Ss oe TEE 3 17 boe A IA ee E 3 17 a AA II A EET 3 17 POG GUD ss sorna na cr AAA AR RN 3 18 AM O Pare 8 Gg a EG DAE Hd Ob Fee ee 8S OE 3 18 E wiekada sends A ee bee Oa ae IS 3 18 a 4 oe f ioe Leucpo dey ee dade iwe4 dens Ouse Ga cans cnet obese bes tses 3 18 Engine Selling 1 iRNOUORN 4 lt codesededaedewe eben se erti see eheas ARA 3 18 POMS ASAS 3 18 os ON odes e040 4 e bees bes 04 06400 ey beeen dae eee EA 3 19 as A A ee ee bee sees 3 19 eee FSS Saas hoe hao E ARAS AAA ARA Ieee eee ears 3 20 ENANA AREA RADAR AER ARA Oe ASA a ek RA 3 20 ESPUMA perrera dira AAA IA A aa 3 20 FUE Vere rre poeta er rd caia 3 20 DC Charge Adjust
66. off press and hold Left 4 and Select v turn the printer on and release the buttons when the installed memory and processor speed displays Select Printer Setup and press Select y Select Reset Fuser Cnt and press Select y Reset Fuser Cnt Reset appears on the display Select Back 5 twice and select Exit Diags and press Select y Repair information 4 31 5025 2xx 4xx Fuser drive motor assembly removal See Fuser drive motor assembly on page 7 5 for the part number 1 Open 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 cable be sure to return the toroid to the cable when you re install 4 Remove the two screws C 5 Remove the fuser drive motor assembly 4 32 Service Manual 5025 2xx 4xx Fuser exit sensor removal See Fuser exit sensor on page 7 7 for the part number Open the front cover Remove the right cover assembly See Right cover assembly removal on page 4 12 Remove the left cover See Left cover assembly removal on page 4 6 Disconnect the two wire fuser cable A from the LVPS Note You do not have to extract the cable AAN 5 Remove the screw and grounding washer B on the right side of the frame Note Be careful not to los
67. page 3 16 Front Door ep Fuser exit Sensr Standard Bin C TMC Sensor M TMC Sensor Y TMC Sensor K TMC Sensor Input MISC TESTS Motor Detect See Motor Detect on page 3 17 DEVICE TESTS Flash Test if flash memory is See Flash Test on page 3 17 installed Printer Setup Defaults See Defaults on page 3 18 Prt Color Pg Count Prt Mono Pg Count Perm Page Count Serial Number See Serial Number on page 3 18 Engine Setting 1 See Engine Setting 1 through 4 on page 3 18 See Page counts 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 ITU Barcode on page 3 19 Reset Fuser Cnt See Reset Fuser Cnt on page 3 20 EP Defaults See EP Defaults on page 3 20 Fuser Temp See Fuser Temperature on page 3 20 DC Charge Adjust Dev Bias Adjust Transfer Adjust Right See Right or Left TPS on page 3 21 Left Cal Ref Adjust See Cal Ref Adj on page 3 21 Reset Color Calibration See Reset Color Cal on page 3 21 Menu Settings Page See Menu Settings Page on page 3 22 See DC Charge Adjust Dev Bias Adj Transfer Adjust on page 3 20 Diagnostic aids 3 3 5025 2xx 4xx Diagnostics Menu continued Event Log See Display Log on page 3 22 Display Log Print Log See
68. papers may also cause background problems Some problems occur by running a large amount of graphics in a humid environment Read the current status of the imaging unit Reset the value To reset Go to step 2 from the customer menus this value To view the status of the photoconductor units In Ready mode press Menus l Select Supplies Menu and press Select 7 Select Replace Sup and press Select 7 uni Select the imaging and press Select y Has the imaging unit been recently replaced Select Yes and press Select y If this does not fix the problem go to step 2 Is the background only one of the primary Replace the developer unit Go to step 4 colors yellow cyan magenta or black for the background color and retest See Developer unit removal on page 4 21 Go to step 3 Did replacing the developer unit correct the Problem resolved Go to step 4 problem Replace the photoconductor unit Problem resolved Go to step 5 Does this fix the problem Check the high voltage contact from the HVPS Replace the failing FRU Go to step 6 to the image transfer unit ITU Image transfer unit Is a problem found ITU See Image transfer unit ITU removal on page 4 40 High voltage power supply HVPS See High voltage power supply HVPS assembly removal on page 4 35 Reseat the cable in the JHVPS1 connector Problem resolved Go to step 7 Does this fix the problem
69. the machine cover or on a metal table if you need to put down the ESD sensitive part for any reason first put it into its special bag Machine covers and metal tables are electrical grounds They increase the risk of damage because they make a discharge path from your body through the ESD sensitive part Large metal objects can be discharge paths without being grounded Prevent ESD sensitive parts from being accidentally touched by other personnel Install machine covers when you are not working on the machine and do not put unprotected ESD sensitive parts on a table If possible keep all ESD sensitive parts in a grounded metal cabinet case Be extra careful in working with ESD sensitive parts when cold weather heating is used because low humidity increases static electricity Repair information 4 1 5025 2xx 4xx Removal procedures CAUTION Remove the power cord from the electrical outlet before you connect or disconnect any cable or electronic board or assembly for personal safety and to prevent damage to the printer Disconnect any connections between the printer and PCs peripherals Notes e Remove the waste toner bottle color toner cartridges imaging unit and media tray before removing other printer parts The imaging unit should be carefully set on a clean smooth and flat surface It should also be protected from light while out of the printer e Unless otherwise stated reinstall the parts in reverse order of
70. the page Therefore be sure to set the top margin in REGISTRATION before setting the duplex top margin See Registration on page 3 4 To set the Top Margin duplex Select DUPLEX TESTS from Diag Menu and press Select v Select Quick Test and press Select y Select Single and press Select x Hold the page to the light to see whether the top margin of the back aligns with the top margin of the front Select Top Margin from DUPLEX TESTS Use lt or p to select the margin setting you need to change e Each increment shifts the duplex top margin by 1 100 of an inch e The Top Margin duplex range is 50 to 50 and the default value is 0 e An increase in the value moves the backside top margin down and widens the top margin A decrease moves the top margin upward and narrows the top margin 7 Press Select y to save the new value 8 Print the Quick Test duplex again steps 1 4 to verify the adjustment Repeat if necessary E a Left Margin duplex This setting shifts the image on the back of the duplex sheet to the left or right to correctly position it on the page Therefore be sure to set the top margin in REGISTRATION before setting the duplex top margin See Registration on page 3 4 To set the Left Margin duplex Select DUPLEX TESTS from Diag Menu and press Select v Select Quick Test and press Select y Select Single and press Selec
71. the rear Replace the HVPS See Replace the controller shield See Top cover assembly removal High voltage power board See Controller on page 4 13 supply HVPS assembly board removal on removal on page 4 35 page 4 20 Turn the printer on and check the cable at JHVPS1 connector on the controller board without disconnecting it Verify the following voltage values JHVPS1 Pin Voltage io sava m eave ria ave 44 Ground is Ground Are the values approximately correct Tray x sensor service check When the printer is in Ready state pull the Go to step 2 Go to step 4 standard tray out The display should indicate Tray x Missing Reinsert the tray Does the message remain on the display Diagnostic information 2 51 5025 2xx 4xx Check the vertical wall at the right rear of the Replace the tray Go to step 3 tray for damage Is the tray damaged Check for a dislodged tray present sensor Replace the option tray Contact the next level of present sensor support Is the sensor dislodged e If the 650 sheet tray is affected replace the 650 sheet drawer assembly If the 550 sheet assembly is affected replace the entire 550 sheet drawer assembly Does the message Iray x Missing fail to Go to step 5 Problem resolved appear when the tray is pulled out 2 52 Service Manual 5025 2xx 4xx 1 Turn off the printer Problem resolved Replace the controller 2 Remove
72. to the requirements of IEC 60825 1 Class laser products are not considered to be hazardous The printer contains internally a Class lllb 3b laser that is nominally a 5 milliwatt gallium arsenide laser operating in the wavelength region of 645 670 nanometers The laser system and printer are designed so there is never any human access to laser radiation above a Class level during normal operation user maintenance or prescribed service condition Laser Der Drucker erf llt gem amtlicher Best tigung der USA die Anforderungen der Bestimmung DHHS Department of Health and Human Services 21 CFR Teil J fur Laserprodukte der Klasse 1 In anderen L ndern gilt der Drucker als Laserprodukt der Klasse l der die Anforderungen der IEC International Electrotechnical Commission 60825 1 gem amtlicher Best tigung erf llt Laserprodukte der Klasse gelten als unsch dlich Im Inneren des Druckers befindet sich ein Laser der Klasse Illb 3b bei dem es sich um einen Galliumarsenlaser mit 5 Milliwatt handelt der Wellen der Lange 645 670 Nanometer ausstrahlt Das Lasersystem und der Drucker sind so konzipiert da im Normalbetrieb bei der Wartung durch den Benutzer oder bei ordnungsgem er Wartung durch den Kundendienst Laserbestrahlung die Klasse bersteigen w rde Menschen keinesfalls erreicht Avis relatif l utilisation de laser Pour les Etats Unis cette imprimante est certifi e conforme aux provisions DHHS 21 CFR alin
73. used to verify the correct placement of the top margin on the back side of a duplex page Lesmark CEIT Duck Test Device Ioformation Frat Deva trei MT MARGEN SETTINGS E Note Before you set the duplex top margin be sure to set the registration See Registration on page 3 4 The paper you choose to print the page on should be either Letter or A4 To run the Quick Test duplex 1 Select DUPLEX TESTS from Diag Menu and press Select y 2 Select Quick Test and press Select y 3 Select Single or Continuous and press Select y e The single Duplex Quick test prints the Quick Test on front and back e The printer attempts to print the Quick Test Page from the default paper source e Check the Quick Test Page for the correct offset between the placement of the first scan line on the front and back side of the duplexed sheet For information about changing the margin see Top Margin duplex on page 3 14 The single test stops automatically when a single duplex sheet is printed and the continuous test continues until you press Stop W Diagnostic aids 3 13 5025 2xx 4xx Top Margin duplex This setting controls the offset between the first scan line on the front of the duplex page and the first scan line on the back of
74. w l A C B C Partially reinstall the rear shield to protect the controller board and turn the printer so the rear shield rests on the table and the bottom is facing you Warning For models with a wireless antenna use supports to prevent the antenna from taking the weight of the printer Repair information 4 61 5025 2xx 4xx 7 Remove the two screws D on the bottom AAA a j a D 8 On the right 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 Note Observe the location of the shaft and hole for reinstallation 10 Remove the ACM 4 62 Service Manual 5025 2xx 4xx Installation notes 1 Place the left side of the ACM in the printer Make sure the shaft on the left side aligns with the hole in the frame 2 Install the two springs J wv NE as E E A Reinstall the three screws holding the ACM to the printer Turn the printer to the proper upright position Reroute the cable making sure to place the cables into the two retainers on the left side Remove the rear shield and reconnect the cable Replace the rear shield oO a po Repair information 4 63 5025 2xx 4xx Pick tires removal See Pick tires on page 7 11 for the part number Note You will need to have a soft padded work surfac
75. 0 to 127 V ac at 47 to 63 hertz Hz nominal e 99 to 137 V ac extreme 100 voltage models e 100 V ac at 47 to 63 hertz Hz nominal e 90to 110 V ac extreme 1 6 Service Manual 5025 2xx 4xx High voltage models e 220 to 240 V ac at 47 to 63 hertz Hz nominal not available in all countries e 198 to 259 V ac extreme Notes e Using a 220 V acto 110 V ac power converter with a low voltage printer is not recommended e Using an inverter to change DC to AC voltage 12 V to 120 V for example is not recommended e All duplex models are ENERGY STAR compliant Acoustics All acoustic measurements are made in accordance with ISO 7779 1999 and reported in conformance with ISO9296 1988 04 15 Operating mode 1 Meter average sound pressure at 4800 CQ Lexmark Lexmark Lexmark Lexmark Lexmark C540n C543dn C544n C544dn C546dtn Printing simplex 47 dBA 47 dBA 49 dBA 49 dBA 49 dBA Printing automatic N A 50 dBA N A 51 dBA 51 dBA duplex de Inaudible Inaudible Inaudible Inaudible Inaudible Quiet Mode simplex 46 dBA 46 dBA 46 dBA 46 dBA 46 dBA Environment specifications Environment Specifications Operating Air temperature operating 16 to 32 C 60 to 90 F Air temperature power off 10 to 43 C 50 to 110 F Air relative humidity Relative Humidity 8 to 80 Wet bulb temperature operating 23 C 73 F maximum Wet bulb temperature power off 27 C 80 F maximum Ambient operating environment 16 to 32 C 60 to 90
76. 1 sensors bin full narrow media Base Sensor Test standard bin 3 16 parts catalog 7 6 removal 4 18 service check 2 23 duplex S1 Base Sensor Tests 3 16 locations 5 1 parts catalog 7 6 removal 4 25 service check 2 25 front door service check 2 26 fuser exit Base Sensor Test 3 16 parts catalog 7 6 removal 4 33 service check 2 27 input S2 Base Sensor Test 3 16 Base Sensor Tests 3 16 service check 2 29 toner density sensor TDS parts catalog 7 8 removal 4 69 toner meter cycle Base Sensor Tests 3 16 tray present location 5 1 parts catalog 7 6 removal 4 73 service check 2 51 serial number viewing 3 18 service checks 90x xx error 2 22 925 01 fan error 2 22 950 xx EPROM mismatch failure 2 23 bin full narrow media sensor 2 23 dead printer 2 24 duplex manual feed sensor S1 2 25 front door sensor or switches 2 26 fuser 2 28 fuser exit sensor 2 27 input S2 sensor 2 29 main drive gear assembly 2 30 networking 2 31 operator panel 2 33 operator panel USB cable 2 38 paper pickdrive assembly 2 39 print quality 2 39 printhead 2 49 toner meter cycle TMC card 2 50 toner meter sensors 2 50 transfer roll 2 51 tray x sensor 2 51 trays 2 and 3 2 53 USB 2 54 service error codes 2 13 skew setting 3 5 values 3 5 specifications acoustics 1 7 clearances 1 5 connectivity network 1 3 data streams 1 4 dimensions 1 5 duplex capability 1 9 environmental 1 7 memory 1 2 operating modes 1 4 print quality 1 3 specificati
77. 200 dpi reduced printer speed is supported in PS and PCL only Connectivity network support Supported X Not supported Lexmark C544n Lexmark C540n C544dn C544dn Network protocol C543dn wireless Lexmark C546dtn USB A host ports In front low full speed This port only supports the following flash drives and file types Supported flash drives Lexar FireFly 512 MB 1GB size SanDisk Cruzer Micro 512 MB 1 GB size or Sony 512 MB 1 GB Supported file types pdf gif jpeg jpg omp png tiff tif ocx dcx 802 11n Wireless Network card Manufacturing installs the wireless card A wireless card CANNOT be installed post manufacturing a While other USB flash drives have not been tested and therefore cannot be approved by Lexmark these products may function if the storage device meets the following qualifications e Supports the USB 2 0 specification supporting the Full Speed mode e Uses the FAT file system b PDF files used with Direct USB printing must support PDF standard version 1 5 or earlier PDF files with restricted printing permissions or encryption are not supported General information 1 3 5025 2xx 4xx Operating modes EA Description Quiet Designed for customers where noise levels are a very important factor e Print quality is maintained at factory default level e Speed is reduced Eco Mode Off is default Designed for customers where the environment is a key fac
78. 22 Print Log 3 22 exit diagnostics 3 23 Hardware Tests Button Test 3 12 DRAM Test 3 12 Panel Test 3 11 Input Tray Tests Feed Tests 3 15 Sensor Test 3 15 Miscellaneous Tests Motor Detect 3 17 Print Tests input source tests 3 10 Prt Qual Pgs 3 11 Printer Setup Configuration ID 3 19 Defaults 3 18 Engine Setting 1 4 3 18 ITU Barcode 3 19 Model Name 3 18 Page Counts 3 18 Serial Number 3 18 Registration 3 4 Bottom Margin 3 4 Left Margin 3 4 Quick Test 3 5 Right Margin 3 4 Skew 3 5 Top Margin 3 4 Reports Menu Settings Page 3 22 tests and settings 3 2 TPS Setup Cal Ref Adj 3 21 Left 3 21 Reset Color Cal 3 21 Right 3 21 diagram menu 2 56 l 2 Service Manual DRAM Test 3 12 duplex duplex reference edge removal 4 22 duplex sensor 2 25 4 25 Left Margin 3 14 models 1 9 parts catalog 7 2 Quick Test 3 13 theory 3 48 Top Margin 3 14 E electrophotographic process EP process 3 37 Energy Conserve 3 26 engine setting 3 18 error codes 1xx service error codes 2 13 2xx paper jams 2 11 9xx service error codes 2 17 attendance messages 2 5 ESD sensitive parts 4 1 event log configuration menu 3 25 diagnostics mode 3 22 exit deflector parts catalog 7 4 removal 4 27 F Factory Defaults 3 26 fan service check 2 22 flash updating code 3 28 flash drive firmware 3 28 Flash Test 3 17 Font Sharpening 3 27 frame lower left removal 4 49 right removal 4 55 FTP firmware update 3 28 fuser asse
79. 4 40X2263 Duplex reference edge 40X5403 Image transfer unit ITU assembly 40X1557 Paper pick motor drive assembly standard tray 40X5412 Main drive gear assembly with motors 40X5406 Fuser assembly 115 V 40X5407 Fuser assembly 230 V 40X5408 Fuser assembly 100 V oOo O O NOA O 40X5433 Exit deflector and bin full narrow media sensor flag Parts catalog 7 5 5025 2xx 4xx ics Electron Assembly 3 7 6 Service Manual Assembly 3 Electronics 5025 2xx 4xx Part Units Units Descritor number mach FRU p Oouwrr W Ye OOOO OOO CO O CO OOOO O O N 40X1525 40X1526 40X2268 40X5319 40X5036 40X5404 40X5405 40X5426 40X5409 40X5413 40X1766 40X0288 40X0301 40X4596 40X0273 40X0279 40X0275 40X0270 40X1792 40X3141 40X0303 40X1773 40X1772 40X1791 40X0287 40X0271 h l _b _b _b _ b mb Controller board C544n C544dn C544dw Controller board C540n C543dn Controller board C546dn only Antenna for wireless card C544dw only Wireless network card assembly C544dw only Toner meter cycle card assembly High voltage power supply Photo sensor and retainer one per package used for A Tray present B Duplex C Bin full narrow media sensor Low voltage power supply universal power supply Fuser exit sensor Power cord 2 5M straight USA Canada Bolivia Peru shown Power cord 2 5M straight Argentina Power cord 2 5M straight Aust
80. 5 motor drive assembly See board See Controller Paper pick motor drive board removal on assembly removal page 4 20 standard tray on page 4 61 Is the voltage approximately 5 V dc Main drive gear assembly EP drive service check Turn the printer off and remove the rear Replace the JCARTB1 Go to step 2 shield See Top cover assembly removal cable on page 4 13 Check the cable 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 Verify the following values at JCARTB1 on the Goto step 3 Replace the controller controller board board See Controller board removal on JCARTB1 page 4 20 Value 24 V de 24 Vdc e ava o ferous 42 Ground ria fava is avae Are the values approximately correct 3 Replace the main drive assembly See Main Problem resolved Replace the controller drive gear assembly removal on board See Controller page 4 59 board removal on page 4 20 Does the error clear 2 30 Service Manual 5025 2xx 4xx 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 conf
81. 6 4 in 4 kg 8 7 Ib 550 sheet Duo Drawer only 133 mm 5 2 in 424 mm 16 7 in 416 mm 16 4 in 4 kg 8 7 lb C526dtn Clearances Lexmark C540n C543dn C544n and C544dn w C546dtn 100 mm a Tn General information 1 5 5025 2xx 4xx 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 current is given in Amperes A Average power while printing Simplex 480 W 500 W 500 W Automatic duplex 340 W 340 W 340 W Lexmark C540n Lexmark C544n Printing states C543dn and C544dn Lexmark C546dtn Average power while idle Automatic duplex is not supported on the C540n and C544n Typical electricity consumption Power supply voltage kwh 100 V 50 Hz 115 V 60 Hz 230 V 50 Hz Lexmark C540n and C543dn 3 73 kwh 3 5 kwh 3 92 kwh TEC Eco Mode 3 41 kwh 3 30 kwh 3 55 kwh Lexmark C544n and C544dn 3 97 kwh 4 06 kwh 4 20 kwh TEC Eco Mode 3 57 kwh 3 42 kwh 3 57 kwh Lexmark C546dtn 3 97 kwh 4 06 kwh 4 20 kwh TEC Eco Mode 3 57 kwh 3 42 kwh 3 57 kwh TEC Typical Electricity Consumption Energy measurements are made according to ENERGY STAR Qualified Imaging Equipment Typical Electricity Consumption Test Procedure and are in units of kilowatts per week kwh week Actual electricity consumption will vary by device usage Low voltage models e 11
82. AS B A 7 Rotate the printer to view the right side 8 Remove the screw C securing the spring contacts 9 Release the tabs D on the spring contact to release the spring contacts Repair information 4 67 5025 2xx 4xx 10 Disconnect the cable E from the controller board at JSC1 i E he dd ee tard a saa E 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 unwrap the toroid When you re install be sure to wrap the toroid five times as shown 4 68 Service Manual 5025 2xx 4xx Toner density sensor TDS removal left or right sensor See Toner density sensors left or right one in package on page 7 9 for the part number Note The toner density sensor is also called the toner patch sensor TPS The toner density sensors are the same but the left sensor has a thermistor attached which needs to be removed when you 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 4 13 3 Disconnect the toner density sensor cable from JTDS1 connector A Right or JTDS2 connector A Left on the controller board If you are removing the left toner density sensor also disconnect the thermistor
83. B 3 3 V dc fuser exit sensor 2o TH Bilal nets e Fuser exit sensor pins 4 6 V_BIN_4 FUSER_EXIT_SNSR 3 3 V dc e feom oo JCARTB1 CART1_HALL_U Drive motor for cartridges NC_CARTB1_ 2 e Black drive motor rear motor even pin numbers 2 20 A 4 5 e CMY color drive motor odd pin ENS V_CART2_WING_W 24 V dc numbers 1 19 E CART1 HALL W fee V_CART2 WING V 24 V de 7 EE V CART2 WIND U 24 V de EIN CC e fom Toner meter connector EM omver e eee JCVR1 TY V_24V_CVR 24 V de Cover open switch COVER_OPEN cover open 0 V dc cover closed 24 V dc Connector locations 5 5 5025 2xx 4xx Controller board connectors continued Note SW indicates voltage is switched on during a print cycle otherwise voltages are taken with printer at Ready state door closed and cables plugged in JFAN1 FAN_FG 3 3 V dc 1 V_FUSER_PHA 24 V dc doors closed V_FUSER_PHA 24 V dc doors closed System fan JFUSES1 Fuser V_FUSER_PHB 24 V dc doors closed 3 V_FUSER_PHB 24 V dc doors closed Duplex sensor S1 7 9 Thermistor white wire 10 11 A eo a a a 2 3 4 5 Motor pins 1 4 Thermistor black wire 5 6 u FUSER BUR TAM ATA ground e Ground no ooo JHVPS1 NE Developer transter HVPS 14 11 M DEV PWM OUT MEN K DEV PWM OUT 4 CMY_CHG PWM_OUT 7 ES C DEV PWM OUT EN ICI m oso our 89 V de 7 10 2 Ca CE ca JINT 1 1 VS JINT
84. Dev Bias Adj Transfer Adjust oooooocoooonooooooooooo 3 20 ee SIG os oy oe oh eon bee creo ene dee ee ee ce eee E reas eee sana 3 21 ed ie sheep ars ra rea 3 21 CPPCC EE E EEEE gang eee eee anne E EE be hee E E E E E EEE T E E es 3 21 as e q on A 3 21 a A lt P er ee ee ee TEE ee ee ee ee ee ee 3 22 Te as eg dig cae ore E ee ee ae eo eae 3 22 A 3 22 e AAA 3 22 Pattee b6 6ebocnwss saad odes baa Pou ad FE a eRe eas a eee eee 3 22 Be Bes so we os oe eS ee A 5 540s ee eee es 3 23 Sf oC a II 3 23 Configuration menu Config Menu 00 cece eee eee ees 3 24 AVD TOSS rra 20550 255 000 9654 da AAA ARA RANA ARA 3 24 A A A TT q eee ees 3 24 COOP TAUPO securarrrirndrndr criada RARA 694 06 456500 00 0900068054 RRA 3 24 o en E Pe ea a eee ee eee 3 25 PACHA Selle A no oo had ches 50 be pet een bees 3 25 Ee 5 5464 4450s btw A Sh Seen 3 25 e ha ee ek Od ws bedded A 3 25 PRES EMUO RAR ARAN AOR Loh oe ee AAR N 3 25 VEMO MOCE sided dace ieee i a oe dh ARA AA AA 3 25 POO IS ci o RS A AAA AR ended be eee 3 26 e AAA 3 26 AUS COI Fale oe sation 60040694906 e060 RETR AAA IE A eee os 3 27 FONTE SNA DOMINO surcar A OS OR ee eee eee ied 3 27 EXCMO sarro ee dd tir e RARA AAA ERA AAA RARA NAAA 3 27 Table of contents V 5025 2xx 4xx IRA DMT TIMES circo AAA AS 3 28 sr An 3 28 Using a networked computer to update the printer firmware over a network 3 28 A A bo Ge eee as cay Senn seen eee eee ee eas 3 28 Usng
85. Disconnect the fuser exit sensor cable D 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 exit sensor which remains with the cage E 10 Place the printer on the right side Repair information 4 51 5025 2xx 4xx 11 Remove the tray 2 connector F by pinching the tabs together and pushing the connector into the printer F 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 the plastic shield ww H J G J 14 Remove the AC receptacle from the left lower frame 4 52 Service Manual 5025 2xx 4xx 15 Remove the three screws K securing the left lower frame K 16 Remove the screw L above the frame e Q Repair information 4 53 5025 2xx 4xx 17 Swing the left lower frame away from the printer and remove 4 54 Service Manual 5025 2xx 4xx Right lower frame Note Remove the duplex sensor the tray present sensor the spring spring holder and the wireless antenna plate which are not part of the right and left lower frames The cable cover is part of the FRU Note To properly reinstall the duplex sensor and the tray present sensor also order two photo sensors see page 7 7 and replace the sensor retaining plates
86. F and 8 to 80 RH Cartridges 40 to 43 C 40 to 110 F Printer with cartridges 40 to 43 C 40 to 110 F Printer without cartridges 40 to 43 C 40 to 110 F Air relative humidity Relative Humidity 8 to 80 Altitude 10 300 meters 34 000 feet Wet bulb temperature power off 27 C 80 F Maximum In some cases performance specifications such as paper OCF EP cartridge usage are specified to be measured at an ambient condition General information 1 7 5025 2xx 4xx Media handling Input and output sources and capacities Lexmark Lexmark Sheet numbers are assuming Lexmark C543dn C544dtn Lexmark 20 Ib xerographic paper C540n C544n C544dn C544dn with C546dtn C544dw second tray Standard input sources Standard input tray 250 sheets 250 sheets 250 sheets 250 sheets 250 sheet tray Second tray capacity N A N A 550 sheets 550 sheets 650 sheet Duo Drawer standard on standard C544din optional on C544dn Multipurpose tray capacity N A N A 100 sheets 100 sheets 650 sheet Duo Drawer Optional input sources maximum 1 total of all inputs is 4 650 sheet Duo Drawer 550 sheets 550 sheets includes 100 sheet MP or 100 sheets in or 100 sheets in feeder MP feeder MP feeder Multipurpose try capacity 100 sheets 100 sheets 650 sheet Duo Drawer Optional third tray capacity 550 sheets 550 sheets tray 3 CECI IO S Standard output sources no optional output sources are availabl
87. If the problem persists go to Printhead service check on page 2 49 Perform a POR If the problem persists go to Printhead service check on page 2 49 Perform a POR If the problem persists go to Printhead service check on page 2 49 Perform a POR If the problem persists go to Printhead service check on page 2 49 Perform a POR If the problem persists go to Printhead service check on page 2 49 Perform a POR If the problem persists go to Printhead service check on page 2 49 Perform a POR If the problem persists go to Printhead service check on page 2 49 Perform a POR If the problem persists go to Printhead service check on page 2 49 Perform a POR If the problem persists go to Printhead service check on page 2 49 5025 2xx 4xx Service error messages 1xx 9xx continued O O Ce 109 02 Service The black printhead failed to complete Perform a POR lf the problem persists go Black Printhead Servo to Printhead service check on page 2 49 109 03 Service The black printhead mirror motors Perform a POR If the problem persists go Black Printhead failed to achieve lock to Printhead service check on page 2 49 109 04 Service The black printhead mirror motors lost Perform a POR If the problem persists go Black Printhead motor lock to Printhead service check on page 2 49 109 05 Service Failure reading NVRAM from Pe
88. Magenta Printhead 108 13 Service Magenta Printhead 109 xx Service Black Printhead 109 01 Service Black Printhead 2 14 Service Manual The cyan laser showed bad in testing Failure writing data tot he printhead Failure reading data from the printhead Printhead declared error Magenta printhead error The magenta printhead lost HSYNC The magenta printhead failed to complete servo The magenta printhead mirror motors failed to achieve lock The magenta printhead mirror motors lost motor lock Failure reading NVRAM from the magenta printhead The magenta laser showed bad in testing Failure writing data tot he printhead Failure reading data from the printhead Printhead declared error Black printhead error The black printhead lost HSYNC Perform a POR lf the problem persists go to Printhead service check on page 2 49 Perform a POR If the problem persists go to Printhead service check on page 2 49 Perform a POR If the problem persists go to Printhead service check on page 2 49 Perform a POR If the problem persists go to Printhead service check on page 2 49 Perform a POR If the problem persists go to Printhead service check on page 2 49 Perform a POR If the problem persists go to Printhead service check on page 2 49 Perform a POR If the problem persists go to Printhead service check on page 2 49 Perform a POR
89. N A Maximum possible DORSDRAMP Lexmark C546dtn Connections USB 2 0 High Speed Ethernet 10 100 BaseTx USB A allows direct USB printing using approved USB flash memory device PictBridge allows printing photos directly from a compatible camera Wireless standard 802 11 b g n x Y C544dn x wireless unit only a Dual Inline Memory Module An optional memory card that can be plugged into an available memory slot The maximum usable DDRSDRAM is standard soldered plus 512MB The Lexmark C546dtn ships with a 128MB DIMM in the extra memory slot Increasing memory beyond standard 256MB require the removal of this DIMM 1 2 Service Manual 5025 2xx 4xx Print quality During the life of the printer components are subject to wear based on usage Printers continuously operating at or near the maximum duty cycle may require service for replacement of these components to ensure high quality printing and good performance throughout the life of the printer The fuser and ITU replacement should be determined by checking the last sheet of the Menu Settings Page Either OK or Replace appears To print a Menu Settings page 1 Press Menu f on the operator panel 2 Select Reports from the Admin Menu and press Select y 3 Select Menu Settings and press Select y Replacement is recommended every 30 000 pages for the imaging unit e 4800C Q default full printer speed e 1
90. POR If the problem persists go to Printhead service check on page 2 49 Perform a POR If the problem persists go to Printhead service check on page 2 49 Perform a POR If the problem persists go to Printhead service check on page 2 49 Perform a POR If the problem persists go to Printhead service check on page 2 49 Perform a POR If the problem persists go to Printhead service check on page 2 49 Perform a POR If the problem persists go to Printhead service check on page 2 49 Perform a POR If the problem persists go to Printhead service check on page 2 49 Perform a POR If the problem persists go to Printhead service check on page 2 49 Perform a POR If the problem persists go to Printhead service check on page 2 49 Perform a POR If the problem persists go to Printhead service check on page 2 49 Diagnostic information 2 13 5025 2xx 4xx Service error messages 1xx 9xx continued EN CO CN 107 08 Service Cyan Printhead 107 11 Service Cyan Printhead 107 12 Service Cyan Printhead 107 13 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 108 08 Service Magenta Printhead 108 11 Service Magenta Printhead 108 12 Service
91. Revision October 2 2009 Lexmark C540n C543dn C544n C544dn C544dtn C544dw and C546dtn 5025 2xX 4XX Service Manual e Table of contents e Start diagnostics e Safety and notices e Trademarks e Index 5025 2xx 4xx Edition October 2 2009 The following paragraph does not apply to any country where such provisions are inconsistent with local law 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 express or implied warranties in certain transactions therefore this statement may not apply to you This publication could include technical inaccuracies or typographical errors Changes are periodically made to the information herein these changes will be incorporated in later editions Improvements or changes in the products or the programs described may 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 ServicelnfoAndTraining Lexmark com Lexmark may use or distribute any of the information you supply in any way it believes appropriate without incurring any obligation to you References in this publication to products programs or services do not imply that the manufacturer
92. TEC 825 HERE FET BOC ABURRE ME A TT EN SLA ah amp A or ZE IIb 3b BY BIL GRE REF ES 2AA am A EAO Fie Kw 770 795 nm Z B gt BMI AS MITE P WRI A AR VE ASA PRMEAM AB E F AN amp fi A PR ER fh T DA TE OS Service Manual 10 2 2009 5025 2xx 4xx auie 152 alo ASSO CHSt DHHS 21 CFR Subchapter 39 PAS 24311 ges olol CISHFQIO 129 2 LEHIN E Eo 825 TSS rote 1332 ao AE Oz oles pie a AOA ASSES wae NeR PELO E poe 5 Hele 43 Oop2 ALO E glo H 770 795 Le BELO TAH OF AY SScteE Class Ill 3b Ulo 4S LH O 2a USUCH aol AAD BREE BY As SOIL FX 47 S Eze PAE Mala AEH OIA A7 2l Class Axo doly PESO AHEto Sch YI Aes AAA USL Notices and safety information Xiii 5025 2xx 4xx 10 2 2009 XIV Service Manual 10 2 2009 5025 2xx 4xx Safety information e The safety of this product is based on testing and approvals of the original design and specific components The manufacturer is not responsible for safety in the event of use of unauthorized replacement parts e 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 e There may be an increased risk of electric shock and personal injury during disassembly and servicing of this product Professional service personnel should understand this and take necessary precautions CAUTION When you see this symbol there is a danger from hazardous voltage in the area of the product where
93. YTES SENT fact ie Copyright 2001 2002 2003 Lexmark International Inc Ready A 2 Browse for flash file My Computer My Network Places Type FLS File Size 577 KB Filename fupdemgi Files of type Flash Files fls pil y Cancel Open as read only Copyright 2001 2002 2003 Lexmark International Inc Diagnostic aids 3 29 5025 2xx 4xx 3 Select the printer from the list of printers installed on the computer 4 Press Start USBFlash 1 4 File View Help ENTER FILENAME TO FLASH TO PRINTER A SELECT PRINTER FROM LIST A OM Lexmark C54x series BYTES SENT Copyright 2001 2002 2003 Lexmark International Inc USBFlash 1 4 0 x File View Help ENTER FILENAME TO FLASH TO PRINTER m SELECT PRINTER FROM LIST gt START BYTES SENT g Copyright 2001 2002 2003 Lexmark International Inc Ready te 5 Repeat these steps for every file you are updating on the printer 3 30 Service Manual 5025 2xx 4xx Paper jams Avoiding jams The following hints can help you avoid jams Use only recommended paper or specialty media For more information see the Card Stock amp Label Guide available on the Lexmark Web site at www lexmark com publications Do not load too much paper Make sure the stack height does not exceed the indicated maximum height Do not load wrinkled creased damp o
94. a ee et ee ee nn ee ee ee ee FA IA EC CA E E L a MAMA r ee 0 E E E A ED O EM EA AMA AR Ft 2 a a For MP feeder and manual feeders the Default Source Menu displays Manual Paper and Manual Env Select Manual Env for envelopes or when the type in Custom Type lt x gt is an envelope For other types use Manual Paper b The duplex unit supports this media type as long as the customer has selected the custom type from those types the duplex unit supports General information 1 11 5025 2xx 4xx Weight ranges for each media type CO MS Paper 2 gt 78 Xerographic or 60 to 75 g m grain long Light Paper business paper 16 to 19 9 Ib bond 75 to 90 g m grain long Plain Paper 20 to 24 Ib bond 90 to 105 g m grain long Heavy Paper 24 to 28 Ib bond 105 to 176 g m grain long Card stock 28 to 47 lb bond A a Envelopes Sulfite wood free or 60 to 105 g m to 28 Ib bond 4 Multipurpose ree 100 cotton Card stock upper limit grain long Card Stock upper limit grain short feeder or manual slot only For 60 to 176 g m paper grain long fibers are recommended Paper less than 75 g m 20 Ib must be printed with Paper Type set to Light Paper 100 cotton content maximum weight is 24 Ib bond 28 lb bond envelopes are limited to 25 cotton content The duplex unit supports paper weights between 60 105 g m 16 28 pound grain long bond The duplex unit does not support card stock tran
95. a menu settings page Go to step 9 e If the 550 sheet option Note If two option trays are used the 650 Er appear go to sheet will appear as tray 2 and the 550 sheet i e If the 650 sheet tray tray will appear as tray failed to appear go to Are all the attached option trays listed on the step 10 first page of the menu settings pages 1 Remove the 650 sheet tray from the printer Goto step 11 Replace the 550 sheet tray 2 Attach the 550 sheet tray directly to the printer 3 Print a page from the 550 sheet tray Did the page print With only the 650 sheet tray attached to the Go to step 11 Replace the 650 sheet tray printer print a page from the 650 sheet tray Did the page print 1 Turn off the printer Consult your next level Replace the controller 2 Remove the rear shield see Top cover support board See Controller assembly removal on page 4 13 board removal on 3 Disconnect the cable at JOPT1 on the page 4 20 controller board 4 Turn the printer on 5 Measure the voltages below JOPT1 Voltage Ground Ground 24V Ground a Ground 10 Ground Are the voltages correct USB service check Is the USB cable properly connected to the Go to step 2 Properly connect the cable printer and host PC at both ends Try a different USB cable Issue fixed Go to step 3 Does this fix the issue Connect a different device to the USB cable Replace the Controller There is an issue with the
96. age is transferred from the transfer belt to the media The timing of the paper pick is determined by the speed of the transfer belt The media is carried to the fuser rollers where heat and pressure are applied to the page to permanently bond the toner to the page The fuser rollers push the media into the output bin The transfer unit is cleaned and the process begins again for the next page Diagnostic aids 3 37 5025 2xx 4xx Step 1 Charge During the charge step voltage is sent from the high voltage power supply to the charge roll inside each of the four photoconductors The charge roll is part of the photoconductor unit The charge rolls A put a uniform negative charge over the entire surface of the photoconductor to prepare it for the laser beam Service tips e lf the 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 table that prints from the operator panel Press Menu J l select Reports and select Print Defects e lf the charge roll is severely damaged the surface of the photoconductor will not be charged properly and heavy amounts of toner will be deposited on the photoconductor This causes the printed page to be saturated with 100 of each color The imaging unit will
97. aging unit or to the same point on the residual image corresponding to the color of the photoconductor unit the image See Developer See Imaging unit IU unit removal on removal on page 4 45 page 4 21 Is the distance 43 9 mm Is the distance between the original image and Replace the the residual image 94 2 mm photoconductor See Developer unit removal on page 4 21 4 Run the Menu Setting Page twice to clear any Replace the fuser See Contact your next level of debris Fuser assembly support To print a menu settings page eee Cayenne 1 Press Menu on the operator panel 2 Select Reports from the Admin Menu and press Select 4 3 Select Menu Settings and press Select y Is there still any toner contamination on the fuser assembly Diagnostic information 2 47 5025 2xx 4xx Print quality solid color page lt Service tip A solid color page is generally caused by a problem in the high voltage controller or an incorrect high voltage in the printing process resulting in toner development on the entire photoconductor drum Replace the photoconductor unit part of the Problem resolved Go to step 2 imaging unit Remove the imaging unit and remove the developers Place the original developers in the new photoconductor and then replace the imaging unit See Imaging unit IU removal Does this fix the problem A fault
98. ain 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 may still cause paper feeding problems in any laser printer for example if the paper curls excessively under normal printing conditions 1 14 Service Manual 5025 2xx 4xx Tools required for service Flat blade screwdrivers various sizes 1 Phillips screwdriver magnetic 2 Phillips screwdriver magnetic 2 Phillips 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 cutters Spring hook Feeler gauges Analog or digital multimeter Parallel wrap plug 1319128 Twinax serial debug cable 1381963 Coax serial debug cable 1381964 Flashlight optional General information 1 15 5025 2xx 4xx Acronyms BLDC C DIMM DRAM EEPROM EP ESD FRU GB HVPS ITU IU JIS K LASER LCD LED LVPS M MPF NVRAM PC pixel POR POST PWM RIP ROM SDRAM SIMM TDS TPS Vac V dc Y 1 16 Service Manual Brushless DC Motor Cyan Dual Inline Memory Module Dynamic Random Access Memory Electrically Erasable Programmable Read Only Memory ElectroPhotographic
99. and press Select y The message Printing appears on the display Once the Quick Test Page completes printing the Registration screen displays again 3 6 Service Manual 5025 2xx 4xx Alignment Aligns each of the color planes to the black plane Print the Quick Test under each color Cyan Yellow and Magenta and adjust the Top Margin Left Margin Right Margin Skew and Bow Prints the Print Alignment Pages and requires that the best line in each set of lines must be selected To get started 1 Select Alignment Menu from the Diag Menu and press Select 2 Select a color Cyan Yellow or Magenta and press Select y Note The yellow alignment page markings are more difficult to see so you might not want to pick it first 3 Select the Quick Test and press Select to begin printing The message Printing appears on the display A page similar to the following prints Cyan Alignment Top T Coarse Adjustment St 4 Skew Z Coarse Adjustment 50 60 40 20 0 20 40 60 w 80 00 40 20 0 20 40 60 60 Top T Fine Adjustment Skew Z Fine Adjustment 20 ee 20 a 9 18 16 ee 16 1s mm f 12 __ 12 10 _ ou 1 8 f _ 6 4 a 4 ey _ 8 2 E m of 6 _ E 10 10 gt 12 12 ee gt 4 14 16 16 t 18 20 _ 20 T 0
100. articular object Selecting which Color Samples set to use for a particular color matching problem depends on the Color Correction setting being used Auto Off or Manual the type of object being printed text graphics or images and how the color of the object is specified in the software program RGB or CMYK combinations When the printer Color Correction setting is set to Off the color is based on the print job information and no color conversion is implemented Note The Color Samples pages are not useful if the software program does not specify colors with RGB or CMYK combinations Additionally certain situations exist in which the software program or the computer operating system adjusts the RGB or CMYK combinations specified in the program through color management The resulting printed color may not be an exact match of the Color Samples pages What are detailed Color Samples and how do I access them Detailed Color Samples sets are available only through the Embedded Web Server of a network printer A detailed Color Samples set contains a range of shades displayed as colored boxes that are similar to a user defined RGB or CMYK value The likeness of the colors in the set are dependent on the value entered in the RGB or CMYK Increment box To access a detailed Color Samples set from the Embedded Web Server Open a Web browser In the address bar type the network printer IP address Click Configuration Click Color Sampl
101. 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 amounts of toner lt is important to prevent extensive blank pages from being processed if they should have toner on them Developer unit removal The developer units are not FRUs 1 Open the toner access door 2 Remove the toner cartridges 3 Remove the imaging unit See Imaging unit IU removal Warning Do not touch the underside of the imaging unit This could damage it 4 Remove the developer unit s Repair information 4 21 5025 2xx 4xx Duplex reference edge removal See 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 I e A B A B 4 22 Service Manual 5025 2xx 4xx 4 Remove the four screws D from 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 door ribs B A B 2 Replace the four screws in the duplex reference guide Repair information 4 23 5025 2xx 4xx 3 Be sure the shaft and bearing have not shifted out of the guide If so make sure that the bearing on the left is aligned with the slot C facing down
102. board removal on Does the error clear page 4 20 Input S2 sensor service check Note The input S2 sensor is part of the paper pick motor drive assembly FRU and is not available otherwise Enter Diagnostics Menu turn the printer off Replace the paper pick Go to step 2 press and hold q and y turn the printer on motor drive assembly See and then release the buttons when the Paper pick motor drive installed memory and processor speed assembly removal displays standard tray on Perform the Base Sensor Test See Base page 4 61 Sensor Test on page 3 16 1 Select Base Sensor Test and press Select v 2 Select S2 and press Select y 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 should rotate freely and return to its original position Is the input S2 sensor flag damaged Watch the display while rotating the flag Problem resolved Go to step 3 Does the display indicate Media Clear and Media Present Turn the printer off and remove the rear Go to step 4 Reseat the connector shield See Top cover assembly removal on page 4 13 Is the JSP1 cable connector properly connected to the controller board Diagnostic information 2 29 5025 2xx 4xx Turn the printer on and check the voltage at Replace the paper pick Replace the controller JSP1 pin 1
103. c aids 3 39 5025 2xx 4xx Step 3 Develop Once the laser exposes the photoconductor the high voltage power supply sends charge to the developer roll C For each color the toner cartridge engages the photoconductor so it applies toner to the surface Because of the charge difference between the toner on the developer roll and the electrostatic image created by the laser the toner will cling to the PC The toner will only stick where the laser exposed the surface This process would be similar to using glue to write on a can and then rolling it over glitter The glitter sticks to the glue but won t stick to the rest of the can Service tips e Never touch the surface of the developer roller with your bare hand The oil from your skin may cause a charge differential on the surface and toner will not stick properly The result would be repeating blotches of voids light print on a page Then the affected cartridge will have to be replaced e lf the developer roll is damaged it will not contact the surface of the photoconductor properly The result could be repeating marks thin vertical voids or thin vertical lines of color on the printed page Check the surface of the developer for damage 3 40 Service Manual 5025 2xx 4xx Step 4a First transfer When the latent images are developed on each photoconductor the high voltage p
104. ce Unrecoverable software or error in If unable to clear the error message check Standard Network network or network card x the following or e If installed check network card for 976 xx Service Network Card x 978 xx Service Standard Network or 978 xx Service Network Card x 979 xx Service Standard Network or 979 xx Service Network Card x 982 xx Service lt device gt Comm 990 xx Service lt device gt Bad checksum while programming Standard Network or Network Card x port Flash parts failed while programming the Standard Network or Network Card x port Communications error detected by the specified device Note lt device gt can be one of the following e Tray 2 e Tray 3 This error message indicates that an equipment check condition has occurred in the specified device Note lt device gt can be one of the following e Tray 2 e Tray 3 correct installation 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 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 See Controller board rem
105. clude Off and numbers 1 5 the default is 2 Values 1 through 5 indicate the amount of color remaining beneath the black content Each setting increments by 1 600 of an inch The more inaccurate the registration setting the higher the setting needs to be adjusted Selecting Off disables color trapping 3 24 Service Manual 5025 2xx 4xx Reports Menu Settings Page Print the menu settings pages to list the customer settings and to verify printer options are installed correctly It is helpful to print the customer settings before you restore factory defaults or make major changes To print the menu settings 1 Select Reports from the Config Menu and press Select v 2 Select Menu Setting Page and press Select v Event Log Lets the system support person print a limited set of the information contained in the Diagnostics Menu version of the printed Event Log For a sample of a printout see Event Log on page 3 22 The limited Configuration log and the full Diagnostics log printed versions show the same operator panel messages when they print and follow the same layout guidelines To print the event log 1 Select Reports from the Config Menu and press Select y 2 Select Print Log and press Select v to begin printing the log Panel Menus Lets the system support person enable or disable the operator panel menus Selecting On the default allows users to chan
106. correct paper size Jam in the primary tray tray 1 Pull the primary tray out and remove the jam Jam in the 650 sheet Duo Drawertray Pull the 640 sheet Duo Drawer tray out tray 2 MP feeder and remove the jam Jam in the optional 550 sheet tray tray 3 Pull the tray out and remove the jam Jam in the multipurpose feeder Pull tray 2 out and remove the jam E o Jam in the duplex Open the front door and remove the jam 3 35 ls m ES co E 3 32 Service Manual 5025 2xx 4xx 200 paper jams 1 Remove the standard 250 sheet tray tray 1 2 Remove the jam Note Make sure all paper fragments are removed 3 Insert the tray 4 Press Select v 201 paper jam 1 Grasp the front door at the side handholds and then pull it toward you to open it 2 Remove the jammed paper Note Make sure all paper fragments are removed 3 Close the top door 4 Press Select Diagnostic aids 3 33 5025 2xx 4xx 202 paper jam 1 Grasp the front door at the side handholds and then pull it toward you to open it 2 Grasp the green lever and pull the fuser cover toward you Er soir pp 3 Hold the fuser cover down and then remove the jammed paper The fuser cover closes when released 4 Close the fuser cover 5 Close the front door 6 Press Select 3 34 Service Manual y to continue 5025 2xx 4xx 230 paper jam
107. ct y to print the contents of the buffer e Cancel the current print job Wait for the message to clear Warning Potential Damage Do not turn the printer off while this message appears on the display The waste toner bottle is nearly full Press Select to clear the message and continue printing The specified toner cartridge is missing Re install the missing toner cartridge to clear the message and then continue printing If the message recurs remove and re install the cartridge Listen for the click to ensure the cartridge is installed properly Close the front cover The specified cartridge is defective The following actions can be taken e Remove and re install the imaging kit e Open and close the top cover e Remove and re install the cartridge s Listen for the click to ensure the cartridge is installed properly e 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 Diagnostic information 2 7 5025 2xx 4xx ee primary Explanation message 31 xx Defective Defective imaging kit Imaging Kit The following actions can be taken e Open and close the top cover e Remove and re install the imaging kit e Turn the printer power off and after a few seconds turn the printer power back on If the message persists determine if the imaging kit counter is greater than 15 000 cycles
108. d 908 03 Service NVM_OK was not received from NV2 Go to 90x xx error on page 2 22 Engine Software server for successfully submitted request 908 04 Service Over temperature condition detected Go to 90x xx error on page 2 22 Engine Software 925 01 Service The printer fan has stalled Go to 925 01 Fan error service check Fan Stalled on page 2 22 Diagnostic information 2 17 5025 2xx 4xx Service error messages 1xx 9xx continued EN CO CS 930 xx Service Low voltage power supply did not Replace the LVPS See Low voltage LVPS detect zero crossing power supply LVPS assembly removal on page 4 47 930 09 Service Fuser zero crossings out of range Go to Fuser service check on LVPS Zero crossing detected page 2 28 940 0x Service The cyan cartridge toner meter cycle Go to Toner meter sensors Y C M K Cyan TMC Sensor TMC switch error on TMC card on page 2 50 01 Recoverable 02 Nonrecoverable 941 0x Service The magenta cartridge toner meter Go to Toner meter sensors Y C M K Magenta TMC cycle TMC switch error on TMC card on page 2 50 Sensor 01 Recoverable 02 Nonrecoverable 942 0x Service The yellow cartridge toner meter cycle Goto Toner meter sensors Y C M K Yellow TMC Sensor TMC switch error on TMC card on page 2 50 01 Recoverable 02 Nonrecoverable 943 0x Service The black cartridge toner meter cycle Go Toner
109. d the job continues e Press Select yj and choose an alternate source for media e Press Stop gg and then press Select y to cancel printing Load single sheet Printer does not detect media meeting the description lt size gt in the single sheet feeder with lt size gt feeder The following actions can be taken e Load the single sheet feeder with the correct paper type and size If no paper is in the feeder load a sheet of paper and then press Select y to clear the message and continue printing e Press Select x to clear the message and continue printing The printer manually overrides the manual request and then paper prints from an automatic source e Press Stop gg and then press Select y to cancel printing Load single sheet Printer does not detect media meeting the description lt type gt and lt size gt in the single feeder with lt type gt sheet feeder manual feeder SEn The following actions can be taken e Load the manual feeder with the correct paper type and size If no paper is in the feeder load a sheet and then press Select x to clear the message and continue printing e Press Select x to clear the message and continue printing The printer manually overrides the manual request and then paper prints from an automatic source e Press Stop MM and then press Select v to cancel printing Power Saver The printer
110. d tray on e eave S 5V when paper s picked a Grune pao sve 12 5 V de when paper is picked 15 5 ve SSS feom OSS Are the values approximately correct Print quality service check Note This symptom may require replacement of one or more CRUs Customer Replaceable Units designated as supplies or maintenance items which are the responsibility of the customer With the customer s permission you may need to install a developer toner cartridge or photoconductor unit Service tip Before troubleshooting any print quality problems do the following 1 Print a menu settings page and check the life status of all supplies Any supplies 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 y 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 Color Correction Set to Auto Print Resolution Set to 600 dpi print quality problems should be checked at different resolution settings Toner Darkness Set to 4 default Color Saver Set to OFF Diagnostic information 2 39 5025 2xx 4xx RGB Brightness RGB Contrast RGB Saturation Set to 0 Color Balance Select Reset Defaults to ze
111. de of the paper regardless of the duplex setting Press Back s to return to PRINT TESTS 3 10 Service Manual 5025 2xx 4xx Print quality test pages Prt Qual Pgs The print quality test consists of five pages Pages one and two contain a mixture of graphics and text The remainder of the pages contain only graphics The test prints on the media in tray 1 Lexmark C544 Print Quality Test A ame A ie TS E n ee A This test may be printed from either the Configuration Menu or the Diagnostics Menu To run the 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 started it cannot be canceled When the test pages print the printer returns to the original screen Hardware Tests Panel Test This test verifies the operator panel LCD function To run the Panel Test 1 Select Hardware Tests from Diag Menu and press Select 2 Select Panel Test and press Select y The Panel Test continually executes Press Stop W to cancel the test Diagnostic aids 3 11 5025 2xx 4xx Button Test This test verifies the operator panel button function To run the Button Test 1 Select Hardware Tests from Diag Menu and press Sel
112. der Quality Menu Color Correction Print Resolution Toner Darkness Enhance Fine Lines Color Saver RGB Brightness RGB Contrast RGB Saturation Color Balance Color Samples Manual Color Color Adjust Utilities Menu Format Flash Defragment Flash Hex Trace Coverage Estimator PDF Menu PostScript Menu PCL Emul Menu PPDS Menu Image Menu PictBridge Menu Flash Drive Menu 5025 2xx 4xx 3 Diagnostic aids Accessing service menus There are different test menus that can be accessed during POR to identify problems with the printer Diagnostics Menu 1 Turn the printer off The Diagnostics menu group contains the settings 2 Press and hold Left 4 and and operations used while manufacturing and Select servicing the printer See Diagnostics Menu Diag Menu on A J gt page 3 2 for more information 3 Turn the printer on 4 Release the buttons when the installed memory and processor speed displays Configuration Menu Turn the printer off The Configuration menu group contains a set of 2 Press and hold Select menus settings and operations which are and Right p infrequently required by a user Generally the options made available in this menu group are lt 4 y gt used to configure a printer for operation See Configuration menu Config Menu on page 3 24 for more information 3 Turn the printer on 4 Release
113. e Press Menus to open the Admin menus Select Settings and press Select y Select Quality and press Select 4 Select Color Correction and press Select y Select Manual and press Select y The printer is in manual mode and you need to select a color conversion table Press Back s to return to the Quality menu select Manual Color and press Select y Select the appropriate color conversion table for the affected object type Object type Color conversion tables RGB Image Vivid Produces brighter more saturated colors and may be applied to RGB Text all incoming color formats RGB Graphics sRGB Display Produces an output that approximates the colors displayed on a computer monitor Black toner usage is optimized for printing photographs Display True Black Produces an output that approximates the colors displayed on a computer monitor Uses only black toner to create all levels of neutral gray sRGB Vivid Provides an increased color saturation for the sRGB Display color correction Black usage is optimized for printing business graphics Off No color correction is implemented eS SS dd CMYK Image US CMYK Applies color correction to approximate the SWOP CMYK Text Specifications for Web Offset Publishing color output CMYK Graphics Euro CMYK Applies color correction to approximated EuroScale color
114. e a In the 650 sheet Duo Drawer and the integrated MP feeder count as two independent input sources The MP feeder is configured as cassette does not show up as Configure MP in the Paper Menu Only one 650 sheet Duo Drawer can be used on a printer If a third tray is needed the third one needs to be an optional 550 sheet drawer The third drawer is compatible only with the Lexmark C546dtn model 1 8 Service Manual 5025 2xx 4xx Duplex capability Supported X Not supported Models Lexmark C543dn Lexmark C544n Lexmark C544dn Lexmark C544dw Lexmark C546dtn Media output size and type There is a single 100 sheet output bin on this printer and no additional output options Media input size specifications Y Supported without size sensing X Not supported Input source Optional 650 sheet 650 sheet Duo Drawer 250 sheet tray Duo Drawer Optional 550 sheet drawer model C546dtn only MP feeder in the A4 210 x 297mm A52 148 x 210mm JIS B52 182 x 257mm Letter 8 5 x 11 in Legal 8 5 x 14 in Executive 7 25 x 10 5 in Oficio Mexico Folio 8 5 x 13 in Statement 5 5 x 8 5 in FH FH FHH FHH FH dhidhi General information 1 9 5025 2xx 4xx W Supported without size sensing X Not supported Input source 250 sheet tray Optional 650 sheet Duo Drawer Optional 550 sheet drawer model C546dtn only MP feeder in the 650 sheet Duo Drawer
115. e Warning Remove only the rubber tires and not the paper pick tire assembly to avoid losing small parts The paper pick tires for the standard media tray are located in the base printer There are also tires in the optional 650 sheet Duo Drawer MP feeder and the optional 550 sheet drawer lf you have one or both of these additional options and you are having problems with media picking replace these tires also Always replace the paper pick tires in pairs The tires come in a package of two Remove the media tray Place the printer so the front edge extends over the edge of the table or desk Lower the paper pick motor drive assembly Remove the rubber tire A from the pick roll assembly B Repeat for the other tire Warning Be very careful not to unlatch the right side hub or the clutch may be damaged If the ball bearings come out of the clutch it will have to be reassembled on a flat surface and may be very difficult A a Installation notes Install the new rubber tires with the surface texture turning in the direction as shown Note Feel each rubber surface to verify it turns properly in the direction shown The smoother surface pushes the paper toward the front of the printer 4 64 Service Manual 5025 2xx 4xx Printhead removal See Printhead on page 7 5 for the part number 1 Remove the top cover See Top cover assembly removal on page 4 13 2 Di
116. e L e R T g A 2 12 0 i y L 04 14 R s0 ie ff A x 1 A Current New Current New 12 Cyan Cyan Cyan Cyan 12 L value L value P RA value A value 3 Pal 4 sp Aix a T Cl p Ps 0 4 FE ai be A M 4 s a Current New i lt T7 Cyan Cyan an P value P value 4n 4 4 Sel F 9 Continue on the other two colors in the same manner Diagnostic aids 3 9 5025 2xx 4xx Print Tests Input source tests The purpose of the diagnostic Print Tests is to verify that the printer can print on media from each of the installed input options The contents of the Print Test Page vary depending on the media installed in the selected input source Check each Test Page from each source to assist in print quality and paper feed problems To run the Print Test Page 1 2 Select PRINT TESTS from the Diag Menu and press Select y Select the media source Tray 1 Tray 2 Manual Feeder or Multi Purpose Feeder and press Select y Select Single or Continuous and press Select yj e lf Single is selected a single page is printed e f Continuous is selected printing continues until Stop MW is pressed to cancel the test If a source is selected that contains envelopes an envelope test pattern is printed If Continuous is selected the test pattern is printed only on the first envelope Note The Print Test Page always prints on one si
117. e controller board the operator panel assembly cable part of the front cover assembly or the operator panel assembly if POST does not complete The printer emits five beeps and sticks in a continuous pattern until the printer is turned off Is the operator panel assembly cable properly Go to step 2 Reinstall the cable installed at controller board JOPP1 and at the operator panel assembly Check continuity of the operator panel Replace the operator panel Replace the front cover assembly cable assembly See Operator assembly See Front panel logo plate on cover assembly removal page 4 9 on page 4 2 Is there continuity Turn the printer off and remove the rear Go to step 3 Replace the controller shield See Top cover assembly removal board See Controller on page 4 13 board removal on Turn the printer on and verify the following paga 4u values at JOPP1 JOPP1 Pin Value 2 5 Vd0 4 Ground 5 5 Vd0 6 3 3 Vdc Ground Are the values approximately correct 2 34 Service Manual 5025 2xx 4xx Operator panel display blank printer beeps five times and pauses Turn the printer off and remove the rear Go to step 2 Replace the controller shield See Top cover assembly removal board See Controller on page 4 13 board removal on page 4 20 Turn the printer on and verify the following values at JOPP1 on the controller board Pin Value aove 2 sve s ove Ea EN 6
118. e of media is jammed between the input and exit sensors Multiple pages of media are jammed between the input and exit sensors A single page of media is jammed at the exit sensor Multiple pages of media are jammed at the exit sensor A single page of media is jammed at the inner door Multiple pages of media are jammed at the inner door Paper jam in the duplex area Paper jam in the primary tray A single or multiple page media jam in the 650 sheet Duo Drawer tray 2 Multiple pages of media are jammed in the 650 sheet Duo Drawer tray 2 Pull out tray 1 open the front door and then remove the print cartridge to access the jam area Remove the jammed page s See 200 paper jams on page 3 33 Open the front door and then remove the jammed page or pages See 201 paper jam on page 3 33 Open the front door to access the jam area Remove the jammed page or pages See 202 paper jam on page 3 34 Open the front door and then remove the jammed page or pages See 230 paper jam on page 3 35 The printer does not support narrow media in for duplex printing If that was the issue select a supported paper size Open the door and remove all the jammed pages See 235 paper jam on page 3 35 Open the door and remove all the jammed pages See 241 paper jam in primary tray on page 3 35 Verify the proper tray settings for the media Fan the media Check the condition o
119. e papers As an environmentally conscious company Lexmark supports the use of recycled office paper produced specifically for use in laser electrophotographic printers In 1998 Lexmark presented to the US government a study demonstrating that recycled paper produced by major mills in the US fed as well as non recycled paper However 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 world using chamber tests for different temperature and humidity conditions Lexmark has found no reason to discourage the use of today s recycled office papers but generally the following property guidelines apply to recycled paper e Low moisture content 4 5 e 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 have been engineered to work very well in laser printers despite surface texture Before using these types of paper consult your paper supplier e Suitable sheet to sheet coefficient of friction 0 4 0 6 e Sufficient bending resistance in the direction of feed Recycled paper paper of lower weight lt 60 g m 16 Ib bond and or lower caliper lt 3 8 mils 0 1 mm and paper that is cut gr
120. e se ooh ener dese bed i A 9G ee er heOws dees 2 27 PUSH Service CNSR curada ENEE AAA AAA 2 28 DUT SZ SOncoOr SOIVICO CROCK 6 665 00 065 26466406609 58966460500 040002 62900600 058 06 2 29 Main drive gear assembly EP drive service check 00 cece eee eee ees 2 30 NETWOFKINO SOIVICO CHGCK sarria AAA AA ARA ARA AA AAA 2 31 Operator panel service Check oocooccooocn 2 33 One or more operator panel buttons fall o oooooooooonromoronnm 2 33 Operator panel display blank five beepS o ooooocooooroaa o 2 34 Operator panel display blank printer beeps five times and pauses o oo ooooooomoo 2 35 Operator panel displays all diamonds no beepS oooooooonoorrn 2 36 Operator panel displays all diamonds five beeps ooooooooononneoa ees 2 37 Operator panel display is dim and unchanging 00 00 cece ee eee 2 38 Operator panel USB cable service Check 000 c cece e eee ee 2 38 Paper pick motor drive assembly service Check 0 00 eee eee es 2 39 Sale iyi0 6 6946 eer ENERCON Ee COW ORE eee RAREN ae ve 2 39 Pr aU DaChOIOUN sicario ire 2 41 Pee te pank PAGE A A bean eh dee aes bea 2 42 Prnt gualty biured OF MZZY DAA x ciiodcebndvdeaes cadens a eed FORE HESS RR ORE REYES 2 43 Printgualty hal color Pade escenario iaa 2 43 PAR gualiy honzonial DANCING tra iS 2 44 Print ouality h orzontal NE sis add ARA AAA da 2 44 Print quality insufficient
121. e the grounding washer 6 Disconnect the thermistor cables C 7 Disconnect the exit deflector from the fuser shaft See Exit deflector and bin full narrow media sensor flag removal on page 4 27 Note You do not have to remove grounding screw or the bin full narrow media sensor flag Repair information 4 33 5025 2xx 4xx 8 Disconnect the bin full narrow medial sensor cable and remove the cable from the fuser frame See Bin full narrow media sensor removal on page 4 18 Note Observe the cable routing 9 Unhook the springs D from both sides of the fuser Wie aS A D 10 Rotate the fuser toward the front of the printer until the screw E can be accessed and removed 11 Disconnect the cable G from the fuser exit sensor 12 Remove the screw F securing the fuser exit sensor 13 Remove the lower end of the sensor with a flat blade screwdriver and gently pull the sensor from the frame 4 34 Service Manual 5025 2xx 4xx High voltage power supply HVPS assembly removal See High voltage power supply on page 7 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 e Goto AA power supply HVPS with spring on page 4 38 a MG wee men 200293 e If there is no spring go to High voltage power supply HVPS with no spring on page 4 36 bel
122. e the product hardware or software There are several types of caution statements you may see in this book CAUTION A caution identifies something that might cause a servicer harm CAUTION This type of caution indicates there is a danger from hazardous voltage in the area of the product 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 Service Manual 5025 2xx 4xx 1 General information The Lexmark C54x printer 5024 2xx 4xx is a color network printer in a compact size Some models have internal duplex printing USB A host ports for flash drives on the operator panel and an optional 650 sheet Duo Drawer with 550 sheets in the input tray and 100 sheets for the multipurpose feeder The Lexmark C546dtn has a standard 650 sheet Duo Drawer and the option to add a 550 sheet drawer which brings the input for that model up to 1 451 sheets The Lexmark C544dw comes with wireless network and duplex printing Models Machine type 5025 210 Ethernet network 5025 230 Ethernet network duplex 5025 410 Ethernet network USB A host port for flash drives Lexmark C544dn 5025 430 USB A host port for flash drive duplex Ethernet network Lexmark C544dw 5025 43W 802 11n network wireless network duplex ethernet USB A host port for flash Lexmark C546dtn 5025 439 USB A host port for flash drive duplex Ethernet network 650 sheet Duo Drawe
123. ect y 2 Select Button Test and press Select y Press count 0 appears Press each operator panel button and watch to see if the count of button presses increases by one for each press Note If you press Stop W you end the test Press Stop W to cancel the test DRAM Test This test checks the validity of DRAM both standard and optional The test writes patterns of data to DRAM to verify that each bit in memory can be set and read correctly To run the DRAM Test 1 Select Hardware Tests in Diag Menu and press Select 7 2 Select DRAM Test and press Select v a The printer displays DRAM Test Testing b The printer initiates a POR of the printer and the following screen is displayed Resetting the Printer C After the POR the printer begins testing the memory DRAM Test 128M P HHRHH F HHHH P represents the number of times the memory test has passed and finished successfully Initially 000000 displays with the maximum pass count being 99 999 F represents the number of times the memory test has failed and finished with errors Initially 0000 displays with the maximum fail count being 99 999 3 Once the all the memory is tested the test stops To stop the test early turn the printer off 3 12 Service Manual Duplex Tests Quick Test duplex 5025 2xx 4xx This test prints a duplex version of the Quick Test that can be
124. ed Go to step 4 IU removal on page 4 45 Does this fix the problem 4 Run the Motor Detect Test 1 Remove the imaging unit and the waste toner bottle See Imaging unit IU removal on page 4 45 Reinstall the right cover assembly Close the front cover Enter Diagnostics menu Turn the printer off press and hold Left 4 and Select y turn the printer on and release the buttons when the installed memory and processor speed displays Select MISC TESTS in the Diag Menu and press Select y Select Motor Detect and press Select lv Motor Detection In Progress appears Go to step 5 Replace the Main drive gear assembly See Main drive gear assembly removal on page 4 59 The motor detection 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 2 42 Service Manual 5025 2xx 4xx Remove the developer unit See Developer Go to step 6 Clean the developer unit removal on page 4 21 Check the cartridge contacts See developer cartridge contacts from the HVPS to Developer unit removal the IU on page 4 21 Are all the toner cartridge contacts clean on both the pins and IU Are all the spring loaded pins in the HVPS free Go to step 7 Replace the HVPS See to move in and out with an equal
125. ee eaeewees 3 49 Repair information ananunua aana nn enn teen ene nes 4 1 Handling ESO Sensive Daris cir RADA a a a a 4 1 Pr a PO AAPP EEA AEAEE 4 2 Front cover assembly removal ococcoococco nnn 4 2 Left cover assembly removal s 0000 ri A A RR ICAA AA ORAR A RDA RA 4 6 Operator panel bezel and name plate removal 0 00 cence eee ees 4 8 Operator panel logo plat iio nee cede AAA AAA ee ee kes 4 9 Operator panel removal 00 cee eee eee 4 10 Roar SIGO TOMOVA 0er AAA AA AAA ARANA 4 11 Right cover assembly removal cara O NAAA NR ee AAA 4 12 Top cover assembly removal sra rasa rra rr 4 13 Bin full narrow media sensor removal 0 oooocooocoo es 4 18 Bin full narrow media sensor flag and exit deflector removal 0 0 0ooooooooooo 4 19 Controller DOIG AMOO 4 24 cen rr A RARA AAA 4 20 DeveloPer UNILTOMOVAl sirarorciarrraia rin AAA AAA ARA 4 21 Duplex reference edge reMoVal oococccococ nnn 4 22 Duplex sensor removal scort RARA A A AA ARA RARA RAMA A 4 25 Exit deflector and bin full narrow media sensor flag removal 0 ooooooooooo 4 27 Fuser assembly removal ococoocccc es 4 29 Fuser drive motor assembly removal 0 0 cece ees 4 32 Fuser exit sensor removal icocrriic dei nde a AA AAA AAA 4 33 High voltage power supply HVPS assembly removal ooooooooomommomo 4 35 High voltage power supply HVPS with no spring 0 ce ees 4 36
126. elettriche e danni alla persona e piu elevato Il personale di assistenza autorizzato deve quindi adottare le precauzioni necessarie ATTENZIONE Questo simbolo indica la presenza di tensione pericolosa nell area del prodotto Scollegare il prodotto prima di iniziare o usare cautela se il prodotto deve essere alimentato per eseguire l intervento Safety information XV 5025 2xx 4xx 10 2 2009 Sicherheitshinweise e Die Sicherheit dieses Produkts basiert auf Tests und Zulassungen des urspr nglichen Modells und bestimmter Bauteile Bei Verwendung nicht genehmigter Ersatzteile wird vom Hersteller keine Verantwortung oder Haftung f r die Sicherheit bernommen e Die Wartungsinformationen fur dieses Produkt sind ausschlie lich f r die Verwendung durch einen Wartungsfachmann bestimmt e W hrend des Auseinandernehmens und der Wartung des Ger ts besteht ein zus tzliches Risiko eines elektrischen Schlags und k rperlicher Verletzung Das zust ndige Fachpersonal sollte entsprechende Vorsichtsma nahmen treffen ACHTUNG Dieses Symbol weist auf eine gef hrliche elektrische Spannung hin die in diesem Bereich des Produkts auftreten kann Ziehen Sie vor den Arbeiten am Ger t den Netzstecker des Ger ts bzw arbeiten Sie mit gro er Vorsicht wenn das Produkt f r die Ausf hrung der Arbeiten an den Strom angeschlossen sein mu Pautas de Seguridad e La seguridad de este producto se basa en pruebas y aprobaciones del dise o orig
127. er is started it will sense the new cartridge and perform the automatic color adjustment even though the page counter for Auto Color Adj is fewer than required The Auto Color Adj page counter is then reset Font Sharpening This setting allows a user to set a text point size value below the setting of the high frequency screens used when printing font data This menu item affects only the PostScript PCL 5 PCL XL and PDF emulators Settings are in the range of 0 150 24 is the default For example if the value is set to 24 then all fonts sized 24 points or less use the high frequency screens To increase the value by 1 press the right arrow to decrease the value by 1 press the left arrow Exit Config Press Select to exit the Configuration Menu The printer performs a power on reset and returns to normal mode Diagnostic aids 3 27 5025 2xx 4xx Updating printer firmware Warning Before performing a firmware update on the printer contact your next level support to confirm or obtain the correct code The wrong code or wrong level of code could lead to a malfunction or render the device inoperable From a flash drive The printer firmware can be updated from a USB flash drive on models equipped with a USB Direct Interface on the operator panel The printer must be in a Ready state in order to perform the code update A printer that is in Invalid Code mode cannot be updated via the flash drive Note Ma
128. erasjoner Notices and safety information XI 5025 2xx 4xx 10 2 2009 Av xii s sobre el L ser Segons ha estat certificat als Estats Units aquesta impressora compleix els requisits de DHHS 21 CFR apartat J pels productes laser de classe 1 i segons ha estat certificat en altres llocs s un producte laser de classe que compleix els requisits d IEC 60825 1 Els productes laser de classe 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 longitud d ona de 645 670 nanometres El sistema laser i la impressora han sigut concebuts de manera que mai hi hagi exposici a la radiaci laser per sobre d un nivell de classe durant una operaci normal durant les tasques de manteniment d usuari ni durant els serveis que satisfacin les condicions prescrites Y P ichtS4ehot TOTII y3 KHBTUDAHHS 21 CERYTF xr 77 J OZIAI 1 ORB LHMKLEV P HHRCHSZCOLAAWS ATUETF EXRABDIIATHIEC 8250 XML LA075 R10L PF HRTIIACE DEMIAN TUETFA GGSXRIOL P BECERRO AFRO NTU TO CO FUYF lZ7FAMD 3b OL P AWRMETIEF CO LP BEOT7TO TISbt VA F OMRAC BH SL UDybhOAUUDLIEWMERAT ALP ECF COL Y Y VAFELIVU gt Sh BHROME 2a VPOA LY FIV AL R ES MCB HIC BW TI AAR ZFATOVANVEEOL ik HIM SMS CEOBWKGRAHANTWES elt AX FT EN L a Se ES LA WE 3 DHHS 21 CFR Subchapter 1 X D I 1 6 75 mm AI R E MA R E He X N A UE E FE
129. ered and you press Select y Submitting changes should appear If the entered number is incorrect Check Sum Does Not Match displays Check and reenter the number Diagnostic aids 3 19 5025 2xx 4xx Reset Fuser Cnt Resets the fuser count value to zero The Event Log records each time that a user executes the Reset Fuser Count operation See Event Log on page 3 25 for more information This setting appears only if the Maintenance Warning and Intervention function is enabled in the printer Configuration ID To reset the fuser count 1 Select Printer Setup from Diag Menu and press Select y 2 Select Reset Fuser Cnt and press Select y 3 Select Reset and press Select v Reset Resetting appears To cancel a reset press Back EP Setup EP Defaults This setting is used to restore each printer setting listed in EP Setup to its factory default value Sometimes this is used to help correct print quality problems To restore EP Defaults 1 Select EP Setup from Diag Menu and press Select 2 Select EP Defaults and press Select v 3 Select Restore to reset the values to the factory settings and select Do Not Restore lt J To cancel and return to the menus press Back Fuser Temperature This adjustment can be used to help solve some
130. errors Turn the printer off and remove the rear Replace the printhead See Go to step 2 shield See Top cover assembly removal Printhead removal on on page 4 13 Check the cable at JMIRR1 for page 4 65 proper connection to the controller board the printhead cable for pinch points and the cable or connector for any other damage Is the cable damaged Turn the printer on and then wait until the Replace the controller board Replace the printhead See printer posts an error Using a voltmeter check See Controller board Printhead removal on the following values at JMIRR1 removal on page 4 20 page 4 65 JMIRR1 Are the values approximately correct Diagnostic information 2 49 5025 2xx 4xx Toner meter cycle TMC card Replace the toner cartridge Replace the toner meter cycle TMC card See 1 Enter Diagnostics menu turn the printer Toner meter cycle TMC off press and hold q and Select v turn tard romoval on the printer on and release the buttons when the installed memory and processor speed displays Select Base Sensor Test and press Select y Select the sensor you want to test open page 4 71 the toner door remove the corresponding toner cartridge and press Select y Note whether the operator panel shows a change in state Note If the reflective disk is not showing on the cartridge rotate the gear clockwise
131. es Click Detailed Options to narrow the set to one color range When the Detailed Options page appears select a color conversion table Enter the RGB or CMYK color number Enter an Increment value from 1 255 Note The closer the value is to 1 the narrower the color sample range will appear Click Print to print the detailed Color Samples set O AAA AN Diagnostic aids 3 51 5025 2xx 4xx 3 52 Service Manual 5025 2xx 4xx 4 Repair information Warning Read the following before handling electronic parts Handling ESD sensitive parts Many electronic products use parts that are known to be sensitive to electrostatic discharge ESD To prevent damage to ESD sensitive parts use the following instructions in addition to all the usual precautions such as turning off power before removing logic boards Keep the ESD sensitive part in its original shipping container a special ESD bag until you are ready to install the part into the machine Make the least possible movements with your body to prevent an increase of static electricity from clothing fibers carpets and furniture Put the ESD wrist strap on your wrist Connect the wrist band to the system ground point This discharges any static electricity 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 ESD sensitive part on
132. est fit search to find a similar font and this error does not occur This error also displays when the printer receives invalid PPDS download font data The following actions can be taken e Press Select to clear the message and continue printing The job may not print correctly e The printer cannot find the requested font From the PPDS menu select Best Fit and then select On The printer will find a similar font and reformat the affected text e Press Stop MM and then press Select to cancel printing 51 Defective Flash Press Select y to clear the message and continue printing Detected You must install different flash memory before you can download any resources to flash 52 Not enough free The following actions can be taken a bol memory Press Select to clear the message and continue printing e Delete fonts macros and other data stored on the flash memory e Upgrade to a larger capacity flash memory e Press Stop MM and then press Select to cancel printing 53 Unformatted flash The following actions can be taken detected e Press Select y to clear the message and continue printing e Format the flash memory before you store any resources on it If the error message remains the flash memory may be defective and require replacing Diagnostic information 2 9 5025 2xx 4xx TAST primary Explanat
133. f the pick tires and replace if necessary See Pick tires removal on page 4 64 Open the door and remove all the jammed pages See 242 paper jam in the 650 sheet Duo Drawer on page 3 35 Diagnostic information 2 11 5025 2xx 4xx Paper jam messages 2xx continued ae ee Error code 243 xx Paper Jam Check lt area gt or 243 xx Paper Jam lt x gt Pages Jammed 250 xx Paper Jam Check Manual Feeder or 250 xx Paper Jam lt x gt Pages Jammed 2 12 Service Manual A single or multiple page media jam in the optional 550 sheet drawer tray 3 Multiple pages of media are jammed in the optional 550 sheet drawer tray 3 A single page of media is jammed in the multipurpose feeder Multiple pages of media are jammed in the multipurpose feeder Open the door and remove all the jammed pages See 242 paper jam in the 650 sheet Duo Drawer on page 3 35 Open tray 2 to access the jam area Remove the jammed page or pages See 250 paper jam on page 3 36 5025 2xx 4xx Service error messages Service error messages 1xx 9xx CO LI p 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 08 Service Yellow Printhead 106 11 Service Yellow Printhead 106 12 Service Yellow Printhead 106 13 Service Yellow P
134. ference edge 230 V Maintenance kit fuser ITU duplex reference edge 100 V Maintenance kit fuser ITU duplex reference edge 128MB DDR DRAM DIMM card assembly 256MB DDR DRAM DIMM card assembly 512MB DDR DRAM DIMM card assembly 64MB Flash card assembly Korean font card assembly Simplified Chinese font card assembly Traditional Chinese font card assembly Japanese font card assembly USB cable packaged 2 m Field relocation package assembly Index Numerics 3x 9x user messages 2 7 2 11 1xx service errors 2 13 2 17 2xx paper jam locations 3 32 messages 2 11 2 12 250 sheet media tray paper pick motor drive assembly 4 61 pick tires removal 4 64 550 sheet drawer configurations 1 1 description 1 2 parts catalog 7 10 service check 2 53 650 sheet Duo Drawer configurations 1 1 description 1 2 parts catalog 7 10 service check 2 53 9xx service errors 2 17 2 21 A accessing service menus 3 1 acoustics 1 7 acronyms 1 16 alignment 3 7 antenna wireless network parts catalog 7 6 removal 4 79 attendance messages 2 5 Auto Color Adj 3 27 B bezel parts catalog 7 2 removal 4 8 bin full narrow media sensor flag removal 4 27 locations 5 1 parts catalog 7 6 removal 4 18 service check 2 23 bin full narrow media sensor flag 4 19 locations 5 1 parts catalog 7 4 7 5 Button Test 3 12 buttons operator panel 2 55 C clearances printer 1 5 CMYK color 3 49 code updating 3 28 color conversion tables 3 50 col
135. ge the cover Carefully lift the cover just enough for clearance for the toner meter cycle card Position the toner meter cycle card Replace the two screws B Replace the screws D and replace the top cover Nao N 4 72 Service Manual 5025 2xx 4xx Tray present sensor removal See photo sensors on page 7 7 for the part number Remove the media tray Remove the imaging unit See Imaging unit IU removal on page 4 45 Remove the rear 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 Remove the four screws B from the cable cover and remove the cable cover A PANES B A 5 Carefully place the printer on its left side 6 Remove the three screws C securing the lower right frame to the printer 7 Remove the screw D closer to the front of the printer el Repair information 4 73 5025 2xx 4xx 8 Next to screw D lift the right lower frame pin E out of the hole in the printer frame 9 Swing the rear of the lower frame away from the printer to access the tray present sensor latches 10 Remove and secure the spring F from the right lower frame Note The spring easily gets lost 11 Disconnect the tray present sensor cable 4 74 Service Manual 5025 2xx 4xx 12 Remove the sensor retaining plate G and then pinch the latches together to remove the t
136. ge values for the printer Off disables the users access to menus If a user presses Menu lt 1 they receive a message that the panel menus are locked When set to Off this setting restricts all menu access even to menus or items set for PIN access However when set to On all PIN restrictions are restored This menu item appears only when the PUL PASSWORD Environment variable is set to 0 PPDS Emulation Activates or deactivates default the Personal Printer Data Stream PPDS emulation language This menu item appears only if the PPDS interpreter is available Demo Mode Lets marketing personnel or merchandisers demonstrate the printer to potential customers by printing the demo page Selections include Deactivate default and Activate Select Deactivate to turn Demo Mode off or select Activate to turn Demo Mode on Diagnostic aids 3 25 5025 2xx 4xx Factory Defaults Sets the majority of printer values back to their factory default settings Warning This selection cannot be reversed so this operation should be used only as a last resort to fix any printer problem When factory default settings are restored e All downloaded resources fonts macros symbol sets in the printer memory RAM are deleted e All menu settings return to the factory default setting except The Display Language setting in the Setup Menu All settings in the Parallel Menu Serial Menu Network Menu Infrared Menu LocalTal
137. he AC pewerveltagepower voltage Go to step 2 Inform the customer Is the line voltage correct 2 2 Is the AC power cord damaged Replace the line cord Go to step 3 Is the LVPS cable correctly connected at Go to step 5 Reconnect the cable at JLVPS1 on the controller board JLVPS1 and then go to step 4 Turn the printer off and then on Go to step 5 Problem resolved Does the problem persist Warning Damage to the printer is possible Replace the controller Replace the LVPS See Be careful to touch only one conductor at a board See Controller Low voltage power time Rest the probe against the connector to board removal on supply LVPS assembly steady it page 4 20 removal on page 4 47 With the printer on verify the following values at JLVPS1 JLVPS1 exposed conductors EXC O Are the values approximately correct E EN EA Es EN i a 2 24 Service Manual 5025 2xx 4xx Duplex manual feed sensor S1 service check Is the printer setting on a hard flat surface Go to step 2 Make sure the printer is setting on a level flat surface Enter Diagnostics Menu turn the printer off Go to step 3 Go to step 5 press and hold q and yj turn the printer on and then release the buttons when the installed memory and processor speed displays Perform the Base Sensor Test See Base Sensor Test on page 3 16 1 Select Base Sensor Test and press Select 2 Select S1 and press Select
138. he PostScript driver provide the preferred color quality for the majority of printouts Why doesn t the printed color match the color see on the computer screen The color conversion tables used in Auto Color Correction mode generally approximate the colors of a standard computer monitor However because of technology differences that exist between printers and monitors there are many colors that can also be affected by monitor variations and lighting conditions For recommendations on how the printer color sample pages may be useful in solving certain color matching problems see How can match a particular color Such as a corporate logo on page 3 51 The printed page appears tinted Can adjust the color Sometimes a printed page may appear tinted for example everything printed seems to be too red This can be caused by environmental conditions paper type lighting conditions or user preference In these instances adjust the Color Balance setting to create a more preferable color Color Balance provides the user with the ability to make subtle adjustments to the amount of toner being used in each color plane Selecting positive or negative values for cyan magenta yellow and black from the Color Balance menu will slightly increase or decrease the amount of toner used for the chosen color For example if a printed page has a red tint then decreasing both magenta and yellow could potentially improve the color balance Diag
139. he card A B 4 Remove the screw C that secures the antenna cover D to the frame and remove the antenna cover and antenna Repair information 4 79 5025 2xx 4xx 5 Gently squeeze the fastener E with needlenose pliers Slide the antenna cable and cable through the hole in the bracket E 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 bend the antenna as it would be positioned and make sure the antenna can move about 30 in each direction from the vertical 4 80 Service Manual 5025 2xx 4xx Wireless network card See Wireless network 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 Carefully disconnect the antenna cable B from the wireless card at the card Repair information 4 81 5025 2xx 4xx 4 82 Service Manual B Connector locations Locations Standard Operator panel output bin Manual slot Standard 250 sheet tray tray 1 Standard output bin Operator panel l P 650 sheet Duo Drawer tray 2 Manual slot Multipurpose feeder 5025 2xx 4xx Standard output bin Operator panel S tray tray 1 R 250 sheet 50 sheet 650 sheet drawer tray 3 Du
140. he flats on the hinges and remove the front cover Note Not all models have all three cables shown See the chart below 4 4 Service Manual 5025 2xx 4xx Installation notes When installing the front cover on the following models note the differences relating to the USB port cable Models Contents of front cover FRU Order front cover P N Lexmark C540n e Operator panel cable E 40X5420 5025 210 e Front door switch cable F Note The USB port cable G is not included Lexmark C543dn e Operator panel cable E 40X5430 5025 230 e Front door switch cable F e USB port cable G not used Note Clip the USB cable at each end before installing There is no place to plug the cable in Lexmark C544n e Operator panel E 40X5430 C544dn C544dw Front door switch cable F C546dtn USB port cable G 5025 410 430 43W 439 Repair information 4 5 5025 2xx 4xx Left cover assembly removal See Left cover assembly on page 7 3 for the part number Remove the media tray Position the printer with the left side hanging over the edge of the table On the rear remove the metal screw A the short plastic screw B and the longer plastic screw C Remove the screw D on the bottom of the cover APDE 4 6 Service Manual 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
141. iagnostics Menu turn the printer off press and hold 4 and y turn the printer on and then release the buttons when the installed memory and processor speed displays Perform the Base Sensor Test See Base Sensor Test on page 3 16 1 Select Base Sensor Test and press Select y 2 Select Front Door and press Select 3 Open and close the front door and observe the display Does the display indicate Value Closed with the door closed and Value Opened with the door opened Open the front door and check the thin tall plastic web pivot plate at the top right of the printer With the other covers in place and closed this web interacts with switches in the door Open the toner cover and check the motion of the web ls the web loose damaged or missing Open the toner door and inspect the vertical web that pushes and rotates the pivot plate Is it damaged With the front cover open inspect the two switches Using a tool such as a spring hook push the metal arms to check the movement Is there any damage to the switches or the surrounding area Turn the printer off and remove the rear shield See Top cover assembly removal on page 4 13 Turn the printer on and verify the following values at JINT1 and JCVR1 JINT1 JCVR1 Pin value Pin Value Pa feve i pave DEA CTI Are the values approximately correct 2 26 Service Manual Sensor
142. ify the cable from the high voltage power supply is seated properly The cable may have come loose from the HVPS Warning 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 amounts of toner It is important to prevent extensive blank pages from being processed if they should have toner on them Check that the same size and type of paper are in each tray Check the location of 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 each tray and adjust on the operator panel if necessary To print a menu settings page 1 Press Menu J on the operator panel 2 Select Reports from the Admin Menu and press Select Lv 3 Select Menu Settings and press Select y Increase the Print Timeout value on the operator panel Settings gt General Settings gt Timeouts gt Print Timeout Remove and flex the paper in the tray Reload the paper and try printing Remove the paper turn it over and place it back in the tray Make sure the feeder is properly installed Make sure the paper is loaded correctly in the tray Make sure the paper is not damaged Make sure the paper meets specifications See
143. igured 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 administrator verify that the device is using the correct SSID and wireless security protocols For more network troubleshooting information consult the Lexmark Network Setup Guide Questions actions Yes If the device is physically connected to the Go to step 3 Go to step 2 network verify that the ethernet cable is properly connected on both ends If the network is wireless go to step 3 Is the cable properly connected Connect the ethernet cable Problem resolved Did this fix the problem Check the printer s online status under Printers Go to step 5 Go to step 4 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 status to online Problem resolved Go to step 5 Did this fix the issue Does the IP address displayed on the network Go to step 10 Go to step 6 settings page match the IP address in the port of the drivers using the printer Does the LAN use DHCP Go to step 7 Go to step 9 Note A printer should use a static IP address on a network Go to step 3 Are the first two segments if the IP address Go to step 8 Go to step 9 169 254 POR the printer Problem resolved Go to step 10 Is the problem resolved Reset the address on the p
144. inal y componentes espec ficos El fabricante no es responsable de la seguridad en caso de uso de piezas de repuesto no autorizadas e La informaci n sobre el mantenimiento de este producto est dirigida exclusivamente al personal cualificado de mantenimiento e Existe mayor riesgo de descarga el ctrica y de da os personales durante el desmontaje y la reparaci n de la m quina El personal cualificado debe ser consciente de este peligro y tomar las precauciones necesarias PRECAUCI N este s mbolo indica que el voltaje de la parte del equipo con la que est trabajando es peligroso Antes de empezar desenchufe el equipo o tenga cuidado si para trabajar con l debe conectarlo Informa es de Seguran a e A seguran a deste produto baseia se em testes e aprova es do modelo original e de componentes espec ficos O fabricante n o respons vel pela segunran a no caso de uso de pe as de substitui o n o autorizadas e As informa es de seguran a relativas a este produto destinam se a profissionais destes servicos e nao devem ser utilizadas por outras pessoas e Risco de choques el ctricos e ferimentos graves durante a desmontagem e manuten o deste produto Os profissionais destes servi os devem estar avisados deste facto e tomar os cuidados necess rios CUIDADO Quando vir este s mbolo existe a poss vel presen a de uma potencial tens o perigosa na zona do produto em que est a trabalhar Antes de come a
145. ing on card stock with the printer programmed to print on a plain paper setting The printer s feed and transport components can 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 shaped paper path see the picture below The tray 1 paper path is shown in red and the optional 650 sheet Duo Drawer paper path is not shown Paper is fed from the rear of the printer and travels upward through the front cover There is a duplex unit on this printer The duplex unit is built into the front cover and tray 1 The duplex process is described later See Duplex process on page 3 48 Exit rolls duplex entry Output bin Operator panel Toner cartridges Bin full narrow Printhead media sensor Controller A board Front cover af duplex y 2 a Developers NON Y C M K LS Ox OF Fuser la j u e N Y a A Fuser Yo O r 4 AQ exit sensor g a eos l w PC unit part of imaging unit Transfer roll part of ITU ies Input sensor S2 Part of nF i Tray 1 Duplex manual feed sensor S1 Paper path 3 46 Service Manual AA A A W u Pick roller ve Paper pick motor drive asm 5025 2xx 4xx Transport components In summary
146. inks or toners can be printed in various amounts to produce a large range of colors observed in nature For example cyan and yellow can be combined to create green Printing presses inkjet printers and color laser printers create colors in this manner CMYK color is a method of describing colors by indicating the amount of cyan magenta yellow and black needed to reproduce a particular color How is color specified in a document to be printed Software programs typically specify document color using RGB or CMYK color combinations Additionally they allow users to modify the color of each object in a document For more information see the software program Help topics How does the printer know what color to print When a user prints a document information describing the type and color of each object is sent to the printer The color information is passed through color conversion tables that translate the color into the appropriate amounts of cyan magenta yellow and black toner needed to produce the desired color The object information determines the application of color conversion tables For 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 use PostScript or PCL emulation printer software What settings should use for the best color The PostScript driver is strongly recommended for best color quality The default settings in t
147. inted forms and letterhead Use these guidelines when selecting preprinted forms and letterhead e Use grain long for 60 to 176 g m weight paper e Use only forms and letterhead printed using an offset lithographic or engraved printing process e Avoid papers with rough or heavily textured surfaces Use papers printed with heat resistant inks designed for use in xerographic copiers The ink must be able to withstand temperatures up to 200 C 392 F without melting or releasing hazardous emissions Use inks that General information 1 13 5025 2xx 4xx are not affected by the resin in toner Inks that are oxidation set or oil based generally meet these requirements latex inks might not When in doubt contact the paper supplier Preprinted papers such as letterhead must be able to withstand temperatures 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 e For best results store paper where the temperature is 21 C 70 F and the relative humidity is 40 Most label manufacturers recommend printing in a temperature range of 18 to 24 C 65 to 75 F with relative humidity between 40 and 60 e Store paper in cartons when possible on a pallet or shelf rather than on the floor e Store individual packages on a flat surface e Do not store anything on top of individual paper packages Using recycled paper and other offic
148. intends to make these 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 equivalent product program or service that does not infringe any existing intellectual property right may be used instead Evaluation and verification of operation in conjunction with other products programs or services except those expressly designated by the manufacturer are the user s responsibility Lexmark Lexmark with diamond design and MarkVision are trademarks of Lexmark International Inc registered in the United States and or other countries PCLO is a registered trademark of the Hewlett Packard Company PCL is Hewlett Packard Company s designation of a set of printer commands language and functions included in its printer products This printer is intended to be compatible with the PCL language This means the printer recognizes PCL commands used in various application programs and that the printer emulates the functions corresponding to the commands All other trademarks are the property of their respective owners 2009 Lexmark International Inc All rights reserved UNITED STATES GOVERNMENT RIGHTS This software and any accompanying documentation provided under this agreement are commercial computer software and documentation developed exclusively at private expense P N 12G9819 5025 2xx 4x
149. inter is processing an incoming job and there is not enough memory available to continue processing the job The following actions can be taken e Determine how to make more memory available to your print job by Deleting fonts and other data in RAM Simplify your print job by reducing the amount of text or graphics on a page Install additional memory e Press Select y to clear the message and continue printing The job may not print correctly e Press Stop gg and then press Select y to cancel printing 39 Complex page This message is displayed when a page is too complex to print some data may not The following actions can be taken have printed e Press Select y to clear the message and continue printing The job may not print correctly e Simplify the print job by reducing the amount of text or graphics on a page e Press Stop gg and then press Select y to cancel printing 40 lt color gt Invalid Replace the toner cartridge with a new one Refill change cartridge 50 PPDS Font Error This error only occurs when a printer is formatting PPDS print data 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 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 b
150. ion message 54 Standard network The printer detects a network port but cannot communicate with it The printer software error disables all communication to the associated network interface The following actions can be taken Press Select x to clear the message and continue printing The job may not print correctly Upgrade the network firmware in the printer or the print server Turn the printer power off and then back on to reset the printer Format the flash memory If the error message remains the flash memory may be defective and require replacing 54 Network lt x gt The printer disables all communications to the associated network interface No data software error may be received or sent from or to the associated interface e Press Select v to clear the message and continue printing The job may not print correctly e Turn the printer power off and then back on to reset the printer e Upgrade the network firmware in the printer or the print server 56 Standard USB This message may appear when data is sent to the printer across a USB port but the Port disabled port is disabled Note Once the error is displayed the first time reporting of further errors is suppressed until the printer is reset or menus are entered The following actions can be taken e Press Select y to clear the message Any data received on the USB port is discarded e Press Menus to access the Admini
151. ions on removing the LVPS shield 3 Remove the screws A on the top cover See Main drive gear assembly with motors on page 7 5 for the part number a ma Ez E 4 Disconnect the cable from the fuser exit sensor 5 Unplug the cables from the motors C and remove all cables from the retainer D Note Observe the cable routing for reinstallation Repair information 4 59 5025 2xx 4xx 6 Remove the two screws E from the rear E C D C 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 drive gear assembly and remove 4 60 Service Manual 5025 2xx 4xx Paper pick motor drive assembly removal standard tray See Paper pick motor drive assembly standard tray on page 7 5 for the part number 1 are 6 Remove the toner cartridges the waste toner bottle and the imaging unit IU See Waste toner bottle removal on page 4 77 and see Imaging unit IU removal on page 4 45 Remove the left cover See Left cover assembly removal on page 4 6 Remove the rear shield See Rear shield removal on page 4 11 Disconnect the paper pick motor drive assembly cable connector A fromJSP1 on the controller board Pull the cable B through the opening and free the cables from the retainers C on the left side rt h Olid MITA WO F J J i p Y i i
152. isconnect the fan cable from JFAN1 A on the controller board Remove the screw B Repair information 4 13 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 e 3 A 4 14 Service Manual 5025 2xx 4xx 9 Remove the two top screws E near the front Ea Ez Ez Ez Es Sy pa f t i l i J L 10 Remove the remaining four screws F 11 Remove the fuser screw G Repair information 4 15 5025 2xx 4xx 12 Disconnect the left fuser spring H from the fuser 13 Disconnect the right fuser spring J from the fuser H J 15 Gently rotate the fuser away from the top cover and let it rest Note If fuser needs to be propped up use something that will not move or shift Avoid putting additional stress on the cables 4 16 Service Manual 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 through the hole Repair information 4 17 5025 2xx 4xx Bin full narrow media sensor removal See Photo sensor on page 7 7 for the part number Open the front cover Remove the cable from the retainer Note Be sure to note the routing for re installation Disconnect the cable from the bin ful
153. it deflector and bin full narrow media sensor flag removal See Exit deflector and bin full narrow media sensor flag on page 7 5 for the part number The exit deflector and 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 the flag Note Be careful to not dislodge the sensor A 3 Remove the exit deflector ground screw B and remove the cable from the retainers Note Note the routing of the cable through the retainers for reinstallation Repair information 4 27 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 4 28 Service Manual 5025 2xx 4xx Fuser assembly removal A See Fuser assembly on page 7 5 for the part number Remove the right cover assembly See Right cover assembly removal on page 4 12 Remove the left cover See Left cover assembly removal on page 4 6 Disconnect the two wire fuser cable A from the LVPS 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 Warning Be careful not to damage the cable by pulling too hard or cutting the cable insulation M 5 Remove the screw and grounding washer B on the right side of the frame Note Be careful not t
154. k Menu and USB Menu To print current menu settings It is recommended that you first print the customer s current settings by printing a copy of the Menu Settings pages Customer settings are available from the Ready prompt Diagnostics Menu settings are available in the Diagnostics Menu and Config Menu settings are available in the Config Menu Turn the printer off or select Exit Config Menu At the Ready prompt select Menus and press Select y Select Reports and press Select y Select Menu Settings Page and press Select y Enter the Diagnostic Menu select Reports Menu Settings Page and press Select y See Menu Settings Page on page 3 22 Turn the printer off or select Exit Diags Enter Configuration Menu select Reports Menu Settings Page and press Select x See Menu Settings Page on page 3 25 aS SNS so To reset factory defaults onl Select Reports from the Config Menu and press Select v 2 Select Factory Defaults and press Select 7 3 Select Restore Base for locally attached printers or Restore STD NET if you have integrated network support Submitting Changes appears on the operator panel and then the printer PORs restarts in Ready mode Energy Conserve Affects the values that appear in the Power Saver menu in the customer Setup Menu This menu item
155. ke sure the Enable Drive and Update Code settings are enabled These settings are found in the Flash Drive menu under the Settings menu in the Administrative menus To update the code using a USB flash drive perform the following steps 1 Insert the flash drive into the USB port located on the operator panel USB Menu Print from USB displays If Print from USB doesn t display by default use 4 or p to navigate to Print from USB 2 Press Select y You now have access to the directory structure of the flash drive 3 Use q or p to navigate to the firmware file The file will have a fls extension 4 When the file is displayed press Select v 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 until the update is complete When the code update is completed the printer will automatically performs a POR and returns to a Ready state Using a networked computer to update the printer firmware over a network Using FTP Note The servicer must have an understanding of how to use FTP before attempting to update the firmware using this method The printer firmware ca be updated by performing the following steps POR the printer to a Ready state Go to the TCP I P menu in the administrative menu to retrieve the IP address From a command line prompt on a computer on
156. ken e Remove paper from the standard exit bin to clear the message and continue printing e Press Select y to clear the message and continue printing Packaging material is detected by the printer Remove the packaging material and press Select x If all the packaging material is removed then the printer resumes Replace the toner cartridge and then press Select to clear the message and continue printing The following actions can be taken e Remove paper from the standard exit bin to clear the message and continue printing e Press Select y to clear the message and continue printing The following actions can be taken e Load the paper tray or other source with the correct paper type and size e Press Stop gg and then press Select y to cancel the current job Load the paper tray or other source with the correct paper type and size Insert the specified tray into the printer Camera is not in a proper mode to use the PictBridge feature Unplug the camera 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 from the USB port on the front of the printer The printer has received data to print but is waiting for an End of job command a Form Feed command or additional data The following actions can be taken e Press Sele
157. l narrow media sensor If there is a sensor retaining plate A on the side the latches connect remove the old adhesive plate E N _ o y e i 5 Gently remove the sensor B from the bracket by pressing the latches s gt na 4 18 Service Manual 5025 2xx 4xx Installation note 1 9 RUN Clean the contact surface where you removed the sensor retaining plate or where you need to install the new one Guide the latches that hold the sensor in the bracket into place Squeeze the latches together until they latch to the metal frame Remove the backing from the new plate and place the plate on the surface between the sensor mounting legs Reconnect the cable and reroute the cable through the retainer Bin full narrow media sensor flag and exit deflector removal The bin full narrow media sensor flag and the exit deflector are in the same FRU See Exit deflector and bin full narrow media sensor flag removal on page 4 27 Repair information 4 19 5025 2xx 4xx Controller board removal See Controller board C544n C544dn C544dw Controller board C540n C543dn or Controller board C546dn only on page 7 7 for the part number CAUTION A After disconnecting the high voltage power cable from the controller board always check that the HVPS connection was not loosened Make this check anytime you are working near the HVPS cable Warning Observe all ESD p
158. letterhead 0 eens 1 13 cs EEEE T E E A E AEN E E E E NE I E eRe eae eee 1 14 Using recycled paper and other office paperS ooooooocoonnnon ee ees 1 14 Tools FE TOS SEVICE ear parte wie oe ee ee es oe eee ees eee 1 15 ACI iaa A AR AAA A ee bse ose ri didas 1 16 Diagnostic information oooooooooooo n nnn nee eee 2 1 S ONE E E Oh be ee ee ee ee ee os 4 eo dee eer eee 2 1 POR Power On Reset Sequence 000 cee ee ees 2 2 ao sete cence eee eee Sree oe ee ee a a a oe eee 2 3 Primier SIDO TAG cia AA AA AA AAA A 2 3 Prntguality symplom table ac ee eed ee penekan AA RIA BATA ee TA ees 2 4 Error codes and messages sinisncnorinnn an AAA ee eRe ee RES 2 5 User status and customer attendance messages 0 0 cccccccccn 2 5 Peper sal NESSES rene aida ewe A erences RRA 2 11 SOI VIES OTOI MESSAGES iiararrrcra rra a AAA ARA 2 13 A Ro eens een T 2 22 SUL ME GGL aria rar 006 59008488804 05 0570S 0524 CTE T 2 22 220 1 Fan error Service COCK uri RR coer ke Ketek ee eee eens 2 22 950 xx NVRAM Failure service check 0 0 0 cece eee 2 23 Table of contents iii 5025 2xx 4xx Bin full narrow media sensor service Check oooooooocooo 2 23 Dead printer service Check 00 cece eee 2 24 Duplex manual feed sensor S1 service Check 00 cece ees 2 25 Front door sensor or switches service Check 0 ccc eee eee eee ees 2 26 Fuser exit sensor service check 6 ci f0 iee
159. lla classe 1 Notices and safety information IX 5025 2xx 4xx 10 2 2009 Avisos sobre el laser Se certifica que en los EE UU esta impresora cumple los requisitos para los productos laser de Clase 1 establecidos en el subcapitulo J de la norma CFR 21 del DHHS Departamento de Sanidad y Servicios y en los demas paises reune todas las condiciones expuestas en la norma IEC 60825 1 para productos laser de Clase 1 Los productos l ser de Clase no se consideran peligrosos La impresora contiene en su interior un l ser de Clase lllb 3b de arseniuro de galio de funcionamiento nominal a 5 milivatios en una longitud de onda de 645 a 670 nan metros El sistema l ser y la impresora est n dise ados de forma que ninguna persona pueda verse afectada por ning n tipo de radiaci n l ser superior al nivel de la Clase durante su uso normal el mantenimiento realizado por el usuario o cualquier otra situaci n de servicio t cnico Declarac o sobre Laser A impressora est certificada nos E U A em conformidade com os requisitos da regulamentac o DHHS 21 CFR Subcap tulo J para a Classe 1 de produtos laser Em outros locais est certificada como um produto laser da Classe I em conformidade com os requisitos da norma IEC 60825 1 Os produtos laser da Classe n o s o considerados perigosos Internamente a impressora cont m um produto laser da Classe lllb 3b designado laser de arseneto de pot ssio de 5 milliwatts opera
160. mbly parts catalog 7 4 removal 4 29 Reset Fuser Cnt 3 20 service check 2 28 fuser exit sensor locations 5 1 parts catalog 7 6 removal 4 33 service check 2 27 H high voltage power supply HVPS connections 5 12 parts catalog 7 6 removal 4 35 image transfer unit ITU ITU Barcode 3 19 parts catalog 7 4 removal 4 40 service check 2 51 imaging unit IU description 4 45 parts catalog 7 4 removal 4 45 input source tests 3 10 L low voltage power supply LVPS connections 5 13 parts catalog 7 6 removal 4 47 lubrication specifications 6 1 main drive gear assembly parts catalog 7 4 removal 4 59 maintenance kit contents 6 1 parts catalog 7 12 maintenance scheduled 6 1 media guidelines 1 12 input size 1 9 input sources 1 8 input type 1 11 output size and type 1 9 recycled 1 14 unacceptable media 1 13 weights 1 12 media jams 3 31 memory 1 2 menu users map 2 56 menu settings page configuration menu 3 25 diagnostics menu 3 22 menus accessing service menus 3 1 diagram 2 56 Menu Settings Page configuration menu 3 25 customer menu 2 39 diagnostic menu 3 22 messages customer attendance 2 5 paper jams 2 11 service error 2 13 Model Name 3 18 models 1 1 motors main drive 4 59 MP feeder parts catalog 7 10 N name plate parts catalog 7 2 removal 4 8 5025 2xx 4xx O operating modes 1 4 operator panel buttons 2 55 overview 2 55 parts catalog 7 2 removal 4 10 service check 2 33 dis
161. moval on page 4 21 Go to step 2 Go to step 3 Go to step 4 Check the various rollers in the printer for debris Either the photoconductor unit or one of the developer units that make up the imaging unit is defective Remove and inspect the imaging unit Replace the damaged part of the imaging unit See Imaging unit IU removal on page 4 45 2 44 Service Manual 5025 2xx 4xx Print quality insufficient fusing Is the printer setup to use the correct media Go to step 2 Change the settings to indicate the correct media Check the fuser connections on the left and Go to step 3 Properly reconnect or right side of the printer replace the cables Are the cables and connection correct Is the fuser properly installed Go to step 4 Install the fuser properly Replace the fuser See Fuser assembly Problem resolved Replace the LVPS See removal on page 4 29 Low voltage power supply LVPS assembly Does this fix the problem removal on page 4 47 Print quality missing image at edge Remove and reseat the following e Toner cartridge e Imaging unit e Developer units Print quality mottle 2 5mm speckles Keep running prints through and the problem normally clears up If the problem persists replace the developer Diagnostic information 2 45 5025 2xx 4xx Print quality narrow vertical line Questions actions Replace the photoconductor unit See Problem res
162. n Connector Pinno Sigmat Smart plck drive paper pick motor E earo fe pona TPS therm connector JTPS1 TPS1 connector CN EIN ICH LIN EN IN JTPS2 TPS2 connector 2 2 A La ca ES JS 1 1 1 1 1 JTRAY1 Bottle sensors 2 DUPLEX_ENT 5 V de oa a JUSB1 Port USB connector 5 10 Service Manual 5025 2xx 4xx Controller board connectors continued Note SW indicates voltage is switched on during a print cycle otherwise voltages are taken with printer at Ready state door closed and cables plugged in Ecco MN LU E A JUSBW1 AT USB wireless connector CI en ds Connector locations 5 11 5025 2xx 4xx High voltage power supply HVPS diagram T IONN O O aa O O 5 12 Service Manual 5025 2xx 4xx Low voltage power supply LVPS diagram on Z wm Connector locations 5 13 5025 2xx 4xx Toner meter cycle TMC card Wireless network card FRONT BACK oXoXoXoYoXo V13 5 14 Service Manual 5025 2xx 4xx 6 Preventive maintenance This chapter describes procedures for printer preventive maintenance Follow these recommendations to help prevent problems and maintain optimum performance Safety inspection guide The purpose of this inspection guide is to aid you in identifying unsafe conditions If any unsafe conditions exist find out how serious the hazard could be and if you can continue before yo
163. nd remove the rear Problem resolved Replace the controller shield See Top cover assembly removal board See Controller on page 4 13 Turn the printer on and then board removal on check the values below at JBIN1 page 4 20 JBIN1 Value O V de 5 V de during cycle 3 3 V de beam blocked O V de unblocked Are the values correct Diagnostic information 2 23 5025 2xx 4xx Dead printer service check A dead printer is one which when powered on from a known good electrical outlet displays no indication of power to the printer by changes to the LCD LED or any movement of the fan or motors If the printer appears dead but makes a beeping sound check the operator panel See Operator panel display blank five beeps on page 2 34 y If a 650 sheet Duo Drawer is installed remove the option and check the base printer for correct operation If the base printer operates correctly replace the 650 sheet Duo Drawer Warning Observe all necessary ESD precautions when removing and handling the controller board or any installed option cards or assemblies See Handling ESD sensitive parts on page 4 1 CAUTION When you see this symbol there is a danger from hazardous voltage in the area of the product 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 options from the printer Check t
164. ndo 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 acesso humano a radiac o laser superior a um n vel de Classe durante a opera o normal a manuten o feita pelo utilizador ou condi es de assist ncia prescritas Laserinformatie De printer voldoet aan de eisen die gesteld worden aan een laserprodukt van klasse l Voor de Verenigde Staten zijn deze eisen vastgelegd in DHHS 21 CFR Subchapter J voor andere landen in IEC 60825 1 Laserprodukten van klasse worden niet als ongevaarlijk aangemerkt De printer is voorzien van een laser van klasse lllb 8b dat wil zeggen een gallium arsenide laser van 5 milliwatt met een golflengte van 645 670 nanometer Het lasergedeelte en de printer zijn Zo ontworpen dat bij normaal gebruik bij onderhoud of reparatie 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 l laserprodukt i overenstemmelse med kravene i IEC 60825 1 Klasse l laserprodukter betragtes ikke som farlige Printeren indeholder internt en Klasse IIIB 3b laser der nominelt er en 5 milliwatt galliumarsenid laser som arbejder p b lgel ngdeomr det 645 670 nanometer Lasersystemet og printeren er udformet s ledes at mennesker aldrig uds ttes for en laserstr ling over Klasse l nivea
165. need to be replaced sooner 3 38 Service Manual 5025 2xx 4xx Step 2 Expose During the expose step the laser fires a focused beam of light at the surface of each photoconductor B and writes an invisible image called a latent image or electrostatic image for each color The laser beam actually discharges the surface only where the beam hits the photoconductor This creates a difference in charge potential between the exposed area and the rest of the photoconductor surface Service tips e The laser beam passes through a glass lens as it exits the laser unit If this 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 e Never touch the surface of the photoconductor with your bare hand The oil from your skin may cause a charge differential on the surface and toner will not stick properly The result would be repeating patches of voids or light print on a page Then the photoconductor will have to be replaced e The surface of the photoconductor is coated with an organic substance that makes it sensitive to light Be sure and cover the photoconductor when you are working on the printer so you don t burn it If exposed to light for too long it will cause light dark print quality problems and have to be replaced Diagnosti
166. ng blade the toner is moved from the cleaning blade to the waste toner area using an auger system 3 44 Service Manual 5025 2xx 4xx Photoconductor clean erase After each plane of color has been transferred to the transfer 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 begin the EP cycle once again This cleaning erasing cycle happens after each plane of color is transferred to the transfer belt Diagnostic aids 3 45 5025 2xx 4xx Paper path transport components In order for an image to be printed the media has to be moved from an input source such as a tray into the printer and eventually exit into the output bin The most important component in this process is this media itself Old damaged or out of specification media can and will cause feed and transport problems If you encounter problems you should always check the media first See Media guidelines on page 1 12 In addition it is always good practice to check the printer and driver settings to see if the media being used matches the user s settings lt is not uncommon to find a user print
167. nostic aids 3 49 5025 2xx 4xx My color transparencies seem dark when they are projected Is there anything can do to improve the color This problem most commonly occurs when projecting transparencies with reflective overhead projectors To obtain the highest projected color quality transmissive overhead projectors are recommended If a reflective projector must be used then adjusting the Toner Darkness setting to 1 2 or 3 will lighten the transparency Make sure to print on the recommended type of color transparencies What is manual color correction When manual color correction is enabled the printer employs user selected color conversion tables to process objects However Color Correction must be set to Manual or no user defined color conversion will be implemented Manual color correction settings are specific to the type of object being printed text graphics or images and how the color of the object is specified in the software program RGB or CMYK combinations Notes e Manual color correction is not useful if the software program does not specify colors with RGB or CMYK combinations It is also not effective in situations in which the software program or the computer operating system controls the adjustment of colors e The color conversion tables applied to each object when Color Correction is set to Auto generate preferred colors for the majority of documents To manually apply a different color conversion tabl
168. o Drawer tray 2 Manual slot Connector locations 5 1 5025 2xx 4xx Note the paper path shown in red Operator panel Bin full narrow media sensor Exit rolls duplex entry Output bin A Toner cartridges Y C M K Ir NaN to o J ARS CF fe p fa 2 eT SO VE VL Fuser E AY WC a AQ r O lt exit sensor DAS RARA aN q O A o 7 a 2e part of ITU LIN Input sensor i Part of a j Tray 1 lr Tray present sensor Pick roller Paper path Paper pick motor drive asm Duplex manual feed sensor S1 5 2 Service Manual Printhead Controller board Developers Y C M K PC unit part of imaging unit ITU 5025 2xx 4xx Connectors Connector locations 5 3 5025 2xx 4xx Controller board diagram Q JNET1 USRI 5 4 Service Manual 000000 0000000000 00 0 0 0 JLVPS1 JOPT1 JCARTB1 JSP1 JTPS2 1 IIe JTHM1 JHVPS1 e oo 1 oo a Oven 1 JFUSES1 4 JINT1 y JTRAY1 JTPS1 4 JSC1 El 4 JusBH1 OOOOOOOOO0O00000000000000000 5025 2xx 4xx Controller board connectors Note SW indicates voltage is switched on during a print cycle otherwise voltages are taken with printer at Ready state door closed and cables plugged in CC EI id Bin full narrow media sensor and 2 S BIN F
169. o lose the grounding washer 6 Disconnect the thermistor cables C wit N Y EA a Repair information 4 29 5025 2xx 4xx 7 Remove the exit deflector and bin full narrow media sensor flag See Exit deflector and bin full narrow media sensor flag removal on page 4 27 8 Remove the bin full narrow media sensor See Bin full narrow media sensor removal on page 4 18 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 of the fuser toward the front then slide it to the left to align the fuser side frames with the flat areas of the shaft F and lift to remove the fuser Warning Be careful to not interfere with or damage the fuser exit sensor to the left of the fuser when rotating the fuser 4 30 Service Manual 5025 2xx 4xx Installation notes e Make sure the springs are resting on the frame so they can be positioned once the new fuser is in place e Be careful not to bump into the fuser exit sensor on the left side They can be difficult to reach if they hang down e When reinstalling on the right side make sure the gears mesh e Reroute the cables back through their retainers A B A B e When you replace a new fuser be sure to reset the Fuser Page Count ol Wy Enter Diagnostics Menu turn the printer
170. o print when the estimated Go to 90x xx error on page 2 22 Fuser Error power is too low 122 07 Service Timed out waiting for home sensor Go to Fuser service check on Fuser Error event page 2 28 122 08 Service Wrong lamp bit is set in NVRAM Go to Fuser service check on Fuser Error page 2 28 122 10 Service Fuser failed to warm up Go to Fuser service check on Fuser Error page 2 28 122 11 Service Fuser under temperature error while in Go to Fuser service check on Fuser Error standby page 2 28 Diagnostic information 2 15 5025 2xx 4xx Service error messages 1xx 9xx continued CE CN 122 12 Service Fuser under temperature error while Go to Fuser service check on Fuser Error printing page 2 28 122 13 Service Fuser open thermistor check failed for Go to Fuser service check on Fuser Error second thermistor page 2 28 122 14 Service Fuser shorted thermistor check failed Go to Fuser service check on Fuser Error for hot roll thermistor page 2 28 122 15 Service Fuser storted thermistor check failed Go to Fuser service check on Fuser Error for second thermistor page 2 28 122 16 Service Estimated power is at or above Go to Fuser service check on Fuser Error maximum power page 2 28 122 17 Service Total failure to close fuser nip Go to Fuser service check on Fuser Error page 2 28 141 xx Service Staging motor error Go to Paper pick motor drive
171. oes AAA DARA 5 4 High voltage power supply HVPS diagram 0 00 cee 5 12 Low voltage power supply LVPS diagram 0 cc eee 5 13 Toner meter cycle TMC ard ri GAO OR eth Re ees 5 14 Wireless network card 6 kes i decane rra A A eh eked teens Benes 5 14 Preventive Maintenance 6 1 os AAA P A ee eee ee ee teweew ee 6 1 Lubrication specifications cier ar KR KE KAR MERA EAE ARE AREER BRASA RARA OES AAA 6 1 Scheduled A 6 1 a RY 245422402004 0009s ena ae wes dee d56 00 os ese whee AGO Od ORES 6 1 elt gc AAA ee ee eer er re eer re err rrr rer ee 7 1 ROW lO Se Inis paris Catalog ssc2 lw dedawdad ehede wwe eed aeweeewh nies rs Oe ce sweetaowe as 7 1 Assembly 1 COW SS rior aria AA EA 7 2 e A A ES OO S44 SOS SEO ORES 7 4 PSSEMDIVS SICCUWONICS circa dira ieee AAA vee es 7 6 PSSOINOIY Ty CDOS coed 55 65 6 5 44h SAGO SSE RRA ee 4G 4 Gh Ge RA 7 8 Assembly 5 Media drawers and trayS 0 0 00 cee eee 7 10 Assembly 6 Options and miscellaneous 0 0000 7 12 lie ee ee ee ee ee ee ee ee eae ee l 1 Parn NOMD o AAA o A l 7 Table of contents Vil 5025 2xx 4xx viii Service Manual 10 2 2009 5025 2xx 4xx Notices and safety information The laser notice label may be affixed to this printer Laser notice The printer is certified in the U S to conform to the requirements of DHHS 21 CFR Subchapter J for Class 1 laser products and elsewhere is certified as a Class laser product conforming
172. olved Replace the developer unit Imaging unit IU removal on page 4 45 See Developer unit removal on page 4 21 Print quality random marks Service tip The primary cause of random marks is loose material moving around inside the printer and attaching to the photoconductor unit developer roll or transfer belt Is there any loose or foreign material on the Inspect the imaging unit by Go to step 2 imaging unit looking at the individual developers and photo conductors Clean or replace the faulty unit See Imaging unit IU removal on page 4 45 Is there any loose or foreign material on the Replace the developer unit Go to step 3 developer roll Is there any loose or foreign material on the Replace the image transfer Contact your next level of transfer belt unit See Image transfer support unit ITU removal on page 4 40 2 46 Service Manual 5025 2xx 4xx Print quality residual image Step Questions actions Yes Check the condition of the imaging unit using Go to step 2 Replace the imaging unit or the customer menus administrative menus the photoconductor unit 1 At the Ready prompt press Menu ci oo unit IU page 4 45 2 Select Supplies Menu and press Select y 3 Select Imaging Kit and press Select y Does the display indicate OK Measure the distance from the original image Replace the developer Replace the im
173. omatically returned to TPS Setup Diagnostic aids 3 21 5025 2xx 4xx Reports Menu Settings Page To print the Menu Settings Page 1 Select Reports from Diag Menu and press Select v 2 Select Menu Settings Page and press Select y Event Log Display Log The event log provides a history of printer errors It contains the most recent errors that have occurred on the printer The most recent error displays in position 1 If an error occurs after the log is full the oldest error is discarded Identical errors in consecutive positions in the log are entered so 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 y 2 Select Display Log and press Select As many error codes display as fit on the screen at a time Press lt or pto view additional error codes Press p to view additional details Press Back 5 to return to the Event Log menu Print Log Additional diagnostic information is available when you print the event log from the Diagnostics Menu rather than the Configuration Menu The Event Log printed from Diag Menu includes e Detailed printer information including code versions e Time and date stamps e Page counts for most errors e Additional debug information in some cases Model and Fvent log Pegs 1 Se
174. on to the controller board the cable for pinch points and the cable or connector for any other damage Is the cable damaged Check the connector JLVPS1 for proper connection to the controller board the cable for pinch points and the cable or connector for any other damage Is the cable damaged Check the power cable on the left side of the fuser and the thermistor cables and connections on the right side of the fuser Are the cables or connectors damaged 2 28 Service Manual sensor See Fuser exit sensor removal on Replace the controller board See Controller board removal on page 4 20 Replace the fuser exit page 4 33 Check the switch on the side of the LVPS to verify the correct voltage is set Go to step 2 Replace the fuser cable Go to step 3 Go to step 4 Go to step 5 Repair or replace the LVPS cable Repair the cables If the cables cannot be repaired replaced the fuser See Fuser assembly removal on page 4 29 5025 2xx 4xx Check the following values at JFUSES1 Go to step 6 Replace the controller board See Controller JFUSES1 board removal on page 4 20 Value 24 V dc doors closed 24 V dc doors closed 24 V dc doors a Ls EN 2 MEX An EJ EF EZ 10 Are the values approximately correct Replace the fuser See Fuser assembly Problem resolved Replace the controller removal on page 4 29 board See Controller
175. ons power and electrical 1 6 start 2 1 symptoms print quality 2 4 printer 2 3 T test pages 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 5025 2xx 4xx toner cartridge contacts parts catalog 7 8 removals 4 67 toner density sensors TDS parts catalog 7 8 removal 4 69 TPS Setup 3 21 toner meter cycle TMC card Base Sensor Tests 3 16 connectors 5 14 parts catalog 7 6 removal 4 71 service check 2 50 toner meter sensors service check 2 50 tools required 1 15 transfer roll ITU removal 4 40 service check 2 51 tray x parts catalog 7 10 service check 2 53 tray 1 parts catalog 7 2 tray 1 tray present sensor location 5 2 tray present sensor removal 4 73 service check 2 51 tray tests Feed Tests 3 15 Sensor Test 3 15 U USB port clipping the cable 4 5 operator panel port service check 2 38 operator panel USB cable 2 38 parts catalog 7 8 printer connection service check 2 54 removal 4 76 W waste toner bottle contact removal 4 78 waste toner bottle removal 4 77 Web server firmware update 3 28 wireless network antenna parts catalog 7 6 removal 4 79 wireless network card connections 5 14 parts catalog 7 6 removal 4 81 Index l 5 5025 2xx 4xx l 6 Service Manual 5025 2xx 4xx Part number index Description and P N 40X0270 40X0271 40X0273 40X0275 40X0279
176. or correction manual 3 50 color samples 3 51 5025 2xx 4xx color theory 3 49 Color Trapping 3 24 configuration ID 3 19 configuration menu accessing 3 1 Auto Color Adj 3 27 available tests 3 24 Color Trapping 3 24 Demo Mode 3 25 Energy Conserve 3 26 Event Log 3 25 exit Config Menu 3 27 Factory Defaults 3 26 Font Sharpening 3 27 Panel Menus 3 25 PPDS Emulation 3 25 Printer Setup Reset Fuser Cnt 3 20 Prt Quality Pages 3 24 Reports Menu Settings Page 3 25 controller board connections 5 4 Motor Detect 3 17 parts catalog 7 6 removal 4 20 covers parts catalog 7 2 removals 4 2 D dead printer service check 2 24 defaults 3 18 EP Defaults 3 20 factory defaults 3 26 Demo Mode 3 25 developer units description 4 45 removal 4 21 diagnostics 2xx paper jam messages 2 11 9xx service error messages 2 13 power on reset POR 2 2 service checks 2 22 service error messages 2 13 start 2 1 symptom tables 2 3 user status attendance messages 2 5 diagnostics menu accessing 3 1 Alignment Menu 3 7 Base Sensor Tests C TMC Sensor 3 16 Fuser Exit 3 16 Input 3 16 Index l 1 5025 2xx 4xx K TMC Sensor 3 16 M TMC Sensor 3 16 S1 3 16 S2 3 16 Standard Bin 3 16 Y TMC Sensor 3 16 Device Tests Flash Test 3 17 Duplex Tests Left Margin 3 14 Quick Test 3 13 Top Margin 3 14 EP Setup DC Charge Adjust 3 20 Dev Bias Adj 3 20 EP Defaults 3 20 Fuser Temp 3 20 Transfer Adjust 3 20 Event Log Clear Log 3 23 Display Log 3
177. oval on page 4 20 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 controller board See Controller board removal on page 4 20 Go to the service check for the device indicated Diagnostic information 2 21 5025 2xx 4xx Service checks 90x xx error Turn the printer off and remove the rear Replace the controller Securely make all the shield See Top cover assembly removal board See Controller connections POR the on page 4 13 Check the cable connections board removal on printer Are all the cable connections secure page 4 20 925 01 Fan error service check Turn the printer off and remove the rear Replace the top cover Replace the controller shield See Top cover assembly removal which includes the fan board See Controller on page 4 13 Check the fan cable at JFAN1 See Top cover assembly board removal on for the following values removal on page 4 13 page 4 20 JFAN1 Pin vale a sva 2 Ground e ornon Are the measured values correct 2 22 Service Manual 5025 2xx 4xx 950 xx NVRAM 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 prin
178. oved Check the tray adjustments for the size of paper used Check the pick tires for foreign material or wear Replace if necessary See Pick tires removal on page 4 64 Close the primary tray Press Select to continue printing Note Make sure all paper fragments are removed Align the tray and insert it Press Select y to continue N SA Eo PE 250 paper jam 1 Push the lever to remove the media jam in the multipurpose feeder Note Make sure all paper fragments are removed 2 Press Select y 3 36 Service Manual 5025 2xx 4xx Theory of operation Print engine theory Electrophotographic process EP process The method that all laser and LED printers use to print is called the electrophotographic process These machines use differences in charge to manipulate and move toner from the toner cartridge to the printed page Even though the basic EP process is the same for every laser and LED printer the specifics for each printer are different Electrophotographic process basics This printer is a single laser printer that uses four toner cartridges cyan yellow magenta and black to create text and images on media The printer has four photoconductors called a photodeveloper cartridge or PC unit and an image transfer unit ITU Each color toner is painted to it s respective photoconductor at the same time The transfer belt passes under the four pho
179. ow Repair information 4 35 5025 2xx 4xx High voltage power supply HVPS with no spring Note This removal requires a magnetized 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 Remove the cable cover A 4 36 Service Manual 5025 2xx 4xx 5 Remove the screw B The screw is accessible from the top of the printer and requires a long shank magnetized Phillips screwdriver It is the only screw without a flanged head and is about 8 inches below the top of the printer Main drive with motors B 6 Remove the screw C securing the HVPS 7 Carefully slide the HVPS out MESE N iL an fy o O a O i Installation notes CAUTION After disconnecting the high voltage power cable from the controller board always check that the HVPS connection was not loosened Make this check anytime you are working near the HVPS cable Warning Connect the high voltage power supply HVPS cable to the high voltage power supply before sliding the board into the printer Pull the HVPS cable through the access hole and plug into the controller board Be careful not to dislodge the cable from the HVPS Loosely replace screw C replace and tighten screw B and then tighten screw C Repair information 4 37 5025 2xx 4xx
180. ower supply sends voltage to the first transfer rolls located in the ITU D The charge difference between the developed toner image on the photoconductor surface and the first transfer roll causes the images to transfer to the surface of the ITU belt for each color This takes place by a direct surface to surface contact between the photoconductors and the ITU belt f GY y Q NCS O e l QUO la l Service tips e Never touch the surface of the ITU belt with your bare hand The oil from your skin will cause a charge differential on the surface and toner will not stick properly The result would be repeating blotches of voids light print on a page Then the ITU belt will have to be replaced e Don t use solvents or other cleaners to clean the ITU belt surface No matter how careful you are the surface will be compromised causing scratches or a charge differential that will produce a void or light blotch on the printed page Then the ITU belt will need to be replaced Diagnostic aids 3 41 5025 2xx 4xx Step 4b Second transfer Once the four planes of color are transferred to the transfer belt from the photoconductors the image is carried towards the transfer roll E The transfer roll is also part of the ITU Based on the speed of the transfer belt the proper time to send the signal to pick the media from an input source is
181. paper feeding or print quality issues Always use paper between 100 and 300 Sheffield points however smoothness between 150 and 200 Sheffield points produces the best print quality e Moisture content The amount of moisture in paper affects both print quality and the ability of the printer to feed the paper correctly Leave paper in its original wrapper until it is time to use it This limits the exposure of paper to moisture changes that can degrade its performance Condition paper before printing by storing it in its original wrapper in the same environment as the printer for 24 to 48 hours before printing Extend the time several days if the storage or transportation environment is very different from the printer environment Thick paper may also require a longer conditioning period e Grain direction Grain refers to the alignment of the paper fibers in a sheet of paper Grain is either grain long running the length of the paper or grain short running the width of the paper For 60 to 176 g m 16 to 47 lb bond paper use grain long fibers e Fiber content Most high quality xerographic paper is made from 100 chemically treated pulped wood This content provides the paper with a high degree of stability resulting in fewer paper feeding problems and better print quality Paper containing fibers such as cotton possesses characteristics that can negatively affect paper handling Unacceptable paper The following paper types are not recommended
182. play blank 5 beeps 2 34 one or more buttons fail 2 33 options and features description 1 2 parts catalog 7 12 P Panel Menus 3 25 Panel Test 3 11 paper guidelines 1 12 input size 1 9 input sources 1 8 input type 1 11 output capacity 1 9 recycled 1 14 unacceptable paper 1 13 weights 1 12 paper jams avoiding 3 31 error messages 2 11 paper path theory 3 46 paper pick drive assembly service checks 2 39 paper pick motor drive assembly parts catalog 7 4 removal 4 61 parts catalog cables 7 8 covers 7 2 electronics 7 6 frames 7 4 media drawers and tray 7 10 options and miscellaneous 7 12 password panel menus 3 25 Perm Page Count 3 18 photoconductor unit description 4 45 imaging kit 4 45 pick tires parts catalog 7 2 7 10 removal 4 64 pogo pin see toner cartridge contacts POR sequence 2 2 power on sequence POR 2 2 PPDS Emulation 3 25 print quality background 2 41 blank page 2 42 blurred or fuzzy print 2 43 Index l 3 5025 2xx 4xx half color page 2 43 horizontal banding 2 44 horizontal line 2 44 insufficient fusing 2 45 menu settings page 2 39 missing image at edge 2 45 mottle 2 5mm speckles 2 45 mottle 2 5mm speckles 2 45 narrow vertical line 2 46 random marks 2 46 residual image 2 47 solid color page 2 48 vertical banding 2 48 printhead parts catalog 7 4 removal 4 65 service check 2 49 Prt Color Pg Count 3 18 Prt Mono Pg Count 3 18 Prt Quality Pgs configuration menu 3 24 diagnostic menu 3 11
183. r Configurations Lexmark C546dtn with standard 650 sheet Duo Drawer and optional 550 sheet drawer Lexmark C540n C543dn Lexmark C544n C544dn with C544n C544dn optional 650 sheet Duo Drawer Standard Operator panel Standard Operator panel Standard Operator panel output bin Multipurpose 50 sheet 650 sheet feeder drawer tray 3 Duo Drawer tray 2 D Y Manual slot Y 650 sheet anual sio Standard Duo Drawer 250 sheet tray 2 LD 250 sheet tray tray 1 Manual elo tray tray 1 Manual slot See Input and output sources and capacities on page 1 8 for paper capacities General information 1 1 5025 2xx 4xx Options and features Certain options are available on selected printer models only Available options include e 650 Sheet Duo Drawer a 550 sheet drawer with a 100 sheet multipurpose feeder MP Feeder e 550 Sheet drawer an optional 550 sheet drawer that can be added to model C546dtn only e Additional memory One 128 256 or 512MB memory card may be added e Flash memory card One 64MB card may be added e Font cards One language card may be added Printer specifications Memory V Supported Lexmark C540n Lexmark C544n X Not supported C543dn C544dn Standard DDRS DRAM sizes 128MB Optional DIMM sizes 256MB 512MB Option Slots single slot is available or either font or flash memory card Font card support N A 1 font card Optional user flash memory card sizes
184. r desligue o produto da tomada el ctrica ou seja cuidadoso caso o produto tenha de estar ligado corrente el ctrica para realizar a tarefa necess ria XVI Service Manual 10 2 2009 5025 2xx 4xx Informacio de Seguretat e La seguretat d aquest producte es basa en l avaluaci i aprovaci del disseny original i els components especifics El fabricant no es fa responsable de les questions de seguretat si s utilitzen peces de recanvi no autoritzades e La informacio pel manteniment d aquest producte esta orientada exclusivament a professionals i no esta destinada a ning que no ho sigui e El risc de xoc electric i de danys personals pot augmentar durant el proc s de desmuntatge i de servei d aquest producte El personal professional ha d estar ne assabentat i prendre les mesures convenients PRECAUCI aquest s mbol indica que el voltatge de la part de l equip amb la qual esteu treballant s perill s Abans de comen ar desendolleu l equip o extremeu les precaucions si per treballar amb l equip l heu de connectar OF Al At St L L O Ms ra E Se Toa a io eS de de do al ls do a ee eS he Ea TIETAS TINTE Eo oe OO eee Bl eee dl a eo he ds o ee E At Ai El H o E B aj Ap 201 A oi AL Cf 10L A L L L oe T WH EMS ATAA eS PA SS HN NSUSHHU VU E UAH Se 2 a a a f Toe te oo nT aan en 0 91 A Ol L Ef A A N 0 2 25 H 2 Al yt TO H TL H PAS We ee ee Rela e APE HEN Ah PE DAR Bh Rp EP a IA
185. r 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 digit numeric value of the new FRU before you begin to install it You may have to rotate the release lever again to install the new ITU but a quick firm push should overcome the latch Repair information 4 43 5025 2xx 4xx e Rotate the spring clamp so it hooks over the new ITU E Note Position the spring on the right side of the gear shaft T de D e When you have replaced the ITU be sure to enter the 16 digit numeric value from the barcode on the new ITU into the printer 1 Enter the Diagnostics Menu a Turn the printer off b Press and hold 4 and N 4 C Turn the printer on d Release the buttons when the installed memory and processor speed displays 2 Select PRINTER SETUP from Diag Menu and press Select y 3 Select ITU Barcode and press Select y 4 To enter the 16 digit numeric value Use to decrease the leftmost digit value or p to increase the value Press Select y to advance to the next digit If a digit is already correct press Select y to accept the number and to continue When the last number is entered press Select y and Submitting changes should appear If the entered number is incorrect Check Sum Does Not Match displays Check and reenter the number
186. r curled paper Flex fan and straighten paper before loading it Do not use paper that has been cut or trimmed by hand Do not mix paper sizes weights or types in the same stack Store the paper in an appropriate environment Do not remove trays while the printer is printing Wait for Load tray lt x gt or Ready to appear before removing a tray Do not load the manual feeder while the printer is printing Wait for Load Manual feeder with lt x gt to appear Push all trays in firmly after loading paper Make sure the guides in the trays are properly positioned and are not pressing too tightly against the paper Make sure all paper sizes and paper types are set correctly in the operator panel menu Make sure all printer cables are attached correctly Diagnostic aids 3 31 5025 2xx 4xx Understanding jam numbers and locations Only C546dtn When a jam occurs a message indicating the jam location appears The following illustration and table list the paper jams that can occur and the location of each jam Open doors and covers and remove trays to access jam locations message 200 Standard 250 sheet tray and manual Pull tray 1 out and remove the jam feeder tray 1 Jam in the input S2 sensor Jam under the fuser Open the front door and remove the jam Jam in the fuser Open the front door and pull the fuser cover toward you Remove the jam Media not supported in the duplex Load the tray with the
187. ralia Power cord 1 8M straight Brazil Power cord 2 5M straight Chile Uruguay Power cord 2 5M straight Denmark Power cord 2 5M straight Israel Power cord 2 5M straight Japan Power cord 2 5M straight Korea Power cord 2 5M straight Paraguay Power cord 2 5M straight PRC Power cord 2 5M straight South Africa Power cord 2 5M straight Switzerland Power cord 2 5M straight Taiwan Power cord 2 5M straight Traditional Italy Power cord 2 5M straight United Kingdom Parts catalog 7 7 5025 2xx 4xx Assembly 4 Cables 7 8 Service Manual Assembly 4 Cables 5025 2xx 4xx Part Units Units Deserivti n number mach FRU p 40X5429 40X5414 40X7046 40X5421 40X5423 40X5425 ITU paper path thermistor Toner density sensors left or right one in package Waste toner bottle contact block Toner cartridge contacts Pogo pin Cable packet used for Fuser exit narrow media to controller board Fuser motor thermistor and duplex sensor to controller board LVPS to controller board CMY K motors to controller board Tray 2 to controller board HVPS to controller board Tray present sensor to controller board AC power to LVPS USB port and cable for portable flash drive A B C D E F G H Parts catalog 7 9 5025 2xx 4xx Assembly 5 Media drawers and trays 7 10 Service Manual 5025 2xx 4xx Assembly 5 Media drawers and tray
188. ray present sensor Installation notes 1 cia Y Clean the contact surface where you removed the sensor retaining plate or where you need to install the new one Install the sensor Note Make sure the clips on the posts latch to the frame Remove the backing from the new plate and place the plate on the surface between the sensor mounting posts Connect the cable to the tray present sensor Replace the spring Repair information 4 75 5025 2xx 4xx USB port connector removal See USB port and cable for portable flash drive on page 7 9 for the part number The FRU includes the USB port connector and cable Remove the operator panel See Operator panel logo plate on page 4 9 Remove the right cover assembly See Right cover assembly removal on page 4 12 Remove the waste toner bottle See Waste toner bottle removal on page 4 77 Remove the rear shield See Top cover assembly removal on page 4 13 Remove the rear 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 Remove the four screws B from the cable cover Se a a A A r EN T AA mn Y A n B 7 Disconnect the USB port cable C from the controller board 4 76 Service Manual 5025 2xx 4xx 8 Remove the USB port cable from the cable channel on the right side Waste toner bottle remo
189. recautions while handling electrostatic discharge sensitive parts See Handling ESD sensitive parts on page 4 1 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 may be rendered inoperable e Operator panel assembly e Controller 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 on the component cannot be used in another printer The component must be returned to the manufacturer 1 Remove the rear shield See Top cover assembly removal on page 4 13 2 Disconnect all the cables from the controller board 3 Remove the nine screws A that are securing the controller board 4 Ifthe unit has a wireless card disconnect the card from the controller board 5 Remove the board 4 20 Service Manual 5025 2xx 4xx Installation notes Warning When replacing the controller board verify the cable from the high voltage power supply is seated properly The cable may have come loose from the HVPS Print a few pages to verify the installation If the pages are blank confirm that the high voltage power supply cable is properly seated The connector may have been loosened at the HVPS A blank page that should have toner on it could
190. reless card Problem resolved Go to step 20 Did this fix the problem Is the antenna damaged Go to step 22 Go to step 21 Is the drop functioning properly Verify that the antenna is properly connected Go to step 24 Go to step 23 to the wireless card Is it connected correctly Properly connect the antenna Problem resolved Go to step 24 Did this fix the problem Check pin 6 for 3 3V and Pin 5 for 5V on Replace the wireless card Replace the controller connector JUSBW1 of the controller board Pin See Wireless network board See Controller 1 and 4 are GND card on page 4 81 board removal on Are the voltages and grounds correct page 4 20 Replace the antenna Problem resolved Go to step 22 Did this fix the problem 2 32 Service Manual Operator panel service check Warning Warning 5025 2xx 4xx 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 e Operator panel assembly e Controller board 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 cannot be used in another printer It must be returned to the manufacturer One or more operator panel buttons fail Questions actions
191. removal e When reinstalling a part held with several screws start all screws before final tightening e Some removal procedures require removing cable ties You must replace cable ties during reassembly to avoid pinching wires obstructing the paper path or restricting mechanical movement Front cover assembly removal See the front cover assembly on page 7 3 for the part number Open the front cover Remove the operator panel See Operator panel logo plate on page 4 9 Remove the right cover assembly See Right cover assembly removal on page 4 12 Remove the waste toner bottle See Waste toner bottle removal on page 4 77 Remove the four screws A from the cable cover and remove the cable cover Remove the screw B from the back of the waste toner cartridge ground connector oS AN AP pi a b e l Ah A B 7 Remove the rear shield See Top cover assembly removal on page 4 13 4 2 Service Manual 5025 2xx 4xx 8 Disconnect the operator panel cable the USB port if installed cable and the 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 Remove the two restraining straps from the printer by turning the end sideways and lifting out of the connector D Repair information 4 3 5025 2xx 4xx 12 Lower the front cover to align t
192. rence edge 40X2261 Preventive maintenance 6 1 5025 2xx 4xx 6 2 Service Manual 5025 2xx 4xx 7 Parts catalog How to use this parts catalog The following legend is used in the parts catalog Asm Part l Units we index Units mach Description e Asm index Identifies the assembly and the item in the diagram For example 3 1 indicates Assembly 3 and item number 1 in the table e Part number Identifies the unique number that identifies this FRU e Units mach Refers to the number of units actually used in the base machine or product e Units FRU Refers to the number of units packaged together and identified by the part number e NS Not shown in the Asm Index column indicates that the part is procurable but is not pictured in the illustration e PP Parts Packet in the parts description column indicates the part is contained in a parts packet e Model information used in the parts catalog Model name Macame ty Pe Description model Lexmark C540n 5025 210 Ethernet network Lexmark C543dn 5025 230 Ethernet network duplex Lexmark C544n 5025 410 Ethernet network USB A host port for flash drives Lexmark C544dn 5025 430 USB A host port for flash drive duplex Ethernet network Lexmark C544dw 5025 43W 802 11n network wireless network duplex ethernet USB A host port for flash Lexmark C546dtn 5025 439 USB A host port for flash drive duplex Ethernet network 650 sheet Duo Drawer Parts catalog 7 1 5025 2
193. rform a POR If the problem persists go Black Printhead printhead to Printhead service check on page 2 49 109 08 Service The black laser showed bad in testing Perform a POR If the problem persists go Black Printhead to Printhead service check on page 2 49 109 11 Service Failure writing data tot he printhead Perform a POR If the problem persists go Black Printhead to Printhead service check on page 2 49 109 12 Service Failure reading data from the Perform a POR If the problem persists go Black Printhead printhead to Printhead service check on page 2 49 109 13 Service Printhead declared error Perform a POR If the problem persists go Black Printhead to Printhead service check on page 2 49 122 xx Service Fuser error Go to Fuser service check on Fuser Error page 2 28 122 01 Service Attempting to print with estimated Go to Fuser service check on Fuser Error power at or below minimum power page 2 28 122 02 Service Fuser over temperature Go to Fuser service check on Fuser Error page 2 28 122 03 Service Fuser open thermistor check failed Go to Fuser service check on Fuser Error page 2 28 122 04 Service Attempting to print with estimated Go to 90x xx error on page 2 22 Fuser Error power at or above minimum power 122 05 Service Fuser failed to reach final temperature Go to 90x xx error on page 2 22 Fuser Error in time 122 06 Service Attempting t
194. rial number Lecmark CSH toi DEP Dewice foformetios Printer information Ereni Leg nfarmerico Panel display when error occurred Page count Earliest error code 3 22 Service Manual 5025 2xx 4xx The printed event log can be faxed to your next level of support for verification or diagnosis To print the event log 1 Select Event Log from Diag Menu and press Select y 2 Select Print Log and press Select 7 Press Back 9 to return to Event Log Clear Log Use 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 y 2 Select Clear Log and press Select y 3 Select YES to clear the Event Log or NO to exit the Clear Log menu If YES is selected Deleting EVENT LOG displays on the screen Press Back 5 to return to Event Log EXIT Diags Press Select to exit Diag Menu The printer performs a power on reset and returns to normal mode Diagnostic aids 3 23 5025 2xx 4xx Configuration menu Config Menu Available tests The tests display on the operator panel in the order shown for all models Configuration menu Exit Config Menu This selection exits Configuration Menu and Resetting the Printer displays The printer performs a POR and returns to
195. ring dlagram o alef 7 9 11 13 15 17 19 21 23 25 27 29 31 33 35 37 30 Petts le ope frefrs e 20 22 24 26 25 0x2 24 26 3820 ey O Ol el o Toner Meter Notes All voltages are DC unless otherwise noted Values including a SW are measurable only during a print cycle PEPE GELEI Eno JMIBR1 RRE RERRERRERERA 2 ofa re 9 20 22 26 26 26 20 22 2 36 9 0 USB Port Operator Panel av DO gt 3 3V DC a OP_IRQ_N gt 4V JLVPS1 m GND 120 CLK V_PANEL 5V o E CITT JOPP1 Kliv ie JWTI JOPT1 JUSBW1 E AL JTPS1 JTRAYA JINT1 JCVRI iaa JBIN1 A JTHM1 JTPS2 dido ipe coe CeEEEEICPE aaa Eee aa En Perera o e ol 1NO ONES gt olc clo lt lo0 o a N 0 T o zjopniz e o miz lt lt a OPPS Sie lt Y a O gt fn lt ala ala 4 S S 3 ps 3 ojo a 4 o S w y lt lt wn D O w 3 O Us lt 2 D S O 5 5 D a e LJ lt Waste Toner Detection SC Cartridge Spring Tray loaded is Front Door Bin Full Fuser pins Switch Sensor Exit Sensor Wireless printer only Fuser HEAT1_ON E avoe 7 a GND 5V_OPTIONS 24V DC XD PP EEE 19po9uy GND ZERO_XING_IN GND GND GND GND GND GND Imaging Unit Supply A Q S
196. rinter to match the Problem fixed Go to step 10 IP address on the driver Did this resolve the issue Have the network admin verify that the printer Go to step 12 Go to step 11 and PC s IP address have identical subnet addresses Are the subnet addresses the same Go to step 12 Using the subnet address supplied by the Problem resolved network admin assign a unique IP address to the printer Note The printer IP address should match the IP address on the printer driver Did this fix the problem Is the device physically connected ethernet Go to step 13 Go to step15 cable to the network Diagnostic information 2 31 5025 2xx 4xx Try using a different ethernet cable Problem resolved Go to step 14 Did this remedy the situation Have the network administrator check the Replace the controller Contact the network network drop for activity board See Controller administrator board removal on page 4 20 Is the printer on the same wireless network as Goto step 17 Go to step 16 the other devices Assign the correct wireless network to the Problem resolved Go to step 17 printer Did this fix the problem 17 Are the other devices on the wireless network Goto step 18 Contact the network communicating properly administrator Verify that the wireless card is properly seated Go to step 20 Go to step 19 on the controller board Is the wireless card seated correctly Properly reseat the wi
197. rinthead 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 Yellow printhead error The yellow printhead lost HSYNC The yellow printhead failed to complete servo The yellow printhead mirror motors failed to achieve lock The yellow printhead mirror motors lost motor lock Failure reading NVRAM from printhead The yellow laser showed bad in testing Failure writing data to the printhead Failure reading data from the printhead Printhead declared error Cyan printhead error The cyan printhead lost HSYNC The cyan printhead failed to complete servo The cyan printhead mirror motor failed to achieve lock The cyan printhead mirror motor lost motor lock Failure reading NVRAM from the cyan printhead Perform a POR If the problem persists go to Printhead service check on page 2 49 Perform a POR If the problem persists go to Printhead service check on page 2 49 Perform a POR If the problem persists go to Printhead service check on page 2 49 Perform a POR If the problem persists go to Printhead service check on page 2 49 Perform a POR If the problem persists go to Printhead service check on page 2 49 Perform a POR If the problem persists go to Printhead service check on page 2 49 Perform a
198. ro 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 Inspect the imaging unit for damage including the developers and toner cartridges Replace if damaged 2 If paper other than 20lb plain letter A4 paper is being used load 20lb plain 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 off press and hold Left 4 and Select x turn the printer on and release when the installed memory and processor speed displays b Select PRINT TESTS and press Select y C Select Print Quality Pgs and press Select y The message Printing Quality Test Pages is displayed ol An incorrect printer driver for the installed software can cause problems Incorrect characters could print and the copy may not fit the page correctly When you measure voltages measure from the connector to the printer ground 2 40 Service Manual 5025 2xx 4xx Print quality background Service tip Some background problems can be caused by using rough paper or incorrectly setting the operator panel settings to rough texture when the texture is not rough Using non Lexmark toner cartridges may also cause the problem Some slick or coated
199. s Part Units Units Deserivti n number opt FRU p 40X5434 Optional 650 sheet Duo Drawer complete includes 100 sheet MPF 40X2284 Optional 650 sheet Duo Drawer complete C546dtn only includes 100 sheet MPF 40X5168 Pick tires 40X5435 650 sheet Duo Drawer tray assembly C544n C544dn C544dw C540n C543dn includes 100 sheet MPF tray assembly using three wear strips Note Use only with P N 40X5434 drawer assembly see illustration and table below 40X2285 650 sheet Duo Drawer tray assembly C546dtn includes 100 sheet MPF using four wear strips Note Use only with P N 40X2284 drawer assembly see illustration and table below 40X1538 Optional 550 sheet drawer complete C546dtn only 40X2512 550 sheet MPF latch cover This drawer has an autoconnect A on the bottom of the drawer assembly as shown below Use only P N 40X2285 tray with this drawer Use the chart below to match the correct trays with the drawers 40X5435 40X5434 without autoconnect All except C565dtn 40X2285 40X2284 with autoconnect A C546din wear strips Parts catalog 7 11 5025 2xx 4xx Assembly 6 Options and miscellaneous Part Units Units HA futs fooson 40X2254 40X2255 40X2261 40X5937 40X5938 40X5939 40X1455 40X5969 40X5970 40X597 1 40X5972 40X1368 40X0395 7 12 Service Manual bh bh h hb bhb _bhb _bhb _b hb _b A mb mb 115 V Maintenance kit fuser ITU duplex re
200. sconnect the cables from the controller board Note Be very careful disconnecting handling the ribbon cable 3 Remove the toroid A from the ribbon cable lich OPTION CA Repair information 4 65 5025 2xx 4xx 4 Remove the three screws B JUUUULU VUVUUUU VUUUUUU JL FS F aa a ed 5 Remove the printhead Installation note When the printhead 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 printhead and push the toriod between the connector and the top frame so that the weight is not supported by the cable 4 66 Service Manual 5025 2xx 4xx Toner cartridge contacts See Toner cartridge contacts Pogo pin on page 7 9 for the part number Remove the right cover assembly See Right cover assembly removal on page 4 12 Remove the waste toner bottle See Waste toner bottle removal on page 4 77 Remove the imaging unit See Imaging unit IU removal on page 4 45 Remove the rear shield See Top cover assembly removal on page 4 13 Remove the rear 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 Remove the four screws B securing the cable cover and remove the cable cover 2 PES
201. sors are working correctly for an individual input tray Select INPUT TRAY TESTS from Diag Menu and press Select Select Sensor Tests and press Select x Select the tray where you want to test the sensors Depending on the tray selected you may have Empty Sensor Low Sensor or Passthru Sensor Sensors will be displayed with either Open or Closed Toggle the sensor you want to test and note the change of state of that sensor oN gt Input Tray Empty Sensor Passthru Sensor x Tray 2 650 sheet duo tray Tray 3 550 sheet tray C546tdn MP Feeder To Exit the text press Back 5 or Stop W Diagnostic aids 3 15 5025 2xx 4xx Base Sensor Test These tests allow you to verify the correct functioning of the front door input and output sensors 1 Select Base Sensor Test from Diag Menu and press Select y 2 Select the sensor you want to test and press Select y The following tests are available CC CTN Front Door Opened Open and close the front door The sensor should Closed change state Standard Bin Bin full Lift up on the bin full narrow media flag and then release The sensor should change state S1 Media clear or Activate the sensor by removing and re inserting the paper tray The sensor should change state Media present S2 Media clear or Remove the media tray Activate the input S2 sensor flag The sensor should change state
202. sparencies envelopes or labels Lexmark transparency part numbers 12A8240 and 12A8241 are supported from the standard tray manual slot and the multi purpose feeder 7 Paper 90 to 104 9 g m 23 9 to 27 8 lb must be printed with Paper Type set to Heavy Paper 3 Paper 105 to 176 g m 27 9 to 47 lb must be printed with Paper Type set to Cardstock Media guidelines Paper characteristics The following paper characteristics affect print quality and reliability Consider these characteristics when evaluating new paper stock e Weight The printer can automatically feed paper weights from 60 to 176 g m 16 to 47 lb bond grain long Paper lighter than 75 g m 20 Ib might not be stiff enough to feed properly causing jams For best performance use 80 g m 21 Ib bond grain long paper For paper smaller than 182 x 257 mm 7 2 x 10 1 in we recommend 90 g m or heavier paper e Curl Curl is the tendency for paper to curl at its edges Excessive curl can cause paper feeding problems Curl can occur after the paper passes through the printer where it is exposed to high temperatures Storing paper unwrapped in hot humid cold or dry conditions even in the trays can contribute to paper curling prior to printing and can cause feeding problems 1 12 Service Manual 5025 2xx 4xx e 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
203. st and press Select 7 2 Select Fuser Exit Sensor and press Select y 3 Open and close the front door and inspect the fuser exit sensor located on the LVPS shield Is the sensor dislodged or damaged Rotate the flag paper diverter in and out of Sensor is good Go to step 3 the sensor Does the display indicate Media Clear and Media Present with the cycle Does the flag rotate freely but return to block Go to step 4 Replace the fuser See the sensor Fuser assembly removal on page 4 29 Turn the printer off and then remove the rear Go to step 5 Recomnect the cable shield See Top cover assembly removal on page 4 13 Is the cable correctly connected to JBIN1 on the controller board and to the sensor No Correct the sensor or Go to step 2 replace it See Fuser exit sensor removal on page 4 33 Diagnostic information 2 27 5025 2xx 4xx Turn the printer on and check the values at JBIN1 JBIN1 Pin vewe Ea 0 V de 5 V de during cycle 0 V dc unblocked 3 3 V dc blocked elema Are the values correct Some low voltage power supply 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 off and remove the rear shield See Top cover assembly removal on page 4 13 Check the cable at JFUSES1 for proper connecti
204. stalled in a printer and the printer is powered on it cannot be used in another printer It must be returned to the manufacturer 1 Remove the operator panel bezel and name plate See Operator panel bezel and name plate removal on page 4 8 2 If you have a model with the USB port remove the two screws A to detach the USB connector A 3 Open the front cover 4 Remove the three screws B attaching the operator panel to the front cover assembly 4 10 Service Manual 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 shield Repair information 4 11 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 the cover b N m a Y T zj k r gt E 4 12 Service Manual 5025 2xx 4xx Top cover assembly removal See Top cover assembly on page 7 3 for the part number UA Remove the right cover assembly See Right cover assembly removal on page 4 12 Remove the waste toner bottle See Waste toner bottle removal on page 4 77 Remove the imaging unit See Imaging unit IU removal on page 4 45 Remove the rear shield See Top cover assembly removal on page 4 13 D
205. strative Menus Make sure the USB Buffer menu item is not set to Disabled Press Menus access the Administrative Menus select Network Ports USB Menu and USB Buffer 58 Too many Flash Too many optional flash memory cards or optional firmware cards are installed on the options installed printer e Press Select y to clear the message and continue printing e Remove extra flash options 1 Turn off and unplug the printer 2 Remove the excess flash memory or optional firmware cards 3 Plug in the printer and turn it on 58 Too many Too many trays are installed trays attached 1 Turn off and unplug the printer 2 Remove the additional trays 3 Plug in the printer and turn it on 59 Incompatible Remove the specified tray trays lt x gt 82 Replace waste Replace the waste toner bottle and press Select y to clear the message and toner box continue printing See Waste toner bottle removal on page 4 77 Note The printer will not continue until the waste toner bottle is replaced 82 xx Waste toner box Replace the waste toner bottle and press Select v to clear the message and missing continue printing 82 xx Waste toner The following actions can be taken nee dul e Replace the waste toner bottle and then press Select v to clear the message and continue printing See Waste toner bottle removal on page 4 77
206. t y Hold the page to the light to see whether the left margin of the back aligns with the left margin of the front Select Left Margin from DUPLEX TESTS Use lt or p to select the margin setting you need to change e Each increment shifts the duplex left margin by 4 pixels at 500 dpi 0 0067 inches or 0 1693 mm e The Left Margin duplex range is 25 to 25 and the default value is 0 e An increase in the value moves the backside left margin to the right and widens the left margin A decrease moves the backside left margin to the left and narrows the left margin 7 Press Select to save the new value 8 Print the Quick Test duplex again steps 1 4 to verify the adjustment Repeat if necessary E NS 3 14 Service Manual 5025 2xx 4xx Input Tray Tests Feed Tests Any installed input tray can be tested The pages fed through the printer are blank To run the Feed Test Select INPUT TRAY TESTS from Diag Menu and press Select Select Feed Tests and press Select y Select the tray to be tested Choices are installed trays including Tray 1 Tray 2 MP Feeder Select Single or Continuous and press Select y e Single a single sheet of blank paper is fed and the test stops e Continuous sheets are fed continuously until Stop E is pressed lt x oN gt Sensor Test This test is used to verify that the sen
207. t a 600 dpi scan rate 0 0133 the top margin No compression or expansion inches or 0 339 mm The default is 0 OCCUIS A positive offset moves text down the page and Bottom margin 25 to 25 Each increment causes approximately 0 55 mm shift in the bottom margin The default is 0 Left margin Right margin 3 4 Service Manual 50 to 50 Each increment corresponds to 4 pixels at 600 dpi 0 00666 in or 0 1693 mm The default is O 50 to 50 Each increment corresponds to an approximate shift of 4 pixels at 600 dpi The default is O narrows the bottom margin while a negative offset moves text up the page and narrows the bottom margin The image is compressed or expanded A positive change moves the image to the left and a negative change moves the image to the right No compression or expansion occurs A positive change moves the image to the left and a negative change moves the image to the right 5025 2xx 4xx Description Direction of change Skew 100 to 100 A positive value causes the left end of the scan l line to move down the page A negative value aa i to causes the left end of the scan line to move up GEA the page The right end stays fixed There is no The default is 0 compression or expansion of the image 6 Print another copy of the Quick Test to verify your changes 7 Continue changing the settings by repeating steps 3 through 5 To exit Registration press Back
208. t 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 Note the reduction of available memory to the link buffers when Resource Save has been enabled and compare it to the memory available when Resource Save is disabled e Press Select x to disable Resource Save and continue printing e Install additional memory 37 Insufficient This message is displayed when the printer memory used to store pages is too full to memory to collate job collate the print job The following actions can be taken e Press Select x to print the portion of the job already stored and begin collating the rest of the job e Press Stop gg and then press Select to cancel printing 37 Insufficient This message is displayed when insufficient printer memory is available to perform Memory for Flash Flash Memory Defragment operation a a This message appears prior to the actual start of the defragment operation Press Select x to stop the defragment operation To perform the defragment operation you can e Delete fonts macros and other data in RAM e Install additional printer memory e Press Stop MM and then press Select to cancel printing 2 8 Service Manual 5025 2xx 4xx al Explanation message 38 Memory Full This message is displayed when the pr
209. tect and press Select y If you press Select before closing the front cover a message appears Close Cover Press Select Motor Detection In Progress appears The motor detection process takes about 10 seconds and stops automatically 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 menu item appears only if the flash card is installed Data is written to the flash card and read back to check the accuracy Warning This test deletes all data stored on the flash device After the test is over reformat the flash using Format Flash in the customer Utilities Menu To run the Flash Test 1 2 Select DEVICE TESTS from Diag Menu and press Select y Select Flash Test and press Select v Contents will be lost Continue appears To continue select Yes and press Select v To end the test select No and press Select y If you continue Flash Test Testing appears e Ifthe test is successful Flash Test Test Passed appears Use Format Flash in the Utilities Menu to reformat the flash card e lf the test is unsuccessful Flash Test Test Failed appears Replace the flash card Press Back 95 to remove the message and return to the Device Tests menu Diagnostic aids
210. ter will be rendered inoperable e Operator panel assembly e 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 cannot be used in another printer It must be returned to the manufacturer This error code indicates a mismatch between the memory on the operator panel assembly and the one on the controller board Have any updates been made to the firmware Reload the firmware and try Replace the controller board again with a new and not previously installed Go to step 2 controller board See Controller board removal on page 4 20 Did reloading the firmware correct the Problem resolved Replace the controller board problem with a new and not previously installed controller board See Controller board removal on page 4 20 Inspect the bin full narrow_media sensor Repair or replace the bin Go to step 2 located towards the front of the top cover full narrowmedianarrow assembly media sensor See Bin full narrow media sensor Is the bin full parrewmedianarrow media removal on page 4 18 sensor dislodged or damaged Does the flag rotate freely and interrupt the Go to step 3 Reposition or replace the sensor beam when in normal position flag See Bin full narrow media sensor flag and exit deflector removal on page 4 19 Turn the printer off a
211. th the 2 scale line In this example it is 18 If none 0 of the colored lines match up use the 2 coarse adjustment to get close reprint this 4 page and then use the fine adjustment 6 8 6 Use q or p 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 current value no change is needed If change is still needed repeat steps 4 6 When the observed values and the current value are the same continue to the next step T 0 18 18 A A Current New Cyan Cyan T value T value 3 8 Service Manual 5025 2xx 4xx 7 Select the Skew value in the same way enter the value press Select v and print the Quick Test to see if the observed values and the current values are the same Z 0 18 14 4 I A Current Current Cyan Cyan T value Z value 8 On the second page of the latest Quick Test you printed proceed to Step 2 adjust the left right and bow settings Continue printing the Quick Test after each adjustment to verify your settings Cyan Alignment Left L Fine Adjustment Right R Fine Adjustment Step 2 00 t s Loft L Bow P Coarse Adjustment Right R sa WI Coarse Coarse IH pa Adjustment E Adjustment a 240 e 12 50 40 40 20 0 20 40 ON 1x p 0 y 0 an Bow P Fine Adjustment 0 30 120 x 10 a s 20 f 24 14
212. the buttons when the installed memory and processor speed displays The following menus do not require a POR Network SE Menu 1 From the Ready prompt press Menu 2 Select Customer Network Ports menu 3 Press and hold Left 4 and Right p gt d gt 4 Release the buttons when the menu appears SE Menu In a browser add se to printer 7 Enters the SE menus online IP address For example http 158 183 3 2 se Additional error While the error displays on the Access secondary debug information message panel press Back s and information Right gt Invalid Engine Code 1 Turn the printer off This mode is used if the machine has invalid code Mode 2 Press and hold Back 5 and needs the correct code loaded After entering and Left 4 this mode the firmware code can be updated Firmware update For use on machines with See Updating printer firmware on page 3 28 from USB operator panel USB port To run the printer diagnostic tests described in this chapter you must put the printer in Diagnostics Menu or in the Configuration Menu Diagnostic aids 3 1 5025 2xx 4xx Diagnostics Menu Diag Menu Note Tray 2 refers to the 550 sheet tray located in the 650 sheet Duo Drawer Diagnostics Menu structure When the Diagnostics menu is entered each Diagnostics main menu item displays on the operator panel When a diagnos
213. the media is fed from the tray into the printer by a feed roll and carried to the transfer roll ITU The pick rollers time the media to enter the EP process at just the right moment The pick rollers push the media 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 bin and past the exit sensor The exit rollers guide the paper into the output bin Service tip If the printer posts a paper jam message but no paper is found paper dust or paper particles may have fallen on one of the sensors Use a can of compressed air to gently clean the sensor Diagnostic aids 3 47 5025 2xx 4xx Duplex process The duplex paper path is a secondary paper path in the front cover and the 250 sheet paper tray to print on the second side of a sheet of paper After the first side of the media is printed and the trailing edge of the paper clears the fuser exit sensor the fuser motor reverses The reversed motor pulls the media into the duplex paper path In addition to the fuser motor reversing the pick motor also reverses The pick motor drives the duplex aligner rolls A which push the media down to the bottom turnaround in the paper tray and gate aligner B Note While the sheet is being transported through the front door and paper tray it is the only piece of media being processed by the print engine
214. the network open an FTP session to the IP address Use a PUT command to place the firmware file on the printer Various status and progress messages will appear The printer will reboot The FTP session will terminate 5 Repeat steps 2 through 4 for any other files eS Using the Web server On a computer attached to the network open a Web browser Enter the printer s IP address in the address bar of the Web browser When the home page opens click Configuration Click the Update Firmware link on the Configuration page Click the Browse button In the browser that opens browse to the file you want to use SIF a Ss 3 28 Service Manual 5025 2xx 4xx 7 Click Open Various status and progress messages will appear The printer will reboot The HTTP session will terminate 8 Repeat steps 2 through 7 for any other files Using the host computer to update the firmware over USB 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 printer must be installed on the host computer so a USB virtual printer port can be established on the host computer The virtual printer port is needed so the host computer can communicate with the printer 1 Open the USB Utility xi File View Help ENTER FILENAME TO FLASH TO PRINTER SELECT PRINTER FROM LIST START B
215. the rear shield See Top cover board See Controller assembly removal on page 4 13 board dd on 3 Disconnect the cable at JTRAY1 connector page 4 20 for tray1 or JOPT1 for tray 2 and 3 on the controller board 4 Turn the printer on and measure the voltages below JTRAY1 for tray 1 JOPT1 for tray 2 or 3 Voltage 5 V do Pin Voltage svo 2 Ground Ground 3 Ground 5 eN e Ground io Ground Are the voltage values approximately correct Trays 2 and 3 optional service check Are two option trays being used Go to step 2 Go to step 4 If two option trays are being used is the 550 Go to step 4 Go to step 3 sheet tray on the bottom Switch the order of the trays so the 500 sheet Problem resolved Go to step 4 tray is on the bottom and print a page from both trays Did the pages print from both trays Inspect the paperfeed pick tires on the tray that Goto step 5 Go to step 6 fails to pick Do they appear worn or damaged Replace the pick tires on the faulty tray and Problem resolved Go to step 6 print a page with media from the affected tray See Pick tires removal on page 4 64 Did the page print Check the option cable connected to JOPT1 Go to step 8 Go to step 7 for continuity Is there continuity 7 Replace the cable and print from both option Problem resolved Go to step 8 trays Did the pages print from both trays Diagnostic information 2 53 5025 2xx 4xx Print
216. tic test is selected from the main menu a sub menu displays and each individual test displays in the order shown Any options that are referred to in the menus are displayed when the option is installed Available tests The tests display on the operator panel in the order shown Diagnostics Menu Registration black registration Top Margin See Registration on page 3 4 Bottom Margin Left Margin Right Margin Skew See Skew on page 3 5 Quick Test See Quick Test on page 3 5 Cyan See Alignment on page 3 7 Yellow Magenta Factory Scanner A summary page for all the color alignment settings it can be used in f hi color Factory Manual place of alignment pages for each individual color Tray 1 See Input source tests on page 3 10 Tray 2 if installed Manual Feeder if installed MP Feeder if installed Prt Qual Pgs See Print quality test pages Prt Qual Pgs on page 3 11 Panel Test See Panel Test on page 3 11 Button Test See Button Test on page 3 12 DRAM Test See DRAM Test on page 3 12 DUPLEX TESTS if installed Quick Test See Quick Test duplex on page 3 13 Top Margin See Top Margin duplex on page 3 14 Left Margin See Left Margin duplex on page 3 14 INPUT TRAY TESTS Feed Tests See Feed Tests on page 3 15 3 2 Service Manual 5025 2xx 4xx Diagnostics Menu continued Base Sensor Test See Base Sensor Test on
217. to Print quality random marks on page 2 46 Residual image Go to Print quality residual image on page 2 47 Skew image not parallel to sides or to top Check to see if the right tray is in the proper drawer for the 650 and bottom sheet Duo Drawer See the note on page 7 11 Check the printhead alignment See Solid color page Go to Print quality solid color page on page 2 48 Vertical banding Go to Print quality vertical banding on page 2 48 2 4 Service Manual 5025 2xx 4xx Error codes and messages User status and customer attendance messages User primary message Calibrating Close door Defragmenting Flash DO NOT POWER OFF Flushing buffer Formatting Flash DO NOT POWER OFF Imaging Kit Insert Tray lt x gt Invalid Engine Code Invalid Network Code Load lt source gt with lt custom string gt Load lt source gt lt custom type gt Load lt SOUrce gt lt type or size gt Explanation Wait for the message to clear The printer is performing a color adjustment Wait for the message to clear The printer is performing the defragmentation operation of flash memory Wait for the message to clear a Message clears when front cover right cover and toner door are closed or securely fastened Warning Do not turn the printer off while this message appears on the display Wait for the message to clear Wait for the message to appear Warning Do not
218. to expose the reflective surface For additional information about the Base Sensor Test see Base Sensor Test on page 3 16 Does the operator panel display a change of state Toner meter sensors Y C M K on TMC card Step Questions actions Remove the toner cartridge and inspect the lenses on the toner meter cycle TMC card Are the lenses blocked damaged or dirty No Repair or replace the TMC Go to step 2 card See Toner meter cycle TMC card removal on page 4 71 Replace the controller Replace the TMC card See board See Controller Toner meter cycle TMC board removal on card removal on page 4 20 page 4 71 Turn the printer off and remove the rear shield See Top cover assembly removal on page 4 13 Turn the printer on and al the values below at JCTM1 during JCTM1 Value 5 Vdc 3 3 V de 3 3 V de 3 3 V de Ground Pin EN 2 3 3 3V de Aa 5 6 Are any of the values incorrect 2 50 Service Manual 5025 2xx 4xx Transfer roll service check Remove the ITU See Image transfer unit Replace the ITU See Problem resolved ITU removal on page 4 40 Check the Image transfer unit ITU contacts between the HVPS and the ITU removal on page 4 40 Clean the contacts and recheck Go to step 2 Does the error recur 2 Does the new ITU fix the problem Problem resolved Go to step 3 Turn the printer off and remove
219. toconductors and the four color image is produced and transferred to the media in one pass During the printing process the printer follows the six basic EP process steps to create its output to the page These six steps are Charge the photoconductor PC unit Expose the photoconductor PC unit Develop the toner on the photoconductor PC unit First and second transfer of toner to the ITU and then to the media Fuse the toner to the media Clean erase the photoconductor and the ITU SN a TE In summary the printer s controller board receives print data and the command to print The controller board then initiates the print process The controller board is the command center for the EP process and coordinates the various motors and signals The high voltage power supply sends charge to various components in the EP process The laser fires on the photoconductors and alters the surface charge relative to the planned image for each photoconductor Each photoconductor rotates past its respective developer roll and toner is developed on the surface of each photoconductor The four separate color images are then transferred to the transfer belt on the ITU as it passes under the photoconductors After the image is transferred to the transfer belt the photoconductors are cleaned and recharged The transfer belt carries the four colored image towards the transfer roll Media is picked up from the tray and carried to the transfer roll where the im
220. tor There are three options Energy Paper and Energy Paper e Paper e Duplex is on if Energy Paper or Paper is selected duplex models only can be overwritten by the driver e Energy e Print quality is maintained e Power Saver is set to one minute e Fuser standby is off e The operator panel back light is off e Power supply energy consumption is reduced e Energy Paper All of the above Data streams Supported X Not ted Lexmark C540n Lexmark C544n si C543dn C544dn C544dwn Lexmark C546dtn Data streams PostScript Level III emulation Y A Y Version 3011 of the Adobe definition of PostScript 3 is supported PDF x Y v Supports version 1 6 PPDS x v v By default the PPDS interpreter is inactive A user can activate the data stream by PJL or by the PPDS Emulation setting in the Configuration Menu 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 Interface GDI Version 3 color uses PCL XL 1 4 Service Manual 5025 2xx 4xx Dimensions Lexmark C540n C543dn 291 mm 11 5 in 424 mm 16 7 in 400 mm 15 7 in 21 kg 46 2 lbs C544n C544dn w l YA 15 Lexmark C546din includes 422 mm 16 6 in 424mm 16 7 in 416 mm 16 4 in 25 kg 55 Ib 650 sheet Duo Drawer YA 16 650 sheet Duo Drawer 133 mm 5 2 in 424 mm 16 7 in 416 mm 1
221. transferred to the media the transfer roll helps move the paper into the fuser area The fuser F applies heat and pressure to the page to melt the tiny toner particles and bond them permanently to the media The fuser moves the paper from the rollers and into the exit bin Service tips e lf the fuser rolls are damaged they can cause toner to be pulled off the page or cause paper jams e Toner that rubs off a printed page can be a sign of a malfunctioning fuser or an improper media setting Always check the paper type setting before replacing the fuser A common mistake is to print on heavier media such as card stock with the paper type set to plain paper e Never pull media with unfused toner up through the fuser if you can help it try to back the jammed page out of the fuser in the opposite direction it was traveling Diagnostic aids 3 43 5025 2xx 4xx Step 6 Clean erase There are two main cleaning processes that take place during the EP process One process cleans the transfer belt and the other cleans the photoconductors Transfer unit clean Once the toner image on the transfer belt has been transferred to the page the transfer belt rotates around and is cleaned by the cleaning blade G This occurs for every page that is printed After the toner is moved to the cleani
222. troller board See System Board maximum value limit Controller board removal on page 4 20 959 28 Service Invalid SP memory configuration Replace the controller board See System Board Controller board removal on page 4 20 960 xx Service RAM memory error RAM soldered on Replace the controller board See Memory Error the board is bad Controller board removal on page 4 20 961 xx Service RAM memory error slot 1 RAM is bad Check RAM If RAM is OK replace the Memory Failure controller board See Controller board removal on page 4 20 962 xx Service RAM memory error slot 2 RAM is bad Check RAM If RAM is OK replace the Memory Failure controller board See Controller board removal on page 4 20 964 xx Service Download emulation cyclic redundancy The following actions may be taken Emulation Error check CRC failure has occurred A l checksum failure detected in the 1 Disable the Download Emulation emulation header or emulation file 2 Program the download emulation into the code overlay SIMM again 3 If the problem is not resolved replace the code overlay SIMM and download emulation again 975 xx Service Network error unrecognizable network Replace the standard network card or the Standard Network port card in the specified slot or 975 xx Service Network Card x 2 20 Service Manual 5025 2xx 4xx Service error messages 1xx 9xx continued mo E O 976 xx Servi
223. turn the printer off while this message appears on the display This message appears between status messages and warnings Wait for the message to clear sa Replace the imaging kit and then press Select y to clear the message and continue printing 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 missing tray or the trays below it Tray x Tray 1 Tray 2 Tray 3 Note This message displays when refilling the trays during a job Before filling a tray take the printer offline by pressing Stop and wait for pages to stop feeding into the output bin The following actions can be taken e Insert the requested tray e Press Stop MM and then press to cancel printing The engine code is invalid The Network code is invalid Printer does not detect media meeting the description lt custom string gt in lt source gt where lt source gt is Tray 1 Tray 2 Tray 3 or multipurpose feeder e Load the input source with the correct type and size media e Press Stop MM and then press Select to cancel printing Printer does not detect media meeting the description lt custom type gt in lt source gt where lt source gt is Tray 1 Tray 2 Tray 3 or Multi Page feeder e Load the input source with the correct type and size media e Press Stop MM and then press Select
224. u correct the hazard Check the following items e Damaged missing or altered parts especially in the area of the On Off switch and the power supply e Damaged missing or altered covers especially in the area of the top cover and the power supply cover e Possible safety exposure from any non Lexmark attachments Lubrication specifications Lubricate only when parts are replaced or as needed not on a scheduled basis 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 Mobil DTE27 Shell Tellus 100 Fuchs Renolin MR30 IBM no 23 grease Approved equivalent Shell Darina 1 and grease P N 99A0394 to lubricate appropriate areas Use Nyogel type 774 to lubricate the Fuser Drive Assembly and Nyogel 744 to lubricate the ITU and Cartridge Drive assemblies Scheduled maintenance Maintenance kit After 60 000 printed pages sides a maintenance kit may be required lt is necessary to replace the fuser assembly ITU and duplex reference plate to maintain the print quality and reliability of the printer The parts are available as a maintenance kit with the following part numbers Maintenance kits 115 V Maintenance kit 115 V fuser ITU duplex reference edge 40X2254 230 V Maintenance kit 230 V fuser ITU duplex reference edge 40X2255 100 V Maintenance kit 100 V fuser ITU duplex refe
225. u ved normal drift brugervedligeholdelse eller obligatoriske servicebetingelser X Service Manual 10 2 2009 5025 2xx 4xx Laserilmoitus Tama tulostin on sertifioitu Yhdysvalloissa DHHS 21 CFR Subchapter J standardin mukaiseksi luokan 1 lasertuotteeksi ja muualla IEC 60825 1 standardin mukaiseksi luokan lasertuotteeksi Luokan lasertuotteita ei pidet haitallisina Tulostimen sis ll on luokan IIIb 3b laser joka on nimellisteholtaan 5 mW n galliumarsenidilaser ja toimii 645 670 nanometrin aallonpituuksilla Laserjarjestelma ja tulostin ovat rakenteeltaan sellaisia ett k ytt j ei joudu alttiiksi luokkaa 1 suuremmalle s teilylle normaalin k yt n yll pidon tai huollon aikana Huomautus laserlaitteesta T m kirjoitin on Yhdysvalloissa luokan I 1 laserlaitteiden DHHS 21 CFR Subchapter J m rityksen mukainen ja muualla luokan laserlaitteiden IEC 60825 1 m rityksen mukainen Luokan laserlaitteiden ei katsota olevan vaarallisia k ytt j lle Kirjoittimessa on sis inen luokan lllb 3b 5 milliwatin galliumarsenidilaser joka toimii aaltoalueella 645 670 nanometri Laserj rjestelm ja kirjoitin on suunniteltu siten ett k ytt j ei altistu luokan m rityksi voimakkaammalle s teilylle kirjoittimen normaalin toiminnan k ytt j n tekemien huoltotoimien tai muiden huoltotoimien yhteydess VARO Avattaessa ja suojalukitus ohitettaessa olet alttiina n kym tt m lle lasers teilylle
226. val The waste toner bottle is not a FRU Open the front cover Lift the toner cover by sliding the latch to the left Remove the right cover assembly See Right cover assembly removal on page 4 12 Press the two tabs A to release the waste toner bottle and remove it P d N m e om Is Vir Repair information 4 77 5025 2xx 4xx Waste toner bottle contact block removal See the on Waste toner bottle contact block on page 7 9 for the part number Open the front cover Remove the right cover assembly See Right cover assembly removal on page 4 12 Remove the waste toner bottle See Waste toner bottle removal on page 4 77 Remove the screw A from the back of the waste toner bottle contact block APDE A NS i As AZ MA ee v n z C t ASS i Le i y A a ca F i A 5 Remove the rear shield See Top cover assembly removal on page 4 13 6 Disconnect the waste toner bottle contact block cable B from the controller board 7 Remove the waste toner bottle contact block 4 78 Service Manual 5025 2xx 4xx Wireless network antenna removal See Antenna for wireless card 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 disconnect the wireless card A from the controller board 3 Carefully disconnect the antenna cable B from the wireless card at t
227. value of a character or digit press lt to decrease or p to increase the underlined value and press Select y to move to the next character or digit e To move to the next character or digit without changing the current value press Select y e When you press Select y on the last digit the value will be submitted If Invalid ID appears the entry is discarded and the previous Configuration ID 1 is displayed on the screen If the process is successful Submitting Selection appears on the display followed by the current value for Configuration ID 2 4 Repeat the steps for entering the Configuration ID 2 and press Select v If the Configuration ID 2 is validated Submitting Selection appears and a check y appears next to Printer Setup 5 Restart the printer A POR is not automatically performed ITU Barcode The 16 digit numeric value matches the ITU installed in the printer If you replace the ITU reenter this value Stop E exits the menu To enter the ITU barcode 1 Select PRINTER SETUP from Diag Menu and press Select 7 2 Select ITU Barcode and press Select v 3 To enter the 16 digit numeric value Use to decrease the leftmost digit value or p to increase the value Press Select v to advance to the next digit If a digit is already correct press Select x to accept the number and to continue When the last number is ent
228. x Table of contents E e AAA ee ene eae ee a eer eee ys iii Notices and safety information 0 000 ees ix Eo ee e E Sa ies A eee eee eee es IX SUS NOTION seo eo hep hopes bon GO05555 a bee radar XV gic CO eae E PRO E E E E Uno ee ee ee ee es ee ee xviii Soo AAA xviii General information auaa anaana aaea 1 1 o A A 1 1 Eo AAPP N een Ener ceeeeeee er aree see oecawecers 1 1 OPIGAS A POTES sevi rra dd ria AAA AAA ARANDA AAA 1 2 Fnr Spo CNCA ica e AR IO A A ER IA AR AAA RARA RA ANA AA EERE 1 2 a A AR 1 2 si ee re ee re ees ee ee ee eS re ee ee eee ee ere ee 1 3 Connectivity network Support oocococcc ee 1 3 GA O MOOS aras a he ew ee oh ewe eae edness 1 4 ee A AA be eee eee 1 4 FMD A ey bea oe db E oh ereoe eb gree eh eed eG 1 5 det crescit OSE n OR oe ee Re ews eed ea eee ee kee eewes 1 5 Power and electrical specifications 0 00 cee 1 6 eC A e ee ee ee 1 7 Environment SOCCIICAIONS 6 c44460 05 5 0 59 5 5096404454 0066400045006 0 A AAA AA 1 7 o AP eee ees 1 8 Input and output sources and capacities 0 2 c ce 1 8 PIO CONGO a aa E eee AR A RRA eed heeds wee EAA 1 9 Media output size and type o occcco 1 9 Media input size specifications 0 0 c cee nnne 1 9 Media input type specifications 0 00 cee 1 11 MARIS GQUIGGIINGS 6 cians ir RAR A ARA Ae eke RRA RANA 1 12 PODEIS rT E E E A 1 12 Misas cla 9 AA 1 13 o ASS 1 13 Selecting preprinted forms and
229. xx 4xx Assembly 1 Covers 7 2 Service Manual 5025 2xx 4xx Assembly 1 Covers Part Units Units Description number mach FRU p 40X5418 40X5441 40X5416 40X5419 40X5168 40X5430 40X5420 40X5431 40X5436 40X5432 40X2867 40X5417 Top cover assembly Dust cover Right cover assembly 250 sheet tray assembly Pick tires Front cover assembly including duplex and USB port cable C543dn C544dn C544n C546dtn Front cover assembly excluding duplex and USB port cable C540n Operator panel and display assembly Operator panel DBCS and display assembly Operator panel bezel and name plates including e Bezel 1 e Name plates 4 e Logo plate 1 Name plate C546dtn Left cover assembly Parts catalog 7 3 5025 2xx 4xx Assembly 2 Frames AT es at Ep en Mica i A oe k le Pie A m F f j te i a i 1 a Oo of E a a oe be AN a 7 4 Service Manual 5025 2xx 4xx Assembly 2 Frames Part Units Units Descritor number mach FRU p 40X5411 Printhead 40X5415 Fuser drive motor assembly 40X5422 Lower left frame and lower right frame with cable cover 40X5424 Screw packet miscellaneous screws e TAPTITE M3 L6 panhead 4 Tray Bias 2 Fuser Latch 2 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 e PLAST ROLN 3 5 6L
230. y 3 Install tray 1 Does the display indicate InputS1 Media Clear Pull tray 1 out The sensor is functioning Go to step 4 Does the display indicate InputS1 Media correctly PRESENT Remove the tray and inspect the sensor Remove the obstruction Go to step 5 Is there something obstructing the sensor and restart the test Inspect the spring loaded shaft flag in the tray Go to step 6 Replace the tray with a new The flag portion of the shaft intercepts the one sensor except when a sheet is being staged for duplexing Does the shaft rotate freely and return to home position flag at top of rotation Is the flag on the shaft broken Replace the tray Go to step 7 Verify the cable is correctly connected to Go to step 8 Reconnect the cable ae on the controller board and to the If the problem persists go to step 8 Is the sensor cable properly connected Turn the printer off and remove the rear Replace the duplex sensor Replace the controller shield See Top cover assembly removal See Duplex sensor board See Controller on page 4 13 Turn the printer on and check removal on page 4 25 board removal on the values at JFUSES1 page 4 20 JFUSES1 7 Value Pin 8 Ground 3 3 V dc Are the values approximately correct Diagnostic information 2 25 5025 2xx 4xx Front door sensor or switches service check Enter D
231. y printhead can cause the problem To Replace the printhead See Go to step 3 test the printhead for solid colors place a Printhead removal on narrow strip of paper over the gap between the page 4 65 developers Make sure the paper stays in place 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 Turn the printer off and check the continuity of Go to step 5 Replace the cable the HVPS cable assembly Is there continuity Replace the HVPS See High voltage power Problem resolved Replace the controller supply HVPS assembly removal on board See Controller page 4 35 board removal on page 4 20 Check the high voltage contact from the HVPS Replace the transfer contact Go to step 4 to the photoconductor charge roll Ensure the assembly See Toner contact springs are properly mounted and that cartridge contacts on the charge roll contact spring is making good page 4 67 contact with the HPVS spring that runs through the left printer frame See Toner cartridge contacts on page 4 67 to view the proper mounting and for removal procedures Are the spring s defective Did this solve the problem Print quality vertical banding Replace the developer unit 2 48 Service Manual 5025 2xx 4xx Printhead service check This service check includes the following
232. you are working Unplug the product before you begin or use caution if the product must receive power in order to perform the task Consignes de securite e La s curit de ce produit repose sur des tests et des agr ations portant sur sa conception d origine et sur des composants particuliers Le fabricant n assume aucune responsabilit concernant la s curit en cas d utilisation de pieces de rechange non agr es e Les consignes d entretien et de r paration de ce produit s adressent uniquement a un personnel de maintenance qualifi e Le d montage et l entretien de ce produit pouvant pr senter certains risques lectriques le personnel d entretien qualifi devra prendre toutes les pr cautions n cessaires ATTENTION Ce symbole indique la pr sence d une tension dangereuse dans la partie du produit sur laquelle vous travaillez D branchez le produit avant de commencer ou faites preuve de vigilance si l ex cution de la t che exige que le produit reste sous tension Norme di sicurezza e La sicurezza del prodotto si basa sui test e sull approvazione del progetto originale e dei componenti specifici Il produttore non e responsabile per la sicurezza in caso di sostituzione non autorizzata delle parti e Le informazioni riguardanti la manutenzione di questo prodotto sono indirizzate soltanto al personale di assistenza autorizzato e Durante lo smontaggio e la manutenzione di questo prodotto il rischio di subire scosse

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