Lexmark C544N - Color Laser Printer Service manual
advertisement
Revision
: October 2, 2009
Lexmark
™
C540n, C543dn, C544n, C544dn,
C544dtn, C544dw, and C546dtn
5025-2xx, 4xx
• Table of contents
• Start diagnostics
• Safety and notices
• Trademarks
• Index
Lexmark and Lexmark with diamond design are trademarks of Lexmark International, Inc., registered in the United States and/or other countries.
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 [email protected]. 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 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.
PCL® 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, 4xx
Table of contents
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
xv
xviii
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-1
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Connectivity (network support)
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
1-5
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Power and electrical specifications
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
Input and output sources and capacities
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
Media input size specifications
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
Media input type specifications
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-16
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-1
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
User status and customer attendance messages
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22
925.01—Fan error service check
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22
950.xx NVRAM Failure service check
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-23
Table of contents
iii
5025-2xx, 4xx
Bin-full/narrow media sensor service check
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-23
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-24
Duplex/manual feed sensor (S1) service check
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-25
Front door sensor or switches service check
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-26
Fuser exit sensor service check
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-27
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-28
Input (S2) sensor service check
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-29
Main drive gear assembly (EP drive) service check
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-30
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-31
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-33
Operator panel display blank, five
beeps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-34
Operator panel display blank, printer
five times and pauses . . . . . . . . . . . . . . . . . . . . . .2-35
Operator panel displays all diamonds, no
beeps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-36
Operator panel displays all diamonds, five
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-37
Operator panel USB cable service check
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-38
Paper pick motor drive assembly service check
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-39
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-39
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-49
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-50
Toner meter sensors (Y, C, M, K) on TMC card
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-50
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-51
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-51
Trays 2 and 3 (optional) service check
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-53
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-54
User operator panel and Administration menus
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-55
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-55
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-55
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-56
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-1
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
iv
Service Manual
5025-2xx, 4xx
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23
Configuration menu (Config Menu)
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-24
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-24
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-24
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-24
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-26
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-26
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-27
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-27
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-27
Table of contents
v
5025-2xx, 4xx
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-28
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-28
Using a networked computer to update the printer firmware over a network
. . . . . . . . . . . . . .3-28
Using the host computer to update the firmware over USB
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-29
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-31
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-31
Understanding jam numbers and locations
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-32
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-37
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-37
Paper path, transport components
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-46
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-49
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-1
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
Operator panel bezel and name plate removal
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-10
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13
Bin-full/narrow media sensor removal
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18
Bin-full/narrow media sensor flag and exit deflector removal
. . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-21
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-22
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-25
Exit deflector and bin-full/narrow media sensor flag removal
. . . . . . . . . . . . . . . . . . . . . . . . . . . 4-27
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-29
Fuser drive motor assembly removal
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-32
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-33
High-voltage power supply (HVPS) assembly removal
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-35
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Image transfer unit (ITU) removal
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-40
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-45
Low-voltage power supply (LVPS) assembly removal
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-47
Lower frame removal, right and left
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-49
Main drive gear assembly removal
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-59
Paper pick motor drive assembly removal—standard tray
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-61
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-64
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-65
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-67
Toner density sensor (TDS) removal—left or right sensor
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-69
Toner meter cycle (TMC) card removal
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-71
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-73
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-76
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-77
Waste toner bottle contact block removal
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-78
Wireless network antenna removal
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-79
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-81
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-1
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
High-voltage power supply (HVPS) diagram
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12
Low-voltage power supply (LVPS) diagram
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-1
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-1
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-2
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-4
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-6
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-8
Assembly 5: Media drawers and trays
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-10
Assembly 6: Options and miscellaneous
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-12
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Notices and safety information
The laser notice label may be affixed to this printer.
5025-2xx, 4xx
Laser notice
The printer is certified in the U.S. to conform to the requirements of DHHS 21 CFR Subchapter J for Class I (1) laser products, and elsewhere is certified as a Class I laser product conforming to the requirements of IEC
60825-1.
Class I laser products are not considered to be hazardous. The printer contains internally a Class IIIb (3b) laser that is nominally a 5 milliwatt 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
I level during normal operation, user maintenance, or prescribed service condition.
Laser
Der Drucker erfüllt gemäß amtlicher Bestätigung der USA die Anforderungen der Bestimmung DHHS
(Department of Health and Human Services) 21 CFR Teil J für Laserprodukte der Klasse I (1). In anderen
Ländern gilt der Drucker als Laserprodukt der Klasse I, der die Anforderungen der IEC (International
Electrotechnical Commission) 60825-1 gemäß amtlicher Bestätigung erfüllt.
Laserprodukte der Klasse I gelten als unschädlich. Im Inneren des Druckers befindet sich ein Laser der Klasse
IIIb (3b), bei dem es sich um einen Galliumarsenlaser mit 5 Milliwatt handelt, der Wellen der Länge 645-670
Nanometer ausstrahlt. Das Lasersystem und der Drucker sind so konzipiert, daß im Normalbetrieb, bei der
Wartung durch den Benutzer oder bei ordnungsgemäßer Wartung durch den Kundendienst Laserbestrahlung, die Klasse I übersteigen würde, Menschen keinesfalls erreicht.
Avis relatif à l’utilisation de laser
Pour les Etats-Unis : cette imprimante est certifiée conforme aux provisions DHHS 21 CFR alinéa J concernant les produits laser de Classe I (1). Pour les autres pays : cette imprimante répond aux normes IEC 60825-1 relatives aux produits laser de Classe I.
Les produits laser de Classe I sont considérés comme des produits non dangereux. Cette imprimante est
équipée d’un laser de Classe IIIb (3b) (arséniure de gallium d’une puissance nominale de 5 milliwatts) émettant sur des longueurs d’onde comprises entre 645 et 670 nanomètres. L’imprimante et son système laser sont conçus pour impossible, dans des conditions normales d’utilisation, d’entretien par l’utilisateur ou de révision, l’exposition à des rayonnements laser supérieurs à des rayonnements de Classe I .
Avvertenze sui prodotti laser
Questa stampante è certificata negli Stati Uniti per essere conforme ai requisiti del DHHS 21 CFR Sottocapitolo
J per i prodotti laser di classe 1 ed è certificata negli altri Paesi come prodotto laser di classe 1 conforme ai requisiti della norma CEI 60825-1.
I prodotti laser di classe non sono considerati pericolosi. La stampante contiene al suo interno un laser di classe
IIIb (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 della classe 1.
Notices and safety information
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Avisos sobre el láser
Se certifica que, en los EE.UU., esta impresora cumple los requisitos para los productos láser de Clase I (1) establecidos en el subcapítulo J de la norma CFR 21 del DHHS (Departamento de Sanidad y Servicios) y, en los demás países, reúne todas las condiciones expuestas en la norma IEC 60825-1 para productos láser de
Clase I (1).
Los productos láser de Clase I no se consideran peligrosos. La impresora contiene en su interior un láser de
Clase IIIb (3b) de arseniuro de galio de funcionamiento nominal a 5 milivatios en una longitud de onda de 645 a
670 nanómetros. El sistema láser y la impresora están diseñados de forma que ninguna persona pueda verse afectada por ningún tipo de radiación láser superior al nivel de la Clase I durante su uso normal, el mantenimiento realizado por el usuario o cualquier otra situación de servicio técnico.
Declaração sobre Laser
A impressora está certificada nos E.U.A. em conformidade com os requisitos da regulamentação DHHS 21 CFR
Subcapítulo J para a Classe I (1) de produtos laser. Em outros locais, está certificada como um produto laser da
Classe I, em conformidade com os requisitos da norma IEC 60825-1.
Os produtos laser da Classe I não são considerados perigosos. Internamente, a impressora contém um produto laser da Classe IIIb (3b), designado laser de arseneto de potássio, de 5 milliwatts ,operando numa faixa de comprimento de onda entre 645 e 670 nanómetros. O sistema e a impressora laser foram concebidos de forma a nunca existir qualquer possiblidade de acesso humano a radiação laser superior a um nível de Classe I durante a operação normal, a manutenção feita pelo utilizador ou condições de assistência prescritas.
Laserinformatie
De printer voldoet aan de eisen die gesteld worden aan een laserprodukt van klasse I. Voor de Verenigde
Staten zijn deze eisen vastgelegd in DHHS 21 CFR Subchapter J, voor andere landen in IEC 60825-1.
Laserprodukten van klasse I worden niet als ongevaarlijk aangemerkt. De printer is voorzien van een laser van klasse IIIb (3b), 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 I-laserprodukt, i overenstemmelse med kravene i IEC 60825-1.
Klasse I-laserprodukter betragtes ikke som farlige. Printeren indeholder internt en Klasse IIIB (3b)-laser, der nominelt er en 5 milliwatt galliumarsenid laser, som arbejder på bølgelængdeområdet 645-670 nanometer.
Lasersystemet og printeren er udformet således, at mennesker aldrig udsættes for en laserstråling over Klasse
I-niveau ved normal drift, brugervedligeholdelse eller obligatoriske servicebetingelser.
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Laserilmoitus
Tämä tulostin on sertifioitu Yhdysvalloissa DHHS 21 CFR Subchapter J -standardin mukaiseksi luokan I (1) lasertuotteeksi ja muualla IEC 60825-1 -standardin mukaiseksi luokan I lasertuotteeksi.
Luokan I lasertuotteita ei pidetä haitallisina. Tulostimen sisällä on luokan IIIb (3b) laser, joka on nimellisteholtaan
5 mW:n galliumarsenidilaser ja toimii 645 - 670 nanometrin aallonpituuksilla. Laserjärjestelmä ja tulostin ovat rakenteeltaan sellaisia, että käyttäjä ei joudu alttiiksi luokkaa 1 suuremmalle säteilylle normaalin käytön, ylläpidon tai huollon aikana.
Huomautus laserlaitteesta
Tämä kirjoitin on Yhdysvalloissa luokan I (1) laserlaitteiden DHHS 21 CFR Subchapter J -määrityksen mukainen ja muualla luokan I laserlaitteiden IEC 60825-1 -määrityksen mukainen.
Luokan I laserlaitteiden ei katsota olevan vaarallisia käyttäjälle. Kirjoittimessa on sisäinen luokan IIIb (3b) 5 milliwatin galliumarsenidilaser, joka toimii aaltoalueella 645 - 670 nanometriä. Laserjärjestelmä ja kirjoitin on suunniteltu siten, että käyttäjä ei altistu luokan I määrityksiä voimakkaammalle säteilylle kirjoittimen normaalin toiminnan, käyttäjän tekemien huoltotoimien tai muiden huoltotoimien yhteydessä.
VARO! Avattaessa ja suojalukitus ohitettaessa olet alttiina näkymättömälle lasersäteilylle. Älä katso säteeseen.
VARNING! Osynlig laserstrålning när denna del är öppnad och spärren är urkopplad. Betrakta ej strålen.
Laser-notis
Denna skrivare är i USA certifierad att motsvara kraven i DHHS 21 CFR, underparagraf J för laserprodukter av
Klass I (1). I andra länder uppfyller skrivaren kraven för laserprodukter av Klass I enligt kraven i IEC 60825-1.
Laserprodukter i Klass I anses ej hälsovådliga. Skrivaren har en inbyggd laser av Klass IIIb (3b) som består av en laserenhet av gallium-arsenid på 5 milliwatt som arbetar i våglängdsområdet 645-670 nanometer.
Lasersystemet och skrivaren är utformade så att det aldrig finns risk för att någon person utsätts för laserstrålning över Klass I-nivå vid normal användning, underhåll som utförs av användaren eller annan föreskriven serviceåtgärd.
Laser-melding
Skriveren er godkjent i USA etter kravene i DHHS 21 CFR, underkapittel J, for klasse I (1) laserprodukter, og er i andre land godkjent som et Klasse I-laserprodukt i samsvar med kravene i IEC 60825-1.
Klasse I-laserprodukter er ikke å betrakte som farlige. Skriveren inneholder internt en klasse IIIb (3b)-laser, som består av en gallium-arsenlaserenhet som avgir stråling i bølgelengdeområdet 645-670 nanometer.
Lasersystemet og skriveren er utformet slik at personer aldri utsettes for laserstråling ut over klasse I-nivå under vanlig bruk, vedlikehold som utføres av brukeren, eller foreskrevne serviceoperasjoner.
Notices and safety information
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Avís sobre el Làser
Segons ha estat certificat als Estats Units, aquesta impressora compleix els requisits de DHHS 21 CFR, apartat
J, pels productes làser de classe I (1), i segons ha estat certificat en altres llocs, és un producte làser de classe
I que compleix els requisits d’IEC 60825-1.
Els productes làser de classe I no es consideren perillosos. Aquesta impressora conté un làser de classe IIIb
(3b) d’arseniür de gal.li, nominalment de 5 mil.liwats, i funciona a la regió de longitud d’ona de 645-670 nanòmetres. El sistema làser i la impressora han sigut concebuts de manera que mai hi hagi exposició a la radiació làser per sobre d’un nivell de classe I durant una operació normal, durant les tasques de manteniment d’usuari ni durant els serveis que satisfacin les condicions prescrites.
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Notices and safety information
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Safety information
•
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.
•
The maintenance information for this product has been prepared for use by a professional service person and is not intended to be used by others.
•
There may be an increased risk of electric 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 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 sécurité
•
La sécurité de ce produit repose sur des tests et des agréations portant sur sa conception d'origine et sur des composants particuliers. Le fabricant n'assume aucune responsabilité concernant la sécurité en cas d'utilisation de pièces de rechange non agréées.
•
Les consignes d'entretien et de réparation de ce produit s'adressent uniquement à un personnel de maintenance qualifié.
•
Le démontage et l'entretien de ce produit pouvant présenter certains risques électriques, le personnel d'entretien qualifié devra prendre toutes les précautions nécessaires.
•
ATTENTION :
Ce symbole indique la présence d'une tension dangereuse dans la partie du produit sur laquelle vous travaillez. Débranchez le produit avant de commencer ou faites preuve de vigilance si l'exécution de la tâche exige que le produit reste sous tension.
Norme di sicurezza
•
La sicurezza del prodotto si basa sui test e sull'approvazione del progetto originale e dei componenti specifici. Il produttore non è responsabile per la sicurezza in caso di sostituzione non autorizzata delle parti.
•
Le informazioni riguardanti la manutenzione di questo prodotto sono indirizzate soltanto al personale di assistenza autorizzato.
•
Durante lo smontaggio e la manutenzione di questo prodotto, il rischio di subire scosse elettriche e danni alla persona è più 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
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Sicherheitshinweise
•
Die Sicherheit dieses Produkts basiert auf Tests und Zulassungen des ursprünglichen Modells und bestimmter Bauteile. Bei Verwendung nicht genehmigter Ersatzteile wird vom Hersteller keine
Verantwortung oder Haftung für die Sicherheit übernommen.
•
Die Wartungsinformationen für dieses Produkt sind ausschließlich für die Verwendung durch einen
Wartungsfachmann bestimmt.
•
Während des Auseinandernehmens und der Wartung des Geräts besteht ein zusätzliches Risiko eines elektrischen Schlags und körperlicher Verletzung. Das zuständige Fachpersonal sollte entsprechende
Vorsichtsmaßnahmen treffen.
•
ACHTUNG:
Dieses Symbol weist auf eine gefährliche elektrische Spannung hin, die in diesem
Bereich des Produkts auftreten kann. Ziehen Sie vor den Arbeiten am Gerät den Netzstecker des
Geräts, bzw. arbeiten Sie mit großer Vorsicht, wenn das Produkt für die Ausführung der Arbeiten an den Strom angeschlossen sein muß.
Pautas de Seguridad
•
La seguridad de este producto se basa en pruebas y aprobaciones del diseño original y componentes específicos. El fabricante no es responsable de la seguridad en caso de uso de piezas de repuesto no autorizadas.
•
La información sobre el mantenimiento de este producto está dirigida exclusivamente al personal cualificado de mantenimiento.
•
Existe mayor riesgo de descarga eléctrica y de daños personales durante el desmontaje y la reparación de la máquina. El personal cualificado debe ser consciente de este peligro y tomar las precauciones necesarias.
•
PRECAUCIÓN:
este símbolo indica que el voltaje de la parte del equipo con la que está trabajando es peligroso. Antes de empezar, desenchufe el equipo o tenga cuidado si, para trabajar con él, debe conectarlo.
Informações de Segurança
•
A segurança deste produto baseia-se em testes e aprovações do modelo original e de componentes específicos. O fabricante não é responsável pela segunrança, no caso de uso de peças de substituição não autorizadas.
•
As informações de segurança relativas a este produto destinam-se a profissionais destes serviços e não devem ser utilizadas por outras pessoas.
•
Risco de choques eléctricos e ferimentos graves durante a desmontagem e manutenção deste produto.
Os profissionais destes serviços devem estar avisados deste facto e tomar os cuidados necessários.
•
CUIDADO:
Quando vir este símbolo, existe a possível presença de uma potencial tensão perigosa na zona do produto em que está a trabalhar. Antes de começar, desligue o produto da tomada eléctrica ou seja cuidadoso caso o produto tenha de estar ligado à corrente eléctrica para realizar a tarefa necessária.
xvi
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5025-2xx, 4xx
Informació de Seguretat
•
La seguretat d'aquest producte es basa en l'avaluació i aprovació del disseny original i els components específics.
El fabricant no es fa responsable de les qüestions de seguretat si s'utilitzen peces de recanvi no autoritzades.
•
La informació pel manteniment d’aquest producte està orientada exclusivament a professionals i no està destinada a ningú que no ho sigui.
•
El risc de xoc elèctric i de danys personals pot augmentar durant el procés de desmuntatge i de servei d’aquest producte. El personal professional ha d’estar-ne assabentat i prendre les mesures convenients.
•
PRECAUCIÓ:
aquest símbol indica que el voltatge de la part de l'equip amb la qual esteu treballant és perillós. Abans de començar, desendolleu l'equip o extremeu les precaucions si, per treballar amb l'equip, l'heu de connectar.
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.
2.
Diagnostic information
contains an error indicator table, symptom tables, and service checks used to isolate failing field replaceable units (FRUs).
3.
Diagnostic aids
contains tests and checks used to locate or repeat symptoms of printer problems.
4.
Repair information
provides instructions for making printer adjustments and removing and installing
FRUs.
5.
Connector locations
uses illustrations to identify the connector locations and test points on the printer.
6.
Preventive maintenance
contains the lubrication specifications and recommendations to prevent problems.
7.
Parts catalog
contains illustrations and part numbers for individual FRUs.
Conventions
Note:
A note provides additional information.
Warning:
A warning identifies something that might damage 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.
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Service Manual
5025-2xx, 4xx
1. General information
Models
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.
Model name
Lexmark C540n
Lexmark C543dn
Lexmark C544n
Lexmark C544dn
Lexmark C544dw
Lexmark C546dtn
Machine type/ model
5025-210
5025-230
5025-410
5025-430
5025-43W
5025-439
Description
Ethernet network
Ethernet network, duplex
Ethernet network, USB-A host port for flash drives
USB-A host port for flash drive, duplex, Ethernet network
802.11n network wireless network, duplex, ethernet,
USB-A host port for flash.
USB-A host port for flash drive, duplex, Ethernet network,
650-sheet Duo Drawer.
Configurations
Lexmark C540n, C543dn,
C544n, C544dn
Lexmark C544n, C544dn with optional 650-sheet Duo Drawer
Lexmark C546dtn with standard
650-sheet Duo Drawer and optional
550-sheet drawer
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:
•
650-Sheet Duo Drawer—a 550-sheet drawer with a 100-sheet multipurpose feeder (MP Feeder).
•
550-Sheet drawer—an optional 550-sheet drawer that can be added to model C546dtn only.
•
Additional memory—One 128, 256, or 512MB memory card may be added.
•
Flash memory card—One 64MB card may be added.
•
Font cards—One language card may be added.
Printer specifications
Memory
✔
—Supported
✘
—Not supported
Lexmark C540n,
C543dn
Lexmark C544n,
C544dn,
Lexmark C546dtn
Memory
Optional slots One slot
Standard DDRS DRAM sizes
Optional DIMM a
sizes
128MB
128MB, 256MB, and 512MB
Maximum printer memory b
640MB
Option Slots (single slot is available or either font or flash memory card)
Font card support
Optional user flash memory card sizes c
Maximum possible DORSDRAM b
N/A
N/A
1 font card
64MB
256MB
256MB, 512MB
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
✘ ✔ ✔
✘
✔
(C544dn wireless unit only)
✘ a b c
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 highquality 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
( ) on the operator panel.
2.
Select
Reports
from the Admin Menu, and press
Select
( ).
3.
Select
Menu Settings
, and press
Select
( ).
Replacement is recommended every 30,000 pages for the imaging unit.
•
4800C Q (default) full printer speed
•
1200 dpi (reduced printer speed) is supported in PS and PCL only
Connectivity (network support)
✔
—Supported
✘
—Not supported
Network protocol
Standard Ethernet 10/100 Base T
Lexmark C540n,
C543dn
✔
✔
Lexmark C544n,
C544dn, C544dn
(wireless)
✔
✔
Lexmark C546dtn
✔
✔
Standard USB-B (Full speed) device port
USB-A host ports
(In front, low/full speed) This port only supports the following flash drives and file types:
Supported flash drives a
: Lexar FireFly
(512 MB/1GB size), SanDisk Cruzer
Micro (512 MB/1 GB size), or
Sony (512 MB/1 GB).
Supported file types b
: .pdf, .gif, .jpeg, .jpg,
.bmp, .png, .tiff, .tif, .pcx, .dcx
✘ ✔ ✔
802.11n Wireless Network card
Manufacturing installs the wireless card. A wireless card CANNOT be installed postmanufacturing.
✘ ✔ ✘ 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:
• Supports the USB 2.0 specification supporting the Full-Speed mode b
• Uses the FAT file system
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
Mode Description
Normal
Quiet
Eco-Mode (Off is default):
• Paper
Factory default
Designed for customers where noise levels are a very important factor.
• Print quality is maintained at factory default level.
• Speed is reduced.
Designed for customers where the environment is a key factor.
There are three options; Energy, Paper, and Energy/Paper.
• Duplex is on if
Energy/Paper
or
Paper
is selected (duplex models only) (can be overwritten by the driver).
• Energy • Print quality is maintained.
• Power Saver is set to one minute.
• Fuser standby is off.
• The operator panel back light is off.
• Power supply energy consumption is reduced.
• Energy + Paper All of the above.
Data streams
✔
—Supported
✘
—Not supported
Data streams
PCL 6 emulation
PostScript Level III emulation
Version 3011 of the Adobe definition of
PostScript 3 is supported.
Supports version 1.6
PPDS
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.
PictBridge
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.
Lexmark C540n,
C543dn
Lexmark C544n,
C544dn, C544dwn
Lexmark C546dtn
✔
✔
✘
✘
✘
✘
✔
✔
✔
✔
✔
✔
✔
✔
✔
✔
✔
✔
✔
✔
✔
1-4
Service Manual
5025-2xx, 4xx
Dimensions
Models
Lexmark C540n, C543dn,
C544n, C544dn(w)
Lexmark C546dtn (includes
650 sheet Duo Drawer)
650-sheet Duo Drawer
550-sheet Duo Drawer (only
C526dtn)
Height
291 mm (11.5 in.)
422 mm (16.6 in.)
133 mm (5.2 in.)
133 mm (5.2 in.)
Clearances
Width
424 mm (16.7 in.)
424mm (16.7 in.)
424 mm (16.7 in.)
424 mm (16.7 in.)
Depth
400 mm (15.7 in.)
416 mm (16.4 in.)
416 mm (16.4 in.)
416 mm (16.4 in.)
Weight
21 kg (46.2 lbs)
25 kg (55 lb)
4 kg (8.7 lb)
4 kg (8.7 lb)
1 Rear
2 Front
3 Right side
4 Left side
5 Above
Direction Dimensions
Lexmark C540n, C543dn,
C544n, and C544dn (w),
C546dtn
100 mm (4 in.)
500 mm (20 in.)
150 mm (6 in.)
75 mm (3 in.)
250 mm (10 in.)
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).
Printing states
Lexmark C540n,
C543dn
Average power while printing
Simplex
Automatic duplex*
480 W
340 W
Average power while idle
Power Saver
Ready
Off
18 W
34 W
0 W
* Automatic duplex is not supported on the C540n and C544n.
Lexmark C544n, and C544dn
500 W
340 W
18 W
36 W
0 W
Lexmark C546dtn
500 W
340 W
18 W
36 W
0 W
Typical electricity consumption
2
Power supply voltage (kwh)
Model Mode
100 V/50 Hz 115 V/60 Hz 230 V/50 Hz
Lexmark C540n and C543dn
TEC
1
TEC
1
—Eco Mode
Lexmark C544n and C544dn
TEC
1
TEC
1
—Eco Mode
3.73 kwh
3.41 kwh
3.5 kwh
3.30 kwh
3.92 kwh
3.55 kwh
3.97 kwh
3.57 kwh
4.06 kwh
3.42 kwh
4.20 kwh
3.57 kwh
1
2
Lexmark C546dtn
TEC
1
TEC
1
—Eco Mode
3.97 kwh
3.57 kwh
4.06 kwh
3.42 kwh
4.20 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
•
110 to 127 V ac at 47 to 63 hertz (Hz) nominal
•
99 to 137 V ac, extreme
100 voltage models
•
100 V ac at 47 to 63 hertz (Hz) nominal
•
90 to 110 V ac, extreme
1-6
Service Manual
5025-2xx, 4xx
High-voltage models
•
220 to 240 V ac at 47 to 63 hertz (Hz) nominal (not available in all countries)
•
198 to 259 V ac, extreme
Notes
:
•
Using a 220 V ac to 110 V ac power converter with a low voltage printer is not recommended.
•
Using an inverter to change DC to AC voltage (12 V to 120 V for example) is not recommended.
•
All 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
Printing (simplex)
Printing (automatic duplex)
Idle
Quiet Mode (simplex)
1-Meter average sound pressure at 4800 CQ
Lexmark
C540n
47 dBA
N/A
Inaudible
46 dBA
Lexmark
C543dn
47 dBA
50 dBA
Inaudible
46 dBA
Lexmark
C544n
49 dBA
N/A
Inaudible
46 dBA
Environment specifications
Lexmark
C544dn
49 dBA
51 dBA
Inaudible
46 dBA
Lexmark
C546dtn
49 dBA
51 dBA
Inaudible
46 dBA
Environment Specifications
Operating
Air temperature—operating
Air temperature—power off
Air relative humidity
16 to 32°C (60 to 90°F)
10 to 43°C (50 to 110°F)
Relative Humidity 8% to 80%
Wet bulb temperature—operating
Wet bulb temperature—power off
Altitude
Atmospheric pressure
23°C (73°F) maximum
27°C (80°F) maximum
0–3,048 meters (10,000 ft.)
74.6 kPa
16 to 32°C (60 to 90°F) and 8% to 80% RH Ambient operating environment*
Ship / Storage
Cartridges
Printer with cartridges
Printer without cartridges
Air relative humidity
Altitude
Wet bulb temperature—power off
-40 to 43°C (-40 to 110°F)
-40 to 43°C (-40 to 110°F)
-40 to 43°C (-40 to 110°F)
Relative Humidity 8% to 80%
10,300 meters (34,000 feet)
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
Sheet numbers are assuming
20 lb. xerographic paper
Lexmark
C540n, C544n
Lexmark
C543dn,
C544dn,
C544dw
Standard input sources
Standard input tray
(250-sheet tray)
Manual feed slot (1-sheet)
Second tray capacity
(650-sheet Duo Drawer)
250 sheets
1 sheet
N/A
250 sheets
1 sheet
N/A
Lexmark
C544dtn
(C544dn with second tray)
250 sheets
1 sheet
550 sheets
(standard on
C544dtn, optional on
C544dn)
100 sheets
Lexmark
C546dtn
250 sheets
1 sheet
550 sheets
(standard)
Multipurpose tray capacity
(650-sheet Duo Drawer)
Optional 550-sheet drawer
N/A N/A 100 sheets
N/A N/A N/A 550 sheets
Optional input sources (maximum 1, total of all inputs is 4)
650-sheet Duo Drawer ab
(includes 100-sheet MP feeder)
Multipurpose try capacity
(650-sheet Duo Drawer)
Optional third tray capacity
(550 sheets)
Maximum total input capacity
550 sheets
(or 100 sheets in
MP feeder)
100 sheets
N/A
901
550 sheets
(or 100 sheets in
MP feeder)
100 sheets
N/A
901
Duplex
N/A
0
N/A
N/A
901
Duplex
0
N/A
550 sheets
(tray 3)
1,451
Standard output sources (no optional output sources are available)
Standard 100-sheet bin 100 100 100 100 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.
b
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
Duplex capability
✔
—Supported
✘
—Not supported
Models
Lexmark C540n
Lexmark C543dn
Lexmark C544n
Lexmark C544dn
Lexmark C544dw
Lexmark C546dtn
Duplex capability
✔
✔
✔
✘
✔
✘
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
✔
—Supported
without
size sensing
✘
—Not supported
Input source
A4
210 x 297mm
A5
a
148 x 210mm
A6
JIS
b
B5
a
182 x 257mm
Letter
8.5 x 11 in.
Legal
8.5 x 14 in.
Executive
a
7.25 x 10.5 in.
Oficio (Mexico)
Folio
8.5 x 13 in.
Statement
a
5.5 x 8.5 in.
✔
✔
✔
✘
✔
✔
✔
✔
✔
✘
✔
✔
✔
✘
✔
✔
✔
✔
✔
✘
✔
✔
✔
✔
✔
✔
✔
✔
✔
✔
✔
✔
✔
✘
✔
✔
✔
✔
✔
✘
✔
✔
✔
✔
✔
✔
✔
✔
✔
✔
5025-2xx, 4xx
✔
✔
✔
✘
✔
✔
✘
✔
✘
✘
General information
1-9
5025-2xx, 4xx
✔
—Supported
without
size sensing
✘
—Not supported
Input source
Universal
c
148 x 210mm to
216 x 356mm
(5.8 x 8.3 in. to
8.5 x 14 in.) a
76.x 127mm to
216 x 356mm
(3 x 5 in. to 8.5 x 14 in.) a
✔
✘
✔
✘
✔
✘
✔
✔
✔
✔
✘
✘
210mm x 279.4mm to
216mm x 356mm
(8.27 in. x 11 in. to
8.5 in. to 14 in.)
7¾ Envelope
a
98 x 191mm
✔ ✔ ✔ ✔ ✔
✔
9 Envelope
a
✘
✘
✘
✘
✘
✘
✘
✘
✘
✔
✔
✔
✔
✔
✔
✘
✘
✘
10 Envelope
a
105 x 241mm
(4.12 x 9.5 in.)
DL Envelope
a
(4.3 x 8.7 in.)
110 x 220mm
✘ ✘ ✘
✔ ✔
✘
C5 Envelope
a
162 x 229mm
(6.4 x 9 in.)
B5 Envelope
a
Other envelope
a
Length: 98–432mm
(3.8–17 in.)
Width: 89–297mm (3.5–11.7 in.)
✘
✘
✘
✘
✘
✘
✘
✘
✘
✔
✔
✔
✔
✔
✔
✘
✘
✘ a
The MP feeder runs slower if A5, Statement, B5, A6, Executive, Statement, Universal (narrower than
210mm), or envelopes are loaded.
b
Japanese Industry Standard.
c
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
Media input type specifications
✔
—Supported
✘
—Not supported
5025-2xx, 4xx
Input type
Plain paper
Card stock
Transparency
Recycled b
✔
✔
✔
✔
✔
✔
✔
✔
✔
✔
✔
✔
✔
✔
✔
✔
✔
✔
✔
✔
✔
✘
✘
✔
Glossy
Paper-backed labels
Bond
Envelopes
Rough envelopes
Letterhead
Preprinted
Colored paper
Light paper
Heavy paper
✔
✔
✔
✘
✘
✔
✔
✔
✔
✔
✔
✔
✔
✘
✘
✔
✔
✔
✔
✔
✔
✔
✔
✘
✘
✔
✔
✔
✔
✔
✔
✔
✔
✔
✔
✔
✔
✔
✔
✔
✔
✔
✔
✔
✔
✔
✔
✔
✔
✔
✔
✔
✘
✘
✔
Rough or cotton
Custom type <x> b
✔
✔
✔
✔
✔
✔
✔
✔
✔
✔
✔
✔ a
For MP feeder and manual feeders, the Default Source Menu displays
Manual Paper
and
Manual Env.
Select
Manual Env.
for envelopes or when the type in Custom Type <x> is an envelope. For other types, use
Manual Paper
.
b
The duplex 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
Material Type Weight Select
Paper
2, 5, 7, 8
Specialty papers business paper
Gloss Book
60 to 75 g/m
2
grain long
(16 to 19.9 lb bond)
2, 5
75 to 90 g/m
2
grain long
(20 to 24 lb bond)
90. to 105 g/m
2
grain long
(24 to 28 lb bond)
105 to 176 g/m
2
grain long
(28 to 47 lb bond)
7
88 to 176 g/m
2 grain long (60 to 120 lb book)
Light Paper
Plain Paper
Heavy Paper
Card stock
Card stock—upper limit (grain long)
1
Gloss Cover
Index Bristol
Tag
Cover
162 to 176 g/m
2 grain long (60 to 65 lb cover)
120 g/m
2
(67 lb)
120 g/m
2
(74 lb)
135 g/m
2
(50 lb)
Card Stock—upper limit (grain short)
1
Index Bristol
Tag
Cover
163 g/m
2
(90 lb)
163 g/m
2
(100 lb)
176 g/m
2
(65 lb)
170 to 180 g/m
2
(45 to 48 lb bond) Transparency
6
Laser printer
Labels—upper limit
Envelopes
(Multipurpose feeder or manual slot only)
Paper
Sulfite, wood-free or up to 100% cotton bond
131 g/m
2
(35 lb bond)
60 to 105 g/m
2 to 28 lb bond)
3, 4
1
2
For 60 to 176 g/m
2
paper, grain long fibers are recommended.
Paper less than 75 g/m
2
(20 lb) must be printed with Paper Type set to
Light Paper
.
3
100% cotton content maximum weight is 24 lb bond.
4
5
28 lb bond envelopes are limited to 25% cotton content.
The d uplex unit supports paper weights between 60–105 g/m
2
(16–28 poun d) g rain long bond. The duplex unit does not support card stock, transparencies, envelopes, or labels.
6
7
8
Lexmark transparency part numbers 12A8240 and 12A8241 are supported from the standard tray, manual slot, and the multi-purpose feeder.
Paper 90 to 104.9 g/m
2
(23.9 to 27.8 lb) must be printed with Paper Type set to
Heavy Paper
.
Paper 105 to 176 g/m
2
(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.
•
Weight
—The printer can automatically feed paper weights from 60 to 176 g/m
2
(16 to 47 lb bond) grain long. Paper lighter than 75 g/m
2
(20 lb) might not be stiff enough to feed properly, causing jams. For best performance, use 80 g/m
2
(21 lb bond) grain long paper. For paper smaller than 182 x 257 mm (7.2 x 10.1 in.), we recommend 90 g/m
2
or heavier paper.
•
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.
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Service Manual
5025-2xx, 4xx
•
Smoothness
—Paper smoothness directly affects print quality. If paper is too rough, toner cannot fuse to it properly. If paper is too smooth, it can cause paper feeding or print quality issues. Always use paper between 100 and 300 Sheffield points; however, smoothness between 150 and 200 Sheffield points produces the best print quality.
•
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.
•
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
2
(16 to 47 lb bond) paper, use grain long fibers.
•
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 for use with the printer:
•
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
•
Preprinted papers with chemicals that may contaminate the printer
•
Preprinted papers that can be affected by the temperature in the printer fuser
•
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.
•
Coated papers (erasable bond), synthetic papers, thermal papers
•
Rough-edged, rough or heavily textured surface papers, or curled papers
•
Recycled papers that fail EN12281:2002 (European)
•
Paper weighing less than 60 g/m
2
(16 lb)
•
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:
•
Always use new, undamaged paper.
•
Before loading paper, know the recommended print side of the paper. This information is usually indicated on the paper package.
•
Do not use paper that has been cut or trimmed by hand.
•
Do not mix paper sizes, types, or weights in the same source; mixing results in jams.
•
Do not use coated papers unless they are specifically designed for electrophotographic printing.
Selecting preprinted forms and letterhead
Use these guidelines when selecting preprinted forms and letterhead:
•
Use grain long for 60 to 176 g/m
2
weight paper.
•
Use only forms and letterhead printed using an offset lithographic or engraved printing process.
•
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:
•
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%.
•
Store paper in cartons when possible, on a pallet or shelf, rather than on the floor.
•
Store individual packages on a flat surface.
•
Do not store anything on top of individual paper packages.
Using recycled paper and other office 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.
•
Low moisture content (4–5%)
•
Suitable smoothness (100–200 Sheffield units, or 140–350 Bendtsen units, European)
Note:
Some much smoother papers (such as premium 24 lb laser papers, 50–90 Sheffield units) and much rougher papers (such as premium cotton papers, 200–300 Sheffield units) have been engineered to work very well in laser printers, despite surface texture. Before using these types of paper, consult your paper supplier.
•
Suitable sheet-to-sheet coefficient of friction (0.4–0.6)
•
Sufficient bending resistance in the direction of feed
Recycled paper, paper of lower weight (<60 g/m
2
[16 lb bond]) and/or lower caliper (<3.8 mils [0.1 mm]), and paper that is cut grain-short for portrait (or short-edge) fed printers may have lower bending resistance than is required for reliable paper feeding. Before using these types of paper for laser (electrophotographic) printing, consult your paper supplier. Remember that these are general guidelines only and that paper meeting these guidelines 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
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)
5025-2xx, 4xx
General information
1-15
5025-2xx, 4xx
Acronyms
BLDC
C
DIMM
DRAM
EEPROM
EP
ESD
FRU
GB
ITU
IU
JIS
K
LASER
LCD
Brushless DC Motor
Cyan
Dual Inline Memory Module
Dynamic Random Access Memory
Electrically Erasable Programmable Read-Only Memory
ElectroPhotographic
Electrostatic Discharge
Field Replaceable Unit
Gigabyte
Image Transfer Unit
Imaging Unit
Japanese Industry Standard
Black
Light Amplification by Stimulated Emission of Radiation
Liquid Crystal Display
LVPS
M
MPF
NVRAM
Low-Voltage Power Supply
Magenta
Multipurpose Feeder (also MP feeder)
Nonvolatile Random Access Memory
PC Photoconductor pixel Picture elements (same as pel)
POR
POST
Power-On Reset
Power-On Self Test
PWM
RIP
ROM
SDRAM
SIMM
TDS
TPS
V ac
V dc
Y
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
1-16
Service Manual
2. Diagnostic information
5025-2xx, 4xx
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
•
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
–
–
•
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:
1.
The LED turns on.
2.
The main fan turns on.
3.
The operator panel turns on.
4.
A partial row of pixels appears.
5.
The operator panel display clears.
6.
Another row of pixels appears.
7.
The operator panel display clears again.
8.
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.
The operator panel LED starts blinking.
11.
The following errors or messages may appear:
•
Close Door
or
Insert Cartridge
displays if the upper front cover is open or the print cartridge is missing.
•
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.
2-2
Service Manual
5025-2xx, 4xx
Symptom tables
Printer symptom table
Symptom Action
Dead printer
Operator panel—one or more buttons do not work.
Operator panel—display is blank.
Operator panel continuously displays all diamonds and does not complete POST.
Operator panel display is dim and unchanging.
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.
Go to
“Dead printer service check” on page 2-24
Go to
“One or more operator panel buttons fail” on page 2-33
Go to
“Operator panel display blank, five beeps” on page 2-34
Go to
“Operator panel displays all diamonds, no beeps” on page 2-36
Go to
“Operator panel display is dim and unchanging” on page 2-38
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.
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
( ) on the operator panel.
2. Select
Reports
from the Admin Menu, and press
Select
( ).
3. Select
Menu Settings
, and press
Select
( ).
• Increase the Print Timeout value on the operator panel
(
Settings
–>
General Settings
–>
Timeouts
–>
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
• 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
–>
General settings
–>
Recovery
–>
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 Action
Blank page Go to
“Print quality—blank page” on page 2-42
Blurred or fuzzy print
Color matching problems
Half-color page
Horizontal banding
Go to
See
Go to
Go to
“Print quality—blurred or fuzzy print” on page 2-43
.
“Print quality—half-color page” on page 2-43
.
“Print quality—horizontal banding” on page 2-44
.
.
Horizontal line
Insufficient fusing
Light print on solids
Missing image at edge
Mottle (2–5mm speckles)
Narrow vertical line
Random marks
Residual image
Skew (image not parallel to sides or to top and bottom)
Solid color page
Vertical banding
Go to
Go to
See
Go to
Go to
“Print quality—horizontal line” on page 2-44
“Print quality—insufficient fusing” on page 2-45
“Media guidelines” on page 1-12
“Print quality—missing image at edge” on page 2-45
“Print quality—mottle (2–5mm speckles)” on page 2-45
.
“Print quality—narrow vertical line” on page 2-46
Go to
“Print quality—random marks” on page 2-46
.
Go to
“Print quality—residual image” on page 2-47
.
Check to see if the right tray is in the proper drawer for the 650sheet Duo Drawer. See the note on
.
Check the printhead alignment. See
Go to
“Print quality—solid color page” on page 2-48
.
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
Explanation
Busy
Calibrating
Close door
Check Config ID
Check Model Name
Check Serial Num
Wait for the message to clear.
The printer is performing a color adjustment. Wait for the message to clear.
Message clears when front cover, right cover, and toner door are closed or securely fastened.
The printer configuration ID is invalid.
Message clears when a valid model name is set.
Message clears when a valid serial number is set.
<
color
> Low
Defragmenting Flash
DO NOT POWER
OFF
Flushing buffer
Formatting Flash
DO NOT POWER
OFF
Hex Trace
Replace the toner cartridge, and then wait for the message to clear.
The printer is performing the defragmentation operation of flash memory. Wait for the message to clear.
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 turn the printer off while this message appears on the display.
Imaging Kit
Insert Tray <
x
>
This message appears between status messages and warnings. Wait for the message to clear.
Replace the imaging kit, and then press
Select
( ) 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:
• Insert the requested tray.
• Press
Stop
( ), and then press to cancel printing.
The engine code is invalid.
Invalid Engine Code
Invalid Network Code The Network code is invalid.
Load <
source
> with
<
custom string
>
Printer does not detect media meeting the description < where <
source custom string
> is Tray 1, Tray 2, Tray 3, or multipurpose feeder.
• Load the input source with the correct type and size media.
• Press
Stop
( ), and then press
Select
( ) to cancel printing.
> in <
source
>,
Load <
source
>
<
custom type
>
Printer does not detect media meeting the description <
custom type
> in <
source
>, where <
source
> is Tray 1, Tray 2, Tray 3, or Multi-Page feeder.
• Load the input source with the correct type and size media.
• Press
Stop
( ), and then press
Select
( ) to cancel printing.
Load <
source
>
<
type or size
>
Printer does not detect media meeting the size requested in the source indicated.
• Load the input source with the correct type and size media.
• Press
Stop
( ), and then press
Select
( ) to cancel printing.
Diagnostic information
2-5
5025-2xx, 4xx
User primary message
Load <
<
<
Load single sheet feeder with
<
<
type size
>
source
> <
size
feeder with
Load single sheet feeder with <
Load single sheet feeder with <
Power Saver
>
>
Load single sheet
custom type name custom string
>
size type
>
>
Programming Code
>
Programming Flash
Ready
Reload printed paged in Tray <
x
>
Explanation
Printer does not detect media meeting the size or type requested in the source indicated.
• Load the input source with the correct type and size media.
• Press
Stop
( ), and then press
Select
( ) to cancel printing.
Printer does not detect media meeting the description <
custom type name
> in the single sheet feeder.
The following actions can be taken:
• Load paper, press
Select
( ), and the job continues.
• Press
Select
( ) to override the source, and an alternate source for media is selected.
• Press
Stop
( ), and then press
Select
( ) 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.
Printer does not detect media meeting the description <
custom string
> in the single sheet feeder.
The following actions can be taken:
• Load paper and the job continues.
• Press
Select
( ), and choose an alternate source for media.
• Press
Stop
( ), and then press
Select
( ) to cancel printing.
Printer does not detect media meeting the description <
size
> in the single sheet feeder.
The following actions can be taken:
• 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
( ) to clear the message and continue printing.
• Press
Select
( ) to clear the message and continue printing.
The printer manually overrides the manual request, and then paper prints from an automatic source.
• Press
Stop
( ), and then press
Select
( ) to cancel printing.
Printer does not detect media meeting the description <
type
> and <
size
> in the single sheet feeder (manual feeder).
The following actions can be taken:
• 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
( ) to clear the message and continue printing.
• Press
Select
( ) to clear the message and continue printing.
The printer manually overrides the manual request, and then paper prints from an automatic source.
• Press
Stop
( ), and then press
Select
( ) to cancel printing.
The printer is saving power while it waits for the next print job.
• Send a job to print.
• Press
Select
( ) to warm the printer to normal operating temperature.
Afterwards,
Ready
appears.
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.
Fonts and macros are being written to flash. Wait for the message to clear.
The printer is ready to print.
• Press
Select
( ) to clear the message and continue processing the second side of the sheet.
• Press
Stop
( ), and then press
Select
( ) to cancel printing.
2-6
Service Manual
5025-2xx, 4xx
User primary message
Explanation
Remote Management
Active
Remove paper from standard output bin
Remove packaging material
Replace < cartridge
color
Std Bin Full
Tray <
Tray <
Tray <
Unplug and Change
Mode
x x x
>
> Empty
> Low
> Missing
Unsupported USB device, please remove
Unsupported USB hub, please remove
Waiting
The printer is offline while it configures settings. Wait for the message to clear.
The following actions can be taken:
• Remove paper from the standard exit bin to clear the message and continue printing.
• Press
Select
( ) to clear the message and continue printing.
Packaging material is detected by the printer. Remove the packaging material, and press
Select
( ). 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:
• Remove paper from the standard exit bin to clear the message and continue printing.
• Press
Select
( ) to clear the message and continue printing.
The following actions can be taken:
• Load the paper tray or other source with the correct paper type and size.
• Press
Stop
( ) and then press
Select
( ) 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.
Waiting, too many events
Waste Toner Box
30 <
color
Missing
> Toner Cart
31.xx Defective
<
color
> Cartridge
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:
• Press
Select
( ) to print the contents of the buffer.
• 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:
• Remove and re-install the imaging kit.
• Open and close the top cover.
• Remove and re-install the cartridge(s). Listen for the
click
to ensure the cartridge is installed properly.
• Turn the printer power off and turn the printer power on.
If the message persists, replace the cartridge with a new one, and close the front cover.
Diagnostic information
2-7
5025-2xx, 4xx
User primary message
31.xx Defective
Imaging Kit
32.xx Replace
Unsupported <color>
Cartridge
34 Short paper
Explanation
Defective imaging kit.
The following actions can be taken:
• Open and close the top cover.
• Remove and re-install the imaging kit.
• 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. 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.
Remove the specified cartridge, replace with a supported cartridge, and close the front cover.
35 Insufficient memory to support
Resource Save feature
37 Insufficient memory to collate job
37 Insufficient
Memory for Flash memory Defragment operation
• 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
( ), and then press
Select
( ) to cancel printing.
This message displays when the printer lacks sufficient memory to enable Resource
Save. This message usually indicates the user has allocated too much memory for one or more of the printer link buffers; however, modification of other printer settings which affect the amount of available memory may also create this condition. If restoration of Resource Save is required after this message is received, the customer should install additional memory or set each link buffer to Auto. Once all link buffers are returned to Auto, you should exit the menu to activate the link buffer changes.
Once the printer returns to the Ready state, you can enable Resource Save and go back and modify the link buffers again. 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.
• Press
Select
( ) to disable Resource Save and continue printing.
• Install additional memory.
This message is displayed when the printer memory used to store pages is too full to collate the print job.
The following actions can be taken:
• Press
Select
( ) to print the portion of the job already stored, and begin collating the rest of the job.
• Press
Stop
( ), and then press
Select
( ) to cancel printing.
This message is displayed when insufficient printer memory is available to perform
Flash Memory Defragment operation.
This message appears prior to the actual start of the defragment operation.
Press
Select
( ) to stop the defragment operation.
To perform the defragment operation, you can:
• Delete fonts, macros, and other data in RAM.
• Install additional printer memory.
• Press
Stop
( ), and then press
Select
( ) to cancel printing.
2-8
Service Manual
5025-2xx, 4xx
User primary message
Explanation
38 Memory Full
39 Complex page, some data may not have printed
This message is displayed when the printer is processing an incoming job and there is not enough memory available to continue processing the job.
The following actions can be taken:
• Determine how to make more memory available to your print job by:
- Deleting fonts and other data in RAM.
- Simplify your print job by reducing the amount of text or graphics on a page.
- Install additional memory
• Press
Select
( ) to clear the message and continue printing.
The job may not print correctly.
• Press
Stop
( ), and then press
Select
( ) to cancel printing.
This message is displayed when a page is too complex to print.
The following actions can be taken:
• Press
Select
( ) to clear the message and continue printing.
The job may not print correctly.
• Simplify the print job by reducing the amount of text or graphics on a page.
• Press
Stop
( ), and then press
Select
( ) to cancel printing.
Replace the toner cartridge with a new one.
40 <
color
> Invalid
Refill, change cartridge
50 PPDS Font Error
51 Defective Flash
Detected
52 Not enough free space in flash memory for resources
53 Unformatted flash detected
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 best 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:
• Press
Select
( ) to clear the message and continue printing.
The job may not print correctly.
• 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.
• Press
Stop
( ), and then press
Select
( ) to cancel printing.
Press
Select
( ) to clear the message and continue printing.
You must install different flash memory before you can download any resources to flash.
The following actions can be taken:
• Press
Select
( ) to clear the message and continue printing.
• Delete fonts, macros, and other data stored on the flash memory.
• Upgrade to a larger capacity flash memory.
• Press
Stop
( ), and then press
Select
( ) to cancel printing.
The following actions can be taken:
• Press
Select
( ) to clear the message and continue printing.
• 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
User primary message
Explanation
54 Standard network software error
54 Network < software error
x
56 Standard USB
Port disabled
58 Too many trays attached
>
58 Too many Flash options installed
The printer detects a network port, but cannot communicate with it. The printer disables all communication to the associated network interface.
The following actions can be taken:
• Press
Select
( ) 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.
The printer disables all communications to the associated network interface. No data may be received or sent from or to the associated interface.
• Press
Select
( ) to clear the message and continue printing.
The job may not print correctly.
• Turn the printer power off and then back on to reset the printer.
• Upgrade the network firmware in the printer or the print server.
This message may appear when data is sent to the printer across a USB port, but the 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:
• Press
Select
( ) to clear the message.
Any data received on the USB port is discarded.
• Press
Menus
( ) to access the Administrative Menus.
Make sure the USB Buffer menu item is not set to Disabled. (Press
Menus
( ) to access the Administrative Menus, select
Network/Ports
,
USB Menu
, and
USB Buffer
.)
Too many optional flash memory cards or optional firmware cards are installed on the printer.
• Press
Select
( ) to clear the message and continue printing.
• 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.
Too many trays are installed.
1. Turn off and unplug the printer.
2. Remove the additional trays.
3. Plug in the printer, and turn it on.
Remove the specified tray.
59 Incompatible trays <x>
82 Replace waste toner box
82.xx Waste toner box missing
82.xx Waste toner nearly full
Replace the waste toner bottle, and press
Select
( ) to clear the message and continue printing. See
“Waste toner bottle removal” on page 4-77
Note:
The printer will not continue until the waste toner bottle is replaced.
Replace the waste toner bottle, and press
Select
( ) to clear the message and continue printing.
The following actions can be taken:
• Replace the waste toner bottle, and then press
Select
( ) to clear the message and continue printing. See
“Waste toner bottle removal” on page 4-77
.
• Press
Select
( ) to clear the message and continue printing.
• 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
User primary message
88.xx <
color
>
Cartridge is low
88 Replace <
color
>
Cartridge
Explanation
The term <
color
> includes black, cyan, magenta, and yellow. Replace the toner cartridge, and then close the toner door to clear the message and continue printing.
The term <
color
> includes black, cyan, magenta, and yellow. Replace the toner cartridge, and then close the toner door to continue printing.
Paper Jam messages
Paper jam messages (2xx)
Error code
200.
xx
Paper Jam
Check <
area
>
or
200.
xx
Paper Jam
<
x
> Pages Jammed
201.
xx
Paper Jam
Check <
area
>
or
201.
xx
Paper Jam
<
x
> Pages Jammed
202.
xx
Paper Jam
Check <
area
>
or
202.
xx
Paper Jam
<
x
> Pages Jammed
230.
xx
Paper Jam
Check <
area
>
or
230.
xx
Paper Jam
<
x
> Pages Jammed
235.
xx
Paper Jam
Check Duplex
Description Action
A single page of media jam at the input
(S2) sensor.
Multiple pages of media are jammed at the input sensor.
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
.
A single page 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.
Open the front door, and then remove the jammed page or pages. See
See
.
Open the front door to access the jam area. Remove the jammed page or pages.
.
Open the front door, and then remove the jammed page or pages. See
.
241.xx Paper Jam
Check <
area
or
>
241.xx Paper Jam
<
x
> Pages Jammed
242.
xx
Paper Jam
Check <
area
or
>
242.
xx
Paper Jam
<
x
> Pages Jammed
Paper jam in the duplex area.
Paper jam in the primary tray.
• 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
.
• 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 of the pick tires, and replace if necessary. See
“Pick tires removal” on page 4-64
.
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).
Open the door, and remove all the jammed pages. See
“242 paper jam in the 650sheet Duo Drawer” on page 3-35
.
Diagnostic information
2-11
5025-2xx, 4xx
Paper jam messages (2xx) (continued)
Error code
243.
xx
Paper Jam
Check <
area
>
or
243.
xx
Paper Jam
<
x
> Pages Jammed
250.
xx
Paper Jam
Check Manual
Feeder
or
250.
xx
Paper Jam
<
x
> Pages Jammed
Description Action
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).
Open the door, and remove all the jammed pages. See
“242 paper jam in the 650sheet Duo Drawer” on page 3-35
.
A single page of media is jammed in the multipurpose feeder.
Multiple pages of media are jammed in the multipurpose feeder.
Open tray 2 to access the jam area.
Remove the jammed page or pages. See
2-12
Service Manual
5025-2xx, 4xx
Service error messages
Service error messages (1xx, 9xx)
Error code
106.
xx
Service
Yellow Printhead
106.01 Service
Yellow Printhead
106.02 Service
Yellow Printhead
106.03 Service
Yellow Printhead
106.04 Service
Yellow Printhead
106.05 Service
Yellow Printhead
106.08 Service
Yellow Printhead
106.11 Service
Yellow Printhead
106.12 Service
Yellow Printhead
106.13 Service
Yellow Printhead
107.
xx
Cyan
Printhead Error
107.01 Service
Cyan Printhead
107.02 Service
Cyan Printhead
107.03 Service
Cyan Printhead
107.04 Service
Cyan Printhead
107.05 Service
Cyan Printhead
Description Action
Yellow printhead error.
The yellow printhead lost HSYNC.
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
.
The yellow printhead failed to complete servo.
Perform a POR. If the problem persists, go to
“Printhead service check” on page 2-49
.
The yellow printhead mirror motors failed to achieve lock.
Perform a POR. If the problem persists, go to
“Printhead service check” on page 2-49
.
The yellow printhead mirror motors lost motor lock.
Perform a POR. If the problem persists, go to
“Printhead service check” on page 2-49
.
Failure reading NVRAM from printhead.
Perform a POR. If the problem persists, go to
“Printhead service check” on page 2-49
.
The yellow laser showed bad in testing.
Perform a POR. If the problem persists, go to
“Printhead service check” on page 2-49
.
Failure writing data to the printhead.
Perform a POR. If the problem persists, go to
“Printhead service check” on page 2-49
.
Failure reading data from the printhead.
Perform a POR. If the problem persists, go to
“Printhead service check” on page 2-49
.
Printhead declared error.
Cyan printhead error.
The cyan printhead lost HSYNC.
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
.
The cyan printhead failed to complete servo.
The cyan printhead mirror motor failed to achieve lock.
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
.
The cyan printhead mirror motor lost motor lock.
Perform a POR. If the problem persists, go to
“Printhead service check” on page 2-49
.
Failure reading NVRAM from the cyan printhead.
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)
Error code
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
Magenta Printhead
108.13 Service
Magenta Printhead
109.
xx
Service
Black Printhead
109.01 Service
Black Printhead
Description Action
The cyan laser showed bad in testing.
Perform a POR. If the problem persists, go to
“Printhead service check” on page 2-49
.
Failure writing data tot he printhead.
Perform a POR. If the problem persists, go to
“Printhead service check” on page 2-49
.
Failure reading data from the printhead.
Printhead declared error.
Magenta printhead error.
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
.
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.
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
.
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. 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
.
2-14
Service Manual
5025-2xx, 4xx
122.
xx
Service
Fuser Error
122.01 Service
Fuser Error
122.02 Service
Fuser Error
122.03 Service
Fuser Error
122.04 Service
Fuser Error
122.05 Service
Fuser Error
122.06 Service
Fuser Error
122.07 Service
Fuser Error
122.08 Service
Fuser Error
122.10 Service
Fuser Error
122.11 Service
Fuser Error
Service error messages (1xx, 9xx) (continued)
Error code
109.02 Service
Black Printhead
109.03 Service
Black Printhead
109.04 Service
Black Printhead
109.05 Service
Black Printhead
109.08 Service
Black Printhead
109.11 Service
Black Printhead
109.12 Service
Black Printhead
109.13 Service
Black Printhead
Description Action
The black printhead failed to complete servo.
Perform a POR. If the problem persists, go to
“Printhead service check” on page 2-49
.
The black printhead mirror motors failed to achieve lock.
Perform a POR. If the problem persists, go to
“Printhead service check” on page 2-49
.
The black printhead mirror motors lost motor lock.
Failure reading NVRAM from 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
.
The black laser showed bad in testing.
Perform a POR. If the problem persists, go to
“Printhead service check” on page 2-49
.
Failure writing data tot he printhead.
Failure reading data from the printhead.
Printhead declared error.
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
.
Fuser error
Attempting to print with estimated power at or below minimum power.
Fuser over temperature.
Go to
“Fuser service check” on page 2-28
.
Go to
“Fuser service check” on page 2-28
.
Go to
“Fuser service check” on page 2-28
.
Fuser open thermistor check failed.
Go to
“Fuser service check” on page 2-28
.
Go to
Attempting to print with estimated power at or above minimum power.
Fuser failed to reach final temperature in time.
Go to
Attempting to print when the estimated power is too low.
Go to
Timed out waiting for home sensor event.
Wrong lamp bit is set in NVRAM.
Go to
Go to
“Fuser service check” on page 2-28 page 2-28
.
.
Fuser failed to warm up.
Go to
“Fuser service check” on page 2-28
.
Fuser under temperature error while in standby.
Go to
“Fuser service check” on page 2-28
.
Diagnostic information
2-15
5025-2xx, 4xx
Error code
122.12 Service
Fuser Error
122.13 Service
Fuser Error
122.14 Service
Fuser Error
122.15 Service
Fuser Error
122.16 Service
Fuser Error
122.17 Service
Fuser Error
141.
xx
Service
Staging Motor
141.01 Service
Staging Motor
141.02 Service
Staging Motor
141.03 Service
Staging Motor
141.04 Service
Staging Motor
141.05 Service
Staging Motor
150.
xx
Service
Black/ITU cartridge
Motor
150.01 Service
Black/ITU cartridge
Motor
150.02 Service
Black/ITU cartridge
Motor
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
Service error messages (1xx, 9xx) (continued)
Description Action
Fuser under temperature error while printing.
Fuser open thermistor check failed for second thermistor.
Fuser shorted thermistor check failed for hot roll thermistor.
Fuser storted thermistor check failed for second thermistor
Estimated power is at or above maximum power.
Go to
“Fuser service check” on page 2-28
.
Go to
“Fuser service check” on page 2-28
.
Go to
“Fuser service check” on page 2-28
.
Go to
“Fuser service check” on page 2-28
.
Go to
“Fuser service check” on page 2-28
.
Total failure to close fuser nip.
Staging motor error.
Go to
“Fuser service check” on page 2-28
.
Go to
“Paper pick motor drive assembly service check” on page 2-39
.
Staging motor has exceeded the ramp up table.
Go to
“Paper pick motor drive assembly service check” on page 2-39
.
Staging motor has exceeded number of encoders at minimum PWM.
Staging motor has exceeded number of encoders at maximum PWM.
Motor encoder count did not change between interrupts.
Go to
Go to
Go to
“Paper pick motor drive assembly service check” on page 2-39
“Paper pick motor drive assembly service check” on page 2-39
.
.
“Paper pick motor drive assembly service check” on page 2-39
.
Staging motor has encountered a stall timeout.
Black/ITU Cartridge Motor
Go to
“Paper pick motor drive assembly service check” on page 2-39
.
Go to
“Main drive gear assembly (EP drive) service check” on page 2-30
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.
Go to
Go to
Go to
“Main drive gear assembly (EP drive) service check” on page 2-30
Go to
drive) service check” on page 2-30
Go to
drive) service check” on page 2-30
Go to
drive) service check” on page 2-30
“Main drive gear assembly (EP drive) service check” on page 2-30
“Main drive gear assembly (EP drive) service check” on page 2-30
2-16
Service Manual
5025-2xx, 4xx
Service error messages (1xx, 9xx) (continued)
Error code
150.07 Service
Black/ITU cartridge
Motor
152.
xx
Service
CMY Cartridge Motor
152.01 Service
CMY Cartridge Motor
152.02 Service
CMY Cartridge Motor
152.03 Service
CMY Cartridge Motor
152.04 Service
CMY Cartridge Motor
152.05 Service
CMY Cartridge Motor
152.06 Service
CMY Cartridge Motor
152.07 Service
CMY Cartridge Motor
900.
xx
Service
RIP Software
902.
xx
Service
Engine Software
903.
xx
Service
Engine Software
904.
xx
Service
Engine Software
905.
xx
Service
Engine Software
906.
xx
Service
Engine Software
907.
xx
Service
Engine Software
908.01 Service
Engine Software
908.02 Service
Engine Software
908.03 Service
Engine Software
908.04 Service
Engine Software
925.01 Service
Fan Stalled
Description
Motor stalled in time-based commutation.
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.
Motor stalled in time-based commutation.
Unrecoverable RIP software error/ illegal trap.
A general engine software error.
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
Go to
“Main drive gear assembly (EP drive) service check” on page 2-30
Go to
Go to
A general engine software error.
A general engine software error.
A general engine software error.
A general engine software error.
A general engine software error.
Board level was not obtained.
Timeout waiting for bullet serial data to be updated.
Go to
Go to
NVM_OK was not received from NV2 server for successfully submitted request.
Over temperature condition detected.
Go to
The printer fan has stalled.
Action
Go to
“Main drive gear assembly (EP drive) service check” on page 2-30
Go to
Go to
Go to
Go to
Go to
Go to
“925.01—Fan error service check” on page 2-22
.
Diagnostic information
2-17
5025-2xx, 4xx
Service error messages (1xx, 9xx) (continued)
Error code
930.xx Service
LVPS
930.09 Service
LVPS
940.0
Cyan TMC Sensor
941.0
Magenta TMC
Sensor
942.0
x x x
Service
Service
Service
Yellow TMC Sensor
943.0
Black TMC Sensor
950.
NVRAM Failure
951.
NVRAM Failure
952.
x xx xx xx
Service
Service
Service
Service
NVRAM Failure:
953.
xx
Service
NVRAM Failure
954.
xx
Service
NVRAM Failure
n
Description
The NVRAM chip failure with controller part.
Action
Low voltage power supply did not detect zero crossing.
Fuser zero crossings out of range.
Zero crossing detected.
The cyan cartridge toner meter cycle
(TMC) switch error.
.01—Recoverable
.02—Nonrecoverable
“Low-voltage power supply (LVPS) assembly removal” on page 4-47
Go to
Go to
“Fuser service check” on page 2-28
.
“Toner meter sensors (Y, C, M, K) on TMC card” on page 2-50
The magenta cartridge toner meter cycle (TMC) switch error.
.01—Recoverable
.02—Nonrecoverable
The yellow cartridge toner meter cycle
(TMC) switch error.
.01—Recoverable
.02—Nonrecoverable
The black cartridge toner meter cycle
(TMC) switch error.
.01—Recoverable
.02—Nonrecoverable
Go to
“Toner meter sensors (Y, C, M, K) on TMC card” on page 2-50
Go to
“Toner meter sensors (Y, C, M, K) on TMC card” on page 2-50
“Toner meter sensors (Y, C, M, K) on
.
There is a mismatch between controller
EEPROM and mirror.
• 950.00 through 950.29 codes: mismatch between controller and mirror
• 950.30 through 950.60 codes: mismatch between secure and controller
Go to
“950.xx NVRAM Failure service check” on page 2-23
.
Mismatch between controller EEPROM and mirror.
• 951.00 through 951.29 codes: mismatch between controller and mirror
• 951.30 through 951.60: mismatch between secure and controller
A recoverable MVRAM Cyclic
Redundancy Check (CRC) error occurred.
n
is the offset at which the error occurred.
NVRAM chip failure with mirror.
Performing a POR will clear this error.
2-18
Service Manual
5025-2xx, 4xx
Service error messages (1xx, 9xx) (continued)
Error code
955.
xx
Service
Code CRC <
loc
>
956.00 Service
System Board
Description Action
The Code ROM or NAND flash failed the Cyclic Redundancy Check (CRC) check or the NAND experienced an uncorrectable multi-bit failure. <
loc
> indicates the source of the failure and has one of the following values:
•
CRC Failure
: The source is a failing package indicated by P
n
where
n
is the package number.
This error could occur on a controller with ROM or NAND flash and could occur as a result of the
CRC check done when the machine is powered on. The range of package numbers is from 0 to
15.
•
Error Correction Code (ECC)
Failure
: The source is a failing page indicated by B
n
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.
Controller board failure. Processor failure.
Replace the controller board. See
“Controller board removal” on page 4-20
.
Processor over temperature.
956.01 Service
System Board
957.
xx
Service
System Board
958.
xx
Service
NAND Failure
Controller board failure. ASIC failure.
959.01 Service
Invalid Firmware
959.02 Service
Invalid Firmware
959.03 Service
Invalid Firmware
959.04 Service
Invalid Firmware
959.05 Service
Invalid Firmware
959.20 Service
System Board
Printer has performed more than 100
“shift and reflash” operations as a result of ECC bit corrections.
Controller verification failure of system boot code
Failure to authenticate Signature
Verification Code.
Update firmware or replace the controller board. See
“Controller board removal” on page 4-20
.
Update firmware or replace the controller board. See
“Controller board removal” on page 4-20
.
Signature verification Code failure to authenticate a code partition.
Jump to unverified address.
Update firmware or replace the controller board. See
“Controller board removal” on page 4-20
.
Update firmware or replace the controller board. See
“Controller board removal” on page 4-20
.
Unknown Boot Failure.
System hardware failure.
Update firmware or replace the controller board. See
“Controller board removal” on page 4-20
.
Replace the controller board. See
“Controller board removal” on page 4-20
.
Diagnostic information
2-19
5025-2xx, 4xx
Service error messages (1xx, 9xx) (continued)
Error code
959.21 Service
System Board
Description
System did not respond to command request.
Challenge Secret Failure.
Action
Replace the controller board. See
“Controller board removal” on page 4-20
.
ASIC/SP mismatch. 959.22 Service
System Board
959.23 Service
System Board
959.24 Service
System Board
959.25 Service
System Board
959.26 Service
System Board
959.27 Service
System Board
959.28 Service
System Board
960.
962.
964.
xx xx xx
Service
Memory Error
961.
Memory Failure
Service
Memory Failure
Emulation Error
975.
xx xx
Service
Service
Service
Standard Network or
975.
xx
Service
Network Card
x
System self test failure during initialization.
EEPROM Retention Error (write failure)
Insufficient device space during hardware programming.
Incremental counter reset exceeds maximum value.
Increment count failed due to maximum value limit.
Invalid SP memory configuration.
Replace the controller board. See
“Controller board removal” on page 4-20
.
Replace the controller board. See
“Controller board removal” on page 4-20
.
Replace the controller board. See
“Controller board removal” on page 4-20
.
Replace the controller board. See
“Controller board removal” on page 4-20
.
Replace the controller board. See
“Controller board removal” on page 4-20
.
Replace the controller board. See
“Controller board removal” on page 4-20
.
RAM memory error: RAM soldered on the board is bad.
Replace the controller board. See
“Controller board removal” on page 4-20
.
RAM memory error: slot 1 RAM is bad.
Check RAM. If RAM is OK, replace the controller board. See
“Controller board removal” on page 4-20
RAM memory error: slot 2 RAM is bad.
Check RAM. If RAM is OK, replace the controller board. See
“Controller board removal” on page 4-20
Download emulation cyclic redundancy check (CRC) failure has occurred. A checksum failure detected in the emulation header or emulation file.
The following actions may be taken:
1. Disable the Download Emulation.
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.
Network error: unrecognizable network port.
Replace the standard network card or the card in the specified slot.
2-20
Service Manual
5025-2xx, 4xx
Service error messages (1xx, 9xx) (continued)
Error code
976.
xx
Service
Standard Network
or
976.
xx
Service
Network Card
x
978.
Standard Network
978.
979.
xx xx xx
Service
or
Service
Network Card
Service
x
Standard Network
or
979.xx Service
Network Card
x
982.
<
990.
<
xx xx
Service
device
> Comm.
Service
device
>
Description Action
Unrecoverable software or error in network or network card
x.
This error message indicates that an equipment check condition has occurred in the specified device.
Note
: <
device
> can be one of the following:
• Tray 2
• Tray 3.
If unable to clear the error message, check the following:
• If installed, check network card for correct installation.
• If correctly installed, replace the network card.
• If a network card is not installed, replace the controller board. See
“Controller board removal” on page 4-20
Bad checksum while programming
Standard Network or Network Card port.
x
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
“Controller board removal” on page 4-20
Flash parts failed while programming the Standard Network or Network Card
x
port.
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
Communications error detected by the specified device.
Note
: <
device
> can be one of the following:
• Tray 2
• Tray 3.
Go to the service check for the device indicated.
Diagnostic information
2-21
5025-2xx, 4xx
Service checks
90x.xx error
Step Questions / actions
1
Turn the printer off, and remove the rear
“Top cover assembly removal” on page 4-13
. Check the cable connections.
Are all the cable connections secure?
Yes
Replace the controller board. See
“Controller board removal” on page 4-20
.
925.01—Fan error service check
No
Securely make all the connections. POR the printer.
Step Questions / actions
1
Turn the printer off, and remove the rear
“Top cover assembly removal” on page 4-13
. Check the fan cable at JFAN1 for the following values:
JFAN1
Pin Value
1
+3.3 V dc
2
Ground
3
0 (fan off)
Are the measured values correct?
Yes
Replace the top cover
(which includes the fan).
See
“Top cover assembly removal” on page 4-13
No
Replace the controller board. See
“Controller board removal” on page 4-20
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 printer will be rendered inoperable:
•
Operator panel assembly
•
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.
Step Questions / actions Yes No
1
Have any updates been made to the firmware?
Reload the firmware and try again.
Go to step 2.
2
Did reloading the firmware correct the problem?
Problem resolved.
Replace the controller board with a new, and not previously installed controller board. See
“Controller board removal” on page 4-20
.
Replace the controller board with a new, and not previously installed controller board. See
“Controller board removal” on page 4-20
.
Bin-full/narrow media sensor service check
Step Questions / actions
1
Inspect the bin-full/narrow media sensor located towards the front of the top cover assembly.
Is the bin-full/ narrowmedia narrow media sensor dislodged or damaged?
2
Does the flag rotate freely and interrupt the sensor beam when in normal position?
3
Turn the printer off, and remove the rear
“Top cover assembly removal” on page 4-13
. Turn the printer on, and then check the values below at JBIN1:
JBIN1
Pin Value
1
0 V dc (+5 V dc during cycle)
2
+3.3 V dc beam blocked
0 V dc unblocked
3
Ground
Are the values correct?
Yes
Repair or replace the binfull/ narrowmedia narrow media sensor. See
“Binfull/narrow media sensor removal” on page 4-18
Go to step 3.
Go to step 2.
No
Problem resolved.
Reposition or replace the
“Bin-full/narrow media sensor flag and exit deflector removal” on page 4-19
Replace the controller board. See
“Controller board removal” on page 4-20
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
.
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.
No
Inform the customer.
Step Questions / actions
1
Check the AC powervoltage power voltage .
Is the line voltage correct?
2
Is the AC power cord damaged?
3
Is the LVPS cable correctly connected at
JLVPS1 on the controller board?
Go to step 2.
Yes
Replace the line cord.
Go to step 5.
4
Turn the printer off, and then on.
Does the problem persist?
5 Warning:
Damage to the printer is possible.
Be careful to touch only one conductor at a time. Rest the probe against the connector to steady it.
With the printer on, verify the following values at JLVPS1:
JLVPS1 (exposed conductors)
Pin Value
1
+5 V dc
3
+5 V dc
5
+5 V dc
7
+24 V dc
9
+24 V dc
11
+24 V dc
Pin
2
4
6
8
10
12
Value
Ground
Ground
Ground
Ground
Ground
Ground
16
Ground
Are the values approximately correct?
Go to step 5.
Replace the controller board. See
“Controller board removal” on page 4-20
.
Go to step 3.
Reconnect the cable at
JLVPS1, and then go to step 4.
Problem resolved.
Replace the LVPS. See
“Low-voltage power supply (LVPS) assembly removal” on page 4-47
.
2-24
Service Manual
5025-2xx, 4xx
Duplex/manual feed sensor (S1) service check
Step Questions / actions
1
Is the printer setting on a hard, flat surface?
Go to step 2.
Yes No
Make sure the printer is setting on a level, flat surface.
Go to step 5.
2
Enter Diagnostics Menu (turn the printer off, press and hold and , turn the printer on, and then release the buttons when the installed memory and processor speed displays).
Perform the Base Sensor Test. See
.
1. Select
Base Sensor Test
, and press
Select
( ).
2. Select
S1
, and press
Select
( ).
3. Install tray 1.
Does the display indicate
InputS1
—
Media
Clear…
?
3
Pull tray 1 out.
Does the display indicate
InputS1
—
Media
Present…
?
4
Remove the tray, and inspect the sensor.
Is there something obstructing the sensor?
5
Inspect the spring-loaded shaft/flag in the tray.
The flag portion of the shaft intercepts the sensor, except when a sheet is being staged for duplexing.
Does the shaft rotate freely and return to home position (flag at top of rotation)?
6
Is the flag on the shaft broken?
7
Verify the cable is correctly connected to
JFUSES1 on the controller board and to the sensor.
Is the sensor cable properly connected?
8
Turn the printer off, and remove the rear
“Top cover assembly removal” on page 4-13
. Turn the printer on, and check the values at JFUSES1:
JFUSES1
Pin Value
8
Ground
9
+3.3 V dc
Are the values approximately correct?
Go to step 3.
The sensor is functioning correctly.
Remove the obstruction, and restart the test.
Go to step 6.
Replace the tray.
Go to step 8.
Replace the duplex sensor.
See
“Duplex sensor removal” on page 4-25
Go to step 4.
Go to step 5.
Replace the tray with a new one.
Go to step 7.
Reconnect the cable.
If the problem persists, go to step 8.
Replace the controller board. See
“Controller board removal” on page 4-20
Diagnostic information
2-25
5025-2xx, 4xx
Front door sensor or switches service check
Step Questions / actions Yes
1
Enter Diagnostics Menu (turn the printer off, press and hold and , turn the printer on, and then release the buttons when the installed memory and processor speed displays).
Perform the Base Sensor Test. See
.
1. Select
Base Sensor Test
, and press
Select
( ).
2. Select
Front Door
, and press
Select
( ).
3. Open and close the front door, and observe the display.
Does the display indicate
Value Closed
with the door closed and
Value Opened
with the door opened?
2
Open the front door, and check the thin, tall, plastic web (pivot plate) at the top right of the printer. With the other covers in place and closed, this web interacts with switches in the door.
Open the toner cover, and check the motion of the web. Is the web loose, damaged, or missing?
3
Open the toner door, and inspect the vertical web that pushes and rotates the pivot plate.
Is it damaged?
Sensor, toner door, and right doors are OK.
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
.
4
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?
5
Turn the printer off, and remove the rear
“Top cover assembly removal” on page 4-13
. Turn the printer on, and verify the following values at JINT1 and JCVR1:
JINT1
Pin Value
1
+5 V dc
2
Ground
JCVR1
Pin Value
1
+24 V dc
Are the values approximately correct?
Go to step 6.
Go to step 2.
No
Go to step 3.
Go to step 4.
Go to step 5.
Replace the controller board. See
“Controller board removal” on page 4-20
2-26
Service Manual
5025-2xx, 4xx
Step Questions / actions Yes
6
Close the front cover and the toner door. Be sure the right cover is in place. Turn the printer off, and then disconnect the cables at JINT1 and JCVR1. Test continuity at the connector under the following conditions:
•
With front cover and toner door closed
:
Test pin 1 and pin 3 at JINT1 cable end and pin 1 and pin 2 at JCVR1 cable end.
•
With one or both doors open
:
Pin 2 and 3 at JINT1 cable end should indicate continuity, but pins 1 and 2 at
JCVR1 should have no continuity.
Are the tests verified?
Contact your next level of support.
Fuser exit sensor service check
No
Replace the front cover assembly. See
“Front cover assembly removal” on page 4-2
.
Step Questions / actions
1
Enter Diagnostics Menu (turn the printer off, press and hold and , turn the printer on, and then release the buttons when the installed memory and processor speed displays).
Perform the Base Sensor Test. See
.
1. Select
Base Sensor Test
, and press
Select
( ).
2. Select
Fuser Exit Sensor
, and press
Select
( ).
3. Open and close the front door, and inspect the fuser exit sensor located on the LVPS shield.
Is the sensor dislodged or damaged?
2
Rotate the flag (paper diverter) in and out of the sensor.
Does the display indicate
Media Clear
and
Media Present
with the cycle?
3
Does the flag rotate freely, but return to block the sensor?
Yes
Correct the sensor, or replace it. See
“Fuser exit sensor removal” on page 4-33
.
Sensor is good.
Go to step 4.
Go to step 5.
Go to step 2.
No
Go to step 3.
Replace the fuser. See
“Fuser assembly removal” on page 4-29
.
Reconnect the cable.
4
Turn the printer off, and then remove the rear
“Top cover assembly removal” on page 4-13
.
Is the cable correctly connected to JBIN1 on the controller board and to the sensor?
Diagnostic information
2-27
5025-2xx, 4xx
Step Questions / actions
5
Turn the printer on, and check the values at
JBIN1:
JBIN1
Pin Value
4
0 V dc (+5 V dc during cycle)
5
+0 V dc (unblocked), +3.3 V dc
(blocked)
6
Ground
Are the values correct?
Fuser service check
Yes
Replace the fuser exit
“Fuser exit sensor removal” on page 4-33
.
Step Questions / actions
1
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.
Yes
Check the switch on the side of the LVPS to verify the correct voltage is set.
No
Replace the controller board. See
“Controller board removal” on page 4-20
Go to step 2.
No
Has the LVPS been changed?
2
Turn the printer off, and remove the rear
“Top cover assembly removal” on page 4-13
. Check the cable at JFUSES1 for proper connection to the controller board, the cable for pinch points, and the cable or connector for any other damage.
Is the cable damaged?
3
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?
4
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?
Replace the fuser cable.
Repair the cables. If the cables cannot be repaired, replaced the fuser. See
“Fuser assembly removal” on page 4-29
Go to step 3.
Repair or replace the LVPS cable.
Go to step 4.
Go to step 5.
2-28
Service Manual
5025-2xx, 4xx
Step Questions / actions
5
Check the following values at JFUSES1:
JFUSES1
Pin Value
1
+24 V dc (doors closed)
2
+24 V dc (doors closed)
3
+24 V dc (doors closed)
4
+24 V dc (doors closed)
5
Between 0.6 and 3.28 V dc
6
Ground
8
Ground
10
Between -3 and +3.3 V dc
11
Ground (no wire )
Are the values approximately correct?
6
Replace the fuser. See
“Fuser assembly removal” on page 4-29
Does the error clear?
Go to step 6.
Yes
Problem resolved.
No
Replace the controller board. See
“Controller board removal” on page 4-20
Replace the controller board. See
“Controller board removal” on 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.
Step Questions / actions
1
Enter Diagnostics Menu (turn the printer off, press and hold and , turn the printer on, and then release the buttons when the installed memory and processor speed displays).
Perform the Base Sensor Test. See
.
1. Select
Base Sensor Test
, and press
Select
( ).
2. Select
S2
, and press
Select
( ).
3. Pull tray 1 out, and rotate the S2 sensor flag (S2 is located in front of the center paper pick motor drive assembly housing.)
It should rotate freely and return to its original position.
Is the input (S2) sensor flag damaged?
2
Watch the display while rotating the flag.
Does the display indicate
Media Clear
and
Media Present
?
3
Turn the printer off, and remove the rear
“Top cover assembly removal” on page 4-13
.
Is the JSP1 cable connector properly connected to the controller board?
Yes
Replace the paper pick motor drive assembly. See
“Paper pick motor drive assembly removal— standard tray” on page 4-61
.
Problem resolved.
Go to step 4.
Go to step 2.
No
Go to step 3.
Reseat the connector.
Diagnostic information
2-29
5025-2xx, 4xx
Step Questions / actions
4
Turn the printer on, and check the voltage at
JSP1 pin 15.
Is the voltage approximately +5 V dc?
Yes
Replace the paper pick motor drive assembly. See
“Paper pick motor drive assembly removal— standard tray” on page 4-61
.
No
Replace the controller board. See
“Controller board removal” on page 4-20
Main drive gear assembly (EP drive) service check
Step Questions / actions Yes
1
Turn the printer off, and remove the rear
“Top cover assembly removal” 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?
2
Verify the following values at JCARTB1 on the controller board.
JCARTB1
Pin Value
4
+24 V dc
6
+24 V dc
8
+24 V dc
9
Ground
12
Ground
13
+24 V dc
15
+24 V dc
17
+24 V dc
Are the values approximately correct?
3
Replace the main drive assembly. See
“Main drive gear assembly removal” on page 4-59
.
Does the error clear?
Replace the JCARTB1 cable.
Go to step 3.
Problem resolved.
Go to step 2.
No
Replace the controller board. See
“Controller board removal” on page 4-20
Replace the controller board. See
“Controller board removal” on page 4-20
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 configured. If a wireless network is used, verify that the printer is in range of the host computer or wireless access point, and there is no electronic interference. Have the network 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.
Step Questions / actions Yes No
1
If the device is physically connected to the network, verify that the ethernet cable is properly connected on both ends.
Is the cable properly connected?
2
Connect the ethernet cable.
Did this fix the problem?
3
Check the printer’s online status under Printers and Faxes on the host computer. Delete all print jobs in the print queue.
Is the printer online and in a
Ready
state.
4
Change the printer status to online.
Did this fix the issue?
5
Does the IP address displayed on the network settings page match the IP address in the port of the drivers using the printer?
6
Does the LAN use DHCP?
Note:
A printer should use a static IP address on a network.
7
Are the first two segments if the IP address
169.254?
8
POR the printer.
Is the problem resolved
9
Reset the address on the printer to match the
IP address on the driver.
Did this resolve the issue?
10
Have the network admin verify that the printer and PC’s IP address have identical subnet addresses.
Are the subnet addresses the same?
11
Using the subnet address supplied by the 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?
12
Is the device physically connected (ethernet cable) to the network?
Go to step 3.
If the network is wireless, go to step 3.
Go to step 2.
Problem resolved
Go to step 5.
Problem resolved.
Go to step 10.
Go to step 7.
Go to step 8.
Problem resolved
Problem fixed.
Go to step 12.
Problem resolved.
Go to step 13.
Go to step 3.
Go to step 4.
Go to step 5.
Go to step 6.
Go to step 9.
Go to step 9
Go to step 10.
Go to step 10.
Go to step 11.
Go to step 12.
Go to step15.
Diagnostic information
2-31
5025-2xx, 4xx
Step Questions / actions Yes
13
Try using a different ethernet cable.
Did this remedy the situation?
14
Have the network administrator check the network drop for activity.
Is the drop functioning properly?
15
Is the printer on the same wireless network as the other devices?
16
Assign the correct wireless network to the printer.
Did this fix the problem?
17
Are the other devices on the wireless network communicating properly?
18
Verify that the wireless card is properly seated on the controller board.
Is the wireless card seated correctly?
19
Properly reseat the wireless card.
Did this fix the problem?
20
Is the antenna damaged?
21
Replace the antenna.
Did this fix the problem?
22
Verify that the antenna is properly connected to the wireless card.
Is it connected correctly?
23
Properly connect the antenna.
Did this fix the problem?
24
Check pin 6 for +3.3V, and Pin 5 for +5V. on connector JUSBW1 of the controller board. Pin
1 and 4 are GND.
Are the voltages and grounds correct?
Problem resolved
Replace the controller board. See
“Controller board removal” on page 4-20
.
Go to step 17.
Problem resolved
Go to step 18.
Go to step 20.
Problem resolved.
Go to step 22.
Problem resolved
Go to step 24.
Problem resolved
Replace the wireless card.
See
“Wireless network card” on page 4-81
.
No
Go to step 14.
Contact the network administrator.
Go to step 16.
Go to step 17.
Contact the network administrator.
Go to step 19.
Go to step 20.
Go to step 21.
Go to step 22.
Go to step 23.
Go to step 24.
Replace the controller board. See
“Controller board removal” on page 4-20
2-32
Service Manual
5025-2xx, 4xx
Operator panel service check
Warning:
Replace one of the following components, and perform a POR before replacing a second component. Never replace both of the components without performing a POR after installing each one, or the printer will be rendered inoperable:
•
Operator panel assembly
•
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.
One or more operator panel buttons fail
Step Questions / actions Yes No
1
Enter Diagnostics Menu (turn the printer off, press and hold and , turn the printer on, and then release the buttons when the installed memory and processor speed displays).
Perform the Panel Test. See
. 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?
2
in Diagnostics Menu.
Did any of the buttons fail the test?
Replace the operator panel assembly. See
“Operator panel logo plate” on page 4-9
3
Remove the rear shield.
“Top cover assembly removal” on page 4-13
Turn the printer on, and verify the following values at JOPP1:
JOPP1
Pin Value
2
+5 V dc
4
Ground
5
+5 V dc
6
+3.3 V dc
7
Ground
Are the values approximately correct?
Go to step 2.
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
“Front cover assembly removal” on page 4-2
Go to step 3.
Replace the controller board. See
“Controller board removal” on page 4-20
Diagnostic information
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5025-2xx, 4xx
Operator panel display blank, five beeps
Service tip: The printer has detected a problem with the 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.
Step Questions / actions
1
Is the operator panel assembly cable properly installed at controller board JOPP1 and at the operator panel assembly?
2
Turn the printer off, and remove the rear
“Top cover assembly removal” on page 4-13
.
Turn the printer on, and verify the following values at JOPP1:
JOPP1
Pin Value
2
+5 V dc
4
Ground
5
+5 V dc
6
+3.3 V dc
7
Ground
Are the values approximately correct?
3
Check continuity of the operator panel assembly cable.
Is there continuity?
Go to step 2.
Yes
Go to step 3.
No
Reinstall the cable.
Replace the controller board. See
“Controller board removal” on page 4-20
Replace the operator panel assembly. See
“Operator panel logo plate” on page 4-9
Replace the front cover assembly. See
“Front cover assembly removal” on page 4-2
.
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Operator panel display blank, printer beeps five times and pauses
Step Questions / actions Yes No
1
Turn the printer off, and remove the rear
“Top cover assembly removal” on page 4-13
.
Turn the printer on, and verify the following values at JOPP1 on the controller board:
JOPP1
Pin Value
1
0 V dc
2
+5 V dc
3
0 V dc
4
Ground
5
+5 V dc
6
+3.3 V dc
7
Ground
Are all these values approximately correct?
2
Turn the printer off, and check for continuity in the operator panel cable.
Note:
Remove the three screws holding the operator panel, and place it facedown on top of the printer. The cable connector pins will be exposed and easier to contact.
Do all the conductors indicate continuity?
Go to step 2.
Replace the controller board. See
“Controller board removal” on page 4-20
Replace the operator panel.
See
“Operator panel logo plate” on page 4-9
Replace the front cover assembly. See
“Front cover assembly removal” on page 4-2
.
Diagnostic information
2-35
5025-2xx, 4xx
Operator panel displays all diamonds, no beeps
Step Questions / actions Yes No
1
Turn the printer off, and remove the rear
“Top cover assembly removal” on page 4-13
.
Disconnect the cable at JOPP1 on the controller board. Verify the following values:
JOPP1
Pin Value
1
0 V dc
2
+5 V dc
3
0 V dc
4
Ground
5
+5 V dc
6
+3.3 V dc
7
Ground
Are all these values approximately correct?
2
Check for continuity in the operator panel cable connector.
Note:
Remove the three screws holding the operator panel, and place it facedown on top of the printer. The cable connector pins will be exposed and easier to contact.
Do all the conductors indicate continuity?
Go to step 2.
Replace the controller board. See
“Controller board removal” on page 4-20
Replace the operator panel.
See
“Operator panel logo plate” on page 4-9
Replace the front cover assembly. See
“Front cover assembly removal” on page 4-2
.
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Operator panel displays all diamonds, five beeps
Step Questions / actions Yes No
1
Turn the printer off, and remove the rear
“Top cover assembly removal” on page 4-13
.
Turn the printer on, and verify the following values at JOPP1:
JOPP1
Pin Value
1
0 V dc
2
+5 V dc
3
0 V dc
4
Ground
5
+5 V dc
6
+3.3 V dc
7
Ground
Are all these values approximately correct?
2
Check for continuity in the operator panel cable connector.
Note:
Remove the three screws holding the operator panel, and place it facedown on top of the printer. The cable connector pins will be exposed and easier to contact.
Do all the conductors indicate continuity?
Go to step 2.
Replace the controller board. See
“Controller board removal” on page 4-20
Replace the operator panel.
See
“Operator panel logo plate” on page 4-9
Replace the front cover assembly. See
“Front cover assembly removal” on page 4-2
.
Diagnostic information
2-37
5025-2xx, 4xx
Operator panel display is dim and unchanging
Step Questions / actions Yes No
1
Turn the printer off, and remove the rear
“Top cover assembly removal” on page 4-13
.
Turn the printer on, and verify the following values at JOPP1 on the controller board:
JOPP1
Pin Value
1
0 V dc
2
+5 V dc
3
0 V dc
4
Ground
5
+5 V dc
6
+3.3 V dc
7
Ground
Are all these values approximately correct?
2
Check for continuity in the operator panel cable connector.
Note:
Remove the three screws holding the operator panel, and place it facedown on top of the printer. The cable connector pins will be exposed and easier to contact.
Do all the conductors indicate continuity?
Go to step 2.
Replace the controller board. See
“Controller board removal” on page 4-20
Replace the operator panel.
See
“Operator panel logo plate” on page 4-9
Replace the front cover assembly. See
“Front cover assembly removal” on page 4-2
.
Operator panel USB cable service check
Step
1
Questions / actions
Check the operator panel USB cable for continuity.
Is there continuity?
Yes
Replace the controller board. See
“Controller board removal” on page 4-20
No
Replace the USB port
“USB port connector removal” on page 4-76
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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.
Step Questions / actions Yes
1
Turn the printer off, and then remove the rear
“Top cover assembly removal” on page 4-13
. Check the cable at JSP1 on the
controller board for proper connection.
Is the cable properly connected?
2
Did the printer function correctly after reconnecting the cables?
3
Turn the printer on, and then verify the following approximate values at JSP1:
JSP1
Pin Value
2
+24 V dc
4
+24 V dc
5
+5V (when paper is picked)
7
Ground
8
Ground
10
+5 V dc
12
_5 V dc (when paper is picked)
15
+5 V dc
16
Ground
Are the values approximately correct?
Go to step 3.
Problem resolved.
Replace the paper pick motor drive assembly. See
“Paper pick motor drive assembly removal— standard tray” on page 4-61
.
No
Properly connect the cables, and POR the printer.
Go to step 2.
Go to step 3.
Replace the controller board. See
“Controller board removal” on page 4-20
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
( ).
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
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5025-2xx, 4xx
–
RGB Brightness, RGB Contrast, RGB Saturation: Set to 0.
–
Color Balance: Select Reset Defaults to zero out all colors.
–
Check the paper type, texture, and weight settings against what is loaded in the printer.
Once the printer has been restored to its default levels, do the following:
1.
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
( ) and
Select
( ), turn the printer on, and release when the installed memory and processor speed displays).
b.
Select
PRINT TESTS
, and press
Select
( ).
c.
Select
Print Quality Pgs
, and press
Select
( ).
The message
Printing Quality Test Pages
is displayed.
An incorrect printer 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.
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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 papers may also cause background problems. Some problems occur by running a large amount of graphics in a humid environment.
Step Questions / actions Yes No
1
Read the current status of the imaging unit from the customer menus.
To view the status of the photoconductor units:
1. In Ready mode, press
Menus
( ).
2. Select
Reports
, and press
Select
( ).
3. Select
Device Statistics
, and press
Select
( ).
It is possible a new imaging unit was installed, but the counter was not reset.
Has the imaging unit been recently replaced?
2
Is the background only one of the primary colors; yellow, cyan, magenta, or black?
Reset the value. To reset this value:
1. In Ready mode, press
Menus
( ).
2. Select
Supplies Menu
, and press
Select
( ).
3. Select
Replace Supply
, and press
Select
( ).
4. Select the imaging unit, and press
Select
( ).
5. Select
Yes
, and press
Select
( ).
If this does not fix the problem, go to step 2.
Replace the developer unit for the background color
“Developer unit removal” on page 4-21
.
Go to step 3.
Problem resolved.
Go to step 2.
Go to step 4.
Go to step 4.
3
Did replacing the developer unit correct the problem?
4
Replace the photoconductor unit.
Does this fix the problem?
5
Check the high-voltage contact from the HVPS to the image transfer unit (ITU).
Is a problem found?
Problem resolved.
Go to step 5.
Replace the failing FRU:
• Image transfer unit
“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
Problem resolved.
Go to step 6.
Go to step 7.
6
Reseat the cable in the JHVPS1 connector.
Does this fix the problem?
7
Replace the HVPS. See
“High-voltage power supply (HVPS) assembly removal” on page 4-35
.
Does this fix the problem?
8
Clean the printhead.
Does this fix the problem?
Problem resolved.
Problem resolved.
Go to step 8.
Replace the printhead. See
“Printhead removal” on page 4-65
Diagnostic information
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Print quality—blank page
Step Questions / actions Yes
1
Is all the packing material for the imaging unit in question removed?
2
Print a document that requires all four colors with just a few characters to verify if one specific color is a problem. For example, print the Print Quality Test Pages:
1. Enter Diagnostic mode. (Turn the printer off, press and hold
Left
( ) and
Select
( ), turn the printer on, and then release the buttons when the installed memory and processor speed displays.)
2. Select
PRINT TESTS
, and press
Select
( ).
3. Select
Prt Qual Pgs
, and press
Select
( ).
Is only one color missing?
3
Does this fix the problem?
4
Run the Motor Detect Test:
1. Remove the imaging unit and the waste
“Imaging unit (IU) removal” on page 4-45
.
2. Reinstall the right cover assembly.
3. Close the front cover.
4. Enter Diagnostics menu (Turn the printer off, press and hold
Left
( ) and
Select
( ), turn the printer on, and release the buttons when the installed memory and processor speed displays.
5. Select
MISC TESTS
in the Diag Menu, and press
Select
( ).
6. Select
Motor Detect
, and 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).
Did the motor run?
Go to step 2.
Replace the developer unit for the missing color.
Problem resolved.
Go to step 5.
No
Remove the packing material.
Go to step 3.
Go to step 4.
Replace the Main drive gear assembly. See
“Main drive gear assembly removal” on page 4-59
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Step Questions / actions
5
Remove the developer unit. See
“Developer unit removal” on page 4-21
. Check the developer cartridge contacts from the HVPS to the IU.
Are all the toner cartridge contacts clean on both the pins and IU?
6
Are all the spring-loaded pins in the HVPS free to move in and out with an equal amount of spring force?
Go to step 6.
Go to step 7.
Yes No
Clean the developer cartridge contacts. See
“Developer unit removal” on page 4-21
Replace the HVPS. See
“High-voltage power supply (HVPS) assembly removal” on page 4-35
.
Replace the cable.
7
Turn the printer off, and remove the rear
“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?
8
Replace the printhead. See
“Printhead removal” on page 4-65
Did this fix the problem?
Go to step 8.
Problem resolved.
Replace the controller board. See
“Controller board removal” on page 4-20
Print quality—blurred or fuzzy print
Run the automatic alignment. The TPS sensor may be damaged. To run Reset Color
Cal:
1.
Enter the Diagnostics Menu. (Turn the printer off, press and hold and , turn the printer on, and release the buttons when installed memory and processor speed displays.
2.
Select
TPS Setup
from Diag Menu, and press
Select
( ).
3.
Select
Reset Color Cal
, and press
Select
( ).
Resetting
appears. 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 not bent, corroded, or damaged. Replace the highvoltage 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
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Print quality—horizontal banding
Print the Print Defect Page:
1.
At the Ready prompt, press
Menu
( ).
2.
Select
Reports
, and press
Select
( ).
3.
Select
Print Defects,
and press
Select
( ).
Step Questions / actions Yes No
1
Measure the distance between repeating bands.
Is the distance between bands either 34.6 or
94.2 mm?
2
Does the distance measure 95 mm or
108 mm?
Replace the photoconductor unit. Remove the imaging unit and remove the original developer units, and then put them back into the new photoconductor unit, 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
3
Does the distance measure 37.7, 55, or
78.5 mm?
Replace the ITU. See
“Image transfer unit (ITU) removal” on page 4-40
4
Does the distance measure 43.9 mm or 45.5?
Replace the developers that match the missing color
(black, cyan, magenta, or yellow). See
“Developer unit removal” 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.
Print quality—horizontal line
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
.
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Print quality—insufficient fusing
5025-2xx, 4xx
Step Questions / actions
1
Is the printer setup to use the correct media?
Go to step 2.
Yes
2
Check the fuser connections on the left and right side of the printer.
Are the cables and connection correct?
3
Is the fuser properly installed?
4
Replace the fuser. See
“Fuser assembly removal” on page 4-29
Does this fix the problem?
Go to step 3.
Go to step 4.
Problem resolved.
No
Change the settings to indicate the correct media.
Properly reconnect or replace the cables.
Install the fuser properly.
Replace the LVPS. See
“Low-voltage power supply (LVPS) assembly removal” on page 4-47
.
Print quality—missing image at edge
Remove and reseat the following:
•
Toner cartridge
•
Imaging unit
•
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
ABCDE
ABCDE
ABCDE
Step Questions / actions
1
Replace the photoconductor unit. See
“Imaging unit (IU) removal” on page 4-45
.
Yes
Problem resolved.
No
Replace the developer unit.
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.
Step Questions / actions
1
Is there any loose or foreign material on the imaging unit?
2
Is there any loose or foreign material on the developer roll?
3
Is there any loose or foreign material on the transfer belt?
Yes
Inspect the imaging unit by looking at the individual developers and photo conductors. Clean or replace the faulty unit. See
“Imaging unit (IU) removal” on page 4-45
Go to step 2.
Replace the developer unit.
Go to step 3.
No
Replace the image transfer unit. See
“Image transfer unit (ITU) removal” on page 4-40
.
Contact your next level of support.
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Print quality—residual image
ABCDE
ABCDE
ABCDE
Step Questions / actions Yes No
1
Check the condition of the imaging unit using the customer menus (administrative menus):
1. At the Ready prompt, press
Menu
( ).
2. Select
Supplies Menu
, and press
Select
( ).
3. Select
Imaging Kit,
and press
Select
( ).
Does the display indicate
OK
?
2
Measure the distance from the original image to the same point on the residual image.
Is the distance 43.9 mm?
Go to step 2.
Replace the imaging unit or the photoconductor unit.
See
“Imaging unit (IU) removal” on page 4-45
.
3
Is the distance between the original image and the residual image 94.2 mm?
4
Run the Menu Setting Page twice to clear any debris.
To print a menu settings page:
1. Press
Menu
( ) on the operator panel.
2. Select
Reports
from the Admin Menu, and press
Select
( ).
3. Select
Menu Settings
, and press
Select
( ).
Is there still any toner contamination on the fuser assembly?
Replace the developer corresponding to the color of the image. See
“Developer unit removal” on page 4-21
.
Replace the imaging unit or the photoconductor unit.
See
“Imaging unit (IU) removal” on page 4-45
.
Replace the photoconductor. See
“Developer unit removal” on page 4-21
.
Replace the fuser. See
“Fuser assembly removal” on page 4-29
Contact your next level of support.
Diagnostic information
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Print quality—solid color page
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.
Step Questions / actions Yes No
1
Replace the photoconductor unit (part of the 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
Does this fix the problem?
2
A faulty printhead can cause the problem. To test the printhead for solid colors, place a narrow strip of paper over the gap between the 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?
3
Check the high-voltage contact from the HVPS to the photoconductor charge roll. Ensure the contact springs are properly mounted and that the charge roll contact spring is making good 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?
4
Turn the printer off, and check the continuity of the HVPS cable.
Is there continuity?
5
Replace the HVPS. See
“High-voltage power supply (HVPS) assembly removal” on page 4-35
.
Did this solve the problem?
Problem resolved.
Replace the printhead. See
“Printhead removal” on page 4-65
.
Replace the transfer contact assembly. See
“Toner cartridge contacts” on page 4-67
.
Go to step 4.
Go to step 5.
Problem resolved.
Go to step 2.
Go to step 3.
Replace the cable assembly.
Replace the controller board. See
“Controller board removal” on page 4-20
Print quality—vertical banding
Replace the developer unit.
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Printhead service check
This service check includes the following errors:
Error code Color
106.xx
Yellow
107.xx
108.xx
109.xx
Cyan
Magenta
Black
Step Questions / actions Yes No
1
Turn the printer off, and remove the rear
“Top cover assembly removal” on page 4-13
. Check the cable at JMIRR1 for 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?
2
Turn the printer on, and then wait until the printer posts an error. Using a voltmeter, check the following values at JMIRR1:
JMIRR1
4
5
2
3
Pin Volt.
(V dc)
1 5
3.3
5
GND
24
Are the values approximately correct?
Replace the printhead. See
“Printhead removal” on page 4-65
.
Go to step 2.
Replace the controller board
See
“Controller board removal” on page 4-20
Replace the printhead. See
“Printhead removal” on page 4-65
Diagnostic information
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Toner meter cycle (TMC) card
Step Questions / actions
1
Perform the Base Sensor Test:
1. Enter Diagnostics menu (turn the printer off, press and hold and
Select
( ), turn the printer on, and release the buttons when the installed memory and processor speed displays).
2. Select
Base Sensor Test,
and press
Select
( ).
3. Select the sensor you want to test, open the toner door, remove the corresponding toner cartridge, and press
Select
( ).
4. 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 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?
Yes No
Replace the toner cartridge.
Replace the toner meter cycle (TMC) card. See
“Toner meter cycle (TMC) card removal” on page 4-71
Toner meter sensors (Y, C, M, K) on TMC card
Step Questions / actions
1
Remove the toner cartridge, and inspect the lenses on the toner meter cycle (TMC) card.
Are the lenses blocked, damaged, or dirty?
2
Turn the printer off, and remove the rear
“Top cover assembly removal” on page 4-13
. Turn the printer on, and measure the values below at JCTM1 during
POR:
JCTM1
Pin Value
1
+5 V dc
2
+3.3 V dc
3
+3.3 V dc
4
+3.3 V dc
5
+3.3 V dc
6
Ground
Are any of the values incorrect?
Yes No
Repair or replace the TMC
“Toner meter cycle (TMC) card removal” on page 4-71
.
Replace the controller board. See
“Controller board removal” on page 4-20
.
Go to step 2.
Replace the TMC card. See
“Toner meter cycle (TMC) card removal” on page 4-71
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Transfer roll service check
Step Questions / actions
1
Remove the ITU. See
contacts between the HVPS and the ITU.
Clean the contacts and recheck.
Does the error r ecur?
2
Does the new ITU fix the problem
3
Turn the printer off, and remove the rear
“Top cover assembly removal” on page 4-13
.
Turn the printer on, and check the cable at
JHVPS1 connector on the controller board without disconnecting it.
Verify the following voltage values:
JHVPS1
Pin Voltage
7
+3.3 V dc
10
+3.3 V dc
11
+3.3 V dc
13
+24 V dc
14
Ground
16
Ground
Are the values approximately correct?
Yes
Replace the ITU. See
“Image transfer unit (ITU) removal” on page 4-40
Go to step 2.
No
Problem resolved.
Problem resolved.
Replace the HVPS. See
“High-voltage power supply (HVPS) assembly removal” on page 4-35
Go to step 3.
Replace the controller board. See
“Controller board removal” on page 4-20
Tray (x) sensor service check
Step Questions / actions
1
When the printer is in Ready state, pull the standard tray out. The display should indicate
Tray (x) Missing
. Reinsert the tray.
Does the message remain on the display?
Go to step 2.
Yes
Go to step 4.
No
Diagnostic information
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Step Questions / actions
2
Check the vertical wall at the right rear of the tray for damage.
Yes
Replace the tray.
Go to step 3.
No
3
Is the tray damaged?
Check for a dislodged tray present sensor.
Is the sensor dislodged?
4
Does the message
Tray (x) Missing
fail to appear when the tray is pulled out?
Replace the option tray present sensor.
• If the 650 sheet tray is affected replace the 650 sheet drawer assembly.
• If the 550 sheet assembly is affected, replace the entire 550 sheet drawer assembly.
Go to step 5.
Contact the next level of support.
Problem resolved.
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Step Questions / actions Yes
5
1. Turn off the printer
2. Remove the rear shield. See
“Top cover assembly removal” on page 4-13
.
3. Disconnect the cable at JTRAY1 connector 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
Pin Voltage
1
+5 V dc
2
+5 V dc
3
Ground
JOPT1 for tray 2 or 3
Pin Voltage
2
Ground
3
Ground
5
+24V
6
Ground
7
+5V
9
Ground
10
Ground
Are the voltage values approximately correct?
Problem resolved.
Trays 2 and 3 (optional) service check
Step Questions / actions Yes
1
Are two option trays being used?
2
If two option trays are being used, is the 550 sheet tray on the bottom?
3
Switch the order of the trays so the 500 sheet tray is on the bottom, and print a page from both trays.
Did the pages print from both trays?
4
Inspect the paperfeed pick tires on the tray that fails to pick.
Do they appear worn or damaged.
5
Replace the pick tires on the faulty tray, and print a page with media from the affected tray.
See
“Pick tires removal” on page 4-64
Did the page print?
6
Check the option cable connected to JOPT1 for continuity.
Is there continuity?
7
Replace the cable, and print from both option trays.
Did the pages print from both trays?
Go to step 2.
Go to step 4.
Problem resolved.
Go to step 5.
Problem resolved.
Go to step 8.
Problem resolved.
5025-2xx, 4xx
No
Replace the controller board. See
“Controller board removal” on page 4-20
Go to step 4.
Go to step 3.
No
Go to step 4.
Go to step 6.
Go to step 6.
Go to step 7.
Go to step 8.
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5025-2xx, 4xx
Step Questions / actions Yes
8
Print a menu settings page.
Note:
If two option trays are used, the 650 sheet will appear as tray 2, and the 550 sheet tray will appear as tray 3.
Are all the attached option trays listed on the first page of the menu settings pages?
9
1. Remove the 650 sheet tray from the printer
2. Attach the 550 sheet tray directly to the printer
3. Print a page from the 550 sheet tray.
Did the page print?
10
With only the 650 sheet tray attached to the printer, print a page from the 650 sheet tray.
Did the page print?
11
1. Turn off the printer.
2. Remove the rear shield.
“Top cover assembly removal” on page 4-13
.
3. Disconnect the cable at JOPT1 on the controller board.
4.
T urn the printer on.
5. Measure the voltages below:
JOPT1
Pin Voltage
2
Ground
3
Ground
5
+24V
6
Ground
7
+5V
9
Ground
10
Ground
Are the voltages correct?
Go to step 9.
Go to step 11.
Go to step 11.
Consult your next level support.
USB service check
Step
1
2
3
Questions / actions Yes
Is the USB cable properly connected to the printer and host PC?
Try a different USB cable.
Does this fix the issue?
Connect a different device to the USB cable.
Did the host PC see the device?
Go to step 2.
Issue fixed.
Replace the Controller board.See
“Controller board removal” on page 4-20
No
• If the 550 sheet option failed to appear, go to step 9.
• If the 650 sheet tray failed to appear, go to step 10.
Replace the 550 sheet tray.
Replace the 650 sheet tray.
Replace the controller board. See
“Controller board removal” on page 4-20
No
Properly connect the cable at both ends.
Go to step 3.
There is an issue with the host machine.
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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
Navigation button
Select button
Navigation button
Operator panel buttons
Button or indicator
Select
Function
Press
Select
( ) to initiate action on a menu item.
Indicator light
Stop/Cancel
Navigation buttons
Indicates the printer status:
Status Indicates
Off The power is off.
Blinking green The printer is warming up, processing data, or printing a job.
Solid green The printer is on, but idle.
Blinking red Operator intervention is needed.
Stops all printer activity.
A list of options is offered once
Stopped
appears on the display.
Press or 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.
Back
Menu Opens the menu index.
USB Direct interface
Note:
The USB connector is available on some models.
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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. 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
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 Border
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
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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.
2. Press and hold
Left
( ) and
Select
( ).
The Diagnostics menu group contains the settings and operations used while manufacturing and servicing the printer.
See
“Diagnostics Menu (Diag Menu)” on page 3-2
3. Turn the printer on.
4. Release the buttons when the installed memory and processor speed displays.
Configuration Menu 1. Turn the printer off.
2. Press and hold
Select
( ) and
Right
( ).
The Configuration menu group contains a set of menus, settings, and operations which are infrequently required by a user. Generally, the options made available in this menu group are used to configure a printer for operation.
See
“Configuration menu (Config Menu)” on page 3-24
3. Turn the printer on.
4. Release 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
( ) and
Right
( ).
SE Menu
Additional error message information
Invalid Engine Code
Mode
Firmware update from USB
4. Release the buttons when the menu appears.
In a browser, add
/se
to printer’s
IP address. For example, http://
158.183.3.2/se
.
While the error displays on the panel, press
Back
( ) and
Right
( ).
1. Turn the printer off.
2. Press and hold
Back
( ) and
Left
( ).
For use on machines with operator panel USB port.
Enters the SE menus online.
Access secondary debug information.
This mode is used if the machine has invalid code and needs the correct code loaded. After entering this mode, the firmware code can be updated.
See
“Updating printer firmware” on page 3-28
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 diagnostic 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
Bottom Margin
Left Margin
Right Margin
Skew
Quick Test
.
Alignment Menu (color alignment)
Cyan
.
Yellow
Magenta
Factory Scanner
Factory Manual
PRINT TESTS
Tray 1
Tray 2 (if installed)
Manual Feeder (if installed)
A summary page for all the color alignment settings: it can be used in place of alignment pages for each individual color.
“Input source tests” on page 3-10
MP Feeder (if installed)
Prt Qual Pgs
Hardware Test
Panel Test
Button Test
DRAM Test
DUPLEX TESTS
(if installed)
Quick Test
Top Margin
Left Margin
INPUT TRAY TESTS
Feed Tests
Sensor Test
.
“Quick Test (duplex)” on page 3-13
“Top Margin (duplex)” on page 3-14
.
“Left Margin (duplex)” on page 3-14
.
“Print quality test pages (Prt Qual Pgs)” on page 3-11
.
.
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Service Manual
5025-2xx, 4xx
Diagnostics Menu (continued)
Base Sensor Test
Front Door
S1
S2
Fuser exit Sensr
Standard Bin
C-TMC Sensor
M-TMC Sensor
Y-TMC Sensor
K-TMC Sensor
Input
MISC TESTS
Motor Detect
DEVICE TESTS
Flash Test (if flash memory is installed)
Printer Setup
“Base Sensor Test” on page 3-16
.
.
Defaults
Prt Color Pg Count
Prt Mono Pg Count
Perm Page Count
Serial Number
Engine Setting 1
Engine Setting 2
Engine Setting 3
.
“Engine Setting 1 through 4” on page 3-18
.
Engine Setting 4
Model Name
Reset Fuser Cnt
EP Setup
.
Config ID (Configuration ID)
“Configuration ID” on page 3-19
.
ITU Barcode
.
“Reset Fuser Cnt” on page 3-20
.
EP Defaults
Fuser Temp
DC Charge Adjust
Dev Bias Adjust
“Fuser Temperature” on page 3-20
.
“DC Charge Adjust, Dev Bias Adj, Transfer Adjust” on page 3-20
.
Transfer Adjust
TPS Setup
Right
Left
Cal Ref Adjust
Reset Color Calibration
Reports
Menu Settings Page
“Right or Left TPS” on page 3-21
“Reset Color Cal” on page 3-21
.
“Menu Settings Page” on page 3-22
Diagnostic aids
3-3
5025-2xx, 4xx
Diagnostics Menu (continued)
Event Log
Display Log
Print Log
Clear Log
Exit Diags
.
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
. 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
( ).
2.
Use or to select
Print Quick Test
, and press . See
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
( ) to enter the
Registration
.
4.
Use or to select the margin setting you need to change, and press
Select
( ).
5.
Use to decrease or to increase the offset values, and press
Select
( ) to confirm the value.
The message
Submitting changes
displays, and the original margin setting screen appears.
The print registration ranges are:
Description Value Direction of change
Top margin -50 to +50
Each increment corresponds to 8 scans at a 600 dpi scan rate (0.0133 inches or 0.339 mm)
.
The default is 0.
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
-50 to +50
Each increment corresponds to 4 pixels at 600 dpi (0.00666 in. or
0.1693 mm).
The default is 0.
-50 to +50
Each increment corresponds to an approximate shift of 4 pixels at 600 dpi.
The default is 0.
A positive change moves the image down the page and increases the top margin. A negative change moves the image up and decreases the top margin. No compression or expansion occurs.
A positive offset moves text down the page and 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.
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Service Manual
5025-2xx, 4xx
Description
Skew
Value
-100 to +100
Each increment corresponds to
1/1200 of an inch.
The default is 0.
Direction of change
A positive value causes the left end of the scan line to move down the page. A negative value causes the left end of the scan line to move up the page. The right end stays fixed. There is no 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
(
)
or
Stop
( ).
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
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.
Lexmark C544
Quick Test
Printer Information
Page Count xx
PSAC
Installed Memory
Processor Speed
Serial Number
CalStat
CalSet xx xxx MB xxxMHz xxxxxxx xxxx x.xx
x.xx
x.xx
Engine ID x.xx
xx
FSpeed
Printer Rev isi on Lev els xxx
Loader
Kernel
Base
Network
Network Drvr
Engine
Font xx.xx.xxxx-x xxx.xx.xxxx-x xx.xx.xxxx-x x.xx
xxx.xx.xxxxx-x xx.xx.xxxx-x xx.xx.xxxx-x x.xxxxx-xx.x
Margin Settings
Top Margin
Bottom Margin
Left Margin
Right Margin
Skew
Cyan Top Margin
Cyan Left Margin
Cyan Right Margin
Cyan Skew
Cyan Bow
Yellow Top Margin
Yellow Left Margin
Yellow Right Margin
Yellow Skew
= xx
= x
= x
= x
= x
= x
= x
= x
= x
= x
= x
= x
= x
= x
Yellow Bow
Magenta Top Margin
Magenta Left Margin
= x
= x
= x
Magenta Right Margin
Magent Skew magenta Bow
= x
= x
= x
Dup Top Margin = x
Paper Source
Formatted Size
= Tray 1
= xxxxxx
LexmarkC544
Quick Test
Printer Information
Page Count
PSAC
Installed Memory
Processor Speed
Serial Number
CalStat
CalSet
Engine ID
FSpeed
Pri nter Revisi on Levels xxx
Loader
Kernel
Base
Network
Network Drvr
Engine
Font xx xx xxx MB xxxMHz xxxxxxx xxxx x.xx
x.xx
xx x.xx
x.xx
xx.xx.xxxx-x xxx.xx.xxxx-x xx.xx.xxxx-x xxx.xx.xxxxx-x xx.xx.xxxx-x xx.xx.xxxx-x x.xxxxx-xx.x
x.xx
Margin Settings
Top Margin
Bottom Margin
Left Margin
Right Margin
= x
= x
= x
= x
Skew
Cyan Top Margin
Cyan Left Margin
Cyan Right Margin
Cyan Skew
= x
= x
= xx
= x
= x
Cyan Bow
Yellow Top Margin
= x
= x
Yellow Left Margin
Yellow Skew
= x
Yellow Right Margin = x
= x
= x Yellow Bow
Magenta Top Margin
Magenta Left Margin
Magent Skew magenta Bow
Dup Top Margin
= x
= x
= x
= x
= x
Paper Source
Formatted Size
= Tray 1
= xxxxxx
Straight
Quick Test
The Quick Test contains the following information:
•
Print registration settings
•
Alignment diamonds at the left, right, top, and bottom
•
Horizontal lines to check for skew
Skewed
Diagnostic aids
3-5
5025-2xx, 4xx
•
General printer information, including current page count, installed memory, serial number, and code level.
To print the Quick Test page:
Note:
Print the Quick Test Page on letter or A4 paper.
1.
Select
Registration
from Diag Menu, and press
Select
( ).
2.
Select
Quick Test Page
, and press
Select
( ).
The message
Printing… appears on the display.
Once the Quick Test Page completes printing, the Registration screen displays again.
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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
( ).
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:
Diagnostic aids
3-7
5025-2xx, 4xx
4.
Select
Top Margin
, and press
Select
( ).
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.
6.
Use or to enter the sum of the numbers, and press
Select
( ).
Submitting changes…
appears.
Print the Quick Test again to verify the observed value is the same as the 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.
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7.
Select the Skew value in the same way, enter the value, press
Select
( ), and print the Quick Test to see if the observed values and the current values are the same.
8.
On the second page of the latest Quick Test you printed, proceed to Step 2; adjust the left, right, and bow settings. Continue printing the Quick Test after each adjustment to verify your settings.
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.
Select
PRINT TESTS
from the Diag Menu, and press
Select
( ).
2.
Select the media source (
Tray 1
,
Tray 2
,
Manual Feeder
, or
Multi-Purpose Feeder
), and press
Select
( ),
3.
Select
Single
or
Continuous
, and press
Select
( ).
•
If
Single
is selected, a single page is printed.
•
If
Continuous
is selected, printing continues until
Stop
( ) 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 side of the paper, regardless of the duplex setting.
4.
Press
Back
( ) to return to PRINT TESTS.
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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.
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
( ).
The Panel Test continually executes.
Press
Stop
( ) 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
Select
( ).
2.
Select
Button Test
, and press
Select
( ).
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
( ), you end the test.
Press
Stop
( ) 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
( ).
2.
Select
DRAM Test
, and press
Select
( ).
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:###### F:#####
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.
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Duplex Tests
Quick Test (duplex)
This test prints a duplex version of the Quick Test that can be used to verify the correct placement of the top margin on the back side of a duplex page.
Note:
Before you set the duplex top margin, be sure to set the registration. See
.
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
( ).
2.
Select
Quick Test
, and press
Select
( ).
3.
Select
Single
or
Continuous
, and press
Select
( ).
•
The single Duplex Quick test prints the Quick Test on front and back.
•
The printer attempts to print the Quick Test Page from the default paper source.
•
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
( ).
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 the page. Therefore, be sure to set the top margin in REGISTRATION before setting the duplex top margin. See
.
To set the Top Margin (duplex):
1.
Select
DUPLEX TESTS
from Diag Menu, and press
Select
( ).
2.
Select
Quick Test
, and press
Select
( ).
3.
Select
Single
, and press
Select
( ).
4.
Hold the page to the light to see whether the top margin of the back aligns with the top margin of the front.
5.
Select
Top Margin
from DUPLEX TESTS.
6.
Use or to select the margin setting you need to change.
•
Each increment shifts the duplex top margin by 1/100 of an inch.
•
The Top Margin (duplex) range is -50 to +50, and the default value is 0.
•
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
( ) to save the new value.
8.
Print the Quick Test (duplex) again (steps 1–4) to verify the adjustment. Repeat if necessary.
Left Margin (duplex)
This setting shifts the image on the back of the duplex sheet to the left or right to correctly position it on the page.
Therefore, be sure to set the top margin in REGISTRATION before setting the duplex top margin. See
.
To set the Left Margin (duplex):
1.
Select
DUPLEX TESTS
from Diag Menu, and press
Select
( ).
2.
Select
Quick Test
, and press
Select
( ).
3.
Select
Single
, and press
Select
( ).
4.
Hold the page to the light to see whether the left margin of the back aligns with the left margin of the front.
5.
Select
Left Margin
from DUPLEX TESTS.
6.
Use or to select the margin setting you need to change.
•
Each increment shifts the duplex left margin by 4 pixels at 500 dpi (0.0067 inches or 0.1693 mm).
•
The Left Margin (duplex) range is -25 to +25, and the default value is 0.
•
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.
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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:
1.
Select
INPUT TRAY TESTS
from Diag Menu, and press
Select
( ).
2.
Select
Feed Tests
, and press
Select
( ).
3.
Select the tray to be tested. Choices are installed trays, including
Tray 1
,
Tray 2
,
MP Feeder
.
4.
Select
Single
or
Continuous
, and press
Select
( ).
•
Single—a single sheet of blank paper is fed, and the test stops.
•
Continuous—sheets are fed continuously, until
Stop
( ) is pressed.
Sensor Test
This test is used to verify that the sensors are working correctly for an individual input tray.
1.
Select
INPUT TRAY TESTS
from Diag Menu, and press
Select
( ).
2.
Select
Sensor Tests
, and press
Select
( ).
3.
Select the tray where you want to test the sensors.
4.
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.
Input Tray
Tray 1
Tray 2 (650-sheet duo tray)
Tray 3 (550-sheet tray, C546tdn)
MP Feeder
Empty Sensor
✘
✔
✔
✘
To Exit the text, press
Back
( ) or
Stop
( ).
Low Sensor
✘
✔
✔
✘
Passthru Sensor
✘
✔
✔
✘
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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
( ).
2.
Select the sensor you want to test, and press
Select
( ).
The following tests are available:
Sensor
Front Door
Standard Bin
S1
S2
Fuser exit sensr
C-TMC Sensor
M-TMC Sensor
Y-TMC Sensor
K-TMC Sensor
Value
Opened/
Closed
Bin full
Media clear… or
Media present…
Media clear… or
Media present…
Media clear… or
Media present…
Opened/
Closed
Opened/
Closed
Opened/
Closed
Opened/
Closed
How to test
Open and close the front door. The sensor should change state.
Lift up on the bin-full/narrow media flag, and then release. The sensor should change state.
Activate the sensor by removing and re-inserting the paper tray. The sensor should change state.
Remove the media tray. Activate the input (S2) sensor flag. The sensor should change state.
Open the front cover. Activate the fuser exit flag. The sensor should change state.
Remove the cyan toner cartridge. Shine a flashlight on the toner level sensor. The sensor should change state.
Remove the magenta toner cartridge. Shine a flashlight on the toner level sensor. The sensor should change state.
Remove the yellow toner cartridge. Shine a flashlight on the toner level sensor. The sensor should change state.
Remove the black toner cartridge. Shine a flashlight on the toner level sensor. The sensor should change state.
To exit the test, press
Back
( ) or
Stop
( ).
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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:
1.
Remove the imaging unit and the waste toner bottle. See
“Imaging unit (IU) removal” on page 4-45
2.
Reinstall the right cover assembly.
3.
Close the front cover.
4.
Enter Diagnostics menu (Turn the printer off, press and hold
Left
( ) and
Select
( ), turn the printer on, and release the buttons when the installed memory and processor speed displays.
5.
Select
MISC TESTS
in the Diag Menu, and press
Select
( ).
6.
Select
Motor Detect
, and press
Select
( ).
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.
Select
DEVICE TESTS
from Diag Menu, and press
Select
( ).
2.
Select
Flash Test
, and press
Select
( ).
Contents will be lost. Continue?
appears.
3.
To continue, select
Yes
, and press
Select
( ). To end the test, select
No
, and press
Select
( ).
If you continue,
Flash Test Testing…
appears.
•
If the test is successful,
Flash Test Test Passed
appears. Use Format Flash in the Utilities Menu to reformat the flash card.
•
If the test is unsuccessful,
Flash Test Test Failed
appears. Replace the flash card.
4.
Press
Back
( ) to remove the message and return to the Device Tests menu.
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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
( ).
2.
Select
Defaults
, and press
Select
( ).
3.
Select
U.S.
(default) or
Non-U.S.
, and press
Select
( ).
Press
Back
(
)
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
( ).
2.
Select the page count you wish to view:
•
Prt Color Pg Count
•
Prt Mono Pg Count
•
Perm Page Count
3.
Press
Select
( ).
The value of the page count displays.
Press
Back
(
)
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
( ).
The Serial Number is displayed.
Press
Back
(
)
to return to Printer Setup.
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.
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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:
•
The default standard model Configuration ID is used instead.
•
Configuration ID is the only function available in the Diagnostics Menu.
•
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
( ).
T he current value for Configuration ID 1 is displayed.
3.
Enter the Configuration ID 1.
•
Change the left character or digit first.
•
To change the value of a character or digit, press to decrease or to increase the underlined value, and press
Select
( ) to move to the next character or digit.
•
To move to the next character or digit without changing the current value, press
Select
( ).
•
When you press
Select
( ) 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
( )
.
If the Configuration ID 2 is validated,
Submitting Selection
appears, and a check ( ) 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
( ) exits the menu.
To enter the ITU barcode:
1.
Select
PRINTER SETUP
from Diag Menu, and press
Select
( ).
2.
Select
ITU Barcode
, and press
Select
( ).
3.
To enter the 16-digit numeric value:
Use to decrease the leftmost digit value or to increase the value. Press
Select
( ) to advance to the next digit. If a digit is already correct, press
Select
( ) to accept the number and to continue.
When the last number is entered and you press
Select
( ),
Submitting changes…
should appear. If the entered number is incorrect,
Check Sum Does Not Match
displays. Check and reenter the number.
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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
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
( ).
2.
Select
Reset Fuser Cnt
, and press
Select
( ).
3.
Select
Reset
, and press
Select
( ).
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
( ).
3.
Select
Restore
to reset the values to the factory settings, and select
Do Not Restore.
To cancel and return to the menus, press
Back
( ).
Fuser Temperature
This adjustment can be used to help solve some 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
( ).
2.
Select
Fuser Temp
, and press
Select
( ).
3.
Select Normal, High, or Low. The default is Normal.
To return to the menus, press
Back
( ).
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.
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TPS Setup
Right or Left TPS
The value of the toner density sensor (also called toner patch sensor or TPS) is set at manufacturing. If 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
( ).
2.
Select
Right
or
Left
, and press
Select
( ).
TPS Right 1-16
or
TPS Left 1-16
appears above a blinking 0 in the left position.
3.
To enter a character or digit:
a.
Press 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
( ) 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 17-32
appears.
e.
Continue entering and pausing
4.
After the 32nd number is entered and becomes solid, the number is automatically entered.
•
If the number is incorrect,
Checksum does not match
appears, and the original screen appears to reenter the value.
•
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:
1.
Select
TPS Setup
from Diag Menu, and press
Select
( ).
2.
Select
Cal Ref Adj
, and press
Select
( ).
3.
Select
CMY
or
Black
, and press
Select
( ).
4.
Press to decrease or to increase the value.
The values can be -8 to +8, and the default value is 0.
To cancel and return to the menus, press
Back
( ).
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
( ).
2.
Select
Reset Color Cal
, and press
Select
( ).
Resetting
appears. When the reset is complete, the screen is automatically returned to TPS Setup.
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Reports
Menu Settings Page
To print the Menu Settings Page:
1.
Select
Reports
from Diag Menu, and press
Select
( ).
2.
Select
Menu Settings Page
, and press
Select
( ).
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 2
xx
and 9
xx
error messages are stored in the Event Log.
To view the event log:
1.
Select
Event Log
from Diag Menu, and press
Select
( ).
2.
Select
Display Log
, and press
Select
( ).
As many error codes display as fit on the screen at a time. Press or to view additional error codes.
Press to view additional details.
Press
Back
( ) 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:
•
Detailed printer information, including code versions
•
Time and date stamps
•
Page counts for most errors
•
Additional debug information in some cases
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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
( ).
2.
Select
Print Log
, and press
Select
( ).
Press
Back
( ) 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
( ).
2.
Select
Clear Log
, and press
Select
( ).
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
(
)
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.
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Configuration menu (Config Menu)
Available tests
The tests display on the operator panel in the order shown for all models.
Configuration menu
Prt Quality Pgs
Color Trapping
Reports
Panel Menus
PPDS Emulation
Demo Mode
Factory Defaults
Energy Conserve
Auto Color Adj
Font Sharpening
Exit Config Menu
“Prt Quality Pgs” on page 3-24
.
.
.
.
.
.
“Factory Defaults” on page 3-26
.
“Energy Conserve” on page 3-26
.
“Font Sharpening” on page 3-27
This selection exits Configuration Menu, and
Resetting the Printer displays. The printer performs a POR and returns to 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
( ) 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 include 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.
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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
( ).
2.
Select
Menu Setting Page
, and press
Select
( ).
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
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
( ).
2.
Select
Print Log
, and press
Select
( ) to begin printing the log.
Panel Menus
Lets the system support person enable or disable the operator panel menus. Selecting
On
(the default) allows users to change values for the printer.
Off
disables the users’ access to menus. If a user presses
Menu
( ), 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 PJL 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.
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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:
•
All downloaded resources (fonts, macros, symbol sets) in the printer memory (RAM) are deleted.
•
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, LocalTalk 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.
1.
Turn the printer off, or select
Exit Config Menu
.
2.
At the Ready prompt, select
Menus
( ), and press
Select
( ).
3.
Select
Reports
, and press
Select
( ).
4.
Select
Menu Settings Page
, and press
Select
( ).
5.
Enter the Diagnostic Menu, select
Reports
,
Menu Settings Page
, and press
Select
( ).
See
“Menu Settings Page” on page 3-22
6.
Turn the printer off, or select
Exit Diags
.
7.
Enter Configuration Menu, select
Reports
,
Menu Settings Page
, and press
Select
( ).
See
“Menu Settings Page” on page 3-25
To reset factory defaults:
1.
Select
Reports
from the Config Menu, and press
Select
( ).
2.
Select
Factory Defaults
, and press
Select
( ).
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 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.
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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 printer 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.
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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:
Make 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 or to navigate to
Print from USB
.
2.
Press
Select
( ).
You now have access to the directory structure of the flash drive.
3.
Use or to navigate to the firmware file. The file will have a .fls extension.
4.
When the file is displayed, press
Select
( ).
Program Device: Yes
displays.
5.
Press
Select
( ). The printer will start the update process. Various status and progress messages will appear.
Warning: Do not turn the printer off
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:
1.
POR the printer to a
Ready
state.
2.
Go to the
TCP/I{P
menu in the administrative menu to retrieve the IP address.
3.
From a command line prompt on a computer on the network, open an FTP session to the IP address.
4.
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.
Using the Web server
1.
On a computer attached to the network, open a Web browser.
2.
Enter the printer’s IP address in the address bar of the Web browser.
3.
When the home page opens, click
Configuration
.
4.
Click the
Update Firmware
link on the Configuration page.
5.
Click the
Browse
button.
6.
In the browser that opens, browse to the file you want to use
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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.
2.
Browse for flash file.
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3.
Select the printer from the list of printers installed on the computer.
Lexmark C54x series
4.
Press
Start
.
5.
Repeat these steps for every file you are updating on the printer.
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Paper jams
Avoiding jams
The following hints can help you avoid jams:
•
Use only recommended paper or specialty media.
For more information, see the
Card Stock & Label Guide
available on the Lexmark Web site at
www.lexmark.com/publications
.
•
Do not load too much paper. Make sure the stack height does not exceed the indicated maximum height.
•
Do not load wrinkled, creased, damp, or curled paper.
•
Flex, fan, and straighten paper before loading it.
•
Do not use paper that has been cut or trimmed by hand.
•
Do not mix paper sizes, weights, or types in the same stack.
•
Store the paper in an appropriate environment.
•
Do not remove trays while the printer is printing. Wait for
Load tray <x>
or
Ready
to appear before removing a tray.
•
Do not load the manual feeder while the printer is printing. Wait for
Load Manual feeder with <x>
to appear.
•
Push all trays in firmly after loading paper.
•
Make sure the guides in the trays are properly positioned, and are not pressing too tightly against the paper.
•
Make sure all paper sizes and paper types are set correctly in the operator panel menu.
•
Make sure all printer cables are attached correctly.
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Understanding jam numbers and locations
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.
230
235
241
242
243
250
Error message
200
201
202
Jam message Instructions Go to page
Standard 250-sheet tray and manual feeder (tray 1). Jam in the input (S2) sensor.
Jam under the fuser
Jam in the fuser
Pull tray 1 out, and remove the jam.
Open the front door, and remove the jam.
Open the front door, and pull the fuser cover toward you.
Remove the jam.
Jam in the duplex
Media not supported in the duplex
Jam in the primary tray (tray 1)
Jam in the 650-sheet Duo Drawertray
(tray 2) /MP feeder
Open the front door, and remove the jam.
Load the tray with the correct paper size.
Pull the primary tray out, and remove the jam.
Pull the 640-sheet Duo Drawer tray out, 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.
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200 paper jams
1.
Remove the standard 250-sheet tray (tray 1).
2.
Remove the jam.
Note:
Make sure all paper fragments are removed.
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3.
Insert the tray.
4.
Press
Select
( ).
201 paper jam
1.
Grasp the front door at the side handholds, and then pull it toward you to open it.
2.
Remove the jammed paper.
Note:
Make sure all paper fragments are removed.
3.
Close the top door.
4.
Press
Select
( ).
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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.
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
( ) to continue.
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230 paper jam
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
( ) to continue printing.
235 paper jam
1.
Load the tray with the correct paper size (supported for duplex).
2.
Insert the tray.
3.
Close the front door.
4.
Press
Select
( ) to continue printing.
241 paper jam in primary tray
1.
Remove the primary tray.
2.
Remove the jam.
3.
Check the tray adjustments for the size of paper used.
4.
Check the pick tires for foreign material or wear. Replace if necessary. See
“Pick tires removal” on page 4-64
.
5.
Close the primary tray.
6.
Press
Select
( ) to continue printing.
242 paper 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.
3.
Check the tray adjustments for the size of paper used.
4.
Check the pick tires for foreign material or wear. Replace if necessary. See
“Pick tires removal” on page 4-64
.
5.
Close the primary tray.
6.
Press
Select
( ) to continue printing.
Note:
Make sure all paper fragments are removed.
7.
Align the tray, and insert it.
8.
Press
Select
( ) to continue.
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243 paper jam in the 550-sheet drawer
1.
Remove the 550-sheet tray (tray 3).
2.
Remove the jam.
Note:
Make sure all paper fragments are removed.
3.
Check the tray adjustments for the size of paper used.
4.
Check the pick tires for foreign material or wear. Replace if necessary. See
“Pick tires removal” on page 4-64
.
5.
Close the primary tray.
6.
Press
Select
( ) to continue printing.
Note:
Make sure all paper fragments are removed.
7.
Align the tray, and insert it.
8.
Press
Select
( ) to continue.
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
( ).
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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 photoconductors 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:
1.
Charge the photoconductor (PC unit)
2.
Expose the photoconductor (PC unit)
3.
Develop the toner on the photoconductor (PC unit)
4.
First and second transfer of toner to the ITU and then to the media.
5.
Fuse the toner to the media
6.
Clean/erase the photoconductor and the ITU.
In summary, the printer’s controller board receives print data and the command to print. The controller 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 image 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.
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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:
•
If 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
( ), select
Reports
, and select
Print Defects
.)
•
If 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 need to be replaced sooner.
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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:
•
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.
•
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.
•
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.
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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:
•
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.
•
If 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.
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Step 4a: First transfer
When the latent images are developed on each photoconductor, the high-voltage power 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.
Service tips:
•
Never touch the surface of the ITU belt with your bare hand. The oil from your skin will cause a charge differential on 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.
•
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.
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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 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:
•
If 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.
•
If 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.
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Step 5: Fuse
Once the image has been fully 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:
•
If the fuser rolls are damaged, they can cause toner to be pulled off the page or cause paper jams.
•
Toner that rubs off a printed page can be a sign of a malfunctioning fuser or an 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.
•
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.
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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 cleaning blade, the toner is moved from the cleaning blade to the waste toner area using an auger system.
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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.
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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. It is not uncommon to find a user printing 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
.
Bin-full/narrow media sensor
Operator panel
Exit rolls/duplex entry
Output bin
Toner cartridges
Y, C, M, K
Printhead
Controller board
Front cover
/duplex
Developers
Y, C, M, K
Y
C M K
Fuser
Fuser exit sensor
PC unit
(part of imaging unit)
Transfer roll
(part of ITU)
ITU
Input/sensor
(S2)
(Part of ACM)
Tray 1
Duplex/manual feed sensor (S1)
Pick roller
Paper path
Tray present sensor
Paper pick motor drive asm.
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Transport components
In summary, 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.
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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. 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.
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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 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 I use PostScript or PCL emulation printer software? What settings should I use for the best color?
The PostScript driver is strongly recommended for best color quality. The default settings in the PostScript driver provide the preferred color quality for the majority of printouts.
Why doesn't the printed color match the color I 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 I match a particular color (such as a corporate logo)?” on page 3-51
.
The printed page appears tinted. Can I 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.
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My color transparencies seem dark when they are projected. Is there anything I 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:
•
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.
•
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 table:
1.
Press
Menus
( ) to open the Admin menus.
2.
Select
Settings
, and press
Select
( ).
3.
Select
Quality
, and press
Select
( ).
4.
Select
Color Correction
, and press
Select
( ).
5.
Select
Manual
, and press
Select
( ).
The printer is in manual mode, and you need to select a color conversion table.
6.
Press
Back
( ) to return to the Quality menu, select
Manual Color
, and press
Select
( ).
7.
Select the appropriate color conversion table for the affected object type.
Object type
RGB Image
RGB Text
RGB Graphics
CMYK Image
CMYK Text
CMYK Graphics
Color conversion tables
•
Vivid
—Produces brighter, more saturated colors and may be applied to all incoming color formats.
•
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.
•
US CMYK
—Applies color correction to approximate the SWOP
(Specifications for Web Offset Publishing) color output.
•
Euro CMYK
—Applies color correction to approximated EuroScale color output.
•
Vivid CMYK
—Increases the color saturation of the US CMYK color correction setting.
•
Off
—No color correction is implemented.
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How can I 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:
1.
Press
Menu
( ) to open the Admin menus.
2.
Select
Settings
, and press
Select
( ).
3.
Select
Quality
, and press
Select
( ).
4.
Select
Color Samples
, and press
Select
( ).
5.
Select the
Color Conversion
table to print, and press
Select
( ).
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 particular 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 userdefined 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:
1.
Open a Web browser.
2.
In the address bar, type the network printer IP address.
3.
Click
Configuration
.
4.
Click
Color Samples
.
5.
Click
Detailed Options
to narrow the set to one color range.
6.
When the Detailed Options page appears, select a color conversion table.
7.
Enter the RGB or CMYK color number.
8.
Enter an Increment value from 1–255.
Note:
The closer the value is to 1, the narrower the color sample range will appear.
9.
Click
to print the detailed Color Samples set.
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4. Repair information
Warning:
Read the following before handling electronic parts.
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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 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
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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:
•
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.
•
Unless otherwise stated, reinstall the parts in reverse order of removal.
•
When reinstalling a part held with several screws, start all screws before final tightening.
•
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
for the part number.
1.
Open the front cover.
2.
Remove the operator panel. See
“Operator panel logo plate” on page 4-9
.
3.
Remove the right cover assembly. See
“Right cover assembly removal” on page 4-12
4.
Remove the waste toner bottle. See
“Waste toner bottle removal” on page 4-77
5.
Remove the four screws (A) from the cable cover, and remove the cable cover.
6.
Remove the screw (B) from the back of the waste toner cartridge ground connector.
A B
7.
Remove the rear shield. See
“Top cover assembly removal” on page 4-13
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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).
D
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4-3
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12.
Lower the front cover to align the flats on the hinges, and remove the front cover.
Note:
Not all models have all three cables shown. See the chart below.
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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
(5025-210)
Lexmark C543dn
(5025-230)
Lexmark C544n,
C544dn, C544dw,
C546dtn
(5025-410, -430,
-43W, -439)
• Operator panel cable (E)
• Front door switch cable (F)
Note:
The USB port cable (G) is not included.
• Operator panel cable (E)
• Front door switch cable (F)
• 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.
• Operator panel (E)
• Front door switch cable (F)
• USB port cable (G)
Repair information
4-5
5025-2xx, 4xx
Left cover assembly removal
See
“Left cover assembly” on page 7-3
for the part number.
1.
Remove the media tray.
2.
Position the printer with the left side hanging over the edge of the table.
3.
On the rear, remove the metal screw (A), the short plastic screw (B), and the longer plastic screw (C).
4.
Remove the screw (D) on the bottom of the cover.
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5.
Unlatch the front bottom corner tab (E), and lower the front while disengaging from the top cover.
Installation note:
When replacing the left cover, flex the cover slightly to engage the tab (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.
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.
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Operator panel logo plate
See “operator panel bezel and name plates on
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.
5025-2xx, 4xx
3.
Remove the logo plate (B).
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4-9
5025-2xx, 4xx
Operator panel removal
See
“Operator panel and display assembly” on page 7-3
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:
•
Operator panel assembly
•
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.
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.
3.
Open the front cover.
4.
Remove the three screws (B) attaching the operator panel to the front cover assembly.
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5.
Detach the operator panel cable (C) from the panel.
5025-2xx, 4xx
Rear shield removal
The rear shield is not a field replaceable unit (FRU).
1.
Remove the six screws (A).
2.
Remove the rear shield.
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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.
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Top cover assembly removal
See
“Top cover assembly” on page 7-3
for the part number.
1.
Remove the right cover assembly. See
“Right cover assembly removal” on page 4-12
2.
Remove the waste toner bottle. See
“Waste toner bottle removal” on page 4-77
3.
Remove the imaging unit. See
“Imaging unit (IU) removal” on page 4-45
4.
Remove the rear shield. See
“Top cover assembly removal” on page 4-13
5.
Disconnect the fan cable from JFAN1 (A) on the controller board.
6.
Remove the screw (B).
5025-2xx, 4xx
Repair information
4-13
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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.
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9.
Remove the two top screws (E) near the front.
5025-2xx, 4xx
10.
Remove the remaining four screws (F).
11.
Remove the fuser screw (G).
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12.
Disconnect the left fuser spring (H) from the fuser.
13.
Disconnect the right fuser spring (J) from the fuser.
14.
Disengage the bin-full/narrow media sensor cable (K) from the retainer.
15.
Gently rotate the fuser away from the top cover, and let it rest.
Note:
If fuser needs to be propped up, use something that will not move or shift. Avoid putting additional stress on the cables.
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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.
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Bin-full/narrow media sensor removal
for the part number.
1.
Open the front cover.
2.
Remove the cable from the retainer.
Note:
Be sure to note the routing for re-installation.
3.
Disconnect the cable from the bin-full/narrow media sensor.
4.
If there is a sensor retaining plate (A) on the side the latches connect, remove the old adhesive plate.
5.
Gently remove the sensor (B) from the bracket by pressing the latches.
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Installation note:
1.
Clean the contact surface where you removed the sensor retaining plate, or where you need to install the new one.
2.
Guide the latches that hold the sensor in the bracket into place.
3.
Squeeze the latches together until they latch to the metal frame.
4.
Remove the backing from the new plate, and place the plate on the surface between the sensor mounting legs.
5.
Reconnect the cable, and reroute the 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 binfull/narrow media sensor flag removal” on page 4-27
.
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4-19
5025-2xx, 4xx
Controller board removal
See
Controller board—C544n, C544dn, C544dw
Controller board—C540n, C543dn
“Controller board—C546dn only” on page 7-7
for the part number.
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:
Observe all ESD precautions while handling electrostatic-discharge sensitive parts. See
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:
•
Operator panel assembly
•
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.
If the unit has a wireless card, disconnect the card from the controller board.
5.
Remove the board.
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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 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.
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
Warning:
Do not touch the underside of the imaging unit. This could damage it.
4.
Remove the developer unit(s).
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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.
3.
Lift the duplex aligner on the right side, and disengage the gears (C) on the left.
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4.
Remove the four screws (D) from the duplex reference guide, and remove the guide.
5025-2xx, 4xx
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).
2.
Replace the four screws in the duplex reference guide.
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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 (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.
5.
Replace the eight screws in the duplex aligner.
6.
Close the front door.
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Duplex sensor removal
See “photo sensors” on
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.
5025-2xx, 4xx
3.
Pull corner of cable cover (B) away from the right side to access the sensor posts (C).
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4.
If there is a plate on the side the latches of the sensor connected, remove the old adhesive plate (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.
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Exit deflector and bin-full/narrow media sensor flag removal
See
“Exit deflector and bin-full/narrow media sensor flag” on page 7-5
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 un
snap
the bin-full/narrow media sensor flag, and remove the flag.
Note:
Be careful to not dislodge the sensor.
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.
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4-27
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4.
With one hand, gently pull the exit deflector towards the rear, and with the other hand, press to un
snap
the tabs (C).
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Fuser assembly removal
5025-2xx, 4xx
See “Fuser assembly” on
1.
Remove the right cover assembly. See
“Right cover assembly removal” on page 4-12
2.
Remove the left cover. See
“Left cover assembly removal” on page 4-6
3.
Disconnect the two-wire fuser cable (A) from the LVPS.
4.
Position the fuser cable so that it can be pulled through from the front of the printer, and guide the cable through to the front.
Warning:
Be careful not to damage the cable by pulling too hard or cutting the cable insulation.
5.
Remove the screw and grounding washer (B) on the right side of the frame.
Note:
Be careful not to lose the grounding washer.
6.
Disconnect the thermistor cables (C).
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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.
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Installation notes:
•
Make sure the springs are resting on the frame so they can be positioned once the new fuser is in place.
They can be difficult to reach if they hang down.
•
Be careful not to bump into the fuser exit sensor on the left side.
•
When reinstalling on the right side, make sure the gears mesh.
•
Reroute the cables back through their retainers (A, B).
•
When you replace a new fuser, be sure to reset the Fuser Page Count.
1.
Enter Diagnostics Menu (turn the printer off., press and hold
Left
( ) and
Select
( ), turn the printer on, and release the buttons when the installed memory and processor speed displays.
2.
Select
Printer Setup
, and press
Select
( ).
3.
Select
Reset Fuser Cnt
, and press
Select
( ).
Reset Fuser Cnt Reset
appears on the display.
4.
Select
Back
( ) twice, and select
Exit Diags
, and press
Select
( ).
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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 reinstall.
4.
Remove the two screws (C).
5.
Remove the fuser drive motor assembly.
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Fuser exit sensor removal
See
“Fuser exit sensor” on page 7-7
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.
Remove the left cover. See
“Left cover assembly removal” on page 4-6
4.
Disconnect the two-wire fuser cable (A) from the LVPS.
Note:
You do not have to extract the cable.
5025-2xx, 4xx
5.
Remove the screw and grounding washer (B) on the right side of the frame.
Note:
Be careful not to lose 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.
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8.
Disconnect the bin full/narrow medial sensor cable, and remove the cable from the fuser frame. See
“Binfull/narrow media sensor removal” on page 4-18
Note:
Observe the cable routing.
9.
Unhook the springs (D) from both sides of the fuser.
10.
Rotate the fuser toward the front of the printer until the screw (E) can be accessed, and removed.
11.
Disconnect the cable (G) 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.
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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?
•
Go to
“High-voltage power supply (HVPS) with spring” on page 4-38
5025-2xx, 4xx
•
If there is no spring, go to
“High-voltage power supply (HVPS) with no spring” on page 4-36
below.
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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.
Disconnect the high-voltage power supply (HVPS) cable at the HVPS and at the controller board.
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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.
6.
Remove the screw (C) securing the HVPS.
7.
Carefully slide the HVPS out.
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).
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High-voltage power supply (HVPS) with spring
1.
Remove the rear shield. See
“Top cover assembly removal” on page 4-13
2.
Remove the cable cover (A).
3.
Disconnect the high-voltage power supply (HVPS) cable at the HVPS and at the controller board.
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4.
Remove the screw (C) securing the HVPS.
5025-2xx, 4xx
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 note
s:
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.
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Image transfer unit (ITU) removal
See
“Image transfer unit (ITU) assembly” on page 7-5
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
“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
.
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Removal of ITU without the spring clamp kit
1.
Pull the gear (A) straight out to un
snap
it, and then discard it. A new gear is included in the spring clamp kit and must be used with the new spring clamp.
2.
Remove the rubber pad (C).
3.
Place the spring clamp onto the shaft (D).
4.
Snap the new gear onto the shaft (D). The installation is the same as the old gear.
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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.
2.
Rotate the left spring (B), and the cam away from the ITU so the spring is held out of the ITU path.
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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.
4.
Hold the release lever as you pull out the ITU for the first four inches (100 mm), but a quick, firm pull should overcome the latch at this point.
Installation notes:
•
Write down the 16-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.
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•
Rotate the spring clamp so it hooks over the new ITU (E).
Note:
Position the spring on the right side of the gear shaft.
•
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 and .
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
( ).
3.
Select
ITU Barcode
, and press
Select
( ).
4.
To enter the 16-digit numeric value:
Use to decrease the leftmost digit value or to increase the value. Press
Select
( ) to advance to the next digit. If a digit is already correct, press
Select
( ) to accept the number and to continue.
When the last number is entered, press
Select
( ), and
Submitting changes…
should appear. If the entered number is incorrect,
Check Sum Does Not Match
displays. Check and reenter the number.
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Imaging unit (IU) removal
The imaging unit is customer replaceable unit and is not a FRU.
Note:
The imaging unit contains:
•
Photoconductor unit
•
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.
1.
Open the front cover.
2.
Lift the toner cover by sliding the latch to the left.
3.
Remove the right cover assembly. See
“Right cover assembly removal” on page 4-12
4.
Remove the waste toner bottle. See
“Waste toner bottle removal” on page 4-77
5.
Remove the toner cartridges.
6.
Lift the two latches (A) to unlock the imaging unit.
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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.
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Low-voltage power supply (LVPS) assembly removal
“Low-voltage power supply (universal power supply)” on page 7-7
for the part number.
1.
Remove the left cover. See
“Left cover assembly removal” on page 4-6
2.
Disconnect the three cables (A) from the LVPS.
3.
Remove the seven screws (B).
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4.
Remove the LVPS.
Warning:
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.
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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.
2.
Open the front cover.
3.
Remove the waste toner bottle. See
“Waste toner bottle removal” on page 4-77
4.
Remove the imaging unit. See
“Imaging unit (IU) removal” on page 4-45
5.
Remove the low-voltage power supply. See
“Low-voltage power supply (LVPS) assembly removal” on page 4-47
.
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5025-2xx, 4xx
6.
Remove the two top screws (B) near the front holding the top cover to the LVPS shield.
7.
Remove the two screws (C).
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Service Manual
8.
Disconnect the fuser exit sensor cable (D).
5025-2xx, 4xx
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.
10.
Place the printer on the right side.
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11.
Remove the tray 2 connector (F) by pinching the tabs together and pushing the connector into the printer.
12.
At the rear of the printer, remove the two screws (G) from the AC receptacle, and the ground screw (H).
13.
Remove the two screws (J) holding the plastic shield.
14.
Remove the AC receptacle from the left lower frame.
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15.
Remove the three screws (K) securing the left lower frame.
5025-2xx, 4xx
16.
Remove the screw (L) above the frame.
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5025-2xx, 4xx
17.
Swing the left lower frame away from the printer, and remove.
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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
, and replace the sensor retaining plates.
1.
Open the front cover.
2.
Remove the right cover assembly. See
“Right cover assembly removal” on page 4-12
3.
Remove the waste toner bottle. See
“Waste toner bottle removal” on page 4-77
4.
Remove the imaging unit. See
“Imaging unit (IU) removal” on page 4-45
5.
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.
6.
Remove the four screws (B) securing the cable cover.
Note:
The cable cover is part of the right lower frame FRU.
7.
Carefully place the printer on its left side.
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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
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12.
Next to screw (E), lift the right lower frame pin (F) out of the hole in the printer frame.
5025-2xx, 4xx
F
13.
Swing the rear part away from the printer to access the spring (G), and remove the spring (G) from the right lower frame.
14.
Disconnect the cable (H) from the tray present sensor.
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15.
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.
16.
Remove the sensor retaining plate (J), and pinch the latches (K) together to remove the tray present sensor.
17.
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.
M
L K J
Installation notes:
1.
Reinstall the spring bracket, and the wireless antenna plate (or the blank plate).
2.
Clean the contact surface where you removed the sensor retaining plates, or where you need to install the new ones.
3.
Install the sensors.
4.
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.
5.
Connect the cable to the tray present sensor and place the spring in place before installing the right lower frame.
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Main drive gear assembly removal
“Main drive gear assembly, with motors” on page 7-5
for the part number.
5025-2xx, 4xx
1.
Remove the left cover. See
“Left cover assembly removal” on page 4-6
2.
“Left lower frame” on page 4-49
for instructions on removing the LVPS shield.
3.
Remove the screws (A) on the top cover.
4.
Disconnect 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.
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5025-2xx, 4xx
6.
Remove the two screws (E) from the rear.
7.
Remove the two screws (F) from below the main drive gear assembly.
8.
Remove the two screws (G) on the right of the main drive gear assembly
9.
Lift the main drive gear assembly, and remove.
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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.
Remove the toner cartridges, the waste toner bottle, and the imaging unit (IU). See
“Waste toner bottle removal” on page 4-77
“Imaging unit (IU) removal” on page 4-45
.
2.
Remove the left cover. See
“Left cover assembly removal” on page 4-6
3.
Remove the rear shield. See
“Rear shield removal” on page 4-11
4.
Disconnect the paper pick motor drive assembly cable connector (A) fromJSP1 on the controller board.
5.
Pull the cable (B) through the opening, and free the cables from the retainers (C) on the left side.
6.
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.
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7.
Remove the two screws (D) on the bottom.
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.
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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.
3.
Reinstall the three screws holding the ACM to the printer.
4.
Turn the printer to the proper upright position.
5.
Reroute the cable, making sure to place the cables into the two retainers on the left side.
6.
Remove the rear shield, and reconnect the cable.
7.
Replace the rear shield.
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Pick tires removal
See
for the part number.
Note:
You will need to have a soft, padded work surface.
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. If 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.
1.
Remove the media tray.
2.
Place the printer so the front edge extends over the edge of the table or desk.
3.
Lower the paper pick motor drive assembly.
4.
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.
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.
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Printhead removal
See
1.
“Top cover assembly removal” on page 4-13
2.
Disconnect the cables from the controller board.
Note:
Be very careful disconnecting handling the ribbon cable.
3.
Remove the toroid (A) from the ribbon cable.
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Repair information
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5025-2xx, 4xx
4.
Remove the three screws (B).
5.
Remove the printhead.
Installation note:
•
When the printhead is replaced, perform the registration (black planes) and alignment (color planes). See
.
•
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.
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Toner cartridge contacts
See
“Toner cartridge contacts (Pogo pin)” on page 7-9
for the part number.
1.
Remove the right cover assembly. See
“Right cover assembly removal” on page 4-12
2.
Remove the waste toner bottle. See
“Waste toner bottle removal” on page 4-77
3.
Remove the imaging unit. See
“Imaging unit (IU) removal” on page 4-45
4.
Remove the rear shield. See
“Top cover assembly removal” on page 4-13
5.
Remove the rear screw (A) in the waste toner bottle sensor contact to allow access to the cable cover.
Note:
The waste toner bottle sensor contact does not need to be unplugged or removed.
6.
Remove the four screws (B) securing the cable cover, and remove the cable cover.
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.
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10.
Disconnect the cable (E) from the controller board at JSC1.
11.
Remove the cable from the retainer on the bottom of the printer.
12.
Extract the cable through the frame, and remove the cable with the spring contacts.
Note:
To remove the cable, be sure to unwrap the toroid. When you re-install, be sure to wrap the toroid five times as shown.
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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.
“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 from
JFUSES1 connector (B) on the controller board.
Note:
Observe the routing of the cable(s) for reinstallation.
4.
Remove the two screws (C) securing each sensor.
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Installation notes
•
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.
•
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 and .
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
( ).
3.
Select
Right
or
Left
, and press
Select
( ).
TPS Right 1-16
or
TPS Left 1-16
appears above a blinking 0 in the left position.
4.
To enter a character or digit:
a.
Press to decrease or to increase the blinking value.
b.
Pause for several seconds without pressing any buttons. The blinking value becomes solid.
If the value is incorrect, use
Back
( ) 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 17-32
appears.
e.
Continue entering and pausing.
5.
After the 32nd number is entered and becomes solid, the number is automatically entered.
•
If the number is incorrect,
Checksum does not match
appears, and the original screen appears to reenter the value.
•
If the number is correct,
Saving changes to NVRAM
appears.
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Toner meter cycle (TMC) card removal
See
“Toner meter cycle card assembly” on page 7-7
for the part number.
1.
Remove the rear shield. See
“Top cover assembly removal” on page 4-13
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
“Imaging unit (IU) removal” on page 4-45
.
5.
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.
6.
Remove the two plastic screws (B), the two metal screws (C), and remove the card.
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Installation notes:
•
Be sure the cable runs through the retainer.
•
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.
•
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).
2.
Push in on the cover above the locating pins (C) while lifting to disengage the cover. Carefully lift the cover just enough for clearance for the toner meter cycle card.
3.
Position the toner meter cycle card.
4.
Replace the two screws (B).
5.
Replace the screws (D), and replace the top cover.
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Tray present sensor removal
See “photo sensors” on
1.
Remove the media tray.
2.
Remove the imaging unit. See
“Imaging unit (IU) removal” on page 4-45
3.
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.
4.
Remove the four screws (B) from the cable cover, and remove the cable cover.
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.
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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.
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12.
Remove the sensor retaining plate (G), and then pinch the latches together to remove the tray present sensor.
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 sensor.
Note:
Make sure the clips on the posts latch to the frame.
3.
Remove the backing from the new plate, and place the plate on the surface between the sensor mounting posts.
4.
Connect the cable to the tray present sensor.
5.
Replace the spring.
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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.
1.
Remove the operator panel. See
“Operator panel logo plate” on page 4-9
.
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 rear shield. See
“Top cover assembly removal” on page 4-13
5.
Remove the rear screw (A) in the waste toner bottle sensor contact to allow access to the cable cover.
Note:
The waste toner bottle sensor contact does not need to be unplugged or removed.
6.
Remove the four screws (B) from the cable cover.
7.
Disconnect the USB port cable (C) from the controller board.
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8.
Remove the USB port cable from the cable channel on the right side.
5025-2xx, 4xx
Waste toner bottle removal
The waste toner bottle is not a FRU.
1.
Open the front cover.
2.
Lift the toner cover by sliding the latch to the left.
3.
Remove the right cover assembly. See
“Right cover assembly removal” on page 4-12
4.
Press the two tabs (A) to release the waste toner bottle, and remove it.
Repair information
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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.
1.
Open the front cover.
2.
Remove the right cover assembly. See
“Right cover assembly removal” on page 4-12
3.
Remove the waste toner bottle. See
“Waste toner bottle removal” on page 4-77
4.
Remove the screw (A) from the back of the waste toner bottle contact block.
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.
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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 the card.
5025-2xx, 4xx
4.
Remove the screw (C) that secures the antenna cover (D) to the frame, and remove the antenna cover and antenna.
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5.
Gently squeeze the fastener (E) with needlenose pliers. Slide the antenna cable and cable through the hole in the bracket.
6.
If the bushing is damaged, remove it by pressing the tabs on each side.
Note:
Take note of the orientation of the bushing. When reinstalling, place the cover upright, bend the antenna as it would be positioned, and make sure the antenna can move about 30° in each direction from the vertical.
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Wireless network card
See
“Wireless network card assembly—C544dw only” on page 7-7
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.
5025-2xx, 4xx
Repair information
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5. Connector locations
Locations
5025-2xx, 4xx
Connector locations
5-1
5025-2xx, 4xx
Note the paper path shown in red.
Operator panel
Bin-full/narrow media sensor
Front cover
/duplex
Y
C
Exit rolls/duplex entry
Output bin
M K
Toner cartridges
Y, C, M, K
Printhead
Controller board
Developers
Y, C, M, K
Fuser
Fuser exit sensor
PC unit
(part of imaging unit)
Transfer roll
(part of ITU)
Input/sensor
(S2)
(Part of ACM)
Tray 1
Duplex/manual feed sensor (S1)
Pick roller
Paper path
Tray present sensor
Paper pick motor drive asm.
ITU
5-2
Service Manual
Connectors
5025-2xx, 4xx
Connector locations
5-3
5025-2xx, 4xx
Controller board diagram
JFAN1
1
1
JPH1
1
JMIRR1
1
JCTM1
1
1
JNET1
1
JUSB1
JCARTB1
1
JSP1
1
JMOT1
1
JLVPS1 JOPT1
1 1
JTPS2
1
JTHM1
1
JHVPS1
1
JBIN1
1
J1
JWIN1
1
JFUSES1
1
JCVR1
1
JOPP1
1
JINT1
JTRAY1
1
JTPS1
1
JSC1
1
JUSBH1
1
1
JUSBW1
1
JWT1
1
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Service Manual
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.
Connector
JBIN1
Bin-full/narrow media sensor and fuser exit sensor
• Bin-full/narrow media—pins 1–3
• Fuser exit sensor—pins 4–6
JCARTB1
Drive motor for cartridges
• Black drive motor (rear motor) even pin numbers 2–20.
• CMY (color) drive motor odd pin numbers 1–19.
JCTM1
Toner meter connector
JCVR1
Cover open switch
Pin no.
14
15
16
11
12
13
8
9
10
5
6
7
2
3
4
5
6
1
1
2
3
4
6
1
2
3
4
5
20
1
2
17
18
19
Signal
V_BF
S_BIN_FB, +3.3 V dc
Ground
V_BIN_4
FUSER_EXIT_SNSR, +3.3 V dc
Ground
CART1_HALL_U
NC_CARTB1_2
+CART1_HALL_V
V_CART2_WING_W, +24 V dc
CART1_HALL_W
V_CART2_WING_V, +24 V dc
CART1_PG
V_CART2_WIND_U, +24 V dc
Ground
+5 V dc_SW
+5V dc_SW
Ground
V_CARTR1_WIND_U, +24 V dc
CART2_FG
V_CARTR1_WIND_V, +24 V dc
CART2_HALL_W
V_CARTR1_WIND_W, +24 V dc
CART2_HALL_V
NC_JCARTB1_19
CART2_HALL_U
+5V_SW
CART_METER_C_IN
CART_METER_M_IN
CART_METER_Y_IN
CART_METER_K_IN
Ground
V_24V_CVR, +24 V dc
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.
Connector
JFAN1
System fan
JFUSES1
Fuser
Motor pins—1–4
Thermistor—black wire 5–6
Duplex sensor (S1)—7–9.
Thermistor—white wire 10–11
JHVPS1
Developer/transfer HVPS
JINT1
+5V safety interlock connector
Pin no.
2
3
14
15
16
1
10
11
12
13
8
9
6
7
4
5
2
3
10
11
12
1
8
9
6
7
4
5
2
3
3
1
1
2
Signal
FAN_FG, +3.3 V dc
Ground
V_FAN_P3
V_FUSER_PHA+, +24 V dc (doors closed)
V_FUSER_PHA–, +24 V dc (doors closed)
V_FUSER_PHB+, +24 V dc (doors closed)
V_FUSER_PHB–, +24 V dc (doors closed)
FUSER_HQ_THM, +2.3 V dc
FUSER_HK_THM_RTN, ground
+5V_SW, +5 V dc
Ground
S1_MPF_SNS, +3.3 V dc
BUR_THM, +2.5 V dc
FUSER_BUR_THM_RTN, ground
Ground, (no wire)
M_DEV_PWM_OUT
K_DEV_PWM_OUT
C_DEV_PWM_OUT
CMY_CHG)PWM_OUT
Y_DEV_PWM_OUT
K_CHG_PWM_OUT
CMY_SRVO_OUT, +3.3 V dc
ITM_TX_PWM_OUT
CMY_TX_PWM_OUT
ITM_SRVO_OUT, +3.3 V dc
K_SRVO_OUT, +3.3 V dc
K_TX_PWM_OUT
+24 V dc
Ground
5V_HVPS_REF
Ground
VS_JINT–1, +5 V dc
Ground
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.
Connector
JLVPS1
Low-voltage power supply
JMIRR1
Mirror motor connector
JOPP1
Operator panel connector
Pin no.
2
3
5
1
3
4
1
2
6
7
4
5
13
14
15
16
9
10
11
12
7
8
5
6
3
4
1
2
Signal
+5 V dc
Ground
+5 V dc
Ground
+5 V dc
Ground
+24 V dc
Ground
+24 V dc
Ground
+24 V dc
Ground
RELAY_DRIVE
ZERO_XING_IN
HEAT1_ON
Ground
MM_REFR
MM_LOCK, +3.3 V dc
MM_START
Ground
+24 V dc
I2C_DATA
V_PANEL+5 V, +5 V dc
I2C_CLK
Ground
OP_IRQ_N, +4–5 V dc
+3.3 V dc
Ground
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.
Connector
JOPT1
Optional—Tray(s)
JPH1
Printhead flat cable connector
Pin no.
19
20
21
15
16
17
18
11
12
13
14
7
8
9
10
5
6
3
4
1
2
9
10
7
8
5
6
3
4
1
2
Signal
TXD_PP
Ground
Ground
RXD_PP
+24 V dc
Ground
+5V_OPTIONS, +5 V dc
S2
Ground
Ground
VDO_HSYNC1_C, +5 V dc
VDO_PH_OK, +3.3 V dc
VDO_HSYNC0, +5 V dc
VDO_LEN0, +3.3 V dc
VDO_BOOST3
+3.3 V dc
VDO_BOOST1
-5V_PH, +5 V dc
VDO_BOOST2 (Shade B)
+5_PH, +5 V dc
VDO_BOOST0
Ground
D_VDO_7+
D_VDO_7–, +1.5 V dc
Ground
D_VDO_3+, +1.5 V dc
D_VDO_3–
Ground
D_VDO_6+
D_VDO_6–
Ground
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.
Connector
JPH1
Printhead flat cable connector
(continued)
JSC1
SC cartridge
Pin no.
34
35
36
37
30
31
32
33
26
27
28
29
22
23
24
25
2
3
4
38
39
40
1
Signal
D_VDO_2+
D_VDO_2–
Ground
D_VDO_5+
D_VDO_5–
Ground
D_VDO_1+
D_VDO_1–
Ground
D_VDO_4+
D_VDO_4–
Ground
D_VDO_0+
D_VDO_0–
Ground
I2CCLK_PH
VDO_LADJ1, +3.3 V dc
I2CDATA_PH
VDO_LADJ0, +3.3 V dc
+3.3 V dc
DATA_SC, +3.3 V dc
SCK_SC
Ground
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 in.
Connector
JSP1
Smart pick drive (paper pick motor drive assembly)
• Encoder—pins 1, 3, 5, 7, and 9
• Smart pick—pins 2, 4
• Motor—pins6, 8, 10, 12
• Input (S2) sensor—pins 13–16
JTHM1
TPS therm connector
JTPS1
TPS1 connector
JTPS2
TPS2 connector
JTRAY1
Bottle sensors
JUSB1 Port
USB connector
Pin no.
1
2
3
G2
4
5
2
3
3
4
1
2
G1
5
1
3
4
2
1
1
2
13
14
15
16
9
10
11
12
7
8
5
6
3
4
1
2
Signal
ANODE (no wire)
M1_OUT1, +24 V dc (0 V dc with door open)
Ground (no wire)
M1_OUT2, +24 V dc (0 V dc with door open)
VCC, 5 V_SW
Ground (no wire)
Ground
CATHODE
VOUTA
+5 V dc
VOUTB
5 V_SW
Ground (no wire)
ANODE
+5 V dc
Ground
TPS_THERM_SNS, +1.5 V dc
TPS_SNS_RTN, ground
ANODE
CATHODE
Ground (no wire)
+5V_SW
Ground
ANODE
CATHODE
Ground (no wire)
+5 V_SW
Ground
+5V_SW
DUPLEX_ENT, +5 V dc
Ground
Ground
USB +5 V dc
USB D–
USB D+
Ground
Ground
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.
Connector
JUSBW1
USB wireless connector
JWT1
Waste toner detection
Pin no.
1
2
5
6
3
4
3
4
1
2
Signal
Ground
USB_HST_VP
USB_HST_VM
Ground
+5 V dc
+3.3 V dc
SENSE
VREF
+1.5 V dc
Ground (no wire)
Connector locations
5-11
5025-2xx, 4xx
High-voltage power supply (HVPS) diagram
5-12
Service Manual
Low-voltage power supply (LVPS) diagram
5025-2xx, 4xx
Connector locations
5-13
5025-2xx, 4xx
Toner meter cycle (TMC) card
Wireless network card
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 you correct the hazard.
Check the following items:
•
Damaged, missing, or altered parts, especially in the area of the On/Off switch and the power supply
•
Damaged, missing, or altered covers, especially in the area of the top cover and the power supply cover
•
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.
It 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
Description
115 V Maintenance kit (115 V fuser, ITU, duplex reference edge)
230 V Maintenance kit (230 V fuser, ITU, duplex reference edge)
100 V Maintenance kit (100 V fuser, ITU, duplex reference edge)
Part number
40X2254
40X2255
40X2261
Preventive maintenance
6-1
5025-2xx, 4xx
6-2
Service Manual
7. Parts catalog
5025-2xx, 4xx
How to use this parts catalog
The following legend is used in the parts catalog:
Asm- index
Part number
Units/mach
Units/
FRU
Description
•
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.
•
Part number
: Identifies the unique number that identifies this FRU.
•
Units/mach
: Refers to the number of units actually used in the base machine or product.
•
Units/FRU
: Refers to the number of units packaged together and identified by the part number.
•
NS
: (Not shown) in the Asm-Index column indicates that the part is procurable but is not pictured in the illustration.
•
PP
: (Parts Packet) in the parts description column indicates the part is contained in a parts packet.
•
Model information used in the parts catalog:
Model name
Lexmark C540n
Lexmark C543dn
Lexmark C544n
Lexmark C544dn
Lexmark C544dw
Lexmark C546dtn
Machine type/ model
5025-210
5025-230
5025-410
5025-430
5025-43W
5025-439
Description
Ethernet network
Ethernet network, duplex
Ethernet network, USB-A host port for flash drives
USB-A host port for flash drive, duplex, Ethernet network
802.11n network wireless network, duplex, ethernet,
USB-A host port for flash.
USB-A host port for flash drive, duplex, Ethernet network,
650-sheet Duo Drawer.
Parts catalog
7-1
5025-2xx, 4xx
Assembly 1: Covers
7
10
9
8
5
6
4
1
2
3
7-2
Service Manual
5025-2xx, 4xx
Assembly 1: Covers
Asm-
Index
1—1
2
3
4
5
6
7
8
6
7
Part number
40X5418
40X5441
40X5416
40X5419
40X5168
40X5430
Units/ mach
1
1
2
1
1
1
Units/
FRU
1
1
2
1
1
1
40X5420
40X5431
40X5436
40X5432
1
1
1
1
1
1
1
1
9
10
40X2867
40X5417
1
1
1
1
Description
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:
• Bezel (1)
• Name plates (4)
• Logo plate (1)
Name plate, C546dtn
Left cover assembly
Parts catalog
7-3
5025-2xx, 4xx
Assembly 2: Frames
8
9
10
1
2
3
7
6
5
4
3
7-4
Service Manual
9
9
9
10
5
6
7
8
Assembly 2: Frames
Asm-
Index
2—1
2
3
4
Part number
40X5411
40X5415
40X5422
40X5424
40X2263
40X5403
40X1557
40X5412
40X5406
40X5407
40X5408
40X5433
1
1
1
1
1
1
1
Units/ mach
1
1
1
1
1
1
1
1
1
1
1
Units/
FRU
1
1
1
1
Description
Printhead
Fuser drive motor assembly
Lower left frame and lower right frame with cable cover
Screw packet, miscellaneous screws
• 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)
• PLAST ROLN 3.5 6L (4)
Duplex reference edge
Image transfer unit (ITU) assembly
Paper pick motor drive assembly—standard tray
Main drive gear assembly, with motors
Fuser assembly, 115 V
Fuser assembly, 230 V
Fuser assembly 100 V
Exit deflector and bin-full/narrow media sensor flag
5025-2xx, 4xx
Parts catalog
7-5
5025-2xx, 4xx
Assembly 3: Electronics
9
7
8
6C
1
6A
6B
3
2
4
5
7-6
Service Manual
9
9
9
9
9
9
7
8
9
9
9
9
9
9
9
9
9
9
Assembly 3: Electronics
Asm-
Index
3
4
5
6
3—1
1
1
2
Part number
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
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
Units/ mach
1
1
1
3
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
Units/
FRU
1
1
1
1
1
1
1
1
Description
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)—Australia
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
5025-2xx, 4xx
Parts catalog
7-7
5025-2xx, 4xx
Assembly 4: Cables
7-8
Service Manual
Assembly 4: Cables
Asm-
Index
4—1
2
3
4
5
6
Part number
40X5429
40X5414
40X7046
40X5421
40X5423
40X5425
Units/ mach
1
2
1
4
1
1
Units/
FRU
Description
1
1
1
4
1
1
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:
A Fuser exit/narrow media to controller board
B Fuser motor, thermistor, and duplex sensor to controller board
C LVPS to controller board
D CMY/K motors to controller board
E Tray 2 to controller board
F HVPS to controller board
G Tray present sensor to controller board
H AC power to LVPS
USB port and cable (for portable flash drive)
5025-2xx, 4xx
Parts catalog
7-9
5025-2xx, 4xx
Assembly 5: Media drawers and trays
1
2
3
4
2
7-10
Service Manual
5025-2xx, 4xx
Assembly 5: Media drawers and trays
Asm-
Index
Part number
Units/ opt.
Units/
FRU
Description
5—1
1
2
3
3
40X5434 1
40X2284 1
40X5168
40X5435
40X2285
2
1
1
1
2
1
1
Optional 650-sheet Duo Drawer (complete)—
(includes 100-sheet MPF)
*
Optional 650-sheet Duo Drawer (complete)—C546dtn only
(includes 100-sheet MPF)
Pick tires
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).
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).
Optional 550-sheet drawer (complete)—C546dtn only 4 40X1538 1 1
NS 40X2512 1 1 550-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.
A
Use the chart below to match the correct trays with the drawers.
Tray P/N
40X5435
40X2285
Number of wear strips
3
4
Drawer P/N
40X5434 without autoconnect
40X2284 with autoconnect (A)
Models
All except C565dtn
C546dtn
Parts catalog
7-11
5025-2xx, 4xx
Assembly 6: Options and miscellaneous
Asm-
Index
Part number
6—NS 40X2254
NS
NS
NS
40X2255
40X2261
40X5937
NS
NS
NS
NS
NS
NS
NS
NS
NS
40X5938
40X5939
40X1455
40X5969
40X5970
40X5971
40X5972
40X1368
40X0395
Units/ opt.
1
1
1
1
1
1
1
1
1
1
1
1
1
Units/
FRU
1
1
1
1
1
1
1
1
1
1
1
1
1
Description
115 V Maintenance kit (fuser, ITU, duplex reference 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
7-12
Service Manual
Index
Numerics
3x–9x user messages
1xx service errors
–
2xx paper jam
messages
250-sheet media tray
paper pick motor drive assembly
550-sheet drawer
parts catalog
650-sheet Duo Drawer
parts catalog
9xx service errors
–
A
acoustics
antenna, wireless network parts catalog
attendance messages
Auto Color Adj
B
bezel parts catalog
bin-full/narrow media sensor flag removal
parts catalog
bin-full/narrow media sensor flag
parts catalog
,
Button Test
C
CMYK color
code, updating
color correction, manual
color samples
5025-2xx, 4xx
color theory
Color Trapping
configuration menu
Auto Color Adj
available tests
Demo Mode
Energy Conserve
Event Log
Factory Defaults
Font Sharpening
Panel Menus
PPDS Emulation
Printer Setup
Reset Fuser Cnt
Prt Quality Pages
Reports
controller board
Motor Detect
parts catalog
covers parts catalog
D
dead printer service check
defaults
factory defaults
Demo Mode
developer units
diagnostics
2
xx
paper jam messages
9
xx
service error messages
power on reset (POR)
service checks
service error messages
symptom tables
user status/attendance messages
diagnostics menu
Alignment Menu
Base Sensor Tests
C TMC Sensor
Fuser Exit
Input
Index
I-1
5025-2xx, 4xx
K TMC Sensor
M TMC Sensor
Standard Bin
Y TMC Sensor
Device Tests
Flash Test
Duplex Tests
EP Setup
DC Charge Adjust
EP Defaults
Fuser Temp
Event Log
Display Log
Print Log
Hardware Tests
Button Test
DRAM Test
Input Tray Tests
Sensor Test
Miscellaneous Tests
Print Tests input source tests
Printer Setup
Engine Setting 1–4
ITU Barcode
Model Name
Page Counts
Bottom Margin
Skew
Reports
tests and settings
TPS Setup
Cal Ref Adj
Reset Color Cal
diagram, menu
I-2
Service Manual
DRAM Test
duplex
,
Left Margin
models
parts catalog
Quick Test
theory
Top Margin
E
electrophotographic process (EP process)
Energy Conserve
engine setting
error codes
1xx service error codes
2xx paper jams
9xx service error codes
ESD-sensitive parts
event log configuration menu
exit deflector parts catalog
F
Factory Defaults
fan, service check
flash updating code
Flash Test
frame, lower left removal
FTP firmware update
fuser assembly parts catalog
fuser exit sensor
parts catalog
H
high-voltage power supply (HVPS)
parts catalog
I
image transfer unit (ITU)
parts catalog
imaging unit (IU)
parts catalog
input source tests
L
low-voltage power supply (LVPS)
parts catalog
lubrication specifications
M
main drive gear assembly parts catalog
maintenance kit
parts catalog
maintenance, scheduled
media guidelines
input size
input sources
input type
output size and type
recycled
unacceptable media
media jams
memory
menu settings page configuration menu
diagnostics menu
menus accessing service menus
diagram
Menu Settings Page configuration menu
customer menu
diagnostic menu
messages customer attendance
paper jams
Model Name
models
MP feeder parts catalog
N
name plate parts catalog
O
operating modes
operator panel
parts catalog
display blank, 5 beeps
one or more buttons fail
options and features
parts catalog
P
Panel Menus
Panel Test
paper guidelines
input size
input type
output capacity
recycled
unacceptable paper
paper jams avoiding
error messages
paper path, theory
paper pick drive assembly service checks
paper pick motor drive assembly parts catalog
parts catalog
covers
electronics
frames
options and miscellaneous
password, panel menus
Perm Page Count
photoconductor unit
imaging kit
pick tires parts catalog
,
pogo pin
POR sequence
power-on sequence (POR)
PPDS Emulation
print quality background
blurred or fuzzy print
5025-2xx, 4xx
Index
I-3
5025-2xx, 4xx
half-color page
insufficient fusing
missing image at edge
mottle (2-5mm speckles)
mottle (2–5mm speckles)
narrow vertical line
random marks
residual image
solid color page
vertical banding
printhead parts catalog
Prt Color Pg Count
Prt Mono Pg Count
Prt Quality Pgs configuration menu
Q
quick test duplex
single-page
R
removals bin-full/narrow media sensor
bin-full/narrow media sensor flag
controller board
covers
operator panel
operator panel bezel
rear shield
right cover
top cover assembly
developer unit
duplex reference edge
duplex sensor
exit deflector
fuser assembly
fuser drive motor assembly
fuser exit sensor
getting started
high-voltage power supply (HVPS)
imaging unit (IU)
low-voltage power supply (LVPS)
main drive gear assembly
narrow media sensor flag
paper pick motor drive assembly
photoconductor unit
I-4
Service Manual pick tires, 250-sheet media tray
printhead
right lower frame
toner density sensor (TDS), left and right
toner meter cycle (TMC) card
tray present sensor
USB port connector
waste toner bottle
wireless network antenna
wireless network card
reports
,
Print Qual Pages
Print Quality Pages
Quick Test
Quick Test (duplex)
Reset Fuser Cnt
RGB color
S
S1 sensor
,
safety information
safety inspection guide
sensors bin-full/narrow media
Base Sensor Test (standard bin)
parts catalog
removal
service check
duplex (S1)
Base Sensor Tests
parts catalog
removal
service check
front door service check
fuser exit
Base Sensor Test
parts catalog
removal
service check
input (S2)
Base Sensor Test
Base Sensor Tests
service check
toner density sensor (TDS) parts catalog
removal
toner meter cycle
Base Sensor Tests
tray present
parts catalog
removal
service check
serial number
service checks
90x.xx error
925.01—fan error
bin-full/narrow media sensor
duplex/manual feed sensor (S1)
fuser exit sensor
input (S2) sensor
main drive gear assembly
operator panel USB cable
paper pickdrive assembly
print quality
toner meter cycle (TMC) card
transfer roll
tray (x) sensor
trays 2 and 3
skew setting
specifications
connectivity (network)
data streams
dimensions
environmental
memory
operating modes
print quality
specifications power and electrical
start
symptoms print quality
printer
T
test pages print quality test pages
,
theory color theory
EP process
paper path
transport components
toner cartridge contacts parts catalog
toner density sensors (TDS) parts catalog
TPS Setup
toner meter cycle (TMC) card
parts catalog
toner meter sensors service check
transfer roll
tray (x) parts catalog
tray 1 parts catalog
tray 1 tray present sensor location
tray present sensor
tray tests
Feed Tests
U
USB port clipping the cable
operator panel port service check
operator panel USB cable
parts catalog
printer connection service check
W
waste toner bottle contact, removal
waste toner bottle, removal
wireless network antenna parts catalog
wireless network card
parts catalog
5025-2xx, 4xx
Index
I-5
5025-2xx, 4xx
I-6
Service Manual
Part number index
Description and P/N
5025-2xx, 4xx
Page
40X5406
40X5407
40X5408
40X5409
40X5411
40X5412
40X5413
40X5414
40X5415
40X5416
40X5417
40X5418
40X5419
40X5420
40X2284
40X2285
40X2512
40X2867
40X3141
40X4596
40X5036
40X5168
40X5319
40X5403
40X5404
40X5405
40X1538
40X1557
40X1766
40X1772
40X1773
40X1791
40X1792
40X2254
40X2255
40X2261
40X2263
40X2268
40X0270
40X0271
40X0273
40X0275
40X0279
40X0287
40X0288
40X0301
40X0303
40X0395
40X1368
40X1455
40X1525
40X1526
Power cord, 2.5M (straight)—Japan
- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
7-7
Power cord, 2.5M (straight)—United Kingdom
- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
7-7
Power cord, 2.5M (straight)—Chile, Uruguay
- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
7-7
Power cord, 2.5M (straight)—Israel
- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
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 (straight)—Australia
- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
7-7
Power cord, 2.5M (straight)—PRC
- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
7-7
Field relocation package assembly
- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
USB cable, packaged (2 m)
64MB Flash card assembly
Controller board—C544n, C544dn, C544dw
- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
7-7
Controller board—C540n, C543dn
- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
7-7
Optional 550-sheet drawer (complete)—C546dtn only
- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
Paper pick motor drive assembly
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
- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
7-7
Power cord, 2.5M (straight)—Taiwan
- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
7-7
Power cord, 2.5M (straight)—Korea
- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
7-7
115 V Maintenance kit
230 V Maintenance kit
100 V Maintenance kit
Duplex reference edge
7-5
Controller board—C546dn only
7-7
Optional 650-sheet Duo Drawer (complete)—C546dtn only
- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
650-sheet Duo Drawer tray assembly—C546dtn only
- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
550-sheet MPF latch cover
Name plate, C546dtn
7-3
Power cord, 2.5M (straight)—Paraguay
- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
7-7
Power cord, 1.8M (straight)—Brazil
- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
7-7
Wireless network card assembly—C544dw only
- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
7-7
Pick tires
Antenna for wireless card—C544dw only
- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
7-7
Image transfer unit (ITU) assembly
- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
7-5
Toner meter cycle card assembly
7-7
High-voltage power supply
7-7
Fuser assembly, 115 V
7-5
Fuser assembly, 230 V
7-5
Fuser assembly 100 V
7-5
Low-voltage power supply (universal power supply)
- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
7-7
Printhead
7-5
Main drive gear assembly, with motors
- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
7-5
Fuser exit sensor
7-7
Toner density sensors, left or right
- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
7-9
Fuser drive motor assembly
7-5
Right cover assembly
7-3
Left cover assembly
7-3
Top cover assembly
7-3
250-sheet tray assembly
7-3
Front cover assembly (excluding duplex and USB port cable)—C540n
- - - - - - - - - - - - - - - - - - - - - - - - -
7-3
Part number index
I-7
5025-2xx, 4xx
40X5421
40X5422
40X5423
40X5424
40X5425
40X5426
40X5429
40X5430
40X5431
40X5432
40X5433
40X5434
40X5435
40X5436
40X5441
40X5937
40X5938
40X5939
40X5969
40X5970
40X5971
40X5972
40X7046
Toner cartridge contacts (Pogo pin)
- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
7-9
Lower left frame and lower right frame with cable cover
- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
7-5
Cable packet
7-9
Screw packet
7-5
USB port and cable
7-9
Photo sensor and retainer
7-7
ITU paper path thermistor
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
650-sheet Duo Drawer tray only —C544n, C544dn, C544dw, C540n, C543dn
- - - - - - - - - - - - - - - - -
Operator panel (DBCS) and display assembly
- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
7-3
Dust cover
7-3
128MB DDR DRAM DIMM card assembly
- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
256MB DDR DRAM DIMM card assembly
- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
512MB DDR DRAM DIMM card assembly
- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
Korean font card assembly
Simplified Chinese font card assembly
- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
Traditional Chinese font card assembly
- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
Japanese font card assembly
Waste toner bottle contact block
7-9
I-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 marks represents a repeating defect that occurs every 34.6 mm (1.4 in.), which means the photoconductor unit may need to be replaced.
Note: If the defect appears on the printed side of a single-sided print job, replace the
toner cartridge before replacing the fuser.
Replace the
ITU.
78.5 mm
(3.1 in.)
Replace the
photoconductor.
94.2 mm
(3.71 in.)
Replace the
fuser.
95 mm
(3.74 in.)
Replace the
developer.
43.9 mm
(1.7 in.)
Replace the
ITU.
37.7 mm
(1.5 in.)
Replace the
ITU.
55 mm
(2.2 in.)
Replace the
photoconductor.
34.6 mm
(1.4 in.)
advertisement
Key Features
- Laser Colour
- 1200 x 1200 DPI
- A4 23 ppm
- Duplex printing
- Maximum duty cycle: 55000 pages per month
- Total input capacity: 901 sheets Total output capacity: 100 sheets
- Internal memory: 256 MB 500 MHz