Lexmark C540n Service Manual
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Lexmark C540n Service Manual

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Revision: September 17, 2012
™
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.

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Summary of Contents for Lexmark C540n

  • Page 1 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.
  • Page 2 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.

  • Page 3: Table Of Contents

    5025-2xx, 4xx Table of contents Previous Table of contents ............iii Notices and safety information .
  • Page 4 5025-2xx, 4xx 90x.xx error (902.xx–907.xx) ............2-24 Previous 925.01—Fan error service check .
  • Page 5 5025-2xx, 4xx Print quality test pages (Prt Qual Pgs) ......... . . 3-11 Previous Hardware Tests .
  • Page 6 5025-2xx, 4xx Using FTP ..............3-28 Previous Using the Web server .
  • Page 7 5025-2xx, 4xx Low-voltage power supply (LVPS) assembly removal ....... . . 4-51 Previous Lower frame removal, right and left .
  • Page 8 5025-2xx, 4xx Previous Next Go Back Service Manual viii...

  • Page 9: Notices And Safety Information

    9-17-2012 5025-2xx, 4xx Notices and safety information Previous The laser notice label may be affixed to this printer. Next Laser notice Go Back This product 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.

  • Page 10: Aviso Sobre O Laser

    9-17-2012 5025-2xx, 4xx Previous Avvertenze sui prodotti laser Questo prodotto è certificato negli Stati Uniti come prodotto conforme ai requisiti DHHS 21 CFR Sottocapitolo J per i prodotti laser di Classe I (1), mentre in altri paesi è certificato come prodotto laser di Classe I conforme ai requisiti IEC 60825-1.
  • Page 11 9-17-2012 5025-2xx, 4xx Previous Laserinformatie Dit product is in de Verenigde Staten gecertificeerd als een product dat voldoet aan de vereisten van DHHS 21 CFR paragraaf J voor laserproducten van klasse I (1). Elders is het product gecertificeerd als een laserproduct van klasse I dat voldoet aan de vereisten van IEC 60825-1.
  • Page 12 9-17-2012 5025-2xx, 4xx Previous Laser-notis Denna produkt är certifierad i USA i enlighet med kraven i DHHS 21 CFR underkapitel J för klass I (1)- laserprodukter, och på andra platser certifierad som en klass I-laserprodukt i enlighet med kraven i IEC 60825-1. Next Klass I-laserprodukter betraktas inte som skadliga.
  • Page 13 9-17-2012 5025-2xx, 4xx Previous Next Go Back Notices and safety information xiii...
  • Page 14 9-17-2012 5025-2xx, 4xx Previous Next Go Back Service Manual...

  • Page 15: Safety Information

    9-17-2012 5025-2xx, 4xx Previous 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. Next The maintenance information for this product has been prepared for use by a professional service person •...
  • Page 16 9-17-2012 5025-2xx, 4xx Previous 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. Next Die Wartungsinformationen für dieses Produkt sind ausschließlich für die Verwendung durch einen •...
  • Page 17 9-17-2012 5025-2xx, 4xx Previous 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 Next seguretat si s'utilitzen peces de recanvi no autoritzades. •...

  • Page 18: Preface

    9-17-2012 5025-2xx, 4xx Preface Previous This manual contains maintenance procedures for service personnel. It is divided into the following chapters: General information contains a general description of the printer and the maintenance approach used to Next repair it. Special tools and test equipment, as well as general environmental and safety instructions, are discussed.

  • Page 19: Change History

    9-17-2012 5025-2xx, 4xx Previous Change history Revision date Updates 2012/01/06 • Changed PN 40X5405 to PN 40X8395 for the “High-voltage power supply” on Next page 7-7 • Updated the “High-voltage power supply (HVPS) assembly removal” on page 4-38. 2011/11/11 • Changed PN 40X2263 to PN 40X5803 for the “Duplex reference edge”...

  • Page 20: Conventions

    9-17-2012 5025-2xx, 4xx Previous Conventions Note: A note provides additional information. Warning: A warning identifies something that might damage the product hardware or software. Next There are several types of caution statements you may see in this book: CAUTION Go Back A caution identifies something that might cause a servicer harm.

  • Page 21: General Information

    1. General information Previous 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.

  • Page 22: Options And Features

    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.

  • Page 23: Print Quality

    CANNOT be installed post- manufacturing. 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 •...

  • Page 24: Operating Modes

    • The operator panel back light is off. • Power supply energy consumption is reduced. • Energy + Paper All of the above. Data streams ✔ —Supported ✘ Lexmark C540n, Lexmark C544n, —Not supported Lexmark C546dtn C543dn C544dn, C544dwn Data streams ✔...

  • Page 25: Dimensions

    5025-2xx, 4xx Dimensions Previous Models Height Width Depth Weight Lexmark C540n, C543dn, 291 mm (11.5 in.) 424 mm (16.7 in.) 400 mm (15.7 in.) 21 kg (46.2 lbs) C544n, C544dn(w) Next Lexmark C546dtn (includes 422 mm (16.6 in.) 424mm (16.7 in.) 416 mm (16.4 in.)

  • Page 26: Power And Electrical Specifications

    18 W 18 W 18 W Ready 34 W 36 W 36 W Automatic duplex is not supported on the C540n and C544n. Typical electricity consumption Power supply voltage (kwh) Model Mode 100 V/50 Hz 115 V/60 Hz 230 V/50 Hz Lexmark C540n and C543dn 3.73 kwh...

  • Page 27: Acoustics

    All acoustic measurements are made in accordance with ISO 7779-1999 and reported in conformance with ISO9296:1988-04-15. Operating mode 1-Meter average sound pressure at 4800 CQ Lexmark Lexmark Lexmark Lexmark Lexmark C540n C543dn C544n C544dn C546dtn Printing (simplex) 47 dBA 47 dBA 49 dBA...

  • Page 28: Media Handling

    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. Service Manual...

  • Page 29: Duplex Capability

    5025-2xx, 4xx Duplex capability Previous ✔ —Supported ✘ —Not supported Next Models Duplex capability ✘ Lexmark C540n Go Back ✔ Lexmark C543dn ✘ Lexmark C544n ✔ Lexmark C544dn ✔ Lexmark C544dw ✔ Lexmark C546dtn Media output size and type There is a single 100-sheet output bin on this printer, and no additional output options.
  • Page 30 5025-2xx, 4xx Previous ✔ —Supported without size sensing ✘ —Not supported Next Input source Go Back Universal ✔ ✔ ✔ ✔ ✔ 148 x 210mm to ✘ 216 x 356mm (5.8 x 8.3 in. to 8.5 x 14 in.) ✘ ✘...

  • Page 31: Media Input Type Specifications

    5025-2xx, 4xx Media input type specifications Previous ✔ —Supported ✘ —Not supported Next Input type Go Back ✔ ✔ ✔ ✔ ✔ ✔ Plain paper ✘ ✔ ✔ ✔ ✔ ✔ Card stock ✘ ✔ ✔ ✔ ✔ ✔ Transparency ✔...

  • Page 32: Media Guidelines

    (16–28 pound) grain long bond. The duplex unit does not support card stock, transparencies, envelopes, or labels. 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 (23.9 to 27.8 lb) must be printed with Paper Type set to Heavy Paper.

  • Page 33: Unacceptable Paper

    5025-2xx, 4xx Smoothness—Paper smoothness directly affects print quality. If paper is too rough, toner cannot fuse to it • Previous 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.

  • Page 34: Storing Paper

    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.

  • Page 35: Tools Required For Service

    5025-2xx, 4xx Previous Tools required for service Flat-blade screwdrivers, various sizes #1 Phillips screwdriver, magnetic #2 Phillips screwdriver, magnetic Next #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 Go Back 7.0 mm nut driver Needlenose pliers...

  • Page 36: Acronyms

    5025-2xx, 4xx Previous Acronyms BLDC Brushless DC Motor Cyan DIMM Dual Inline Memory Module Next DRAM Dynamic Random Access Memory EEPROM Electrically Erasable Programmable Read-Only Memory ElectroPhotographic Go Back Electrostatic Discharge Field Replaceable Unit Gigabyte HVPS High-Voltage Power Supply Image Transfer Unit Imaging Unit Japanese Industry Standard Black...

  • Page 37: Diagnostic Information

    5025-2xx, 4xx 2. Diagnostic information Previous Start Next CAUTION Unplug power cord from the electrical outlet before you connect or disconnect any cable or Go Back electronic board or assembly for personal safety and to prevent damage to the printer. Disconnect any connections between the printer and PCs/peripherals.

  • Page 38: Por (Power-On Reset) Sequence

    5025-2xx, 4xx Previous 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. Next 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: Go Back The LED turns on.

  • Page 39: Symptom Tables

    5025-2xx, 4xx Previous Symptom tables Printer symptom table Next Symptom Action Dead printer Go to “Dead printer service check” on page 2-27. Operator panel—one or more buttons do Go to Go Back “One or more operator panel buttons fail” on not work.

  • Page 40: Print Quality Symptom Table

    5025-2xx, 4xx Print quality symptom table Previous Symptom Action Background Go to “Print quality—background” on page 2-44. Blank page Go to “Print quality—blank page” on page 2-45. Next Blurred or fuzzy print Go to “Print quality—blurred or fuzzy print” on page 2-46.

  • Page 41: Error Codes And Messages

    5025-2xx, 4xx Previous Error codes and messages User status and customer attendance messages Next User primary Explanation message Busy Wait for the message to clear. Go Back Calibrating The printer is performing a color adjustment. Wait for the message to clear. Close door Message clears when front cover, right cover, and toner door are closed or securely fastened.
  • Page 42 5025-2xx, 4xx Previous User primary Explanation message Load <source> Printer does not detect media meeting the size or type requested in the source <type> <size> indicated. • Load the input source with the correct type and size media. Next • Press Stop ( ), and then press Select ( ) to cancel printing.
  • Page 43 5025-2xx, 4xx Previous User primary Explanation message Remote Management The printer is offline while it configures settings. Wait for the message to clear. Active Remove paper from The following actions can be taken: Next standard output bin • Remove paper from the standard exit bin to clear the message and continue printing.
  • Page 44 5025-2xx, 4xx Previous User primary Explanation message 31.xx Defective Defective imaging kit. Imaging Kit The following actions can be taken: • Open and close the top cover. Next • Remove and re-install the imaging kit. • Turn the printer power off, and after a few seconds, turn the printer power back Go Back If the message persists, determine if the imaging kit counter is greater than 15,000 cycles.
  • Page 45 5025-2xx, 4xx Previous User primary Explanation message 38 Memory Full 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: Next •...
  • Page 46 5025-2xx, 4xx Previous User primary Explanation message 54 Standard network The printer detects a network port, but cannot communicate with it. The printer software error disables all communication to the associated network interface. The following actions can be taken: Next •...

  • Page 47: Paper Jam Messages

    5025-2xx, 4xx Previous User primary Explanation message 88.xx <color> The term <color> includes black, cyan, magenta, and yellow. Replace the toner Cartridge is low cartridge, and then close the toner door to clear the message and continue printing. 88 Replace <color> The term <color>...
  • Page 48 5025-2xx, 4xx Paper jam messages (2xx) (continued) Previous Error code Description Action 243.xx Paper Jam A single or multiple page media jam in Open the door, and remove all the jammed Check <area> the optional 550-sheet drawer (tray 3). pages. See “242 paper jam in the 650- sheet Duo Drawer”...

  • Page 49: Service Error Messages

    5025-2xx, 4xx Service error messages Previous Service error messages (1xx, 9xx) Error code Description Action Next 106.xx Service Yellow printhead error. Perform a POR. If the problem persists, go Yellow Printhead “Printhead service check” on page 2-52. Go Back 106.01 Service The yellow printhead lost HSYNC.
  • Page 50 5025-2xx, 4xx Service error messages (1xx, 9xx) (continued) Previous Error code Description Action 107.08 Service The cyan laser showed bad in testing. Perform a POR. If the problem persists, go Cyan Printhead “Printhead service check” on page 2-52. Next 107.11 Service Failure writing data tot he printhead.
  • Page 51 5025-2xx, 4xx Service error messages (1xx, 9xx) (continued) Previous Error code Description Action 109.02 Service The black printhead failed to complete Perform a POR. If the problem persists, go Black Printhead servo. “Printhead service check” on page 2-52. Next 109.03 Service The black printhead mirror motors Perform a POR.
  • Page 52 5025-2xx, 4xx Service error messages (1xx, 9xx) (continued) Previous Error code Description Action 122.08 Service Wrong lamp bit is set in NVRAM. Go to “Fuser service check” on Fuser Error page 2-31. Next 122.10 Service Fuser failed to warm up. Go to “Fuser service check”...
  • Page 53 5025-2xx, 4xx Service error messages (1xx, 9xx) (continued) Previous Error code Description Action 150.05 Service Lost lock for motor. Go to “Main drive gear assembly (EP Black/ITU cartridge drive) service check” on page 2-33. Motor Next 150.06 Service Excessive SAP BLDC PWM. Go to “Main drive gear assembly (EP Black/ITU cartridge...
  • Page 54 5025-2xx, 4xx Service error messages (1xx, 9xx) (continued) Previous Error code Description Action 908.03 Service NVM_OK was not received from NV2 Go to “90x.xx error (902.xx–907.xx)” on Engine Software server for successfully submitted page 2-24. request. Next 908.04 Service Over temperature condition detected. Go to “90x.xx error (902.xx–907.xx)”...
  • Page 55 5025-2xx, 4xx Service error messages (1xx, 9xx) (continued) Previous Error code Description Action 953.xx Service NVRAM chip failure with mirror. NVRAM Failure Next 954.xx Service The NVRAM chip failure with controller NVRAM Failure part. 955.xx Service The Code ROM or NAND flash failed Go Back Code CRC <loc>...
  • Page 56 5025-2xx, 4xx Service error messages (1xx, 9xx) (continued) Previous Error code Description Action 959.05 Service Unknown Boot Failure. Update firmware or replace the controller Invalid Firmware board. See “Controller board removal” on page 4-20. Next 959.20 Service System hardware failure. Replace the controller board.
  • Page 57 5025-2xx, 4xx Service error messages (1xx, 9xx) (continued) Previous Error code Description Action 976.xx Service Unrecoverable software or error in If unable to clear the error message, check Standard Network network or network card x. the following: Next • If installed, check network card for correct installation.

  • Page 58: Service Checks

    Note: Before troubleshooting, determine the operating system used when the error occured. If possible determine whether a PostScript or PCL file was sent to the device when the error occured. Ask the customer which Lexmark Solutions applications are installed on the device. Step Action and questions POR the device.
  • Page 59 Reinstall the memory, and send a print job to the Go to step 15. Go to step 16. device. Does the 900.xx error reoccur? Install a Lexmark recommended memory option. Send Go to step 31. Problem a print job to the device. resolved.

  • Page 60: 90X.xx Error (902.Xx-907.Xx)

    5025-2xx, 4xx Previous Step Action and questions Reinstall the first ISP option. Restart the device. Go to step 24. Go to step 23. Does the 900.xx error reoccur? Run a job to test the option. Go to step 24. Go to step 26. Next Does the 900.xx error reoccur? Upgrade the firmware.

  • Page 61: 925.01-Fan Error Service Check

    5025-2xx, 4xx 925.01—Fan error service check Previous Step Questions / actions Turn the printer off, and remove the rear Replace the top cover Replace the controller shield. See (which includes the fan). board. See “Top cover assembly removal” “Controller Next 4-13.

  • Page 62: 950.Xx Nvram Failure Service Check

    5025-2xx, 4xx 950.xx NVRAM Failure service check Previous Replace one of the following components, and perform a POR before replacing a second Warning: 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 •...

  • Page 63: Dead Printer Service Check

    5025-2xx, 4xx Dead printer service check Previous 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.

  • Page 64: Duplex/Manual Feed Sensor (S1) Service Check

    5025-2xx, 4xx Duplex/manual feed sensor (S1) service check Previous Step Questions / actions Is the printer setting on a hard, flat surface? Go to step 2. Make sure the printer is setting on a level, flat Next surface. Enter Diagnostics Menu (turn the printer off, Go to step 3.

  • Page 65: Front Door Sensor Or Switches Service Check

    5025-2xx, 4xx Front door sensor or switches service check Previous Step Questions / actions Enter Diagnostics Menu (turn the printer off, Sensor, toner door, and Go to step 2. press and hold , turn the printer on, right doors are OK. Next and then release the buttons when the installed memory and processor speed...

  • Page 66: Fuser Exit Sensor Service Check

    5025-2xx, 4xx Previous Step Questions / actions Close the front cover and the toner door. Be Contact your next level of Replace the front cover sure the right cover is in place. Turn the printer support. assembly. See “Front off, and then disconnect the cables at JINT1 cover assembly removal”...

  • Page 67: Fuser Service Check

    5025-2xx, 4xx Previous Step Questions / actions Turn the printer on, and check the values at Replace the fuser exit Replace the controller JBIN1: sensor. See board. See “Fuser exit “Controller sensor removal” on board removal” on JBIN1 page 4-36. page 4-20.

  • Page 68: Input (S2) Sensor Service Check

    5025-2xx, 4xx Previous Step Questions / actions Check the following values at JFUSES1: Go to step 6. Replace the controller board. See “Controller JFUSES1 board removal” on page 4-20. Next Value +24 V dc (doors closed) +24 V dc (doors closed) Go Back +24 V dc (doors closed) +24 V dc (doors closed)

  • Page 69: Main Drive Gear Assembly (Ep Drive) Service Check

    5025-2xx, 4xx Previous Step Questions / actions Turn the printer on, and check the voltage at Replace the paper pick Replace the controller JSP1 pin 15. motor drive assembly. See board. See “Controller “Paper pick motor drive board removal” on Is the voltage approximately +5 V dc? assembly removal—...

  • Page 70: Networking Service Check

    Next 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. Go Back Step...
  • Page 71 5025-2xx, 4xx Previous Step Questions / actions Try using a different ethernet cable. Problem resolved Go to step 14. Did this remedy the situation? Have the network administrator check the Replace the controller Contact the network Next network drop for activity. board.

  • Page 72: Operator Panel Service Check

    5025-2xx, 4xx Operator panel service check Previous Replace one of the following components, and perform a POR before replacing a second Warning: 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 •...

  • Page 73: Operator Panel Display Blank, Five Beeps

    5025-2xx, 4xx Operator panel display blank, five beeps Previous 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.

  • Page 74: Operator Panel Display Blank, Printer Beeps Five Times And Pauses

    5025-2xx, 4xx Operator panel display blank, printer beeps five times and pauses Previous Step Questions / actions Turn the printer off, and remove the rear Go to step 2. Replace the controller shield. See board. See “Top cover assembly removal” “Controller Next on page...

  • Page 75: Operator Panel Displays All Diamonds, No Beeps

    5025-2xx, 4xx Operator panel displays all diamonds, no beeps Previous Step Questions / actions Turn the printer off, and remove the rear Go to step 2. Replace the controller shield. See board. See “Top cover assembly removal” “Controller Next on page 4-13.

  • Page 76: Operator Panel Displays All Diamonds, Five Beeps

    5025-2xx, 4xx Operator panel displays all diamonds, five beeps Previous Step Questions / actions Turn the printer off, and remove the rear Go to step 2. Replace the controller shield. See board. See “Top cover assembly removal” “Controller Next on page 4-13.

  • Page 77: Operator Panel Display Is Dim And Unchanging

    5025-2xx, 4xx Operator panel display is dim and unchanging Previous Step Questions / actions Turn the printer off, and remove the rear Go to step 2. Replace the controller shield. See board. See “Top cover assembly removal” “Controller Next on page 4-13.

  • Page 78: Paper Pick Motor Drive Assembly Service Check

    5025-2xx, 4xx Paper pick motor drive assembly service check Previous Note: The input (S2) sensor is part of the paper pick motor drive assembly, and is not available separately. Step Questions / actions Next Turn the printer off, and then remove the rear Go to step 3.
  • Page 79 5025-2xx, 4xx RGB Brightness, RGB Contrast, RGB Saturation: Set to 0. – Previous – 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: Next Inspect the imaging unit for damage, including the developers and toner cartridges.

  • Page 80: 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 Next occur by running a large amount of graphics in a humid environment.

  • Page 81: Print Quality-Blank Page

    5025-2xx, 4xx Print quality—blank page Previous Next Go Back Step Questions / actions Is all the packing material for the imaging unit Go to step 2. Remove the packing in question removed? material. Print a document that requires all four colors Replace the developer unit Go to step 3.

  • Page 82: Print Quality-Blurred Or Fuzzy Print

    5025-2xx, 4xx Previous Step Questions / actions Remove the developer unit. See Go to step 6. Clean the developer “Developer 4-21. Check the cartridge contacts. See unit removal” on page developer cartridge contacts from the HVPS to “Developer unit removal” the IU.

  • Page 83: Print Quality-Horizontal Banding

    5025-2xx, 4xx Print quality—horizontal banding Previous Print the Print Defect Page: At the Ready prompt, press Menu ( Select Reports, and press Select ( Next Select Print Defects, and press Select ( Go Back Step Questions / actions Measure the distance between repeating Replace the photoconductor Go to step 2.

  • Page 84: Print Quality-Insufficient Fusing

    5025-2xx, 4xx Print quality—insufficient fusing Previous Next Go Back Step Questions / actions Is the printer setup to use the correct media? Go to step 2. Change the settings to indicate the correct media. Check the fuser connections on the left and Go to step 3.

  • Page 85: Print Quality-Narrow Vertical Line

    5025-2xx, 4xx Print quality—narrow vertical line Previous ABCDE ABCDE Next ABCDE Go Back Step Questions / actions Replace the photoconductor unit. See Problem resolved. Replace the developer unit. “Imaging unit (IU) removal” on page 4-49. “Developer unit removal” on page 4-21.

  • Page 86: Print Quality-Residual Image

    5025-2xx, 4xx Print quality—residual image Previous ABCDE ABCDE Next ABCDE Go Back Step Questions / actions Check the condition of the imaging unit using Go to step 2. Replace the imaging unit or the customer menus (administrative menus): the photoconductor unit. “Imaging unit (IU) 1.

  • Page 87: Print Quality-Solid Color Page

    5025-2xx, 4xx Print quality—solid color page Previous 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. Next Go Back Step...

  • Page 88: Printhead Service Check

    5025-2xx, 4xx Printhead service check Previous This service check includes the following errors: Error code Color Next 106.xx Yellow 107.xx Cyan 108.xx Magenta Go Back 109.xx Black Step Questions / actions Turn the printer off, and remove the rear Replace the printhead. See Go to step 2.

  • Page 89: Toner Meter Cycle (Tmc) Card

    5025-2xx, 4xx Toner meter cycle (TMC) card Previous Step Questions / actions Perform the Base Sensor Test: Replace the toner cartridge. Replace the toner meter cycle (TMC) card. See Next 1. Enter Diagnostics menu (turn the printer “Toner meter cycle (TMC) off, press and hold and Select ( ), turn...

  • Page 90: Transfer Roll Service Check

    5025-2xx, 4xx Transfer roll service check Previous Step Questions / actions Remove the ITU. See Replace the ITU. See Problem resolved. “Image transfer unit 4-44. Check the (ITU) removal” on page “Image transfer unit (ITU) Next contacts between the HVPS and the ITU. removal”...
  • Page 91 5025-2xx, 4xx Previous Step Questions / actions Check the vertical wall at the right rear of the Replace the tray. Go to step 3. tray for damage. Next Go Back Is the tray damaged? Check for a dislodged tray present sensor. Replace the option tray Contact the next level of present sensor.

  • Page 92: Trays 2 And 3 (Optional) Service Check

    5025-2xx, 4xx Previous Step Questions / actions 1. Turn off the printer Problem resolved. Replace the controller board. See 2. Remove the rear shield. See “Controller “Top cover board removal” on assembly removal” on page 4-13. page 4-20. 3. Disconnect the cable at JTRAY1 connector Next for tray1 or JOPT1 for tray 2 and 3 on the controller board.

  • Page 93: Usb Service Check

    5025-2xx, 4xx Previous Step Questions / actions Print a menu settings page. Go to step 9. • If the 550 sheet option failed to appear, go to Note: If two option trays are used, the 650 step 9. sheet will appear as tray 2, and the 550 sheet •...

  • Page 94: User Operator Panel And Administration Menus

    5025-2xx, 4xx Previous 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 Next located to the left of the display and the navigation buttons are located below the display. Go Back Menu Indicator...

  • Page 95: Menu Map

    5025-2xx, 4xx Menu map Previous 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 Next menu items may only be effective for a particular printer language.
  • Page 96 5025-2xx, 4xx Previous Next Go Back Service Manual 2-60...

  • Page 97: Diagnostic Aids

    5025-2xx, 4xx 3. Diagnostic aids Previous Accessing service menus Next There are different test menus that can be accessed during POR to identify problems with the printer. Diagnostics Menu 1. Turn the printer off. The Diagnostics menu group contains the settings Go Back and operations used while manufacturing and 2.

  • Page 98: Diagnostics Menu (Diag Menu)

    5025-2xx, 4xx Previous Diagnostics Menu (Diag Menu) Note: Tray 2 refers to the 550-sheet tray located in the 650-sheet Duo Drawer. Diagnostics Menu structure Next 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 Go Back order shown.
  • Page 99 5025-2xx, 4xx Diagnostics Menu (continued) Previous Sensor Test “Sensor Test (not available on all printers)” on page 3-15. Base Sensor Test Front Door “Base Sensor Test” on page 3-16. Next Input - S1 Input - S2 Fuser exit Sensr Go Back Standard Bin C-TMC M-TMC...
  • Page 100 5025-2xx, 4xx Diagnostics Menu (continued) Previous Event Log Display Log “Display Log” on page 3-22. Print Log “Print Log” on page 3-22. Next Clear Log “Clear Log” on page 3-23. This selection exits the Diagnostics Menu. The printer performs a POR, Exit Diags and returns to normal mode.

  • Page 101: Skew

    See for instructions on setting printhead “Alignment” on page 3-7 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 Margin Settings Page Count...
  • Page 102 5025-2xx, 4xx • General printer information, including current page count, installed memory, serial number, and code level. Previous Next Go Back To print the Quick Test page: Note: Print the Quick Test Page on letter or A4 paper. Select Registration from Diag Menu, and press Select ( Select Quick Test Page, and press Select ( The message Printing…...

  • Page 103: Alignment

    5025-2xx, 4xx Alignment Previous 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. Next To get started: Select Alignment Menu from the Diag Menu, and press Select (...
  • Page 104 5025-2xx, 4xx Select Top Margin, and press Select ( Previous 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. Next Go Back to enter the sum of the numbers, and press Select ( Submitting changes…...
  • Page 105 5025-2xx, 4xx Select the Skew value in the same way, enter the value, press Select ( ), and print the Quick Test to see Previous if the observed values and the current values are the same. Next Go Back On the second page of the latest Quick Test you printed, proceed to Step 2; adjust the left, right, and bow settings.

  • Page 106: Print Tests

    5025-2xx, 4xx Print Tests Previous 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 Next source.

  • Page 107: Print Quality Test Pages (Prt Qual

    5025-2xx, 4xx Print quality test pages (Prt Qual Pgs) Previous 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. Next Go Back This test may be printed from either the Configuration Menu or the Diagnostics Menu.

  • Page 108: Button Test

    5025-2xx, 4xx Button Test Previous This test verifies the operator panel button function. To run the Button Test: Select Hardware Tests from Diag Menu, and press Select ( Next Select Button Test, and press Select ( Press count: 0 appears. Go Back Press each operator panel button, and watch to see if the count of button presses increases by one for each press.

  • Page 109: Duplex Tests

    5025-2xx, 4xx Duplex Tests Previous 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. Next Go Back Note: Before you set the duplex top margin, be sure to set the registration.

  • Page 110: Top Margin (Duplex)

    5025-2xx, 4xx Top Margin (duplex) Previous 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.

  • Page 111: Input Tray Tests

    5025-2xx, 4xx Input Tray Tests Previous Feed Tests Any installed input tray can be tested. The pages fed through the printer are blank. Next To run the Feed Test: Select INPUT TRAY TESTS from Diag Menu, and press Select ( Go Back Select Feed Tests, and press Select ( Select the tray to be tested.

  • Page 112: Base Sensor Test

    5025-2xx, 4xx Base Sensor Test Previous These tests allow you to verify the correct functioning of the front door, input, and output sensors. Select Base Sensor Test from Diag Menu, and press Select ( Select the sensor you want to test, and press Select ( Next The following tests are available: Go Back...

  • Page 113: Miscellaneous Tests

    5025-2xx, 4xx Miscellaneous tests Previous Motor Detect This test initiates an automatic motor detection process that should be performed whenever the controller board is replaced. Next To run Motor Detect: Go Back Remove the imaging unit and the waste toner bottle. See “Imaging unit (IU) removal”...

  • Page 114: Printer Setup

    5025-2xx, 4xx Printer Setup Previous 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. Next Warning: Changing this setting resets the printer to factory defaults, and data may be lost.

  • Page 115: Configuration Id

    5025-2xx, 4xx Configuration ID Previous 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.

  • Page 116: Reset Fuser Cnt

    5025-2xx, 4xx Reset Fuser Cnt Previous 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 “Event Log” on page 3-25 Maintenance Warning and Intervention function is enabled in the printer Configuration ID.

  • Page 117: Tps Setup

    5025-2xx, 4xx TPS Setup Previous 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. Next To enter the value: Go Back...

  • Page 118: Reports

    5025-2xx, 4xx Reports Previous Menu Settings Page To print the Menu Settings Page: Next Select Reports from Diag Menu, and press Select ( Select Menu Settings Page, and press Select ( Go Back 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.

  • Page 119: Clear Log

    5025-2xx, 4xx The printed event log can be faxed to your next level of support for verification or diagnosis. Previous To print the event log: Select Event Log from Diag Menu, and press Select ( Select Print Log, and press Select ( Next Press Back ( ) to return to Event Log.

  • Page 120: Configuration Menu (Config Menu)

    5025-2xx, 4xx Previous Configuration menu (Config Menu) Available tests The tests display on the operator panel in the order shown for all models. Next Configuration menu Go Back Prt Quality Pgs “Prt Quality Pgs” on page 3-24. Color Trapping “Color Trapping” on page 3-24.

  • Page 121: Reports

    5025-2xx, 4xx Reports Previous 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. Next To print the menu settings: Go Back...

  • Page 122: Factory Defaults

    5025-2xx, 4xx Factory Defaults Previous 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: Next All downloaded resources (fonts, macros, symbol sets) in the printer memory (RAM) are deleted.

  • Page 123: Auto Color Adj

    5025-2xx, 4xx Auto Color Adj Previous 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. Next 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.

  • Page 124: Updating Printer Firmware

    5025-2xx, 4xx Previous Updating printer firmware Before performing a firmware update on the printer, contact your next level support to confirm, or Warning: obtain the correct code. The wrong code, or wrong level of code could lead to a malfunction or render the device inoperable.

  • Page 125: Using The Host Computer To Update The Firmware Over Usb

    5025-2xx, 4xx In the browser that opens, browse to the file you want to use. Previous Note: The new file must be available to the computer. Click Open. Various status and progress messages will appear. The printer will reboot. The HTTP session will terminate.
  • Page 126 5025-2xx, 4xx Select the printer from the list of printers installed on the computer. Previous Next Go Back Lexmark C54x series Press Start. Repeat these steps for every file you are updating on the printer. Service Manual 3-30...

  • Page 127: Paper Jams

    Next Use only recommended paper or specialty media. • For more information, see the Card Stock & Label Guide available on the Lexmark Web site at Go Back www.lexmark.com/publications. Do not load too much paper. Make sure the stack height does not exceed the indicated maximum height.

  • Page 128: Understanding Jam Numbers And Locations

    5025-2xx, 4xx Understanding jam numbers and locations Previous Next Go Back 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.

  • Page 129: 200 Paper Jams

    5025-2xx, 4xx 200 paper jams Previous Remove the standard 250-sheet tray (tray 1). Remove the jam. Note: Make sure all paper fragments are removed. Next Go Back Insert the tray. Press Select ( 201 paper jam Grasp the front door at the side handholds, and then pull it toward you to open it. Remove the jammed paper.
  • Page 130 5025-2xx, 4xx 202 paper jam Previous Grasp the front door at the side handholds, and then pull it toward you to open it. Grasp the green lever, and pull the fuser cover toward you. Next Go Back Hold the fuser cover down, and then remove the jammed paper. The fuser cover closes when released.

  • Page 131: 235 Paper Jam

    5025-2xx, 4xx 230 paper jam Previous Grasp the front door at the side handholds, and pull it toward you to open it. Remove the jam. Close the front door. Press Select ( ) to continue printing. Next 235 paper jam Go Back Load the tray with the correct paper size (supported for duplex).

  • Page 132: 243 Paper Jam In The 550-Sheet Drawer

    5025-2xx, 4xx 243 paper jam in the 550-sheet drawer Previous Remove the 550-sheet tray (tray 3). Remove the jam. Note: Make sure all paper fragments are removed. Check the tray adjustments for the size of paper used. Next Check the pick tires for foreign material or wear. Replace if necessary. See “Pick tires removal”...

  • Page 133: Theory Of Operation

    5025-2xx, 4xx Previous Theory of operation Print engine theory Next 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. Go Back Even though the basic EP process is the same for every laser and LED printer, the specifics for each printer are different.

  • Page 134: Step 1: Charge

    5025-2xx, 4xx Step 1: Charge Previous 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.

  • Page 135: Step 2: Expose

    5025-2xx, 4xx Step 2: Expose Previous 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.

  • Page 136: Step 3: Develop

    5025-2xx, 4xx Step 3: Develop Previous 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.

  • Page 137: Step 4A: First Transfer

    5025-2xx, 4xx Step 4a: First transfer Previous 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 Next roll causes the images to transfer to the surface of the ITU belt for each color.

  • Page 138: Step 4B: Second Transfer

    5025-2xx, 4xx Step 4b: Second transfer Previous 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.

  • Page 139: Step 5: Fuse

    5025-2xx, 4xx Step 5: Fuse Previous 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.

  • Page 140: Step 6: Clean/Erase

    5025-2xx, 4xx Step 6: Clean/erase Previous 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 Next 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).
  • Page 141 5025-2xx, 4xx Photoconductor clean/erase Previous 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.

  • Page 142: Paper Path, Transport Components

    5025-2xx, 4xx Paper path, transport components Previous 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 Next can and will cause feed and transport problems.

  • Page 143: Transport Components

    5025-2xx, 4xx Transport components Previous 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.

  • Page 144: Duplex Process

    5025-2xx, 4xx Duplex process Previous 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 Next motor reverses.

  • Page 145: Color Theory

    5025-2xx, 4xx Color theory Previous 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 Next monitors create colors in this manner.
  • Page 146 5025-2xx, 4xx My color transparencies seem dark when they are projected. Is there anything I can Previous 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.
  • Page 147 5025-2xx, 4xx How can I match a particular color (such as a corporate logo)? Previous 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.
  • Page 148 5025-2xx, 4xx Previous Next Go Back Service Manual 3-52...

  • Page 149: Repair Information

    5025-2xx, 4xx 4. Repair information Previous Read the following before handling electronic parts. Warning: Next Handling ESD-sensitive parts Go Back 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 •...

  • Page 150: Removal Procedures

    5025-2xx, 4xx Previous Removal procedures CAUTION Remove the power cord from the electrical outlet before you connect or disconnect any cable Next or electronic board or assembly for personal safety and to prevent damage to the printer. Disconnect any connections between the printer and PCs/peripherals. Go Back Notes: Remove the waste toner bottle, color toner cartridges, imaging unit, and media tray before removing other...
  • Page 151 5025-2xx, 4xx Disconnect the operator panel cable, the USB port (if installed) cable, and the front door open sensor Previous cables from the controller board (C). Next Go Back Pull the cables through the opening in the rear. Position the printer with the front cover overlapping the front edge of the table. Remove the two restraining straps from the printer by turning the end sideways and lifting out of the connector (D).
  • Page 152 5025-2xx, 4xx Lower the front cover to align the flats on the hinges, and remove the front cover. Previous Note: Not all models have all three cables shown. See the chart below. Next Go Back Service Manual...
  • Page 153 Previous 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 • Operator panel cable (E) Next 40X5420 (5025-210) • Front door switch cable (F) Note: The USB port cable (G) is not included.

  • Page 154: Left Cover Assembly Removal

    5025-2xx, 4xx Left cover assembly removal Previous for the part number. “Left cover assembly” on page 7-3 Remove the media tray. Position the printer with the left side hanging over the edge of the table. Next On the rear, remove the metal screw (A), the short plastic screw (B), and the longer plastic screw (C). Remove the screw (D) on the bottom of the cover.
  • Page 155 5025-2xx, 4xx Unlatch the front bottom corner tab (E), and lower the front while disengaging from the top cover. Previous Next Go Back Installation note: When replacing the left cover, flex the cover slightly to engage the tab (E) near the power switch.

  • Page 156: Operator Panel Bezel And Name Plate Removal

    5025-2xx, 4xx Operator panel bezel and name plate removal Previous for the part number. “Operator panel bezel and name plates, including:” on page 7-3 Remove the operator panel logo plate. See “Operator panel logo plate” on page 4-9. Lift the bottom edge of the bezel (A), and remove the bezel. Next Go Back Lift the name plate (B).

  • Page 157: Operator Panel Logo Plate

    5025-2xx, 4xx Operator panel logo plate Previous See “operator panel bezel and name plates on for the part number. page 7-3 This is part of the operator panel bezel and name plate FRU. Next Open the front cover. With a flat-bladed screwdriver, unlatch the two latches (A) on the inside cover. Go Back Remove the logo plate (B).

  • Page 158: Operator Panel Removal

    5025-2xx, 4xx Operator panel removal Previous for the part number. “Operator panel and display assembly” on page 7-3 Replace one of the following components, and perform a POR before replacing a second Warning: component. Never replace both of the components without performing a POR after installing each Next one, or the printer may be rendered inoperable: •...

  • Page 159: Rear Shield Removal

    5025-2xx, 4xx Detach the operator panel cable (C) from the panel. Previous Next Go Back Rear shield removal The rear shield is not a field replaceable unit (FRU). Remove the six screws (A). Remove the rear shield. Repair information 4-11...

  • Page 160: Right Cover Assembly Removal

    5025-2xx, 4xx Right cover assembly removal Previous for the part number. “Right cover assembly” on page 7-3 Open the toner supply door. Open the front cover. Next Release the latches (A), and lift off the cover. Go Back Service Manual 4-12...

  • Page 161: Top Cover Assembly Removal

    5025-2xx, 4xx Top cover assembly removal Previous for the part number. “Top cover assembly” on page 7-3 Remove the right cover assembly. See “Right cover assembly removal” on page 4-12. Remove the waste toner bottle. See “Waste toner bottle removal” on page 4-81.
  • Page 162 5025-2xx, 4xx Remove the machine screws (C), and remove the ground cable from the cover. Previous Lift and slide the paper stop to expose the screw (D), and remove the screw. Next Go Back Service Manual 4-14...
  • Page 163 5025-2xx, 4xx Remove the two top screws (E) near the front. Previous Next Go Back Remove the remaining four screws (F). Remove the fuser screw (G). Repair information 4-15...
  • Page 164 5025-2xx, 4xx Disconnect the left fuser spring (H) from the fuser. Previous Disconnect the right fuser spring (J) from the fuser. Next Go Back Disengage the bin-full/narrow media sensor cable (K) from the retainer. 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.
  • Page 165 5025-2xx, 4xx Push in on the cover above the locating pins (L) while lifting to disengage the cover. Carefully lift the cover Previous while keeping it horizontal. Note: Guide the fan connector through the hole. Next Go Back Repair information 4-17...

  • Page 166: Bin-Full/Narrow Media Sensor Removal

    5025-2xx, 4xx Bin-full/narrow media sensor removal Previous See “Photo sensor” on for the part number. page 7-7 Open the front cover. Remove the cable from the retainer. Next Note: Be sure to note the routing for re-installation. Disconnect the cable from the bin-full/narrow media sensor. If there is a sensor retaining plate (A) on the side the latches connect, remove the old adhesive plate.

  • Page 167: Bin-Full/Narrow Media Sensor Flag And Exit Deflector Removal

    5025-2xx, 4xx Installation note: Previous Clean the contact surface where you removed the sensor retaining plate, or where you need to install the new one. Guide the latches that hold the sensor in the bracket into place. Squeeze the latches together until they latch to the metal frame. Next Remove the backing from the new plate, and place the plate on the surface between the sensor mounting legs.

  • Page 168: Controller Board Removal

    5025-2xx, 4xx Controller board removal Previous C540dw, or Controller board—C544n, C544dn, C544dw, Controller board—C540n, C543dn, for the part number. “Controller board—C546dn only” on page 7-7 CAUTION Next After disconnecting the high-voltage power cable from the controller board, always check that the HVPS connection was not loosened.

  • Page 169: Developer Unit Removal

    5025-2xx, 4xx When replacing the controller board, verify the cable from the high-voltage power supply is seated Warning: Previous 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.

  • Page 170: Duplex Reference Edge Removal

    5025-2xx, 4xx Duplex reference edge removal Previous for the part number. “Duplex reference edge” on page 7-5 Note: If the duplex reference edge is made out of plastic, then replace it. If the duplex reference edge is made out of metal, then do not replace it. Next Go Back Plastic...
  • Page 171 5025-2xx, 4xx Lift the duplex aligner on the right side, and disengage the gears (C) on the left. Previous Next Go Back Remove the four screws (D) from the duplex reference guide, and remove the guide. Repair information 4-23...
  • Page 172 5025-2xx, 4xx Previous Installation notes: Depending on the kind of front cover, follow the procedure below that applies: If the front cover has the slot below, then place the tab in the slot as shown. Next Slot Go Back Service Manual 4-24...
  • Page 173 5025-2xx, 4xx Rotate the tab into position, and replace the three screws (A). Previous Next Go Back If the front cover has no slot, then place the tab against the cover as shown. Repair information 4-25...
  • Page 174 5025-2xx, 4xx Replace the two screws (B). Previous Next Go Back 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). c.
  • Page 175 5025-2xx, 4xx Align the duplex aligner guide so the gears (D) mesh on the left. Previous Next Go Back Replace the eight screws in the duplex aligner. Close the front door. Repair information 4-27...

  • Page 176: Duplex Sensor Removal

    5025-2xx, 4xx Duplex sensor removal Previous See “photo sensors” on for the part number. page 7-7 Remove the waste toner bottle. See “Waste toner bottle removal” on page 4-81. Remove the two screws (A) from the cable cover. Next Go Back Pull corner of cable cover (B) away from the right side to access the sensor posts (C).
  • Page 177 5025-2xx, 4xx If there is a plate on the side the latches of the sensor connected, remove the old adhesive plate (D). Previous Next Go Back Unlatch the sensor by pushing on the latches. 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.

  • Page 178: Exit Deflector And Bin-Full/Narrow Media Sensor Flag Removal

    5025-2xx, 4xx Exit deflector and bin-full/narrow media sensor flag removal Previous for the part number. “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. Next Open the front cover.
  • Page 179 5025-2xx, 4xx With one hand, gently pull the exit deflector towards the rear, and with the other hand, press to unsnap the Previous tabs (C). Next Go Back Repair information 4-31...

  • Page 180: Fuser Assembly Removal

    5025-2xx, 4xx Fuser assembly removal Previous See “Fuser assembly” on for the part number. page 7-5 Next Remove the right cover assembly. See “Right cover assembly removal” on page 4-12. Remove the left cover. See “Left cover assembly removal” on page 4-6.
  • Page 181 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. Next Go Back 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.
  • Page 182 5025-2xx, 4xx Installation notes: Previous • 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. Next Go Back •...

  • Page 183: Fuser Drive Motor Assembly Removal

    5025-2xx, 4xx Fuser drive motor assembly removal Previous for the part number. “Fuser drive motor assembly” on page 7-5 Open the front cover. Remove the right cover assembly. See “Right cover assembly removal” on page 4-12. Next Disconnect the cable (A) from the fuser drive motor assembly. Note: If you remove the toroid (B) from the cable, be sure to return the toroid to the cable when you re- install.

  • Page 184: Fuser Exit Sensor Removal

    5025-2xx, 4xx Fuser exit sensor removal Previous for the part number. “Fuser exit sensor” on page 7-7 Open the front cover. Remove the right cover assembly. See “Right cover assembly removal” on page 4-12. Next Remove the left cover. See “Left cover assembly removal”...
  • Page 185 5025-2xx, 4xx Disconnect the bin full/narrow medial sensor cable, and remove the cable from the fuser frame. See “Bin- Previous full/narrow media sensor removal” on page 4-18. Note: Observe the cable routing. Unhook the springs (D) from both sides of the fuser. Next Go Back Rotate the fuser toward the front of the printer until the screw (E) can be accessed, and removed.

  • Page 186: High-Voltage Power Supply (Hvps) Assembly Removal

    5025-2xx, 4xx High-voltage power supply (HVPS) assembly removal Previous for the part number. “High-voltage power supply” on page 7-7 Before you begin, unplug the printer and remove the imaging unit. See “Imaging unit (IU) removal” on page 4-49. Next Remove the rear shield. See “Rear shield removal”...

  • Page 187: High-Voltage Power Supply (Hvps) With Or Without Spring

    5025-2xx, 4xx High-voltage power supply (HVPS) with or without spring Previous Remove the left cover. See “Left cover assembly removal” on page 4-6. Is there a leaf spring (A) biasing the HVPS upward? If yes, then go to • “High-voltage power supply (HVPS) with spring” on page 4-41.

  • Page 188: High-Voltage Power Supply (Hvps) Without Spring

    5025-2xx, 4xx High-voltage power supply (HVPS) without spring Previous Note: This removal requires a magnetized, long-shank Phillips screwdriver at least 8 in. or 200 mm long. Remove the top cover assembly. See “Top cover assembly removal” on page 4-13. Remove the screw (A). The screw is accessible from the top of the printer, and requires a long-shank, magnetized Phillips screwdriver.

  • Page 189: High-Voltage Power Supply (Hvps) With Spring

    5025-2xx, 4xx High-voltage power supply (HVPS) with spring Previous Remove the screw (A) securing the HVPS. Next Go Back Press down on the spring as shown on the right below while pushing the HVPS toward the right or opposite side of the printer. After about 25mm, pull the HVPS out from the right side. Repair information 4-41...
  • Page 190 5025-2xx, 4xx Installation notes: Previous 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. Next The following procedures apply to installing the new HVPS board. Go Back Note: It is recommended that the cable be attached to the HVPS before inserting the HVPS.
  • Page 191 5025-2xx, 4xx Check the position of the card at the left side of the printer. The small vertical post (A) in the endcap Previous has to be positioned in the hole above it as shown. Next Go Back Install the new cable making sure the connector to the board is locked into position. Reinstall the screw to hold the HVPS on the right side of the printer.

  • Page 192: Image Transfer Unit (Itu) Removal

    5025-2xx, 4xx Image transfer unit (ITU) removal Previous for the part number. “Image transfer unit (ITU) assembly” on page 7-5 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.
  • Page 193 5025-2xx, 4xx Removal of ITU without the spring clamp kit Previous Pull the gear (A) straight out to unsnap it, and then discard it. A new gear is included in the spring clamp kit and must be used with the new spring clamp. Next Go Back Remove the rubber pad (C).
  • Page 194 5025-2xx, 4xx Continuing the removal (with or without the spring clamp kit) Previous Disconnect the two springs (A, B) from the side frames, leaving the right one (A) attached to the ITU or ITU spring clamp. Next Go Back Rotate the left spring (B), and the cam away from the ITU so the spring is held out of the ITU path. Service Manual 4-46...
  • Page 195 5025-2xx, 4xx Rotate the release lever (C) in a counterclockwise direction with a springhook or needlenose pliers to Previous decouple the ITU while pulling the ITU toward the front. Next Go Back 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.
  • Page 196 5025-2xx, 4xx Rotate the spring clamp so it hooks over the new ITU (E). • Previous Note: Position the spring on the right side of the gear shaft. Next Go Back • 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.

  • Page 197: Imaging Unit (Iu) Removal

    5025-2xx, 4xx Imaging unit (IU) removal Previous The imaging unit is customer replaceable unit and is not a FRU. Note: The imaging unit contains: Photoconductor unit • Next Developer units • To remove only the photoconductor, remove the entire imaging unit, remove the developer units, place the Go Back original developer units in the new photoconductor, and re-install the imaging unit.
  • Page 198 5025-2xx, 4xx Pull the two latches until the imaging unit meets resistance. Previous Next Go Back 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. Service Manual 4-50...

  • Page 199: Low-Voltage Power Supply (Lvps) Assembly Removal

    5025-2xx, 4xx Low-voltage power supply (LVPS) assembly removal Previous for the part number. “Low-voltage power supply (universal power supply)” on page 7-7 Next Remove the left cover. See “Left cover assembly removal” on page 4-6. Disconnect the three cables (A) from the LVPS. Go Back Remove the seven screws (B).
  • Page 200 5025-2xx, 4xx Remove the LVPS. Previous If you receive a new low-voltage power supply with a voltage selector switch (C), be sure to set the Warning: switch to the correct setting for your voltage requirements before installing the low-voltage power supply.

  • Page 201: Lower Frame Removal, Right And Left

    5025-2xx, 4xx Lower frame removal, right and left Previous for the part number. “Lower left frame and lower right frame with cable cover” on page 7-5 The right and left lower frames are in the same FRU. Next Left lower frame Remove the media tray, and remove the screw (A) in front.
  • Page 202 5025-2xx, 4xx Remove the two top screws (B) near the front holding the top cover to the LVPS shield. Previous Next Go Back Remove the two screws (C). Service Manual 4-54...
  • Page 203 5025-2xx, 4xx Disconnect the fuser exit sensor cable (D). Previous Next Go Back 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.
  • Page 204 5025-2xx, 4xx Remove the tray 2 connector (F) by pinching the tabs together and pushing the connector into the printer. Previous Next Go Back At the rear of the printer, remove the two screws (G) from the AC receptacle, and the ground screw (H). Remove the two screws (J) holding the plastic shield.
  • Page 205 5025-2xx, 4xx Remove the three screws (K) securing the left lower frame. Previous Next Go Back Remove the screw (L) above the frame. Repair information 4-57...
  • Page 206 5025-2xx, 4xx Swing the left lower frame away from the printer, and remove. Previous Next Go Back Service Manual 4-58...

  • Page 207: Right Lower Frame

    5025-2xx, 4xx Right lower frame Previous 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 7-7, and replace the sensor retaining plates.
  • Page 208 5025-2xx, 4xx For wireless models—Remove the screw (C) and leave the plate and antenna attached to the wireless Previous card. Next Go Back Remove the duplex sensor. See “Duplex sensor removal” on page 4-28. Remove the three screws (D) securing the lower right frame to the printer. Remove the screw (E) closer to the front of the printer Service Manual 4-60...
  • Page 209 5025-2xx, 4xx Next to screw (E), lift the right lower frame pin (F) out of the hole in the printer frame. Previous Next Go Back Swing the rear part away from the printer to access the spring (G), and remove the spring (G) from the right lower frame.
  • Page 210 5025-2xx, 4xx Swing the rear of the lower frame away from the printer, and remove the right lower frame. Previous Note: There are parts in the right lower frame that are not included in the frame. The following instructions show how to remove them. Remove the sensor retaining plate (J), and pinch the latches (K) together to remove the tray present sensor.

  • Page 211: Main Drive Gear Assembly Removal

    5025-2xx, 4xx Main drive gear assembly removal Previous for the part number. “Main drive gear assembly, with motors” on page 7-5 Next Remove the left cover. See “Left cover assembly removal” on page 4-6. Remove the LVPS shield. See for instructions on removing the LVPS Go Back “Left lower frame”...
  • Page 212 5025-2xx, 4xx Remove the two screws (E) from the rear. Previous Next Go Back Remove the two screws (F) from below the main drive gear assembly. Remove the two screws (G) on the right of the main drive gear assembly Lift the main drive gear assembly, and remove.

  • Page 213: Paper Pick Motor Drive Assembly Removal-Standard Tray

    5025-2xx, 4xx Paper pick motor drive assembly removal—standard tray Previous for the part number. “Paper pick motor drive assembly—standard tray” on page 7-5 Remove the toner cartridges, the waste toner bottle, and the imaging unit (IU). See “Waste toner bottle 4-81, and see removal”...
  • Page 214 5025-2xx, 4xx Remove the two screws (D) on the bottom. Previous Next Go Back 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. Move the right side of the ACM out to free the shaft from the hole in the frame.
  • Page 215 5025-2xx, 4xx Installation notes: Previous 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. Install the two springs. Next Go Back Reinstall the three screws holding the ACM to the printer. Turn the printer to the proper upright position.

  • Page 216: Pick Tires Removal

    5025-2xx, 4xx Pick tires removal Previous for the part number. “Pick tires” on page 7-11 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. Next The paper pick tires for the standard media tray are located in the base printer.

  • Page 217: Printhead Removal

    5025-2xx, 4xx Printhead removal Previous for the part number. “Printhead” on page 7-5 Remove the top cover. See “Top cover assembly removal” on page 4-13. Disconnect the cables from the controller board. Next Note: Be very careful disconnecting handling the ribbon cable. Remove the toroid (A) from the ribbon cable.
  • Page 218 5025-2xx, 4xx Remove the three screws (B). Previous Next Go Back Remove the printhead. Installation note: When the printhead is replaced, perform the registration (black planes) and alignment (color planes). See • “Registration” on page 3-4 “Alignment” on page 3-7. Be sure to replace the toroid on the cable when you reinstall the printhead, and push the toriod between •...

  • Page 219: Toner Cartridge Contacts

    5025-2xx, 4xx Toner cartridge contacts Previous for the part number. “Toner cartridge contacts (Pogo pin)” on page 7-9 Remove the right cover assembly. See “Right cover assembly removal” on page 4-12. Remove the waste toner bottle. See “Waste toner bottle removal” on page 4-81.
  • Page 220 5025-2xx, 4xx Disconnect the cable (E) from the controller board at JSC1. Previous Next Go Back Remove the cable from the retainer on the bottom of the printer. 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.

  • Page 221: Toner Density Sensor (Tds) Removal-Left Or Right Sensor

    5025-2xx, 4xx Toner density sensor (TDS) removal—left or right sensor Previous for the part number. “Toner density sensors, left or right (one in package)” on page 7-9 Note: The toner density sensor is also called the toner patch sensor (TPS). Next 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.
  • Page 222 5025-2xx, 4xx Installation notes Previous • 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. •...

  • Page 223: Toner Meter Cycle (Tmc) Card Removal

    5025-2xx, 4xx Toner meter cycle (TMC) card removal Previous for the part number. “Toner meter cycle card assembly” on page 7-7 Remove the rear shield. See “Top cover assembly removal” on page 4-13. Remove the right cover assembly. See “Right cover assembly removal” on page 4-12.
  • Page 224 5025-2xx, 4xx Installation notes: Previous • 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 •...

  • Page 225: Tray Present Sensor Removal

    5025-2xx, 4xx Tray present sensor removal Previous See “photo sensors” on for the part number. page 7-7 Remove the media tray. Remove the imaging unit. See “Imaging unit (IU) removal” on page 4-49. Next 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.
  • Page 226 5025-2xx, 4xx Next to screw (D), lift the right lower frame pin (E) out of the hole in the printer frame. Previous Next Go Back Swing the rear of the lower frame away from the printer to access the tray present sensor latches. Remove and secure the spring (F) from the right lower frame.
  • Page 227 5025-2xx, 4xx Remove the sensor retaining plate (G), and then pinch the latches together to remove the tray present Previous sensor. Next Go Back Installation notes: Clean the contact surface where you removed the sensor retaining plate, or where you need to install the new one.

  • Page 228: Usb Port Connector Removal

    5025-2xx, 4xx USB port connector removal Previous for the part number. “USB port and cable (for portable flash drive)” on page 7-9 The FRU includes the USB port connector and cable. Next Remove the operator panel. See “Operator panel logo plate” on page 4-9.

  • Page 229: Waste Toner Bottle Removal

    5025-2xx, 4xx Remove the USB port cable from the cable channel on the right side. Previous Next Go Back Waste toner bottle removal The waste toner bottle is not a FRU. Open the front cover. Lift the toner cover by sliding the latch to the left. Remove the right cover assembly.

  • Page 230: Waste Toner Bottle Contact Block Removal

    5025-2xx, 4xx Waste toner bottle contact block removal Previous See the on for the part number. “Waste toner bottle contact block” on page 7-9 Open the front cover. Remove the right cover assembly. See “Right cover assembly removal” on page 4-12.

  • Page 231: Wireless Network Antenna Removal

    5025-2xx, 4xx Wireless network antenna removal Previous for the part number. “Antenna for wireless card—C544dw only” on page 7-7 Remove the rear shield. See “Top cover assembly removal” on page 4-13. Lift to disconnect the wireless card (A) from the controller board. Next Carefully disconnect the antenna cable (B) from the wireless card at the card.
  • Page 232 5025-2xx, 4xx Gently squeeze the fastener (E) with needlenose pliers. Slide the antenna cable and cable through the Previous hole in the bracket. Next Go Back If the bushing is damaged, remove it by pressing the tabs on each side. Note: Take note of the orientation of the bushing.

  • Page 233: Wireless Network Card

    5025-2xx, 4xx Wireless network card Previous for the part number. “Wireless network card assembly—C544dw only” on page 7-7 Remove the rear shield. See “Top cover assembly removal” on page 4-13. Lift to remove the wireless card (A) from the controller board. Next Carefully disconnect the antenna cable (B) from the wireless card at the card.
  • Page 234 5025-2xx, 4xx Previous Next Go Back Service Manual 4-86...

  • Page 235: Connector Locations

    5025-2xx, 4xx 5. Connector locations Previous Locations Next Go Back Connector locations...
  • Page 236 5025-2xx, 4xx Note the paper path shown in red. Previous Exit rolls/duplex entry Operator panel Toner cartridges Output bin Y, C, M, K Bin-full/narrow Printhead media sensor Next Controller board Go Back Front cover /duplex Developers Y, C, M, K Fuser Fuser exit sensor...

  • Page 237: Connectors

    5025-2xx, 4xx Previous Connectors Next Go Back Connector locations...

  • Page 238: Controller Board Diagram

    5025-2xx, 4xx Controller board diagram Previous JLVPS1 JOPT1 JFAN1 JCARTB1 JSP1 Next JMOT1 Go Back JTPS2 JTHM1 JHVPS1 JBIN1 JPH1 JFUSES1 JCVR1 JMIRR1 JINT1 JTRAY1 JOPP1 JTPS1 JSC1 JCTM1 JWIN1 JUSBH1 JWT1 JUSBW1 JNET1 JUSB1 Service Manual...
  • Page 239 5025-2xx, 4xx Previous 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 Pin no. Signal Next JBIN1 V_BF Bin-full/narrow media sensor and S_BIN_FB, +3.3 V dc Go Back fuser exit sensor...
  • Page 240 5025-2xx, 4xx Controller board connectors (continued) Previous 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 Pin no. Signal JFAN1 FAN_FG, +3.3 V dc Next System fan Ground...
  • Page 241 5025-2xx, 4xx Controller board connectors (continued) Previous 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 Pin no. Signal JLVPS1 +5 V dc Next Low-voltage power supply Ground...
  • Page 242 5025-2xx, 4xx Controller board connectors (continued) Previous 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 Pin no. Signal JOPT1 TXD_PP Next Optional—Tray(s) Ground Ground...
  • Page 243 5025-2xx, 4xx Controller board connectors (continued) Previous 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 Pin no. Signal JPH1 D_VDO_2+ Next Printhead flat cable connector D_VDO_2–...
  • Page 244 5025-2xx, 4xx Controller board connectors (continued) Previous 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 Pin no. Signal JSP1 ANODE (no wire) Next Smart pick drive (paper pick motor M1_OUT1, +24 V dc (0 V dc with door open)
  • Page 245 5025-2xx, 4xx Controller board connectors (continued) Previous 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 Pin no. Signal JUSBW1 Ground Next USB wireless connector USB_HST_VP USB_HST_VM...

  • Page 246: High-Voltage Power Supply (Hvps) Diagram

    5025-2xx, 4xx High-voltage power supply (HVPS) diagram Previous Next Go Back Service Manual 5-12...

  • Page 247: Low-Voltage Power Supply (Lvps) Diagram

    5025-2xx, 4xx Low-voltage power supply (LVPS) diagram Previous Next Go Back Connector locations 5-13...

  • Page 248: Toner Meter Cycle (Tmc) Card

    5025-2xx, 4xx Toner meter cycle (TMC) card Previous Next Go Back Wireless network card Service Manual 5-14...

  • Page 249: Preventive Maintenance

    • 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.
  • Page 250 5025-2xx, 4xx Previous Next Go Back Service Manual...

  • Page 251: Parts Catalog

    PP: (Parts Packet) in the parts description column indicates the part is contained in a parts packet. • Model information used in the parts catalog: • Machine type/ Model name Description model Lexmark C540n 5025-210 Ethernet network Lexmark C543dn 5025-230 Ethernet network, duplex Lexmark C544n 5025-410...

  • Page 252: Assembly 1: Covers

    5025-2xx, 4xx Assembly 1: Covers Previous Next Go Back Service Manual...
  • Page 253 40X5168 Pick tires 40X5430 Front cover assembly (including duplex and USB port cable)—C543dn, C544dn, C544n, C546dtn 40X5420 Front cover assembly (excluding duplex and USB port cable)—C540n 40X5431 Operator panel and display assembly 40X5436 Operator panel (DBCS) and display assembly 40X5432 Operator panel bezel and name plates, including: •...

  • Page 254: Assembly 2: Frames

    5025-2xx, 4xx Assembly 2: Frames Previous Next Go Back Service Manual...
  • Page 255 5025-2xx, 4xx Assembly 2: Frames Previous Asm- Part Units/ Units/ Description Index number mach 2—1 40X5411 Printhead 40X5415 Fuser drive motor assembly Next 40X5422 Lower left frame and lower right frame with cable cover 40X5424 Screw packet, miscellaneous screws Go Back •...

  • Page 256: Assembly 3: Electronics

    5025-2xx, 4xx Assembly 3: Electronics Previous Next Go Back Service Manual...
  • Page 257 Units/ Units/ Description Index number mach 3—1 40X1525 Controller board—C544n, C544dn, C544dw 40X7096 Controller board—C540n, C543dn, C540dw Next 40X2268 Controller board—C546dn only 40X5319 Antenna for wireless card—C544dw only Go Back 40X5036 Wireless network card assembly—C544dw only 40X5404 Toner meter cycle card assembly...

  • Page 258: Assembly 4: Cables

    5025-2xx, 4xx Assembly 4: Cables Previous Next Go Back Service Manual...
  • Page 259 5025-2xx, 4xx Assembly 4: Cables Previous Asm- Part Units/ Units/ Description Index number mach 4—1 40X5429 ITU paper path thermistor Next 40X5414 Toner density sensors, left or right (one in package) 40X7046 Waste toner bottle contact block 40X5421 Toner cartridge contacts (Pogo pin) Go Back 40X5423 Cable packet, used for:...

  • Page 260: Assembly 5: Media Drawers And Trays

    5025-2xx, 4xx Assembly 5: Media drawers and trays Previous Next Go Back Service Manual 7-10...
  • Page 261 5025-2xx, 4xx Assembly 5: Media drawers and trays Previous Asm- Part Units/ Units/ Description Index number opt. 5—1 40X6997 Optional 650-sheet Duo Drawer (complete)— (includes 100-sheet MPF) Next 40X5168 Pick tires 40X2285 650-sheet Duo Drawer tray assembly Go Back 40X8341 Optional 550-sheet drawer (complete)—C546dtn only Parts catalog 7-11...

  • Page 262: Assembly 6: Options And Miscellaneous

    5025-2xx, 4xx Assembly 6: Options and miscellaneous Previous Asm- Part Units/ Units/ Description Index number opt. 6—NS 40X2254 115 V Maintenance kit (fuser, ITU, duplex reference edge) Next 40X2255 230 V Maintenance kit (fuser, ITU, duplex reference edge) 40X2261 100 V Maintenance kit (fuser, ITU, duplex reference edge) Go Back 40X5937 128MB DDR DRAM DIMM card assembly...

  • Page 263: Index

    5025-2xx, 4xx Index Previous color theory Numerics 3-49 Next Color Trapping 3-24 3x–9x user messages – 2-11 configuration ID 3-19 1xx service errors – 2-13 2-17 configuration menu 2xx paper jam accessing Go Back locations 3-32 Auto Color Adj 3-27 messages –...
  • Page 264 5025-2xx, 4xx K TMC Sensor DRAM Test 3-16 3-12 Previous M TMC Sensor duplex 3-16 duplex reference edge removal 3-16 4-22 duplex sensor 3-16 2-28 4-28 Standard Bin Left Margin 3-16 3-14 Y TMC Sensor models 3-16 Next Device Tests parts catalog Flash Test Quick Test...
  • Page 265 5025-2xx, 4xx parts catalog Previous removal 4-44 operating modes service check 2-54 operator panel imaging unit (IU) buttons 2-58 description 4-49 overview 2-58 parts catalog parts catalog Next removal 4-49 removal 4-10 input source tests 3-10 service check 2-36 display blank, 5 beeps 2-37 Go Back one or more buttons fail...
  • Page 266 5025-2xx, 4xx half-color page pick tires, 250-sheet media tray 2-46 4-68 Previous horizontal banding printhead 2-47 4-69 horizontal line right lower frame 2-47 4-59 insufficient fusing toner cartridge contacts 2-48 4-71 menu settings page toner density sensor (TDS), left and right 2-42 4-73 missing image at edge...
  • Page 267 5025-2xx, 4xx viewing toner density sensors (TDS) 3-18 Previous service checks parts catalog 90x.xx error removal 2-24 4-73 925.01—fan error TPS Setup 2-25 3-21 950.xx EPROM mismatch failure toner meter cycle (TMC) card 2-26 bin-full/narrow media sensor connectors 2-26 5-14 Next dead printer parts catalog...
  • Page 268 5025-2xx, 4xx Previous Next Go Back Service Manual...

  • Page 269: Part Number Index

    250-sheet tray assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40X5420 Front cover assembly (excluding duplex and USB port cable)—C540n - - - - - - - - - - - - - - - - - - - - - - - - - 40X5421...
  • Page 270 5025-2xx, 4xx 40X5432 Operator panel bezel and name plates - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Previous 40X5433 Exit deflector and bin-full/narrow media sensor flag - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -...

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