Service Manual
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... Fuser assembly removal 4-26 Fuser drive motor assembly removal 4-29 Fuser exit sensor removal 4-30 High-voltage power supply (HVPS) assembly removal 4-31 Image transfer unit (ITU) removal 4-33 Imaging unit (IU) removal 4-35 Low-voltage power supply (LVPS) assembly removal 4-37 Lower frame removal, right and left 4-39 Left lower frame 4-39 Right...
... Fuser assembly removal 4-26 Fuser drive motor assembly removal 4-29 Fuser exit sensor removal 4-30 High-voltage power supply (HVPS) assembly removal 4-31 Image transfer unit (ITU) removal 4-33 Imaging unit (IU) removal 4-35 Low-voltage power supply (LVPS) assembly removal 4-37 Lower frame removal, right and left 4-39 Left lower frame 4-39 Right...
Service Manual
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Printers continuously operating at or near the maximum duty cycle may require service for the imaging unit. • 4800C Q (default) full printer speed • 1200 dpi (reduced printer speed) is supported in PS and PCL only 1-2 Service...recommended every 30,000 pages for replacement of the Menu Settings Page. 5025-2xx, 4xx Printer specifications Memory ✔-Supported ✘-Not supported Lexmark C540n, C543dn Lexmark C544n, C544dn, C544dw Memory Optional slots Standard DIMM sizesa Optional (DDR2) Maximum printer memoryb One slot 128MB 128MB, 256MB, and 512MB 640MB...
Printers continuously operating at or near the maximum duty cycle may require service for the imaging unit. • 4800C Q (default) full printer speed • 1200 dpi (reduced printer speed) is supported in PS and PCL only 1-2 Service...recommended every 30,000 pages for replacement of the Menu Settings Page. 5025-2xx, 4xx Printer specifications Memory ✔-Supported ✘-Not supported Lexmark C540n, C543dn Lexmark C544n, C544dn, C544dw Memory Optional slots Standard DIMM sizesa Optional (DDR2) Maximum printer memoryb One slot 128MB 128MB, 256MB, and 512MB 640MB...
Service Manual
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... Only Retract Cyan Dual Inline Memory Module Dynamic Random Access Memory Electrically Erasable Programmable Read-Only Memory ElectroPhotographic Electrostatic Discharge Field Replaceable Unit Gigabyte High-Voltage Power Supply Image Transfer Unit Imaging Unit Japanese Industry Standard Black Light Amplification by Stimulated Emission of Radiation Liquid Crystal Display Light-Emitting Diode Low-Voltage Power Supply Magenta...
... Only Retract Cyan Dual Inline Memory Module Dynamic Random Access Memory Electrically Erasable Programmable Read-Only Memory ElectroPhotographic Electrostatic Discharge Field Replaceable Unit Gigabyte High-Voltage Power Supply Image Transfer Unit Imaging Unit Japanese Industry Standard Black Light Amplification by Stimulated Emission of Radiation Liquid Crystal Display Light-Emitting Diode Low-Voltage Power Supply Magenta...
Service Manual
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...the paper is installed properly. • Turn the printer power off , and then turn the printer power on the front of the printer. See "Imaging unit (IU) removal" on the last page. Keep the developers from the USB port on . If MP Feeder Size is set to cancel printing. ...requesting the correct size of the following : • Open and close the front cover. 31.xx Defective Imaging Kit Defective imaging kit. If the indicator says OK, replace only the photoconductor unit. It will indicate OK, Replace Black, or Replace Black and Color. This message appears prior to the actual...
...the paper is installed properly. • Turn the printer power off , and then turn the printer power on the front of the printer. See "Imaging unit (IU) removal" on the last page. Keep the developers from the USB port on . If MP Feeder Size is set to cancel printing. ...requesting the correct size of the following : • Open and close the front cover. 31.xx Defective Imaging Kit Defective imaging kit. If the indicator says OK, replace only the photoconductor unit. It will indicate OK, Replace Black, or Replace Black and Color. This message appears prior to the actual...
Service Manual
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...1. Print a menu settings page, and check the life status of all colors. - Select Menu Settings, and press Select ( ). Inspect the imaging unit for variations in the printer. Once the printer has been restored to 4 (default). - Look for damage, including the developers and toner cartridges. ...speed displays). 5025-2xx, 4xx 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 low should be replaced. RGB Brightness, RGB Contrast, RGB Saturation: Set to ...
...1. Print a menu settings page, and check the life status of all colors. - Select Menu Settings, and press Select ( ). Inspect the imaging unit for variations in the printer. Once the printer has been restored to 4 (default). - Look for damage, including the developers and toner cartridges. ...speed displays). 5025-2xx, 4xx 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 low should be replaced. RGB Brightness, RGB Contrast, RGB Saturation: Set to ...
Service Manual
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...page 4-31. Does this value: Go to rough texture when the texture is possible a new imaging unit was installed, but the counter was not reset. Problem resolved. Reset the value. Select the imaging unit , and press Select ( ). 5. yellow, cyan, magenta, or black? Does this fix... unit. See "High-voltage power Problem resolved. Using non-Lexmark toner cartridges may also cause background problems. Some problems occur by using rough paper or incorrectly setting the operator panel settings to step 2. Select Device Statistics, and press Select ( ). Has the imaging unit been...
...page 4-31. Does this value: Go to rough texture when the texture is possible a new imaging unit was installed, but the counter was not reset. Problem resolved. Reset the value. Select the imaging unit , and press Select ( ). 5. yellow, cyan, magenta, or black? Does this fix... unit. See "High-voltage power Problem resolved. Using non-Lexmark toner cartridges may also cause background problems. Some problems occur by using rough paper or incorrectly setting the operator panel settings to step 2. Select Device Statistics, and press Select ( ). Has the imaging unit been...
Service Manual
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...printer performs a POR (Power On Reset). Select Prt Qual Pgs, and press Select ( ). Go to step 3. Remove all toner cartridges and the imaging unit. 4. Detect Complete. Replace the Main drive gear assembly. Problem resolved. 4 Enter the Diagnostics Menu (turn the printer off , press and hold ...See "Main drive gear assembly removal" on page 4-35. The motor detection process takes about 10 seconds, and stops automatically. See "Imaging unit (IU) removal" on page 4-45. 2-44 Service Manual Did the motor run the appropriate cartridge drive motor test for the missing ...
...printer performs a POR (Power On Reset). Select Prt Qual Pgs, and press Select ( ). Go to step 3. Remove all toner cartridges and the imaging unit. 4. Detect Complete. Replace the Main drive gear assembly. Problem resolved. 4 Enter the Diagnostics Menu (turn the printer off , press and hold ...See "Main drive gear assembly removal" on page 4-35. The motor detection process takes about 10 seconds, and stops automatically. See "Imaging unit (IU) removal" on page 4-45. 2-44 Service Manual Did the motor run the appropriate cartridge drive motor test for the missing ...
Service Manual
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... on page 4-11. Replace the cable. Blurred or fuzzy print is automatically returned to the IU. Print quality-half-color page The imaging unit and developer units may be caused by a problem in the main drive gear assembly or in and out with an equal amount of the developer... the high-voltage spring contacts to step 6. If that does not work, remove the imaging unit and reseat each of spring force? No Clean the developer cartridge contacts. Go to move in the image transfer unit (ITU). Blurred print can also be damaged. Print quality-blurred or fuzzy print Run the...
... on page 4-11. Replace the cable. Blurred or fuzzy print is automatically returned to the IU. Print quality-half-color page The imaging unit and developer units may be caused by a problem in the main drive gear assembly or in and out with an equal amount of the developer... the high-voltage spring contacts to step 6. If that does not work, remove the imaging unit and reseat each of spring force? No Clean the developer cartridge contacts. Go to move in the image transfer unit (ITU). Blurred print can also be damaged. Print quality-blurred or fuzzy print Run the...
Service Manual
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...: 1. Go to step 2. 2 Does the distance measure 95 mm or 108 mm? Replace the ITU. 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. Step Questions / actions Yes No 1 Measure the distance between bands either 34.6 or 94.2 mm? See...
...: 1. Go to step 2. 2 Does the distance measure 95 mm or 108 mm? Replace the ITU. 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. Step Questions / actions Yes No 1 Measure the distance between bands either 34.6 or 94.2 mm? See...
Service Manual
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...-2xx, 4xx Step Questions / actions 1 Is the printer setup to step 3. Does this fix the problem? Go to step 4. Replace the LVPS. Print quality-missing image at edge Remove and reseat the following: • Toner cartridge • Imaging unit • Developer units. Diagnostic information 2-47
...-2xx, 4xx Step Questions / actions 1 Is the printer setup to step 3. Does this fix the problem? Go to step 4. Replace the LVPS. Print quality-missing image at edge Remove and reseat the following: • Toner cartridge • Imaging unit • Developer units. Diagnostic information 2-47
Service Manual
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... Service tip: The primary cause of support. 2-48 Service Manual 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 page 4-33. Yes Inspect ...the imaging unit by looking at the individual developers and photo conductors. See "Imaging unit (IU) removal" on page 4-35. No Go to step 3. Contact your next level of random marks is loose...
... Service tip: The primary cause of support. 2-48 Service Manual 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 page 4-33. Yes Inspect ...the imaging unit by looking at the individual developers and photo conductors. See "Imaging unit (IU) removal" on page 4-35. No Go to step 3. Contact your next level of random marks is loose...
Service Manual
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... mm? Press Menu ( ) on page 4-35. 3 Is the distance between the original image and the residual image 94.2 mm? Replace the photoconductor. Replace the imaging unit or the photoconductor unit. Replace the developer corresponding to clear any toner contamination on page 4-21. 4 Run the Menu...of support. Is there still any debris. Contact your next level of the image. See "Developer unit removal" on page 4-26. Select Menu Settings, and press Select ( ). Replace the imaging unit or the photoconductor unit. See "Fuser assembly removal" on page 4-21. At the Ready prompt...
... mm? Press Menu ( ) on page 4-35. 3 Is the distance between the original image and the residual image 94.2 mm? Replace the photoconductor. Replace the imaging unit or the photoconductor unit. Replace the developer corresponding to clear any toner contamination on page 4-21. 4 Run the Menu...of support. Is there still any debris. Contact your next level of the image. See "Developer unit removal" on page 4-26. Select Menu Settings, and press Select ( ). Replace the imaging unit or the photoconductor unit. See "Fuser assembly removal" on page 4-21. At the Ready prompt...
Service Manual
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... development on the entire photoconductor drum. Does this solve the problem? Make sure the paper stays in the new photoconductor, and then replace the imaging unit. Go to step 3. Go to step 5. Print a Quality Test Page. Are the spring(s) defective? 4 Turn the printer off, and check ... this fix the problem? 2 A faulty printhead can cause the problem. Replace the transfer contact assembly. Replace the cable assembly. Remove the imaging unit and remove the developers. To test the printhead for removal procedures. Replace the printhead. See "Controller board removal" on page 4-31. See...
... development on the entire photoconductor drum. Does this solve the problem? Make sure the paper stays in the new photoconductor, and then replace the imaging unit. Go to step 3. Go to step 5. Print a Quality Test Page. Are the spring(s) defective? 4 Turn the printer off, and check ... this fix the problem? 2 A faulty printhead can cause the problem. Replace the transfer contact assembly. Replace the cable assembly. Remove the imaging unit and remove the developers. To test the printhead for removal procedures. Replace the printhead. See "Controller board removal" on page 4-31. See...
Service Manual
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... to test The sensor should change state. Remove the yellow toner cartridge. Shine a flashlight on the toner level sensor. Remove all toner cartridges and the imaging unit. 4. If you to test, and press Select ( ). appears, and the printer performs a POR (Power On Reset). 3-16 Service Manual 5025-2xx, 4xx Base Sensor Test...
... to test The sensor should change state. Remove the yellow toner cartridge. Shine a flashlight on the toner level sensor. Remove all toner cartridges and the imaging unit. 4. If you to test, and press Select ( ). appears, and the printer performs a POR (Power On Reset). 3-16 Service Manual 5025-2xx, 4xx Base Sensor Test...
Service Manual
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... color. This causes the printed page to be saturated with 100% of the photoconductor to prepare it will be deposited on the printed page. The imaging unit will cause a repeating mark on the photoconductor. This will need to be replaced sooner. 3-34 Service Manual 5025-2xx, 4xx Step 1: Charge During the charge... the charge roll is part of the four photoconductors. The charge rolls (A) put a uniform negative charge over the entire surface of each of the photoconductor unit.
... color. This causes the printed page to be saturated with 100% of the photoconductor to prepare it will be deposited on the printed page. The imaging unit will cause a repeating mark on the photoconductor. This will need to be replaced sooner. 3-34 Service Manual 5025-2xx, 4xx Step 1: Charge During the charge... the charge roll is part of the four photoconductors. The charge rolls (A) put a uniform negative charge over the entire surface of each of the photoconductor unit.
Service Manual
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...You must replace cable ties during reassembly to the printer. Remove the screw (B) from the cable cover, and remove the cable cover. 6. The imaging unit should also be carefully set on page 7-3 for personal safety and to prevent damage to avoid pinching wires, obstructing the paper path, or restricting ... number. 1. See "Waste toner bottle removal" on page 4-11. 4-2 Service Manual A B 7. Notes: • Remove the waste toner bottle, color toner cartridges, imaging unit, and media tray before final tightening. • Some removal procedures require removing cable ties.
...You must replace cable ties during reassembly to the printer. Remove the screw (B) from the cable cover, and remove the cable cover. 6. The imaging unit should also be carefully set on page 7-3 for personal safety and to prevent damage to avoid pinching wires, obstructing the paper path, or restricting ... number. 1. See "Waste toner bottle removal" on page 4-11. 4-2 Service Manual A B 7. Notes: • Remove the waste toner bottle, color toner cartridges, imaging unit, and media tray before final tightening. • Some removal procedures require removing cable ties.
Service Manual
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... page 4-35. 4. Remove the right cover assembly. Remove the waste toner bottle. Remove the screw (B). 7. See "Imaging unit (IU) removal" on page 7-3 for the part number. 1. See "Rear shield removal" on page 4-10. 2. Remove the imaging unit. See "Right cover assembly removal" on page 4-11. 5. See "Waste toner bottle removal" on the controller board...
... page 4-35. 4. Remove the right cover assembly. Remove the waste toner bottle. Remove the screw (B). 7. See "Imaging unit (IU) removal" on page 7-3 for the part number. 1. See "Rear shield removal" on page 4-10. 2. Remove the imaging unit. See "Right cover assembly removal" on page 4-11. 5. See "Waste toner bottle removal" on the controller board...
Service Manual
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... the left side. Disconnect the autocompensator mechanism (ACM) cable connector (A) from the retainers (C) on page 4-6. 3. See "Waste toner bottle removal" on page 4-60, and see "Imaging unit (IU) removal" on page 4-11. 4. See "Rear shield removal" on page 4-35. 2. 5025-2xx, 4xx Autocompensator mechanism (ACM) removal-standard tray See "Autocompensator mechanism (ACM...
... the left side. Disconnect the autocompensator mechanism (ACM) cable connector (A) from the retainers (C) on page 4-6. 3. See "Waste toner bottle removal" on page 4-60, and see "Imaging unit (IU) removal" on page 4-11. 4. See "Rear shield removal" on page 4-35. 2. 5025-2xx, 4xx Autocompensator mechanism (ACM) removal-standard tray See "Autocompensator mechanism (ACM...
Service Manual
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... 3. Warning: Do not touch the underside of them. Repair information 4-21 Remove the imaging unit. Duplex sensor removal See "photo sensors" on page 4-10. 3. See "Right cover assembly removal" on page 7-7 for the part number. 1. Developer unit removal The developer units are not FRUs. 1. Remove the waste toner bottle. Remove the right cover assembly...
... 3. Warning: Do not touch the underside of them. Repair information 4-21 Remove the imaging unit. Duplex sensor removal See "photo sensors" on page 4-10. 3. See "Right cover assembly removal" on page 7-7 for the part number. 1. Developer unit removal The developer units are not FRUs. 1. Remove the waste toner bottle. Remove the right cover assembly...
Service Manual
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... easier to the ITU. 6. Repair information 4-33 See "Waste toner bottle removal" on page 7-5 for the part number. 1. Remove the imaging unit (IU). Rotate the left spring (B), and pivot the cam away from the side frames, leaving the right one attached to see at this ...digit numeric value from the barcode after the installation, and it . 5025-2xx, 4xx Image transfer unit (ITU) removal See "Image transfer unit (ITU) assembly" on page 4-60. 4. Remove the waste toner bottle. See "Right cover assembly removal" on page 4-35. 5. See "Imaging unit (IU) removal" on page 4-10. 3.
... easier to the ITU. 6. Repair information 4-33 See "Waste toner bottle removal" on page 7-5 for the part number. 1. Remove the imaging unit (IU). Rotate the left spring (B), and pivot the cam away from the side frames, leaving the right one attached to see at this ...digit numeric value from the barcode after the installation, and it . 5025-2xx, 4xx Image transfer unit (ITU) removal See "Image transfer unit (ITU) assembly" on page 4-60. 4. Remove the waste toner bottle. See "Right cover assembly removal" on page 4-35. 5. See "Imaging unit (IU) removal" on page 4-10. 3.