Service Manual
Page 6
... 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 recommended every 30,000 pages for replacement of...life of the Menu Settings Page. Press Menu ( ) on usage. 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 Option...
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 recommended every 30,000 pages for replacement of...life of the Menu Settings Page. Press Menu ( ) on usage. 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 Option...
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 front cover. 34 Short Paper • Make sure the print job is available to clear the message and continue printing. See "Imaging unit (IU) removal" on the last page. If the message recurs remove and re-install the cartridge. If the message persists, determine if the... imaging kit counter indicates it is properly fitted in the tray. • Adjust the Paper Size setting for replacement. Keep the developers from the original unit and reinstall them in RAM. • Install additional printer memory. •...
...the front cover. 34 Short Paper • Make sure the print job is available to clear the message and continue printing. See "Imaging unit (IU) removal" on the last page. If the message recurs remove and re-install the cartridge. If the message persists, determine if the... imaging kit counter indicates it is properly fitted in the tray. • Adjust the Paper Size setting for replacement. Keep the developers from the original unit and reinstall them in RAM. • Install additional printer memory. •...
Service Manual
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... the following is displayed. To print the print Quality pages: a. Select Reports from the connector to 4 (default). - Inspect the imaging unit for variations in the printer. 5025-2xx, 4xx Print quality service check Note: This symptom may require replacement of one or more CRUs... be replaced. Select Menu Settings, and press Select ( ). Color Saver: Set to install a developer (toner) cartridge or photoconductor unit. Look for damage, including the developers and toner cartridges. An incorrect printer driver for the installed software can cause problems. Incorrect characters...
... the following is displayed. To print the print Quality pages: a. Select Reports from the connector to 4 (default). - Inspect the imaging unit for variations in the printer. 5025-2xx, 4xx Print quality service check Note: This symptom may require replacement of one or more CRUs... be replaced. Select Menu Settings, and press Select ( ). Color Saver: Set to install a developer (toner) cartridge or photoconductor unit. Look for damage, including the developers and toner cartridges. An incorrect printer driver for the installed software can cause problems. Incorrect characters...
Service Manual
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...humid environment. 5025-2xx, 4xx Step Questions / actions Yes No 1 Read the current status of the imaging unit from the HVPS to step 4. 4 Replace the photoconductor unit. Problem resolved. Diagnostic information 2-43 To view the status of the primary colors; Select Device Statistics, ...this fix the problem? Replace the failing part: • Image transfer unit (ITU). Problem resolved. See "Printhead removal" on page 4-31. Problem resolved. In Ready mode, press Menus ( ). 2. Using non-Lexmark toner cartridges may also cause background problems. Some problems occur ...
...humid environment. 5025-2xx, 4xx Step Questions / actions Yes No 1 Read the current status of the imaging unit from the HVPS to step 4. 4 Replace the photoconductor unit. Problem resolved. Diagnostic information 2-43 To view the status of the primary colors; Select Device Statistics, ...this fix the problem? Replace the failing part: • Image transfer unit (ITU). Problem resolved. See "Printhead removal" on page 4-31. Problem resolved. In Ready mode, press Menus ( ). 2. Using non-Lexmark toner cartridges may also cause background problems. Some problems occur ...
Service Manual
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...) removal" on page 4-45. 2-44 Service Manual Remove Cartridge. Remove all toner cartridges and the imaging unit. 4. appears. The motor detection process takes about 10 seconds, and stops automatically. Go to step 4. Replace the Main drive gear ...missing? Note: Do not press Select yet. 3. Close the front cover. Detect Complete. No Remove the packing material. Replace the developer unit for the missing color. 3 Replace the imaging unit. Press Select ( ). Select Prt Qual Pgs, and press Select ( ). Motor Detection In Progress... appears, and the printer performs a ...
...) removal" on page 4-45. 2-44 Service Manual Remove Cartridge. Remove all toner cartridges and the imaging unit. 4. appears. The motor detection process takes about 10 seconds, and stops automatically. Go to step 4. Replace the Main drive gear ...missing? Note: Do not press Select yet. 3. Close the front cover. Detect Complete. No Remove the packing material. Replace the developer unit for the missing color. 3 Replace the imaging unit. Press Select ( ). Select Prt Qual Pgs, and press Select ( ). Motor Detection In Progress... appears, and the printer performs a ...
Service Manual
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...incorrect feeding from one of the input paper sources, media trays, or duplex paper path. Reseat the imaging unit. Did this fix the problem? Problem resolved. See "Developer unit removal" on page 4-31. Replace the HVPS. Blurred print can also be damaged. See "High-...the main drive gear assembly and ITU for correct operation. Replace the controller board. Resetting appears. If that does not work, remove the imaging unit and reseat each of spring force? Check the developer cartridge contacts from Diag Menu, and press Select ( ). 3. See "Controller board ...
...incorrect feeding from one of the input paper sources, media trays, or duplex paper path. Reseat the imaging unit. Did this fix the problem? Problem resolved. See "Developer unit removal" on page 4-31. Replace the HVPS. Blurred print can also be damaged. See "High-...the main drive gear assembly and ITU for correct operation. Replace the controller board. Resetting appears. If that does not work, remove the imaging unit and reseat each of spring force? Check the developer cartridge contacts from Diag Menu, and press Select ( ). 3. See "Controller board ...
Service Manual
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...the damaged part of the developer units that match the missing color (black, cyan, magenta, or yellow). Remove the imaging unit and remove the original developer units, and then put them back into the new photoconductor unit, and reinstall the imaging unit. See "Fuser assembly removal"...2. 2 Does the distance measure 95 mm or 108 mm? See "Developer unit removal" on page 4-35. 2-46 Service Manual Remove and inspect the imaging unit. Replace the developers that make up the imaging unit is defective. See "Imaging unit (IU) removal" on page 4-21. Select Reports, and press Select (...
...the damaged part of the developer units that match the missing color (black, cyan, magenta, or yellow). Remove the imaging unit and remove the original developer units, and then put them back into the new photoconductor unit, and reinstall the imaging unit. See "Fuser assembly removal"...2. 2 Does the distance measure 95 mm or 108 mm? See "Developer unit removal" on page 4-35. 2-46 Service Manual Remove and inspect the imaging unit. Replace the developers that make up the imaging unit is defective. See "Imaging unit (IU) removal" on page 4-21. Select Reports, and press Select (...
Service Manual
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... Go to step 4. See "Fuser assembly removal" on page 4-37. Does this fix the problem? Go to step 3. Install the fuser properly. Print quality-missing image at edge Remove and reseat the following: • Toner cartridge • Imaging unit • Developer units. If the problem persists, replace the developer. Diagnostic information 2-47
... Go to step 4. See "Fuser assembly removal" on page 4-37. Does this fix the problem? Go to step 3. Install the fuser properly. Print quality-missing image at edge Remove and reseat the following: • Toner cartridge • Imaging unit • Developer units. If the problem persists, replace the developer. Diagnostic information 2-47
Service Manual
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... looking at the individual developers and photo conductors. See "Imaging unit (IU) removal" on page 4-35. No Go to step 3. See "Imaging unit (IU) removal" on page 4-35. 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 4-21. Clean or replace the faulty unit. Contact your next level of random marks is loose material...
... looking at the individual developers and photo conductors. See "Imaging unit (IU) removal" on page 4-35. No Go to step 3. See "Imaging unit (IU) removal" on page 4-35. 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 4-21. Clean or replace the faulty unit. Contact your next level of random marks is loose material...
Service Manual
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... operator panel. 2. Replace the photoconductor. Press Menu ( ) on page 4-21. Does the display indicate OK? Replace the imaging unit or the photoconductor unit. See "Imaging unit (IU) removal" on page 4-26. Select Supplies Menu, and press Select ( ). 3. Select Imaging Kit, and press Select ( ). Is the distance 43.9 mm? Replace the developer corresponding to step 2. 1. To print...
... operator panel. 2. Replace the photoconductor. Press Menu ( ) on page 4-21. Does the display indicate OK? Replace the imaging unit or the photoconductor unit. See "Imaging unit (IU) removal" on page 4-26. Select Supplies Menu, and press Select ( ). 3. Select Imaging Kit, and press Select ( ). Is the distance 43.9 mm? Replace the developer corresponding to step 2. 1. To print...
Service Manual
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...problem in the high-voltage controller or an incorrect high-voltage in the printing process resulting in the new photoconductor, and then replace the imaging unit. Print a Quality Test Page. See "High-voltage power supply (HVPS) assembly removal" on page 4-49. See "Printhead removal" ...? Make sure the paper stays in place when you replace the imaging unit. Replace the printhead. Replace the cable assembly. Go to step 2. Print quality-vertical banding Replace the developer unit. 2-50 Service Manual See "Imaging unit (IU) removal". Replace the controller board. Did this fix the...
...problem in the high-voltage controller or an incorrect high-voltage in the printing process resulting in the new photoconductor, and then replace the imaging unit. Print a Quality Test Page. See "High-voltage power supply (HVPS) assembly removal" on page 4-49. See "Printhead removal" ...? Make sure the paper stays in place when you replace the imaging unit. Replace the printhead. Replace the cable assembly. Go to step 2. Print quality-vertical banding Replace the developer unit. 2-50 Service Manual See "Imaging unit (IU) removal". Replace the controller board. Did this fix the...
Service Manual
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... re-inserting the paper tray. Press Select ( ). Detect Complete. The sensor should change state. Remove the yellow toner cartridge. Remove all toner cartridges and the imaging unit. 4. Close the front cover. The sensor should change state. Open the front cover. Remove Cartridge. Remove the media tray. Remove the magenta toner cartridge. Shine...
... re-inserting the paper tray. Press Select ( ). Detect Complete. The sensor should change state. Remove the yellow toner cartridge. Remove all toner cartridges and the imaging unit. 4. Close the front cover. The sensor should change state. Open the front cover. Remove Cartridge. Remove the media tray. Remove the magenta toner cartridge. Shine...
Service Manual
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... heavy amounts of toner will be deposited on the photoconductor. Service tips: • If the surface of the charge roll is part of the photoconductor unit. The imaging unit will need to be uneven on the printed page. The charge roll is damaged (such as a nick or pit), it for the laser beam...
... heavy amounts of toner will be deposited on the photoconductor. Service tips: • If the surface of the charge roll is part of the photoconductor unit. The imaging unit will need to be uneven on the printed page. The charge roll is damaged (such as a nick or pit), it for the laser beam...
Service Manual
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The imaging unit should also be carefully set on page 4-60. 5. It should be protected from light while out of the printer. • Unless otherwise stated, reinstall the ..." on a clean, smooth, and flat surface. Remove the rear shield. Remove the right cover assembly. 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. Remove the waste toner bottle. Remove the operator panel. See "Operator...
The imaging unit should also be carefully set on page 4-60. 5. It should be protected from light while out of the printer. • Unless otherwise stated, reinstall the ..." on a clean, smooth, and flat surface. Remove the rear shield. Remove the right cover assembly. 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. Remove the waste toner bottle. Remove the operator panel. See "Operator...
Service Manual
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Remove the rear shield. Remove the screw (B). 7. Remove the right cover assembly. Remove the imaging unit. See "Rear shield removal" on the controller board. 6. Disconnect the fan cable from JFAN1 (A) on page 4-11. 5. See "Waste toner bottle removal" on... page 4-35. 4. Lift the exit deflector, and remove the screw (C) holding the ground cable. 4-12 Service Manual See "Imaging unit (IU) removal" on page 4-60. 3. 5025-2xx, 4xx Top cover assembly removal See "Top cover assembly" on page 4-10. 2. See "Right cover assembly ...
Remove the rear shield. Remove the screw (B). 7. Remove the right cover assembly. Remove the imaging unit. See "Rear shield removal" on the controller board. 6. Disconnect the fan cable from JFAN1 (A) on page 4-11. 5. See "Waste toner bottle removal" on... page 4-35. 4. Lift the exit deflector, and remove the screw (C) holding the ground cable. 4-12 Service Manual See "Imaging unit (IU) removal" on page 4-60. 3. 5025-2xx, 4xx Top cover assembly removal See "Top cover assembly" on page 4-10. 2. See "Right cover assembly ...
Service Manual
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... mechanism (ACM) cable connector (A) from the retainers (C) on page 4-6. 3. Remove the toner cartridges, the waste toner bottle, and the imaging unit (IU). See "Waste toner bottle removal" on page 4-60, and see "Imaging unit (IU) removal" on page 7-5 for the part number. 1. Remove the left side. See "Left cover assembly removal" on the left...
... mechanism (ACM) cable connector (A) from the retainers (C) on page 4-6. 3. Remove the toner cartridges, the waste toner bottle, and the imaging unit (IU). See "Waste toner bottle removal" on page 4-60, and see "Imaging unit (IU) removal" on page 7-5 for the part number. 1. Remove the left side. See "Left cover assembly removal" on the left...
Service Manual
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Open the toner access door. 2. See "Imaging unit (IU) removal". Duplex sensor removal See "photo sensors" on page 4-10. 3. Warning: Do not touch the underside of them. Remove the waste toner bottle. Developer unit removal The developer units are not FRUs. 1. Open the front cover. 2..... 1. Remove the right cover assembly. See "Waste toner bottle removal" on page 4-60. Remove the imaging unit. Remove the developer unit you need or remove all of the imaging unit. Repair information 4-21 Remove the toner cartridges. 5025-2xx, 4xx 3. This could damage the developer...
Open the toner access door. 2. See "Imaging unit (IU) removal". Duplex sensor removal See "photo sensors" on page 4-10. 3. Warning: Do not touch the underside of them. Remove the waste toner bottle. Developer unit removal The developer units are not FRUs. 1. Open the front cover. 2..... 1. Remove the right cover assembly. See "Waste toner bottle removal" on page 4-60. Remove the imaging unit. Remove the developer unit you need or remove all of the imaging unit. Repair information 4-21 Remove the toner cartridges. 5025-2xx, 4xx 3. This could damage the developer...
Service Manual
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... spring (B), and pivot the cam away from the barcode after the installation, and it . See "Right cover assembly removal" on page 4-60. 4. Remove the imaging unit (IU). Repair information 4-33 Write down the number of the ITU path. Remove the waste toner bottle. See "Waste toner bottle removal" on page 4-10... so the spring and the cam are held out of the new ITU before installing it is easier to the ITU. 6. 5025-2xx, 4xx Image transfer unit (ITU) removal See "Image transfer unit (ITU) assembly" on page 4-35. 5. See "Imaging unit (IU) removal" on page 7-5 for the part number. 1.
... spring (B), and pivot the cam away from the barcode after the installation, and it . See "Right cover assembly removal" on page 4-60. 4. Remove the imaging unit (IU). Repair information 4-33 Write down the number of the ITU path. Remove the waste toner bottle. See "Waste toner bottle removal" on page 4-10... so the spring and the cam are held out of the new ITU before installing it is easier to the ITU. 6. 5025-2xx, 4xx Image transfer unit (ITU) removal See "Image transfer unit (ITU) assembly" on page 4-35. 5. See "Imaging unit (IU) removal" on page 7-5 for the part number. 1.
