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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...into an available memory slot. 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 ...the last sheet of the printer. 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...
...into an available memory slot. 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 ...the last sheet of the printer. 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 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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... counter indicates it is installed properly. • Turn the printer power off and turn the printer power on . See "Imaging unit (IU) removal" on the front of paper. • Check tray length and width guides to ensure the cartridge is time for the size paper you.... To perform the defragment operation, you are using. Try one of the following : • Open and close the front cover. 31.xx Defective Imaging Kit Defective imaging kit. If the indicator says Replace Black or Replace Black and Color, then replace the appropriate kit. The printer does not automatically reprint the...
... counter indicates it is installed properly. • Turn the printer power off and turn the printer power on . See "Imaging unit (IU) removal" on the front of paper. • Check tray length and width guides to ensure the cartridge is time for the size paper you.... To perform the defragment operation, you are using. Try one of the following : • Open and close the front cover. 31.xx Defective Imaging Kit Defective imaging kit. If the indicator says Replace Black or Replace Black and Color, then replace the appropriate kit. The printer does not automatically reprint the...
Service Manual
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... ( ). Print a menu settings page, and check the life status of all voltages from the connector to install a developer (toner) cartridge or photoconductor unit. To print a menu settings page: a. c. Select Menu Settings, and press Select ( ). On the menu page, make sure the following : 1.... 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. Inspect the imaging unit for the installed software can cause problems. Incorrect characters could print, and the copy...
... ( ). Print a menu settings page, and check the life status of all voltages from the connector to install a developer (toner) cartridge or photoconductor unit. To print a menu settings page: a. c. Select Menu Settings, and press Select ( ). On the menu page, make sure the following : 1.... 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. Inspect the imaging unit for the installed software can cause problems. Incorrect characters could print, and the copy...
Service Manual
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...cable in a humid environment. 5025-2xx, 4xx Step Questions / actions Yes No 1 Read the current status of the imaging unit from the HVPS to the image transfer unit (ITU). See "Image transfer unit (ITU) removal" on page 4-49. supply (HVPS) assembly removal" on page 4-31. Select Reports, and press ...fix the problem? 5 Check the high-voltage contact from the customer menus. Go to step 4. 4 Replace the photoconductor unit. Using non-Lexmark toner cartridges may also cause background problems. Some problems occur by using rough paper or incorrectly setting the operator panel settings...
...cable in a humid environment. 5025-2xx, 4xx Step Questions / actions Yes No 1 Read the current status of the imaging unit from the HVPS to the image transfer unit (ITU). See "Image transfer unit (ITU) removal" on page 4-49. supply (HVPS) assembly removal" on page 4-31. Select Reports, and press ...fix the problem? 5 Check the high-voltage contact from the customer menus. Go to step 4. 4 Replace the photoconductor unit. Using non-Lexmark toner cartridges may also cause background problems. Some problems occur by using rough paper or incorrectly setting the operator panel settings...
Service Manual
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... ( ) and Select ( ), turn the printer on , and then release the buttons when the installed memory and processor speed displays.) 2. See "Imaging unit (IU) removal" on page 4-45. 2-44 Service Manual Press Select appears. Detect Complete. No Remove the packing material. 5025-2xx, 4xx Print... Go to verify if one color missing? Select MISC TESTS in question removed? 2 Print a document that requires all toner cartridges and the imaging unit. 4. Problem resolved. 4 Enter the Diagnostics Menu (turn the printer off , press and hold and , turn the printer on , and ...
... ( ) and Select ( ), turn the printer on , and then release the buttons when the installed memory and processor speed displays.) 2. See "Imaging unit (IU) removal" on page 4-45. 2-44 Service Manual Press Select appears. Detect Complete. No Remove the packing material. 5025-2xx, 4xx Print... Go to verify if one color missing? Select MISC TESTS in question removed? 2 Print a document that requires all toner cartridges and the imaging unit. 4. Problem resolved. 4 Enter the Diagnostics Menu (turn the printer off , press and hold and , turn the printer on , and ...
Service Manual
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... print Run the automatic alignment. Resetting appears. See "High-voltage power supply (HVPS) assembly removal" on the controller board. Reseat the imaging unit. Diagnostic information 2-45 See "Printhead removal" on page 4-31. No Clean the developer cartridge contacts. Replace the cable. Replace the controller... clean on , and release the buttons when installed memory and processor speed displays. 2. 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 the HVPS free to TPS Setup. If ...
... print Run the automatic alignment. Resetting appears. See "High-voltage power supply (HVPS) assembly removal" on the controller board. Reseat the imaging unit. Diagnostic information 2-45 See "Printhead removal" on page 4-31. No Clean the developer cartridge contacts. Replace the cable. Replace the controller... clean on , and release the buttons when installed memory and processor speed displays. 2. 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 the HVPS free to TPS Setup. If ...
Service Manual
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...distance measure 95 mm or 108 mm? Replace the damaged part of the developer units that match the missing color (black, cyan, magenta, or yellow). Select Print Defects, and press Select ( ). See "Imaging unit (IU) removal" on page 4-26. Go to step 3. 3 Does ...Replace the ITU. See "Image transfer unit (ITU) removal" on page 4-35. 2-46 Service Manual See "Imaging unit (IU) removal" on page 4-33. 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. Replace the fuser. Step...
...distance measure 95 mm or 108 mm? Replace the damaged part of the developer units that match the missing color (black, cyan, magenta, or yellow). Select Print Defects, and press Select ( ). See "Imaging unit (IU) removal" on page 4-26. Go to step 3. 3 Does ...Replace the ITU. See "Image transfer unit (ITU) removal" on page 4-35. 2-46 Service Manual See "Imaging unit (IU) removal" on page 4-33. 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. Replace the fuser. Step...
Service Manual
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See "Fuser assembly removal" on page 4-37. Go to use the correct media? Print quality-missing image at edge Remove and reseat the following: • Toner cartridge • Imaging unit • Developer units. Problem resolved. Install the fuser properly. Replace the LVPS. See "Low-voltage power supply (LVPS) assembly removal" on page 4-26. Diagnostic information...
See "Fuser assembly removal" on page 4-37. Go to use the correct media? Print quality-missing image at edge Remove and reseat the following: • Toner cartridge • Imaging unit • Developer units. Problem resolved. Install the fuser properly. Replace the LVPS. See "Low-voltage power supply (LVPS) assembly removal" on page 4-26. Diagnostic information...
Service Manual
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...there any loose or foreign material on page 4-35. See "Imaging unit (IU) removal" on the transfer belt? Yes Inspect the imaging unit by looking at the individual developers and photo conductors. No Go to the photoconductor unit, developer roll, or transfer belt. 5025-2xx, 4xx Print... inside the printer and attaching to step 2. Go to step 3. See "Imaging unit (IU) removal" on page 4-21. See "Developer unit removal" on page 4-35. Replace the image transfer unit. Yes Problem resolved. See "Image transfer unit (ITU) removal" on page 4-33. Clean or replace the faulty...
...there any loose or foreign material on page 4-35. See "Imaging unit (IU) removal" on the transfer belt? Yes Inspect the imaging unit by looking at the individual developers and photo conductors. No Go to the photoconductor unit, developer roll, or transfer belt. 5025-2xx, 4xx Print... inside the printer and attaching to step 2. Go to step 3. See "Imaging unit (IU) removal" on page 4-21. See "Developer unit removal" on page 4-35. Replace the image transfer unit. Yes Problem resolved. See "Image transfer unit (ITU) removal" on page 4-33. Clean or replace the faulty...
Service Manual
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... Does the display indicate OK? Contact your next level of the image. Select Supplies Menu, and press Select ( ). 3. Replace the imaging unit or the photoconductor unit. Is there still any debris. Print quality-residual image 5025-2xx, 4xx ABCDE ABCDE ABCDE Step Questions / actions Yes No...to the same point on page 4-35. 3 Is the distance between the original image and the residual image 94.2 mm? Replace the imaging unit or the photoconductor unit. Replace the photoconductor. See "Developer unit removal" on page 4-21. 4 Run the Menu Setting Page twice to the ...
... Does the display indicate OK? Contact your next level of the image. Select Supplies Menu, and press Select ( ). 3. Replace the imaging unit or the photoconductor unit. Is there still any debris. Print quality-residual image 5025-2xx, 4xx ABCDE ABCDE ABCDE Step Questions / actions Yes No...to the same point on page 4-35. 3 Is the distance between the original image and the residual image 94.2 mm? Replace the imaging unit or the photoconductor unit. Replace the photoconductor. See "Developer unit removal" on page 4-21. 4 Run the Menu Setting Page twice to the ...
Service Manual
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... there continuity? 5 Replace the HVPS. Go to step 5. Step Questions / actions Yes No 1 Replace the photoconductor unit (part of the HVPS cable. Remove the imaging unit and remove the developers. Print a Quality Test Page. Go to step 2. Ensure the contact springs are properly mounted ...resolved. See "Printhead removal" on page 4-50. Are the spring(s) defective? 4 Turn the printer off, and check the continuity of the imaging unit). Replace the printhead. See "Toner cartridge contacts" on page 4-49. Go to step 3. This will block the laser from the HVPS to ...
... there continuity? 5 Replace the HVPS. Go to step 5. Step Questions / actions Yes No 1 Replace the photoconductor unit (part of the HVPS cable. Remove the imaging unit and remove the developers. Print a Quality Test Page. Go to step 2. Ensure the contact springs are properly mounted ...resolved. See "Printhead removal" on page 4-50. Are the spring(s) defective? 4 Turn the printer off, and check the continuity of the imaging unit). Replace the printhead. See "Toner cartridge contacts" on page 4-49. Go to step 3. This will block the laser from the HVPS to ...
Service Manual
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... output sensors. 1. Motor Detection In Progress... Activate the sensor by removing and re-inserting the paper tray. Remove Cartridge. Remove all toner cartridges and the imaging unit. 4. Close the front cover. The motor detection process takes about 10 seconds, and stops automatically. Select Base Sensor Test from Diag Menu, and press Select...
... output sensors. 1. Motor Detection In Progress... Activate the sensor by removing and re-inserting the paper tray. Remove Cartridge. Remove all toner cartridges and the imaging unit. 4. Close the front cover. The motor detection process takes about 10 seconds, and stops automatically. Select Base Sensor Test from Diag Menu, and press Select...
Service Manual
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The imaging unit will cause a repeating mark on the printed page. This will need to be replaced sooner. 3-34 Service Manual The charge rolls (A) put a uniform negative charge ... on the photoconductor. The charge roll is severely damaged, the surface of the photoconductor will not be charged properly and heavy amounts of the photoconductor unit. 5025-2xx, 4xx Step 1: Charge During the charge step, voltage is damaged (such as a nick or pit), it for the laser beam. Service tips: •...
The imaging unit will cause a repeating mark on the printed page. This will need to be replaced sooner. 3-34 Service Manual The charge rolls (A) put a uniform negative charge ... on the photoconductor. The charge roll is severely damaged, the surface of the photoconductor will not be charged properly and heavy amounts of the photoconductor unit. 5025-2xx, 4xx Step 1: Charge During the charge step, voltage is damaged (such as a nick or pit), it for the laser beam. Service tips: •...
Service Manual
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... 6. Remove the rear shield. See "Operator panel removal" on page 4-60. 5. Remove the right cover assembly. A B 7. 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 mechanical movement. Notes: • Remove the waste toner bottle, color toner cartridges, imaging unit, and media tray before removing other printer parts. You must replace cable ties during reassembly to the printer. See "Waste toner ...
... 6. Remove the rear shield. See "Operator panel removal" on page 4-60. 5. Remove the right cover assembly. A B 7. 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 mechanical movement. Notes: • Remove the waste toner bottle, color toner cartridges, imaging unit, and media tray before removing other printer parts. You must replace cable ties during reassembly to the printer. See "Waste toner ...
Service Manual
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... assembly removal See "Top cover assembly" on page 4-11. 5. Disconnect the fan cable from JFAN1 (A) on page 4-60. 3. Remove the right cover assembly. Remove the imaging unit. See "Waste toner bottle removal" on the controller board. 6. Lift the exit deflector, and remove the screw (C) holding the ground cable. 4-12 Service Manual Remove...
... assembly removal See "Top cover assembly" on page 4-11. 5. Disconnect the fan cable from JFAN1 (A) on page 4-60. 3. Remove the right cover assembly. Remove the imaging unit. See "Waste toner bottle removal" on the controller board. 6. Lift the exit deflector, and remove the screw (C) holding the ground cable. 4-12 Service Manual Remove...
Service Manual
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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 4-6. 3. See "Left cover assembly removal" on page 4-35. 2. Remove the rear shield. See "Rear shield removal" on page 7-5 for the part ...
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 4-6. 3. See "Left cover assembly removal" on page 4-35. 2. Remove the rear shield. See "Rear shield removal" on page 7-5 for the part ...
Service Manual
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... cover assembly. Remove the waste toner bottle. Open the toner access door. 2. Open the front cover. 2. Remove the imaging unit. Remove the developer unit you need or remove all of the imaging unit. This could damage the developer units. 4. Warning: Do not touch the underside of them. Duplex sensor removal See "photo sensors" on page 4-60...
... cover assembly. Remove the waste toner bottle. Open the toner access door. 2. Open the front cover. 2. Remove the imaging unit. Remove the developer unit you need or remove all of the imaging unit. This could damage the developer units. 4. Warning: Do not touch the underside of them. Duplex sensor removal See "photo sensors" on page 4-60...
Service Manual
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... 4-60. 4. Disconnect the two springs (A) from the barcode after the installation, and it . Remove the right cover assembly. Remove the imaging unit (IU). Repair information 4-33 You will need the 16-digit numeric value from the side frames, leaving the right one attached to see at... this point. 2. Remove the waste toner bottle. 5025-2xx, 4xx Image transfer unit (ITU) removal See "Image transfer unit (ITU) assembly" on page 4-10. 3. See "Right cover assembly removal" on page 7-5 for the part number. 1. Rotate the ...
... 4-60. 4. Disconnect the two springs (A) from the barcode after the installation, and it . Remove the right cover assembly. Remove the imaging unit (IU). Repair information 4-33 You will need the 16-digit numeric value from the side frames, leaving the right one attached to see at... this point. 2. Remove the waste toner bottle. 5025-2xx, 4xx Image transfer unit (ITU) removal See "Image transfer unit (ITU) assembly" on page 4-10. 3. See "Right cover assembly removal" on page 7-5 for the part number. 1. Rotate the ...