Lexmark™ C54x Maintenance Guide
July 2009 www.lexmark.com
Contents
Maintaining the printer................................................................................3
Storing supplies.........................................................................................................................................3
Checking the status of supplies.................................................................................................................3
Checking the status of supplies from the printer control panel.........................................................................3
Checking the status of supplies from a network computer................................................................................3
Ordering supplies......................................................................................................................................4
Ordering toner cartridges...................................................................................................................................4
Ordering imaging kits..........................................................................................................................................5
Ordering a waste toner bottle............................................................................................................................6
Replacing supplies.....................................................................................................................................6
Replacing the waste toner bottle........................................................................................................................6
Replacing a black imaging kit..............................................................................................................................9
Replacing a black and color imaging kit............................................................................................................15
Replacing a toner cartridge...............................................................................................................................20
Replacing a developer unit................................................................................................................................22
Cleaning the exterior of the printer........................................................................................................27
Moving the printer..................................................................................................................................28
Before moving the printer.................................................................................................................................28
Moving the printer to another location............................................................................................................28
Shipping the printer..........................................................................................................................................28
Contents
2
Maintaining the printer
Periodically, certain tasks are required to maintain optimum print quality.
Storing supplies
Choose a cool, clean storage area for the printer supplies. Store supplies right side up in their original packing until you
are ready to use them.
Do not expose supplies to:
• Direct sunlight
• Temperatures above 35°C (95°F)
• High humidity above 80%
• Salty air
• Corrosive gases
• Heavy dust
Checking the status of supplies
A message appears on the display when a replacement supply item is needed or when maintenance is required.
Checking the status of supplies from the printer control panel
You can check the status of printer supplies by printing a menu settings page:
1 Make sure the printer is on and Ready appears.
2 From the printer control panel, press .
3 Press the arrow buttons until Reports appears, and then press .
4 Press the arrow buttons until Menu Settings Page appears, and then press .
Checking the status of supplies from a network computer
Note: The computer must be connected to the same network as the printer.
1 Type the printer IP address into the address field of your Web browser.
Note: If you do not know the IP address of the printer, print a network setup page and locate the IP address in the
TCP/IP section.
2 Click Device Status. The Device Status page appears, displaying a summary of supply levels.
Maintaining the printer
3
Ordering supplies
To order supplies in the U.S., contact Lexmark at 1-800-539-6275 for information about Lexmark authorized supplies
dealers in your area. In other countries or regions, visit the Lexmark Web Site at www.lexmark.com or contact the place
where you purchased the printer.
Note: All life estimates for printer supplies assume printing on letter- or A4-size plain paper.
Ordering toner cartridges
When 88 Cyan Cartridge Low, 88 Magenta Cartridge Low, 88 Yellow Cartridge Low, or 88
Black Cartridge low appears, order a new cartridge.
When 88 Replace Cyan Cartridge, 88 Replace Magenta Cartridge, 88 Replace Yellow
Cartridge, or 88 Replace Black Cartridge appears, you must replace the specified toner cartridge.
Part name Part number C540 and C543 C544 C546
Black Return Program
Toner Cartridge
Cyan Return Program
Toner Cartridge
Magenta Return
Program Toner
Cartridge
Yellow Return Program
Toner Cartridge
Black High Yield Return
Program Toner
Cartridge
Cyan High Yield Return
Program Toner
Cartridge
Magenta High Yield
Return Program Toner
Cartridge
Yellow High Yield
Return Program Toner
Cartridge
C540A1KG
C540A1CG
C540A1MG
C540A1YG
C540H1KG
C540H1CG
C540H1MG
C540H1YG
Black High Yield Toner
Cartridge
Cyan High Yield Toner
Cartridge
Magenta High Yield
Toner Cartridge
Yellow High Yield Toner
Cartridge
C540H2KG
C540H2CG
C540H2MG
C540H2YG
Maintaining the printer
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Part name Part number C540 and C543 C544 C546
Black Extra High Yield
Return Program Toner
Cartridge
Cyan Extra High Yield
Return Program Toner
Cartridge
Magenta Extra High
Yield Return Program
Toner Cartridge
Yellow Extra High Yield
Return Program Toner
Cartridge
Black Extra High Yield
Toner Cartridge
Cyan Extra High Yield
Toner Cartridge
Magenta Extra High
Yield Toner Cartridge
Yellow Extra High Yield
Toner Cartridge
C544X1KG X X
C544X1CG X
C544X1MG X
C544X1YG X
C544X2KG X X
C544X2CG X
C544X2MG X
C544X2YG X
Black Extra High Yield
Return Program Toner
Cartridge
Black Extra High Yield
Toner Cartridge
C546U1KG X X
C546U2KG X X
Ordering imaging kits
When Replace black and color imaging kit or Replace black imaging kit appears, order a
replacement imaging kit.
Part name Part number C540, C543, C544 C546
Black and Color Imaging Kit C540X74G
Black Imaging Kit C540X71G
Photoconductor Unit C540X35G Not Supported
Black Developer Unit C540X31G Not Supported
Cyan Developer Unit C540X32G Not Supported
Magenta Developer Unit C540X33G Not Supported
Yellow Developer Unit C540X34G Not Supported
Maintaining the printer
5
Ordering a waste toner bottle
When 82 Replace Waste Toner appears, order a replacement waste toner box. The waste toner box must be
replaced when 82 Replace Waste Toner appears.
Part name Part number
Waste toner bottle C540X75G
Replacing supplies
Replacing the waste toner bottle
Replace the waste toner bottle when 82 Replace waste toner appears. The printer will not continue printing
until the waste toner bottle is replaced.
1 Top door
2 Waste toner bottle
3 Right side cover
4 Front door
Maintaining the printer
6
1 Unpack the replacement waste toner bottle.
2 Grasp the front door at the side handholds, and then pull it toward you.
CAUTION—HOT SURFACE: The inside of the printer might be hot. To reduce the risk of injury from a hot
component, allow the surface to cool before touching.
3 Open the top door.
4 Remove the right side cover.
Maintaining the printer
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5 Press the green levers on each side of the waste toner bottle, and then remove it.
6 Place the waste toner bottle in the enclosed packaging. For more information, see the User’s Guide.
7 Insert the new waste toner bottle.
8 Replace the right side cover.
Maintaining the printer
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9 Close the top door.
10 Close the front door.
Replacing a black imaging kit
Replace the black imaging kit when Imaging Kit appears.
1 Grasp the front door at the side handholds, and then pull it toward you.
CAUTION—HOT SURFACE: The inside of the printer might be hot. To reduce the risk of injury from a hot
component, allow the surface to cool before touching.
Maintaining the printer
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2 Open the top door.
3 Remove the toner cartridges by lifting the handles, and then gently pulling away from the imaging kit.
4 Remove the right side cover.
Maintaining the printer
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5 Press the green levers on each side of the waste toner bottle, and then remove it.
6 Lift the blue levers on the imaging kit, and then pull it toward you.
7 Press down on the blue levers, grasp the green handles on the sides, and then pull the imaging kit out.
Warning—Potential Damage: Do not touch the underside of the imaging kit. This could damage the imaging kit.
Maintaining the printer
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8 Remove the yellow, cyan, and magenta developer units.
9 Unpack the replacement black imaging kit.
Leave the packaging on the black developer unit.
10 Gently shake the black developer unit side to side.
11 Remove the packaging from the black developer unit.
12 Insert the black developer unit.
13 Replace the yellow, cyan, and magenta developer units.
Note: Make sure each developer unit is inserted into a matching color slot.
Maintaining the printer
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14 Place the used black imaging kit in the enclosed package. For more information, see Recycling Lexmark Products.
15 Align and insert the imaging kit.
16 Rotate the blue levers down until the imaging kit drops into place.
17 Replace the waste toner bottle.
Maintaining the printer
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18 Replace the right side cover.
19 Replace the toner cartridges.
20 Close the top door.
Maintaining the printer
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21 Close the front door.
Replacing a black and color imaging kit
Replace the black and color imaging kit when Imaging Kit appears.
1 Grasp the front door at the side handholds, and then pull it toward you to open it.
CAUTION—HOT SURFACE: The inside of the printer might be hot. To reduce the risk of injury from a hot
component, allow the surface to cool before touching.
2 Open the top door.
Maintaining the printer
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3 Remove the toner cartridges by lifting the handles, and then gently pulling away from the imaging kit.
4 Remove the right side cover.
5 Press the green levers on each side of the waste toner bottle, and remove it.
Maintaining the printer
16
6 Lift the blue levers on the imaging kit, and then pull it toward you.
7 Press down on the blue levers, grasp the green handles on the sides, and then pull the imaging kit out.
Warning—Potential Damage: Do not touch the underside of the imaging kit. This could damage the imaging kit.
8 Unpack the replacement black and color imaging kit.
Leave the packaging on the developer units.
9 Gently shake the yellow, cyan, magenta, and black developer units side to side.
10 Remove the packaging from the yellow, cyan, magenta, and black developer units.
11 Insert the yellow, cyan, magenta, and black developer units.
Maintaining the printer
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12 Place the used black and color imaging kit in the enclosed package. For more information, see the User’s Guide.
13 Align and insert the imaging kit.
14 Replace the waste toner bottle.
Maintaining the printer
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15 Replace the right side cover.
16 Replace the toner cartridges.
17 Close the top door.
Maintaining the printer
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18 Close the front door.
Replacing a toner cartridge
Replace the specified toner cartridge (yellow, cyan, magenta, or black) when 88 Replace <color>
Cartridge appears. The printer will not continue printing until the specified cartridge is replaced.
Warning—Potential Damage: Damage caused by use of a non-Lexmark toner cartridge is not covered under warranty.
Note: Degraded print quality may result from using non-Lexmark toner cartridges.
1 Make sure the printer is on and Ready or 88 Replace <color> Cartridge appears.
2 Unpack the new cartridge, and set it near the printer.
3 Open the top door.
Maintaining the printer
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4 Remove the toner cartridge by lifting the handle, and then gently pulling away from the imaging kit.
5 Align the new toner cartridge, and then press down until it is all the way into the slot.
Maintaining the printer
21
6 Close the top door.
Replacing a developer unit
Replace a developer unit when a print quality defect occurs or when damage occurs to the printer.
Note: When a developer unit is replaced, you must manually calibrate the color. For more information, see color-
misregistration-topic.
1 Grasp the front door at the side handholds, and then pull it toward you to open it.
CAUTION—HOT SURFACE: The inside of the printer might be hot. To reduce the risk of injury from a hot
component, allow the surface to cool before touching.
2 Open the top door.
Maintaining the printer
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3 Remove the toner cartridges by lifting the handles and then gently pulling away from the imaging kit.
4 Remove the right side cover.
5 Press the green levers on each side of the waste toner bottle, and then remove it.
Maintaining the printer
23
6 Lift the blue levers on the imaging kit, and then pull it toward you.
7 Press down on the blue levers, grasp the handles on the sides, and then pull the imaging kit out.
Warning—Potential Damage: Do not touch the underside of the imaging kit. This could damage the imaging kit.
8 Remove the used developer unit.
9 Place the used developer in the enclosed package. For more information, see recycling-lexmark-
products-topic.
10 Unpack the replacement developer unit.
Leave the packaging on the developer unit.
11 Gently shake the developer unit side to side.
Maintaining the printer
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12 Remove the red shipping cover from the developer unit.
13 Insert the developer unit.
14 Align and insert the imaging kit.
Maintaining the printer
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15 Replace the waste toner bottle.
16 Replace the right side cover.
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17 Replace the toner cartridges.
18 Close the top door.
19 Close the front door.
Cleaning the exterior of the printer
1 Make sure that the printer is turned off and unplugged from the wall outlet.
CAUTION—SHOCK HAZARD: To avoid the risk of electric shock when cleaning the exterior of the printer,
unplug the power cord from the wall outlet and disconnect all cables from the printer before proceeding.
2 Remove paper from the standard exit tray.
3 Dampen a clean, lint-free cloth with water.
Warning—Potential Damage: Do not use household cleaners or detergents, as they may damage the finish of the
printer.
Maintaining the printer
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4 Wipe only the outside of the printer, making sure to include the standard exit tray.
Warning—Potential Damage: Using a damp cloth to clean the interior may cause damage to your printer.
5 Make sure the standard exit tray is dry before beginning a new print job.
Moving the printer
Before moving the printer
CAUTION—POTENTIAL INJURY: The printer weight is greater than 18 kg (40 lb) and requires two or more trained
personnel to move it safely.
CAUTION—POTENTIAL INJURY: Before moving the printer, follow these guidelines to avoid personal injury or
printer damage:
• Turn the printer off using the power switch, and then unplug the power cord from the wall outlet.
• Disconnect all cords and cables from the printer before moving it.
• Lift the printer off of the optional drawer and set it aside instead of trying to lift the drawer and printer at the same
time.
Note: Use the handholds located on both sides of the printer to lift it off the optional drawer.
Warning—Potential Damage: Damage to the printer caused by improper moving is not covered by the printer warranty.
Moving the printer to another location
The printer and options can be safely moved to another location by following these precautions:
• Any cart used to move the printer must have a surface able to support the full footprint of the printer. Any cart
used to move the options must have a surface able to support the dimensions of the options.
• Keep the printer in an upright position.
• Avoid severe jarring movements.
Shipping the printer
When shipping the printer, use the original packaging or call the place of purchase for a relocation kit.
Maintaining the printer
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