Lexmark C540 Service Manual

Lexmark™ C540n, C543dn, C544n,

C544dn, C544dtn, and C544dw

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.

Edition: October 14, 2008

5025-2xx, 4xx

Edition: October 14, 2008

The following paragraph does not apply to any country where such provisions are inconsistent with local law:

LEXMARK INTERNATIONAL, INC. PROVIDES THIS PUBLICATION “AS IS” WITHOUT WARRANTY OF ANY KIND,
EITHER EXPRESS OR IMPLIED, INCLUDING, BUT NOT LIMITED TO, THE IMPLIED WARRANTIES OF
MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. Some states do not allow disclaimer of express or
implied warranties in certain transactions; therefore, this statement may not apply to you.

This publication could include technical inaccuracies or typographical errors. Changes are periodically made to the
information herein; these changes will be incorporated in later editions. Improvements or changes in the products or the
programs described may be made at any time.

Comments may be addressed to Lexmark International, Inc., Department D22A/032-2, 740 West New Circle Road,
Lexington, Kentucky 40550, U.S.A or e-mail at [e-mail]. Lexmark may use or distribute any
of the information you supply in any way it believes appropriate without incurring any obligation to you.

References in this publication to products, programs, or services do not imply that the manufacturer intends to make these
available in all countries in which it operates. Any reference to a product, program, or service is not intended to state or
imply that only that product, program, or service may be used. Any functionally equivalent product, program, or service that
does not infringe any existing intellectual property right may be used instead. Evaluation and verification of operation in
conjunction with other products, programs, or services, except those expressly designated by the manufacturer, are the
user’s responsibility.

Lexmark and Lexmark with diamond design 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. This printer is intended to be compatible with
the PCL language. This means the printer recognizes PCL commands used in various application programs, and that the
printer emulates the functions corresponding to the commands.

All other trademarks are the property of their respective owners.

© 2008 Lexmark International, Inc.

All rights reserved.

UNITED STATES GOVERNMENT RIGHTS

This software and any accompanying documentation provided under this agreement are commercial computer software
and documentation developed exclusively at private expense.

P/N 12G9819

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Table of contents

Table of contents. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .iii

Notices and safety information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ix

Laser notice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ix

Safety information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xv

Preface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xviii

Conventions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xviii

General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

Options and features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

Printer specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

Memory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

Print quality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

Connectivity (network support) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

Operating modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

Data streams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

Clearances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5

Power and electrical specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6

Acoustics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7

Environment specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7

Media handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8

Input and output sources . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8

Duplex capability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8

Media input size specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9

Media input type specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10

Media output size and type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11

Media guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12

Paper characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12

Unacceptable paper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12

Selecting paper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13

Selecting preprinted forms and letterhead . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13

Storing paper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13

Using recycled paper and other office papers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13

Tools required for service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14

Acronyms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15

Diagnostic information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

POR (Power-On Reset) sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

Symptom tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

Printer symptom table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

Print quality symptom table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

Error codes and messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5

User status and customer attendance messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5

Paper Jam messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11

Service error messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12

Service checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-24

122.xx—Fuser temperature incorrect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-24

90x.xx error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-24

925.01—Fan error service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-25

930.xx–935.xx—Printhead errors service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-25

Table of contents iii

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936.xx, 937.xx—Transport motor service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-26

950.xx NVRAM Failure service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-26

Autocompensator mechanism service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-27

Bin full sensor service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-27

Dead printer service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-28

Duplex/manual feed sensor (S1) service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-29

Front door sensor or switches service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-30

Fuser exit sensor service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-31

Fuser service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-32

Input sensor (S2) service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-34

Main drive gear assembly (EP drive) service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-35

Operator panel service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-36

One or more operator panel buttons fail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-36

Operator panel display blank, five beeps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-37

Operator panel display blank, printer beeps five times and pauses . . . . . . . . . . . . . . . . . . . . . .2-38

Operator panel displays all diamonds, no beeps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-39

Operator panel displays all diamonds, five beeps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-40

Operator panel display is dim and unchanging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-41

Print quality service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-42

Print quality—background . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-43

Print quality—blank page . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-44

Print quality—blurred or fuzzy print . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-45

Print quality—half-color page . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-45

Print quality—horizontal banding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-46

Print quality—horizontal line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-46

Print quality—insufficient fusing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-47

Print quality—missing image at edge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-47

Print quality—mottle (2–5mm speckles) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-47

Print quality—narrow vertical line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-48

Print quality—random marks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-48

Print quality—residual image . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-49

Print quality—solid color page . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-50

Print quality—vertical banding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-50

Printhead service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-51

Toner meter cycle (TMC) card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-52

Toner meter sensors (Y, C, M, K) on TMC card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-52

Transfer roll service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-53

Tray 1 sensor service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-53

User operator panel and Administration menus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-55

Printer operator panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-55

Operator panel buttons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-55

Menu map . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-56

Diagnostic aids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

Accessing service menus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1

Diagnostics Menu (Diag Menu) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-2

Diagnostics Menu structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

Available tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-2

Registration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

Skew . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-5

Quick Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-5

Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-7

Print Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-10

Input source tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-10

Print quality test pages (Prt Quality Pgs) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-11

Hardware Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-11

Panel Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-11

Button Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-12

DRAM Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-12

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Duplex Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13

Quick Test (duplex) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13

Top Margin (duplex) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14

Left Margin (duplex) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14

Input Tray Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15

Feed Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15

Sensor Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15

Base Sensor Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16

Miscellaneous tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16

Motor Detect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16

Device Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17

Flash Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17

Printer Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17

Defaults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17

Page counts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17

Serial Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18

Engine Setting 1 through 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18

Model Name . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18

Configuration ID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18

ITU Barcode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19

Reset Fuser Cnt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19

EP Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19

EP Defaults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19

Fuser Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19

DC Charge Adjust, Dev Bias Adj, Transfer Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20

TPS Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20

Right or Left TPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20

Cal Ref Adj . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20

Reset Color Cal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21

Reports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21

Menu Settings Page . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21

Event Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21

Display Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21

Print Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22

Clear Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22

EXIT Diags . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23

Configuration menu (Config Menu) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-24

Available tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-24

Prt Quality Pgs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-24

Color Trapping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-24

Reports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25

Menu Settings Page . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25

Event Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25

Panel Menus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25

PPDS Emulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25

Demo Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25

Factory Defaults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-26

Energy Conserve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-26

Auto Color Adj . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-27

Font Sharpening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

E

xit Config . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-27

Paper jams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-28

Avoiding jams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-28

Understanding jam numbers and locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-29

200 paper jams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-30

201 paper jam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-30

202 paper jam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-31

230 paper jam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-32

235 paper jam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-32

. . . . . . . . 3-27

Table of contents v

5025-2xx, 4xx

24x paper jam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-32

250 paper jam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-32

Theory of operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-33

Print engine theory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-33

Electrophotographic process (EP process) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-33

Electrophotographic process basics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-33

Step 1: Charge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-34

Step 2: Expose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-35

Step 3: Develop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-36

Step 4a: First transfer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-37

Step 4b: Second transfer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-38

Step 5: Fuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-39

Step 6: Clean/erase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-40

Paper path, transport components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-42

Paper path Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-42

Transport components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-43

Duplex process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-44

Color theory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-45

What is RGB color? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-45

What is CMYK color? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-45

How is color specified in a document to be printed? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-45

How does the printer know what color to print? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-45

Should I use PostScript or PCL emulation printer software? What settings should

I use for the best color? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-45

Why doesn't the printed color match the color I see on the computer screen? . . . . . . . . . . . . .3-45

The printed page appears tinted. Can I adjust the color? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-45

My color transparencies seem dark when they are projected. Is there anything I can

do to improve the color? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-46

What is manual color correction? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-46

How can I match a particular color (such as a corporate logo)? . . . . . . . . . . . . . . . . . . . . . . . .3-47

What are detailed Color Samples, and how do I access them? . . . . . . . . . . . . . . . . . . . . . . . . .3-47

Repair information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

Handling ESD-sensitive parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

Removal procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-2

Front cover assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-2

Left cover assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-6

Operator panel bezel and name plate removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-8

Operator panel removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-9

Right cover assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-10

Rear shield removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11

Top cover assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-12

Autocompensator mechanism (ACM) removal—standard tray . . . . . . . . . . . . . . . . . . . . . . . . . .4-15

Bin full sensor removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-18

Bin full sensor flag and exit deflector removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-18

Controller board removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-19

Developer unit removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-21

Duplex sensor removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-21

Exit deflector and bin full sensor flag removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-24

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 lower frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-41

vi Service Manual

5025-2xx, 4xx

Main drive gear assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-45

Pick tires removal—standard media tray . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-48

Printhead removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-49

Toner cartridge contacts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-50

Toner density sensor (TDS) removal—left or right sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-53

Toner meter cycle (TMC) card removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-55

Tray present sensor removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-57

USB port connector removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-59

Waste toner bottle removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-60

Wireless network antenna removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-61

Wireless network card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-63

Connector locations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2

Controller board diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2

High-voltage power supply (HVPS) diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10

Low-voltage power supply (LVPS) diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12

Toner meter cycle (TMC) card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13

Wireless network card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14

Preventive maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

Safety inspection guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

Parts catalog . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

How to use this parts catalog . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

Assembly 1: Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2

Assembly 2: Frames. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4

Assembly 3: Electronics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6

Assembly 4: Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8

Assembly 5: Options and miscellaneous. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9

Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I-1

Part number index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I-7

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Notices and safety information

CAUTION

This product contains a lithium battery. THERE IS A RISK OF EXPLOSION IF THE BATTERY
IS REPLACED BY AN INCORRECT TYPE. Discard used batteries according to the battery
manufacturer’s instructions and local regulations.

The laser notice label may be affixed to this printer.

Laser notice

The printer 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.

Class I laser products are not considered to be hazardous. The printer contains internally a Class IIIb (3b) laser
that is nominally a 5 milliwatt gallium arsenide laser operating in the wavelength region of 645-670 nanometers.
The laser system and printer are designed so there is never any human access to laser radiation above a Class
I level during normal operation, user maintenance, or prescribed service condition.

Laser

Der Drucker erfüllt gemäß amtlicher Bestätigung der USA die Anforderungen der Bestimmung DHHS
(Department of Health and Human Services) 21 CFR Teil J für Laserprodukte der Klasse I (1). In anderen
Ländern gilt der Drucker als Laserprodukt der Klasse I, der die Anforderungen der IEC (International
Electrotechnical Commission) 60825-1 gemäß amtlicher Bestätigung erfüllt.

Laserprodukte der Klasse I gelten als unschädlich. Im Inneren des Druckers befindet sich ein Laser der Klasse
IIIb (3b), bei dem es sich um einen Galliumarsenlaser mit 5 Milliwatt handelt, der Wellen der Länge 645-670
Nanometer ausstrahlt. Das Lasersystem und der Drucker sind so konzipiert, daß im Normalbetrieb, bei der
Wartung durch den Benutzer oder bei ordnungsgemäßer Wartung durch den Kundendienst Laserbestrahlung,
die Klasse I übersteigen würde, Menschen keinesfalls erreicht.

Avis relatif à l’utilisation de laser

Pour les Etats-Unis : cette imprimante est certifiée conforme aux provisions DHHS 21 CFR alinéa J concernant
les produits laser de Classe I (1). Pour les autres pays : cette imprimante répond aux normes IEC 60825-1
relatives aux produits laser de Classe I.

Les produits laser de Classe I sont considérés comme des produits non dangereux. Cette imprimante est
équipée d’un laser de Classe IIIb (3b) (arséniure de gallium d’une puissance nominale de 5 milliwatts) émettant
sur des longueurs d’onde comprises entre 645 et 670 nanomètres. L’imprimante et son système laser sont
conçus pour impossible, dans des conditions normales d’utilisation, d’entretien par l’utilisateur ou de révision,
l’exposition à des rayonnements laser supérieurs à des rayonnements de Classe I .

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Avvertenze sui prodotti laser

Questa stampante è certificata negli Stati Uniti per essere conforme ai requisiti del DHHS 21 CFR Sottocapitolo
J per i prodotti laser di classe 1 ed è certificata negli altri Paesi come prodotto laser di classe 1 conforme ai
requisiti della norma CEI 60825-1.

I prodotti laser di classe non sono considerati pericolosi. La stampante contiene al suo interno un laser di classe
IIIb (3b) all’arseniuro di gallio della potenza di 5mW che opera sulla lunghezza d’onda compresa tra 645 e 670
nanometri. Il sistema laser e la stampante sono stati progettati in modo tale che le persone a contatto con la
stampante, durante il normale funzionamento, le operazioni di servizio o quelle di assistenza tecnica, non
ricevano radiazioni laser superiori al livello della classe 1.

Avisos sobre el láser

Se certifica que, en los EE.UU., esta impresora cumple los requisitos para los productos láser de Clase I (1)
establecidos en el subcapítulo J de la norma CFR 21 del DHHS (Departamento de Sanidad y Servicios) y, en
los demás países, reúne todas las condiciones expuestas en la norma IEC 60825-1 para productos láser de
Clase I (1).

Los productos láser de Clase I no se consideran peligrosos. La impresora contiene en su interior un láser de
Clase IIIb (3b) de arseniuro de galio de funcionamiento nominal a 5 milivatios en una longitud de onda de 645 a
670 nanómetros. El sistema láser y la impresora están diseñados de forma que ninguna persona pueda verse
afectada por ningún tipo de radiación láser superior al nivel de la Clase I durante su uso normal, el
mantenimiento realizado por el usuario o cualquier otra situación de servicio técnico.

Declaração sobre Laser

A impressora está certificada nos E.U.A. em conformidade com os requisitos da regulamentação DHHS 21 CFR
Subcapítulo J para a Classe I (1) de produtos laser. Em outros locais, está certificada como um produto laser da
Classe I, em conformidade com os requisitos da norma IEC 60825-1.

Os produtos laser da Classe I não são considerados perigosos. Internamente, a impressora contém um produto
laser da Classe IIIb (3b), designado laser de arseneto de potássio, de 5 milliwatts ,operando numa faixa de
comprimento de onda entre 645 e 670 nanómetros. O sistema e a impressora laser foram concebidos de forma
a nunca existir qualquer possiblidade de acesso humano a radiação laser superior a um nível de Classe I
durante a operação normal, a manutenção feita pelo utilizador ou condições de assistência prescritas.

Laserinformatie

De printer voldoet aan de eisen die gesteld worden aan een laserprodukt van klasse I. Voor de Verenigde
Staten zijn deze eisen vastgelegd in DHHS 21 CFR Subchapter J, voor andere landen in IEC 60825-1.

Laserprodukten van klasse I worden niet als ongevaarlijk aangemerkt. De printer is voorzien van een laser van
klasse IIIb (3b), dat wil zeggen een gallium arsenide-laser van 5 milliwatt met een golflengte van 645-670
nanometer. Het lasergedeelte en de printer zijn zo ontworpen dat bij normaal gebruik, bij onderhoud of reparatie
conform de voorschriften, nooit blootstelling mogelijk is aan laserstraling boven een niveau zoals
voorgeschreven is voor klasse 1.

Lasermeddelelse

Printeren er godkendt som et Klasse I-laserprodukt, i overenstemmelse med kravene i IEC 60825-1.

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Klasse I-laserprodukter betragtes ikke som farlige. Printeren indeholder internt en Klasse IIIB (3b)-laser, der
nominelt er en 5 milliwatt galliumarsenid laser, som arbejder på bølgelængdeområdet 645-670 nanometer.
Lasersystemet og printeren er udformet således, at mennesker aldrig udsættes for en laserstråling over Klasse
I-niveau ved normal drift, brugervedligeholdelse eller obligatoriske servicebetingelser.

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Laserilmoitus

Tämä tulostin on sertifioitu Yhdysvalloissa DHHS 21 CFR Subchapter J -standardin mukaiseksi luokan I (1) ­lasertuotteeksi ja muualla IEC 60825-1 -standardin mukaiseksi luokan I lasertuotteeksi.

Luokan I lasertuotteita ei pidetä haitallisina. Tulostimen sisällä on luokan IIIb (3b) laser, joka on nimellisteholtaan
5 mW:n galliumarsenidilaser ja toimii 645 - 670 nanometrin aallonpituuksilla. Laserjärjestelmä ja tulostin ovat
rakenteeltaan sellaisia, että käyttäjä ei joudu alttiiksi luokkaa 1 suuremmalle säteilylle normaalin käytön,
ylläpidon tai huollon aikana.

Huomautus laserlaitteesta

Tämä kirjoitin on Yhdysvalloissa luokan I (1) laserlaitteiden DHHS 21 CFR Subchapter J -määrityksen mukainen
ja muualla luokan I laserlaitteiden IEC 60825-1 -määrityksen mukainen.

Luokan I laserlaitteiden ei katsota olevan vaarallisia käyttäjälle. Kirjoittimessa on sisäinen luokan IIIb (3b) 5
milliwatin galliumarsenidilaser, joka toimii aaltoalueella 645 - 670 nanometriä. Laserjärjestelmä ja kirjoitin on
suunniteltu siten, että käyttäjä ei altistu luokan I määrityksiä voimakkaammalle säteilylle kirjoittimen normaalin
toiminnan, käyttäjän tekemien huoltotoimien tai muiden huoltotoimien yhteydessä.

VARO! Avattaessa ja suojalukitus ohitettaessa olet alttiina näkymättömälle lasersäteilylle. Älä katso
säteeseen.

VARNING! Osynlig laserstrålning när denna del är öppnad och spärren är urkopplad. Betrakta ej strålen.

Laser-notis

Denna skrivare är i USA certifierad att motsvara kraven i DHHS 21 CFR, underparagraf J för laserprodukter av
Klass I (1). I andra länder uppfyller skrivaren kraven för laserprodukter av Klass I enligt kraven i IEC 60825-1.

Laserprodukter i Klass I anses ej hälsovådliga. Skrivaren har en inbyggd laser av Klass IIIb (3b) som består av
en laserenhet av gallium-arsenid på 5 milliwatt som arbetar i våglängdsområdet 645-670 nanometer.
Lasersystemet och skrivaren är utformade så att det aldrig finns risk för att någon person utsätts för
laserstrålning över Klass I-nivå vid normal användning, underhåll som utförs av användaren eller annan
föreskriven serviceåtgärd.

Laser-melding

Skriveren er godkjent i USA etter kravene i DHHS 21 CFR, underkapittel J, for klasse I (1) laserprodukter, og er
i andre land godkjent som et Klasse I-laserprodukt i samsvar med kravene i IEC 60825-1.

Klasse I-laserprodukter er ikke å betrakte som farlige. Skriveren inneholder internt en klasse IIIb (3b)-laser, som
består av en gallium-arsenlaserenhet som avgir stråling i bølgelengdeområdet 645-670 nanometer.
Lasersystemet og skriveren er utformet slik at personer aldri utsettes for laserstråling ut over klasse I-nivå under
vanlig bruk, vedlikehold som utføres av brukeren, eller foreskrevne serviceoperasjoner.

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Avís sobre el Làser

Segons ha estat certificat als Estats Units, aquesta impressora compleix els requisits de DHHS 21 CFR, apartat
J, pels productes làser de classe I (1), i segons ha estat certificat en altres llocs, és un producte làser de classe
I que compleix els requisits d’IEC 60825-1.

Els productes làser de classe I no es consideren perillosos. Aquesta impressora conté un làser de classe IIIb
(3b) d’arseniür de gal.li, nominalment de 5 mil.liwats, i funciona a la regió de longitud d’ona de 645-670
nanòmetres. El sistema làser i la impressora han sigut concebuts de manera que mai hi hagi exposició a la
radiació làser per sobre d’un nivell de classe I durant una operació normal, durant les tasques de manteniment
d’usuari ni durant els serveis que satisfacin les condicions prescrites.

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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.

• The maintenance information for this product has been prepared for use by a professional service person

and is not intended to be used by others.

• There may be an increased risk of electric shock and personal injury during disassembly and servicing of

this product. Professional service personnel should understand this and take necessary precautions.

• CAUTION: When you see this symbol, there is a danger from hazardous voltage in the area of the

product where you are working. Unplug the product before you begin, or use caution if the product
must receive power in order to perform the task.

Consignes de sécurité

• La sécurité de ce produit repose sur des tests et des

agréations portant sur sa conception d'origine et sur des composants particuliers. Le fabricant n'assume

aucune responsabilité concernant la sécurité en cas d'utilisation de pièces de rechange non agréées.

• Les consignes d'entretien et de réparation de ce produit s'adressent uniquement à un personnel de

maintenance qualifié.

• Le démontage et l'entretien de ce produit pouvant présenter certains risques électriques, le personnel

d'entretien qualifié devra prendre toutes les précautions nécessaires.

• ATTENTION : Ce symbole indique la présence d'une tension dangereuse dans la partie du

produit sur laquelle vous travaillez. Débranchez le produit avant de commencer ou faites preuve
de vigilance si l'exécution de la tâche exige que le produit reste sous tension.

Norme di sicurezza

• La sicurezza del prodotto si basa sui test e sull'approvazione del progetto originale e dei componenti

specifici. Il produttore non è responsabile per la sicurezza in caso di sostituzione non autorizzata delle

parti.

• Le informazioni riguardanti la manutenzione di questo prodotto sono indirizzate soltanto al personale di

assistenza autorizzato.

• Durante lo smontaggio e la manutenzione di questo prodotto,

il rischio di subire scosse elettriche e danni alla persona è più elevato. Il personale di assistenza

autorizzato deve, quindi, adottare le precauzioni necessarie.

• ATTENZIONE: Questo simbolo indica la presenza di tensione pericolosa nell'area del prodotto.

Scollegare il prodotto prima di iniziare o usare cautela se il prodotto deve essere alimentato per
eseguire l'intervento.

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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.

• Die Wartungsinformationen für dieses Produkt sind ausschließlich für die Verwendung durch einen

Wartungsfachmann bestimmt.

• Während des Auseinandernehmens und der Wartung des Geräts besteht ein zusätzliches Risiko eines

elektrischen Schlags und körperlicher Verletzung. Das zuständige Fachpersonal sollte entsprechende
Vorsichtsmaßnahmen treffen.

• ACHTUNG: Dieses Symbol weist auf eine gefährliche elektrische Spannung hin, die in diesem

Bereich des Produkts auftreten kann. Ziehen Sie vor den Arbeiten am Gerät den Netzstecker des
Geräts, bzw. arbeiten Sie mit großer Vorsicht, wenn das Produkt für die Ausführung der Arbeiten
an den Strom angeschlossen sein muß.

Pautas de Seguridad

• La seguridad de este producto se basa en pruebas y aprobaciones del diseño original y componentes

específicos. El fabricante no es responsable de la seguridad en caso de uso de piezas de repuesto no
autorizadas.

• La información sobre el mantenimiento de este producto está dirigida exclusivamente al personal

cualificado de mantenimiento.

• Existe mayor riesgo de descarga eléctrica y de daños personales durante el desmontaje y la reparación de

la máquina. El personal cualificado debe ser consciente de este peligro y tomar las precauciones
necesarias.

• PRECAUCIÓN: este símbolo indica que el voltaje de la parte del equipo con la que está

trabajando es peligroso. Antes de empezar, desenchufe el equipo o tenga cuidado si, para
trabajar con él, debe conectarlo.

Informações de Segurança

• A segurança deste produto baseia-se em testes e aprovações do modelo original e de componentes

específicos. O fabricante não é responsável pela segunrança, no caso de uso de peças de substituição
não autorizadas.

• As informações de segurança relativas a este produto destinam-se a profissionais destes serviços e não

devem ser utilizadas por outras pessoas.

• Risco de choques eléctricos e ferimentos graves durante a desmontagem e manutenção deste produto.

Os profissionais destes serviços devem estar avisados deste facto e tomar os cuidados necessários.

• CUIDADO: Quando vir este símbolo, existe a possível presença de uma potencial tensão

perigosa na zona do produto em que está a trabalhar. Antes de começar, desligue o produto da
tomada eléctrica ou seja cuidadoso caso o produto tenha de estar ligado à corrente eléctrica para
realizar a tarefa necessária.

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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

seguretat si s'utilitzen peces de recanvi no autoritzades.

• La informació pel manteniment d’aquest producte està orientada exclusivament a professionals i no està

destinada

a ningú que no ho sigui.

• El risc de xoc elèctric i de danys personals pot augmentar durant el procés de desmuntatge i de servei

d’aquest producte. El personal professional ha d’estar-ne assabentat i prendre

les mesures convenients.

• PRECAUCIÓ: aquest símbol indica que el voltatge de la part de l'equip amb la qual esteu

treballant és perillós. Abans de començar, desendolleu l'equip o extremeu les precaucions si, per
treballar amb l'equip, l'heu de connectar.

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Preface

This manual contains maintenance procedures for service personnel. It is divided into the following chapters:

1. General information contains a general description of the printer and the maintenance approach used to

repair it. Special tools and test equipment, as well as general environmental and safety instructions, are
discussed.

2. Diagnostic information contains an error indicator table, symptom tables, and service checks used to

isolate failing field replaceable units (FRUs).

3. Diagnostic aids contains tests and checks used to locate or repeat symptoms of printer problems.

4. Repair information provides instructions for making printer adjustments and removing and installing

FRUs.

5. Connector locations uses illustrations to identify the connector locations and test points on the printer.

6. Preventive maintenance contains the lubrication specifications and recommendations to prevent

problems.

7. Parts catalog contains illustrations and part numbers for individual FRUs.

Conventions

Note: A note provides additional information.
Warning: A warning identifies something that might damage the product hardware or software.

There are several types of caution statements:

CAUTION

A caution identifies something that might cause a servicer harm.

CAUTION

This type of caution indicates there is a danger from hazardous voltage in the area of the
product where you are working. Unplug the product before you begin, or use caution if the
product must receive power in order to perform the task.

CAUTION

This type of caution indicates a hot surface.

CAUTION

This type of caution indicates a tipping hazard.

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1. General information

The Lexmark™ C54x printer (5024-2xx, 4xx) is a color network printer in a compact size. Some models have
internal duplexing, 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. The Lexmark C544dw
comes with wireless network and duplex printing.

Models

Model name

Lexmark C540n 5025-210 Ethernet network

Lexmark C543dn 5025-230 Ethernet network, duplex

Lexmark C544n 5025-410 Ethernet network, USB-A host ports for flash drives

Lexmark C544dn 5025-430 USB-A host ports for flash drives, duplex

Lexmark C544dw 5025-43W 802.11n network wireless network, duplex

Options and features

Machine type/
model

Description

Certain options are available on selected printer models only.

Available options include:

• 650-Sheet Duo Drawer—a 550-sheet drawer with a 100-sheet multipurpose feeder (MP Feeder).

• Additional memory—One 128, 256, or 512MB memory card may be added.

• Flash memory card—One 64MB card may be added.

• Font cards—One

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Printer specifications

Memory

✔—Supported
✘—Not supported

Memory

Optional slots One slot
Standard DIMM sizes
Optional (DDR2) 128MB, 256MB, and 512MB
Maximum printer memory

Option Slots (single slot is available or either font or flash memory card)

Font card support N/A 1 font card
Optional user flash memory card sizes N/A 64MB

Connections

USB 2.0 High Speed

Ethernet 10/100 BaseTx

USB-A
(allows direct USB printing using
approved USB flash memory device)

PictBridge
(allows printing photos directly from a
compatible camera)

Wireless standard 802.11 b/g/n

a

Dual Inline Memory Module. An optional memory card that can be plugged into an available memory slot.

b

The maximum usable DDRSDRAM is standard (soldered) plus 512MB.

a

128MB

b

640MB

Lexmark C540n, C543dn

✔✔

✔✔

✘✔

✘✔

✘

Lexmark C544n,

C544dn, C544dw

(C544dw only)

✔

Print quality

During the life of the printer, components are subject to wear based on usage. Printers continuously operating at
or near the maximum duty cycle may require service for replacement of these components to ensure high­quality printing and good performance throughout the life of the printer. The fuser and ITU replacement should
be determined by checking the last sheet of the Menu Settings Page. Either OK or Replace appears.

To print a Menu Settings page:

1. Press Menu ( ) on the operator panel.

2. Select Reports from the Admin Menu, and press Select ().

3. Select Menu Settings, and press Select ().

Replacement is recommended every 30,000 pages 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

5025-2xx, 4xx

Connectivity (network support)

✔—Supported
✘—Not supported

Lexmark C540n, C543dn,

Network protocol

C544dn Lexmark C544dw

Standard Ethernet 10/100 Base T

Standard USB-B (Full speed) device port

USB-A host ports

(In front, low/full speed) This port only
supports the following flash drives and file
types:

Supported flash drives
(512 MB/1GB size), SanDisk Cruzer Micro
(512 MB/1 GB size), or Sony (512 MB/
1GB).

Supported file types
.bmp, .png, .tiff, .tif, .pcx, .dcx

802.11n Wireless Network card

Manufacturing installs the wireless card. A
wireless card CANNOT be installed post­manufacturing.

a

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

• Uses the FAT file system

b

PDF files used with Direct USB printing must support PDF standard version 1.5 or earlier. PDF files with

restricted printing permissions or encryption are not supported.

Operating modes

a

: Lexar FireFly

b

:.pdf,.gif,.jpeg,.jpg,

✔✔

✔✔

✘✔

✘✔

Mode Description

Normal Factory default
Quiet Designed for customers where noise levels are a very important

Eco-Mode
(Energy and Energy + Paper)

factor.

• Print quality is maintained at factory default level.

• Speed is reduced.

Designed for customers where the environment is a key factor.
There are three options; Energy, Paper, and Energy+ Paper.

• Print quality is maintained.

• Power Saver is set to one minute.

• Fuser standby is off.

• The operator panel back light is off.

• Power supply energy consumption is reduced.

• Duplex is on if Energy + Paper is selected (duplex models

only) (can be overwritten by the driver).

General information 1-3

5025-2xx, 4xx

Data streams

✔—Supported
✘—Not supported

Data streams

Lexmark C540n, C543dn

Lexmark C544n,

C544dn, C544dw

PCL 6 emulation

PostScript Level III emulation

Version 3011 of the Adobe definition of
PostScript 3 is supported.

PDF

Supports version 1.6

PPDS

By default, the PPDS interpreter is inactive.
A user can activate the data stream by PJL
or by the PPDS Emulation setting in the
Configuration Menu.

PictBridge

Directimage

Devices that support Directimage support
all of the following graphics formats: TIFF,
TIF, JPEG, JPG, GIF, PNG, BMP, PCX,
and DCX.

Host-Based Printing (HBP)/Graphics
Device Interface (GDI)

Version 3 (color) uses PCL XL.

Dimensions

✔✔

✔✔

✘✔

✘✔

✘✔

✘✔

✔✔

Models Height Width D epth Weight

Lexmark C540n, C543dn,
C544n, C544dn, C544dw

Lexmark C544dtn
The Lexmark C544dn printer

with optional 640-sheet duo
drawer

650-sheet duo drawer 133 mm (5.2 in.) 424 mm (16.7 in.) 416 mm (16.4 in.) 4 kg (8.7 lb)

291 mm (11.5 in.) 424 mm (16.7 in.) 400 mm (15.7 in.) 21 kg (46.2 lbs)

422 mm (16.6 in.) 424 mm (16.7 in.) 416 mm (16.4 in.) 25 kg (54.9 lbs)

1-4 Service Manual

5025-2xx, 4xx

Clearances

Description Dimensions

Lexmark C540n, C543dn,

C544n, C544dn, and C544dw

1 Rear 102 mm (4 in.) 102 mm (4 in.)
2 Front 508 mm (20 in.) 508 mm (20 in.)
3 Right side 152 mm (6 in.) 254 mm (10 in.)
4 Left side 76 mm (3 in.) 76 mm (3 in.)
5 Above 254 mm (10 in.)* 254 mm (10 in.)*

* Add 133 mm (5.2 in.) to the top if you want to add an optional 650-sheet Duo Drawer (Lexmark C54x

models only).

C544dtn

General information 1-5

5025-2xx, 4xx

Power and electrical specifications

The following table specified nominal average power requirements for the base printer configurations. All power
levels are shown in Watts (W). Maximum current is given in Amperes (A).

Printing states Lexmark C540n, C543dn

Average power while printing

Simplex 480 W 500 W
Automatic duplex* 340 W 340 W

Average power while idle

Power Saver 18 W 18 W
Ready 34 W 36 W
Off 0 W 0 W

* Automatic duplex is not supported on the C540n and C544n.

Lexmark C544n, C544dn,
C544dw, and C544dtn

Typical electricity consumption2

Model Mode

Lexmark C540n, C543dn

1

3.73 kwh 3.5 kwh 3.92 kwh

TEC

1

—Eco Mode 3.41 kwh 3.30 kwh 3.55 kwh

TEC

Lexmark C544n, C544dn, C544dw, C544dtn

1

TEC

1

—Eco Mode 3.57 kwh 3.42 kwh 3.57 kwh

TEC

1

TEC—Typical Electricity Consumption.

2

Energy measurements are made according to ENERGY STAR Qualified Imaging Equipment Typical
Electricity Consumption Test Procedure, and are in units of kilowatts per week (kwh/week). Actual
electricity consumption will vary by device usage.

100 V/50 Hz 115 V/60 Hz 230 V/50 Hz

3.97 kwh 4.06 kwh 4.20 kwh

Power supply voltage (kwh)

Low-voltage models

• 110 to 127 V ac at 47 to 63 hertz (Hz) nominal

• 99 to 137 V ac, extreme

100 voltage models

• 100 V ac at 47 to 63 hertz (Hz) nominal

• 90 to 110 V ac, extreme

High-voltage models

• 220 to 240 V ac at 47 to 63 hertz (Hz) nominal (not available in all countries)

• 198 to 259 V ac, extreme

Notes:

• Using a 220 V ac to 110 V ac power converter with a low voltage printer is not recommended.

• Using an inverter to change DC to AC voltage (12 V to 120 V for example) is not recommended.

• All duplex models are ENERGY STAR compliant.

1-6 Service Manual

5025-2xx, 4xx

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 C544dn, C544dw

Printing (simplex) 47 dBA 47 dBA 49 dBA 49 dBA 49 dBA
Printing (automatic

duplex)
Idle Inaudible Inaudible Inaudible Inaudible Inaudible
Quiet Mode (simplex) 46 dBA 46 dBA 46 dBA 46 dBA 46 dBA

C540n

N/A 50 dBA N/A 51 dBA 51 dBA

Lexmark
C543dn

Lexmark
C544n

Lexmark
C544dn,
C544dw

Lexmark
C544dtn

Environment specifications

Environment Specifications

Operating

Air temperature—operating 15.6 to 32.20° C (60 to 90.0° F)
Air temperature—power off 10.0 to 43.30° C (50 to 110.0° F)
Air relative humidity Relative Humidity 8 to 80%
Wet bulb temperature—operating 22.80° C (73.0° F) maximum
Wet bulb temperature—power off 26.70° C (80.10° F) maximum
Altitude 0–3,048 meters (10,000 ft.)
Atmospheric pressure 74.6 kPa
Ambient operating environment* 15.6 to 32.2° C (60 to 90° F) and 8% to 80% RH

Ship / Storage

Cartridges -40 to 43.3° C (-40 to 110.0° F)
Printer with cartridges -40 to 43.3° C (-40 to 110.0° F)
Printer without cartridges -40 to 43.3° C (-40 to 110.0° F)
Air relative humidity Relative Humidity 8 to 80%
Altitude 10,300 meters (34,000 feet)
Wet bulb temperature—power off 26.70° C (80.10° F) Maximum
* In some cases, performance specifications (such as paper OCF, EP cartridge usage) are specified to be

measured at an ambient condition.

General information 1-7

5025-2xx, 4xx

Media handling

Input and output sources

Sheet numbers are assuming 20 lb.
xerographic paper

Standard input sources

Standard input tray (250-sheet tray) 250 sheets 250 sheets 250 sheets
Manual feed slot (1-sheet) 1 sheet 1 sheet 1 sheet
Second tray capacity (650-sheet Duo

Drawer)
Multipurpose try capacity (650-sheet Duo

Drawer)

Optional input sources (maximum 1, total of all inputs is 4)

a

650-sheet duo drawer
(includes 100-sheet MP feeder)

Maximum total input capacity 901 901 901

Duplex

Standard output sources (no optional output sources are available)

Standard 100-sheet bin 100 100 100

a In the 650-sheet duo drawer, the 550-sheet tray and the integrated MP feeder count as two independent

input sources. The MF feeder is configured as “cassette” does not show up as Configure MP in the Paper
Menu.

Lexmark C540n,
C544n

N/A N/A 550 sheets

N/A N/A 100 sheets

550 sheets

(or 100 sheets in

MP feeder)

N/A Duplex

Lexmark C543dn,
C544dn, C544dw

550 sheets

(or 100 sheets in

MP feeder)

Lexmark C544dtn
(C544dn with
second tray)

0

Duplex capability

✔—Supported
✘—Not supported

Models

Lexmark C540n
Lexmark C543dn

Lexmark C544n

Lexmark C544dn

Lexmark C544dw

Duplex capability

✘

✔

✘

✔

✔

1-8 Service Manual

5025-2xx, 4xx

Media input size specifications

✔—Supported without size

sensing

✘—Not supported

(in the

a

Input source

A4 210 x 297mm

A5a 148 x 210mm

A6 ✘✘

JISb B5a 182 x 257mm

JISb B4 ✘✘✘✘✘

Letter 8.5 x 11 in.

Legal 8.5 x 14 in.

Executive 7.25 x 10.5 in.

Oficio (Mexico)

Foliod 8.5 x 13 in.

Statement 5.5 x 8.5 in. ✘✘

Universalc

148 x 210mm to

215.9 x 355.6mm
(5.83 x 8.27 in. to

8.5 x 14 in.)

d

250-sheet tray

Optional 650-sheet

duo drawer

MP feeder

650-sheet duo drawer)

Manual slot

Duplex

✔✔✔✔✔

✔✔✔✔

✔

✔✘

✘

✔✔✔✔✔

✔✔✔✔✔

✔✔✔✔✔

✔✔✔✔

✔✔✔✔

✔✔✔✔

✔✔

✔✔✔✔

✘

✔

✔

✘

✘

76.2.x 127mm to

215.9 x 355.6mm
(3 x 5 in. to 8.5 x 14 in.)

210mm x 279.4mm to

215.9mm x 355.6mm
(8.27 in. x 11 in. to

8.5 in. to 14 in.)

7¾ Envelopea 98.4 x 190.5mm ✘✘

9 Envelopea ✘✘

10 Envelopea 104.8 x 241.3mm

(4.12 x 9.5 in.)

DL Envelopea 110 x 220mm

(4.33 x 8.66 in.)

C5 Envelopea 162 x 229mm

(6.38 x 9.01 in.)

✘

✔✔✔✔

✘✘

✘✘

✘✘✔✔✘

✘

✔✔

✔✔

✔✔

✔✔

✔✔

General information 1-9

✘

✔

✘

✘

✘

✘

5025-2xx, 4xx

✔—Supported without size

sensing

✘—Not supported

(in the

a

Input source

B5 Envelopea ✘✘✔✔✘

Other envelopea

Length: 98.4–431.8mm
(3.8–17 in.)
Width: 89–297mm (3.5–11.7 in.)

a

The MP feeder runs slower if A5, statement, B5, or envelopes are loaded.

b

Japanese Industry Standard.

c

Although the user may select Universal paper size for these sources, not all tray guides can be adjusted to
all Universal media sizes.

d

If a source supports size sensing and this feature is activated, then neither Oficio or Folio appear in the list
of supported media sizes. These values only appear in a list of supported media sizes when the source is
non-size sensing or the size sensing is deactivated.

Media input type specifications

✔—Supported
✘—Not supported

Input type

250-sheet tray

Optional 650-sheet

duo drawer

✘✘

250-sheet tray

Optional

650-sheet

Duo Drawer

MP feeder

650-sheet duo drawer)

Manual slot

✔✔

a

MP feeder

(in 650-sheet

Duo Drawer)

Manual feeder

Duplex

✘

Duplex

Plain paper ✔✔✔✔✔

Card stock ✔✔✔✔

Transparency ✔✔✔✔✘

Recycled

Glossy ✔✔✔✔✔

Heavy glossy

Paper-backed labels ✔✔✔✔

Bond ✔✔✔✔✔

Envelopes

Rough envelopes ✘✘✔✔✘

Letterhead ✔✔✔✔✔

Preprinted ✔✔✔✔✔

1-10 Service Manual

✘

b

✔✔✔✔✔

✘✘✘✘✘

✘✘✔✔✘

5025-2xx, 4xx

✔—Supported
✘—Not supported

Input type

Colored paper ✔✔✔✔✔

Light paper ✔✔✔✔✔

Heavy paper ✔✔✔✔✔

Rough or cotton ✔✔✔✔✔

Custom type <x>

a

For MP feeder and manual feeders, the Default Source Menu displays Manual Paper and Manual
Env. Select Manual Env. for envelopes or when the type in Custom Type <x> is an envelope. For other
types, use Manual Paper.

b

The duplex unit supports this media type as long as the customer has selected the custom type from those
types the duplex unit supports.

b

Media output size and type

There is a single 100-sheet output bin available for this printer and no additional output options.

a

250-sheet tray

✔✔✔✔✔

Optional

650-sheet

Duo Drawer

MP feeder

(in 650-sheet

Duo Drawer)

Manual feeder

Duplex

Weight ranges for each media type

Material Type Weight Select

2, 5, 7, 8

Paper

Specialty papers Gloss Book 88 to 176 g/m

Card stock—upper
limit (grain long)

Card Stock—upper
limit (grain short)

Transparency
Labels—upper limit Paper 131 g/m

Xerographic or

6

business paper

Gloss Cover 162 to 176 g/m
Index Bristol 120 g/m2 (67 lb)

1

Tag 120 g/m
Cover 135 g/m
Index Bristol 163 g/m2 (90 lb)

1

Tag 163 g/m
Cover 176 g/m

Laser printer 170 to 180 g/m2 (45 to 48 lb bond)

60 to 74. 9 g/m2 grain long
(16 to 19.9 lb bond)

75 to 89.9 g/m
(20 to 23.8 lb bond)

90. to 104.9 g/m
(23.9 to 27.8 lb bond)

105 to 176 g/m
(27.9 to 47 lb bond)

2

(74 lb)

2

(50 lb)

2

(100 lb)

2

(65 lb)

2

(35 lb bond)

2, 5

2

grain long

2

grain long

2

grain long

7

2

grain long (60 to 120 lb book)

2

grain long (60 to 65 lb cover)

Light Paper

Plain Paper

Heavy Paper

Card stock

General information 1-11

5025-2xx, 4xx

Material Type Weight Select

Envelopes
(Multipurpose

feeder or manual
slot only)

1

For 60 to 176 g/m2 paper, grain long fibers are recommended.

2

Paper less than 75 g/m2 (20 lb) must be printed with Paper Type set to Light Paper.

3

100% cotton content maximum weight is 24 lb bond.

4

28 lb bond envelopes are limited to 25% cotton content.

5

The duplex unit supports paper weights between 60–105 g/m2 (16–28 pound) grain long bond. The duplex

unit does not support card stock, transparencies, envelopes, or labels.

6

Lexmark transparency part numbers 12A8240 and 12A8241 are supported from the standard tray, manual
slot, and the multi-purpose feeder.

7

Paper 90 to 104.9 g/m2 (23.9 to 27.8 lb) must be printed with Paper Type set to Heavy Paper.

8

Paper 105 to 176 g/m2 (27.9 to 47 lb) must be printed with Paper Type set to Cardstock.

Sulfite, wood-free or
up to 100% cotton
bond

60 to 105 g/m

2

to 28 lb bond)

3, 4

Media guidelines

Paper characteristics

The following paper characteristics affect print quality and reliability. Consider these characteristics when
evaluating new paper stock.

• Weight—The printer can automatically feed paper weights from 60 to 176 g/m

long. Paper lighter than 75 g/m
performance, use 80 g/m
in.), we recommend 90 g/m

2

(20 lb) might not be stiff enough to feed properly, causing jams. For best

2

(21 lb bond) grain long paper. For paper smaller than 182 x 257 mm (7.2 x 10.1

2

or heavier paper.

• Curl—Curl is the tendency for paper to curl at its edges. Excessive curl can cause paper feeding

problems. Curl can occur after the paper passes through the printer, where it is exposed to high
temperatures. Storing paper unwrapped in hot, humid, cold, or dry conditions, even in the trays, can
contribute to paper curling prior to printing and can cause feeding problems.

• Smoothness—Paper smoothness directly affects print quality. If paper is too rough, toner cannot fuse to it

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.

• Moisture content—The amount of moisture in paper affects both print quality and the ability of the printer

to feed the paper correctly. Leave paper in its original wrapper until it is time to use it. This limits the
exposure of paper to moisture changes that can degrade its performance. Condition paper before printing
by storing it in its original wrapper in the same environment as the printer for 24 to 48 hours before printing.
Extend the time several days if the storage or transportation environment is very different from the printer
environment. Thick paper may also require a longer conditioning period.

• Grain direction—Grain refers to the alignment of the paper fibers in a sheet of paper. Grain is either grain

long, running the length of the paper, or grain short, running the width of the paper. For 60 to 176 g/m
to 47 lb bond) paper, use grain long fibers.

• Fiber content—Most high-quality xerographic paper is made from 100% chemically treated pulped wood.

This content provides the paper with a high degree of stability resulting in fewer paper feeding problems
and better print quality. Paper containing fibers such as cotton possesses characteristics that can
negatively affect paper handling.

2

(16 to 47 lb bond) grain

2

(16

Unacceptable paper

The following paper types are not recommended for use with the printer:

• Preprinted papers with chemicals that may contaminate the printer

• Preprinted papers that can be affected by the temperature in the printer fuser

• Coated papers (erasable bond), synthetic papers, thermal papers

• Rough-edged, rough or heavily textured surface papers, or curled papers

1-12 Service Manual

5025-2xx, 4xx

• Recycled papers containing more than 25% post-consumer waste that do not meet DIN 19 309, and

weighing more than 80 g/m

• Paper weighing less than 80 g/m

2

2

(21 lb)

• Multiple-part forms or documents

Selecting paper

Using appropriate paper prevents jams and helps ensure trouble-free printing. To help avoid jams and poor print
quality:

• Always use new, undamaged paper.

• Before loading paper, know the recommended print side of the paper. This information is usually indicated

on the paper package.

• Do not use paper that has been cut or trimmed by hand.

• Do not mix paper sizes, types, or weights in the same source; mixing results in jams.

• Do not use coated papers unless they are specifically designed for electrophotographic printing.

Selecting preprinted forms and letterhead

Use these guidelines when selecting preprinted forms and letterhead:

• Use grain long for 60 to 176 g/m

2

weight paper.

• Use only forms and letterhead printed using an offset lithographic or engraved printing process.

• Avoid papers with rough or heavily textured surfaces.

Use papers printed with heat-resistant inks designed for use in xerographic copiers. The ink must be able to
withstand temperatures up to 200° C (392° F) without melting or releasing hazardous emissions. Use inks that
are not affected by the resin in toner. Inks that are oxidation-set or oil-based generally meet these requirements;
latex inks might not. When in doubt, contact the paper supplier.

Preprinted papers such as letterhead must be able to withstand temperatures up to 200° C (392° F) without
melting or releasing hazardous emissions.

Storing paper

Use these paper storage guidelines to help avoid jams and uneven print quality:

• For best results, store paper where the temperature is 21°C (70°F) and the relative humidity is 40%. Most

label manufacturers recommend printing in a temperature range of 18 to 24°C (65 to 75°F) with relative

humidity between 40 and 60%.

• Store paper in cartons when possible, on a pallet or shelf, rather than on the floor.

• Store individual packages on a flat surface.

• Do not store anything on top of individual paper packages.

Using recycled paper and other office papers

As an environmentally conscious company, Lexmark supports the use of recycled office paper produced
specifically for use in laser (electrophotographic) printers. In 1998, Lexmark presented to the US government a
study demonstrating that recycled paper produced by major mills in the 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. Lexmark has found no reason to
discourage the use of today's recycled office papers, but generally the following property guidelines apply to
recycled paper.

• Low moisture content (4–5%)

• Suitable smoothness (100–200 Sheffield units, or 140–350 Bendtsen units, European)

Note: Some much smoother papers (such as premium 24 lb laser papers, 50–90 Sheffield units) and

much rougher papers (such as premium cotton papers, 200–300 Sheffield units) have been engineered to

General information 1-13

5025-2xx, 4xx

work very well in laser printers, despite surface texture. Before using these types of paper, consult your
paper supplier.

• Suitable sheet-to-sheet coefficient of friction (0.4–0.6)

• Sufficient bending resistance in the direction of feed

Recycled paper, paper of lower weight (<60 g/m
paper that is cut grain-short for portrait (or short-edge) fed printers may have lower bending resistance than is
required for reliable paper feeding. Before using these types of paper for laser (electrophotographic) printing,
consult your paper supplier. Remember that these are general guidelines only and that paper meeting these
guidelines may still cause paper feeding problems in any laser printer (for example, if the paper curls
excessively under normal printing conditions).

2

[16 lb bond]) and/or lower caliper (<3.8 mils [0.1 mm]), and

Tools required for service

Flat-blade screwdrivers, various sizes
#1 Phillips screwdriver, magnetic
#2 Phillips screwdriver, magnetic
#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

7.0 mm nut driver
Needlenose pliers
Diagonal side cutters
Spring hook
Feeler gauges
Analog or digital multimeter
Parallel wrap plug 1319128
Twinax/serial debug cable 1381963
Coax/serial debug cable 1381964
Flashlight (optional)

1-14 Service Manual

5025-2xx, 4xx

Acronyms

ACM Autocompensator Mechanism (paper pick mechanism)
BLDC Brushless DC Motor
BOR Black Only Retract
CCyan
DIMM Dual Inline Memory Module
DRAM Dynamic Random Access Memory
EEPROM Electrically Erasable Programmable Read-Only Memory
EP ElectroPhotographic
ESD Electrostatic Discharge
FRU Field Replaceable Unit
GB Gigabyte
HVPS High-Voltage Power Supply
ITU Image Transfer Unit
IU Imaging Unit
JIS Japanese Industry Standard
KBlack
LASER Light Amplification by Stimulated Emission of Radiation
LCD Liquid Crystal Display
LED Light-Emitting Diode
LVPS Low-Voltage Power Supply
M Magenta
MPF Multipurpose Feeder (also MP feeder)
NVRAM Nonvolatile Random Access Memory
PC Photoconductor
pixel Picture elements (same as pel)
POR Power-On Reset
POST Power-On Self Test
PWM Pulse Width Modulation
RIP Raster Imaging Processor
ROM Read Only Memory
SDRAM Synchronous Dual Random Access Memory
SIMM Single Inline Memory Module
TDS Toner Density Sensor (see Toner Patch Sensor)
TPS Toner Patch Sensor (also referred to as Toner Density Sensor)
V ac Volts alternating current
V dc Volts direct current
YYellow

General information 1-15

5025-2xx, 4xx

1-16 Service Manual

5025-2xx, 4xx

2. Diagnostic information

Start

CAUTION

Unplug power cord from the electrical outlet before you connect or disconnect any cable or
electronic board or assembly for personal safety and to prevent damage to the printer.
Disconnect any connections between the printer and PCs/peripherals.

Begin here to locate the service error code, user status message, user error message, symptom table, service
checks, and diagnostic aids in this chapter to determine the corrective action necessary to repair a
malfunctioning printer. They will lead you to solutions or service checks, including use of various tests.

• Does the POR stop? Check the “POR (Power-On Reset) sequence” on page 2-2.

• Do you have a symptom, rather than an error message? Locate your symptom and take the appropriate

action:

– “Printer symptom table” on page 2-3
– “Print quality symptom table” on page 2-4

• Do you have an error message or persistent user message, check the following:
– “Service error messages” on page 2-12
– “User status and customer attendance messages” on page 2-5
– “Paper Jam messages” on page 2-11
– “Paper jams” on page 3-28
– “Service checks” on page 2-24 for individual error messages

• Additional information can be found at the following locations:
– “User operator panel and Administration menus” on page 2-55
– “Theory of operation” on page 3-33

Diagnostic information 2-1

5025-2xx, 4xx

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.

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:

1. The LED turns on.

2. The main fan turns on.

3. The operator panel turns on.

4. A partial row of pixels appears.

5. The operator panel display clears.

6. Another row of pixels appears.

7. The operator panel display clears again.

8. The operator panel displays system information. For example:

*128MB 500Mhz

9. The fuser turns on. The fuser takes longer to warm up from a cold start than a warm start.

10. The operator panel LED starts blinking.

11. The following errors or messages may appear:

• Close Door or Insert Cartridge displays if the upper front cover is open or the print cartridge is

missing.

• Any cartridge errors, such as Defective Cartridge or Missing Cartridge.

12. Ready appears on the display.

13. The main drive motor turns on.

14. The EP drive assembly drives the developer shaft located in the toner cartridge.

15. The printer calibrates.

2-2 Service Manual

5025-2xx, 4xx

Symptom tables

Printer symptom table

Symptom Action

Dead printer Go to “Dead printer service check” on page 2-28.
Operator panel—one or more buttons do

not work.
Operator panel—display is blank. Printer

may sound five beeps.
Operator panel continuously displays all

diamonds and does not complete POST.
Operator panel display is dim and

unchanging.
Pages print blank after replacing the

controller board.

Tray linking does not work. • Check that the same size and type of paper are in each tray.

Unexpected page breaks occur. • Increase the Print Timeout value on the operator panel

Multipurpose feeder has constant misfeeds
or jams.

Page that jammed does not reprint after
you clear the jam.

Go to “One or more operator panel buttons fail” on

page 2-36.

Go to “Operator panel display blank, five beeps” on

page 2-37.

Go to “Operator panel displays all diamonds, no beeps” on

page 2-39.

Go to “Operator panel display is dim and unchanging” on

page 2-41.

When replacing the controller board, verify the cable from the
high-voltage power supply is seated properly. The cable may
have come loose from the HVPS.

Warning: A blank page that should have toner on it could be an
indication that toner is applied to the ITU belt but not transferred.
Therefore the toner goes into the ITU cleaner which cannot
process massive amounts of toner. It is important to prevent
extensive blank pages from being processed if they should have
toner on them.

• Check the location of the paper guides.

• The multipurpose feeder does not automatically sense the
paper size. You must set the size from the Paper Size/Type
menu.

• Print a menu settings page and compare the settings for
each tray, and adjust on the operator panel, if necessary.

To print a menu settings page:

1. Press Menu ( ) on the operator panel.

2. Select Reports from the Admin Menu, and press Select

().

3. Select Menu Settings, and press Select ().

(Settings–>General Settings–>Timeouts–>Print Timeout.)

• Remove and flex the paper in the tray. Reload the paper,
and try printing.

• Remove the paper, turn it over and place it back in the tray.

• Make sure the feeder is properly installed.

• Make sure the paper is loaded correctly in the tray.

• Make sure the paper is not damaged.

• Make sure the paper meets specifications. See “Media

handling” on page 1-8.

• Make sure the paper guides are positioned correctly for the
paper size loaded in the tray.

Jam Recovery may be set to Off. Change the setting to Auto or
On on the operator panel (Settings–>General settings–>Print
Recovery–>Jam Recovery.)

Diagnostic information 2-3

5025-2xx, 4xx

Print quality symptom table

Symptom Action

Background Go to “Print quality—background” on page 2-43.
Blank page Go to “Print quality—blank page” on page 2-44.
Blurred or fuzzy print Go to “Print quality—blurred or fuzzy print” on page 2-45.
Half-color page Go to “Print quality—half-color page” on page 2-45.
Horizontal banding Go to “Print quality—horizontal banding” on page 2-46.
Horizontal line Go to “Print quality—horizontal line” on page 2-46.
Insufficient fusing Go to “Print quality—insufficient fusing” on page 2-47.
Missing image at edge Go to “Print quality—missing image at edge” on page 2-47.
Mottle (2–5mm speckles) Go to “Print quality—mottle (2–5mm speckles)” on

Narrow vertical line Go to “Print quality—narrow vertical line” on page 2-48.
Random marks Go to “Print quality—random marks” on page 2-48.
Residual image Go to “Print quality—residual image” on page 2-49.
Solid color page Go to “Print quality—solid color page” on page 2-50.
Vertical banding Go to “Print quality—vertical banding” on page 2-50.
Color matching problems See “Color theory” on page 3-45.
Light print on solids See “Media guidelines” on page 1-12.

page 2-47.

2-4 Service Manual

5025-2xx, 4xx

Error codes and messages

User status and customer attendance messages

User primary
message

Calibrating The printer is performing a color adjustment.
Close Door Message clears when front cover, right cover, and toner door are closed or securely

Check Config ID The printer configuration ID is invalid.
Check Model Name Message clears when a valid model name is set.
Check Serial Num Message clears when a valid serial number is set.
Defragmenting Flash

DO NOT POWER
OFF

Formatting Flash
DO NOT POWER
OFF

Insert Tray <x> This message is displayed when the printer requests the user to insert tray x before it

Install Tray <x> or
Cancel job

Invalid Engine Code The engine code is invalid.
Invalid Network Code The network code is invalid.
Load <source>

<custom string>

Load <source>
<custom type>

Load <source>

ze>

<si

Load <source>
<type> <size>

Explanation

fastened.

The printer is performing the defragmentation operation of flash memory. Wait for the
message to clear.

Warning: Do not turn the printer off while this message appears on the display.
Wait for the message to appear.
Warning: Do not turn the printer off while this message appears on the display.

can continue printing the job. The printer needs to pick media from the missing tray or
the trays below it.

Tray x=Tray 1 or Tray 2
Note: This message displays when refilling the trays during a job. Before filling a tray,

take the printer offline by pressing Stop ( ), and wait for pages to stop feeding into
the output bin.

The following actions can be taken:

• Insert the requested tray.

•Press Stop ( ), and then press Select ( ) to cancel printing.

Printer detects that tray <x> is missing, where x is 1 or 2. This message appears if the
job was begun, but the paper has not yet been retrieved. The tray is no longer
detected. Replace the indicated tray.

Printer does not detect media meeting the description <custom string> in <source>,
where <source> is Tray 1, Tray 2, or multipurpose feeder.

• Load the input source with the correct type and size media.

•Press Stop ( ), and then press Select ( ) to cancel printing.

Printer does not detect media meeting the description <custom type> in <source>,
where <source> is Tray 1, Tray 2, or multipurpose feeder.

• Load the input source with the correct type and size media.

•Press Stop ( ), and then press Select ( ) to cancel printing.

Printer does not detect media meeting the size requested in the source indicated.

• Load the input source with the correct type and size media.

•Press Stop ( ), and then press Select ( ) to cancel printing.

Printer does not detect media meeting the size or type requested in the source
indicated.

• Load the input source with the correct type and size media.

•Press Stop ( ), and then press Select ( ) to cancel printing.

Diagnostic information 2-5

5025-2xx, 4xx

User primary
message

Load Manual
<custom string>

Load Manual
<custom type>

Load Manual
<size>

Load Manual
<type> <size>

PJL ST Message Try one or more of the following:

Programming Code The printer is receiving a file that is a code update. Do not power off. Wait for the

Programming Flash Fonts and macros are being written to flash. Do not power off. Wait for the message

Replace <color>
Cartridge

Remote Management
Active

Remove Paper
Standard Bin

emove Packaging

R
Material

Std Bin Full Empty the standard exit bin to clear the message and continue printing.
Toner Low Try one or more of the following:

Tray <x> Empty Load the paper tray or other source with the correct paper type and size.
Tray <x> Low Load the paper tray or other source with the correct paper type and size.
Tray <x> Missing Insert the specified tray into the printer.
Unplug and Change

Mode

Explanation

Printer does not detect media meeting the description <custom string> in the single
sheet feeder (manual feeder).

The following actions can be taken:

• Load paper, press Select ( ), and the job continues.

•Press Select ( ) to override the source, and an alternate source for media is

selected.

•Press Stop ( ), and then press Select ( ) to cancel printing.

Printer does not detect media meeting the description <custom type> in the single
sheet feeder (manual feeder).

The following actions can be taken:

• Load paper and the job continues.

•Press Select ( ), and choose an alternate source for media.

•Press Stop ( ), and then press Select ( ) to cancel printing.

Printer does not detect media meeting the description <size> in the single sheet
feeder (manual feeder).

The following actions can be taken:

• Load paper and the job continues.

•Press Select ( ), and choose an alternate source for media.

•Press Stop ( ), and then press Select ( ) to cancel printing.

Printer does not detect media meeting the description <type> and <size> in the single
sheet feeder (manual feeder).

The following actions can be taken:

• Load paper and the job continues.

•Press Select ( ), and choose an alternate source for media.

•Press Stop ( ), and then press Select ( ) to cancel printing.

•Press Select ( ) to clear the message, and continue printing.

• Wait for the message to clear.

message to clear to continue printing.

to clear to continue printing.
Replace the toner cartridge of the indicated color. The printer continues after the

toner door is closed.
The printer is offline while it configures settings. Do not power off. Wait for the

message to clear to continue printing.
The standard output bin is full or nearly full. Remove the media from the bin.

Packaging material is detected by the printer. Remove the packaging material, and
press Select ( ). If all the packaging material is removed, then the printer resumes.

•Press Select ( ) to clear the message, and continue printing.

• Replace the indicated toner cartridge, and then close the toner door.

Camera is not in a proper mode to use the PictBridge feature. Unplug the camera
cable to the printer, and change the camera mode.

2-6 Service Manual

5025-2xx, 4xx

User primary
message

Unsupported USB
Device, Please
Remove

Unsupported USB
HUB, Please Remove

30.xx <color>
Cartridge Missing

31.xx Defective
<color> Cartridge

31.xx Defective
Imaging Kit

32.xx Unsupported
<color> Cartridge

34 Short Paper • Make sure the print job is requesting the correct size of paper.

37 Insufficient
Memory to Collate Job

37 Insufficient
Memory for Flash
Memory Defragment
Operation

Explanation

Remove the unrecognized device from the USB port on the front of the printer.

Remove the unrecognized USB hub from the USB port on the front of the printer.

The specified toner cartridge is missing. Re-install the missing toner cartridge to clear
the message, and then continue printing. If the message recurs remove and re-install
the cartridge. Listen for the click to ensure the cartridge is installed properly. Close
the front cover.

The specified cartridge is defective. Try one of the following:

• Open and close the top cover.

• Remove and re-install the cartridge(s). Listen for the click to ensure the cartridge
is installed properly.

• Turn the printer power off and turn the printer power on.

If the message persists, replace the cartridge with a new one, and close the front
cover.

Defective imaging kit. Try one or more of the following:

• Open and close the top cover.

• Remove and re-install the cartridge(s). Listen for the click to ensure the cartridge
is installed properly.

• Turn the printer power off, and then turn the printer power on.

If the message persists, determine if the imaging kit counter indicates it is time for
replacement. Print the Menu Setting page, and look on the last page. It will indicate
OK, Replace Black, or Replace Black and Color. If the indicator says Replace Black
or Replace Black and Color, then replace the appropriate kit. See “Imaging unit

(IU) removal” on page 4-35. If the indicator says OK, replace only the

photoconductor unit. Keep the developers from the original unit and reinstall them in
the new photoconductor unit.

Remove the specified cartridge, replace with a supported cartridge, and close the
front cover.

• Check tray length and width guides to ensure paper is properly fitted in the tray.

• Adjust the Paper Size setting for the size paper you are using.
If MP Feeder Size is set to Universal, make sure the paper is large enough for the

formatted data.

•Press Select (
The printer does not automatically reprint the page that prompted the message.

•Press Stop ( ), and then press Select ( ) to cancel printing.

This message is displayed when the printer memory used to store pages is too full to
collate the print job.

Try one of the following:

•Press Select ( ) to clear the message and continue printing.

•Press Stop ( ), and then press Select ( ) to cancel printing.

This message is displayed when insufficient printer memory is available to perform
Flash Memory Defragment operation.

This message appears prior to the actual start of the defragment operation.
Press Select ( ) to stop the defragment operation.
To perform the defragment operation, you can:

• Delete fonts, macros, and other data in RAM.

• Install additional printer memory.

•Press Stop ( ), and then press Select ( ) to cancel printing.

) to clear the message and continue printing.

Diagnostic information 2-7

5025-2xx, 4xx

User primary
message

38 Memory Full This message is displayed when the printer is processing an incoming job and there

39 Complex Page This message is displayed when a page is too complex to print.

40 <color> Invalid
Refill
Change Cartridge

50 PPDS Font Error This error only occurs when a printer is formatting PPDS print data.

51 Defective Flash
Detected

52 Flash Full Not enough free space in flash memory for resources.

53 Unformatted Flash
Detected

Explanation

is not enough memory available to continue processing the job.
The following actions can be taken:

• Determine how to make more memory available to your print job by:

- Deleting fonts and other data in RAM.

- Simplify your print job by reducing the amount of text or graphics on a page.

- Install additional memory

•Press Select ( ) to clear the message and continue printing.

The job may not print correctly.

•Press Stop ( ), and then press Select ( ) to cancel printing.

The following actions can be taken:

•Press Select ( ) to clear the message and continue printing.

The job may not print correctly.

• Simplify the print job by reducing the amount of text or graphics on a page.

•Press Stop ( ), and then press Select ( ) to cancel printing.

Replace the toner cartridge with a new one.

The PPDS interpreter has detected a font error. When a specific font, which is not
installed, is requested based on a PPDS mode Set Font Global command, a Select
Code Page command, or a Comprehensive Font Selection command, and the printer
Best Fit setting is off. If Best Fit is on, the printer performs a best fit search to find a
similar font, and this error does not occur.

This error also displays when the printer receives invalid PPDS download font data.
Try one or more of the following:

•Press Select ( ) to clear the message and continue printing.

The job may not print correctly.

• The printer cannot find the requested font. From the PPDS menu, select Best Fit,
and then select On. The printer will find a similar font and reformat the affected
text.

•Press Stop ( ), and then press Select ( ) to cancel printing.

Press Select ()
You must install different flash memory before you can download any resources to

flash.

Try one or more of the following:

•Press Select ( ) to clear the message and continue printing.

• Delete fonts, macros, and other data stored on the flash memory.

• Install a larger capacity flash memory card.

Try one or more of the following:

•Press Select ( ) to clear the message and continue printing.

• Format the flash memory before you store any resources on it.
If the error message remains, the flash memory may be defective and require

replacing.

to clear the message and continue printing.

2-8 Service Manual

5025-2xx, 4xx

User primary
message

54 Standard Network
Software Error

54 Network <x>
Software Error

56 Standard USB
Port Disabled

58 Too many Flash
Options Installed

58 Too Many
Trays Installed

59 Incompatible
Tray <x>

82 Replace Waste
Toner

82 Waste Toner
Nearly Full

82 Waste Toner
Missing

Explanation

The printer detects a network port, but cannot communicate with it. The printer
disables all communication to the associated network interface.

Try one or more of the following:

•Press Select ( ) to clear the message and continue printing.

The job may not print correctly.

• Upgrade the network firmware in the printer or the print server.

• Turn the printer power off and then back on to reset the printer.

The printer disables all communications to the associated network interface. No data
may be received or sent from or to the associated interface.

•Press Select ( ) to clear the message and continue printing.

The job may not print correctly.

• Turn the printer power off and then back on to reset the printer.

• Upgrade the network firmware in the printer or the print server.

This message may appear when data is sent to the printer across a USB port, but the
port is disabled.

Note: Once the error is displayed the first time, reporting of further errors is
suppressed until the printer is reset or menus are entered.

The following actions can be taken:

•Press Select ( ) to clear the message.

Any data received on the USB port is discarded.

•Press Menus ( ) to access the Administrative Menus.

Make sure the USB Buffer menu item is not set to Disabled. (Press Menus () to
access the Administrative Menus, select Network/Ports, USB Menu, and
USB Buffer.)

Too many optional flash memory cards or optional firmware cards are installed on the
printer.

1. Turn off and unplug the printer.

2. Remove the excess flash memory or optional firmware cards.

3. Plug in the printer, and turn it on.

Too many tray are installed.

1. Turn off and unplug the printer.

2. Remove the additional trays.

3. Plug in the printer, and turn it on.

1. Turn off and unplug the printer.

2. Remove the specified incompatible tray.

3. Plug in the printer, and turn it on.

Replace the waste toner bottle to clear the message and continue printing. See

“Waste toner bottle removal” on page 4-60.

Note: The printer will not continue until the waste toner bottle is replaced.

Try one or more of the following:

• Replace the waste toner bottle, and then press Select ( ) to clear the message
and continue printing. See “Waste toner bottle removal” on page 4-60.

•Press Select ( ) to clear the message and continue printing.

• Order the waste toner bottle so it will be available when the replacement message
is displayed. Once the replacement message is displayed, the printer will not
continue until the waste toner is replaced.

Install a waste toner bottle, and then press Select ( ) to clear the message and
continue printing. See “Waste toner bottle removal” on page 4-60.

Diagnostic information 2-9

5025-2xx, 4xx

User primary
message

88 <color> Cartridge
Low

88 Replace <color>
Cartridge

Explanation

The term <color> includes black, cyan, magenta, and yellow. The cartridge
Try one or more of the following:

• Replace the toner cartridge, and then close the toner door to clear the message
and continue printing.

•Press Select ( ) to clear the message and continue printing.

The term <color> includes black, cyan, magenta, and yellow.
Replace the toner cartridge, and then close the toner door to continue printing.

2-10 Service Manual

5025-2xx, 4xx

Paper Jam messages

Paper jam messages (2xx)

Error code Description Action

200.xx Paper Jam
Check <area>

200.xx Paper Jam
<x> Pages Jammed

201.xx Paper Jam
Check <area>

201.xx Paper Jam
<x> Pages Jammed

202.xx Paper Jam
Check <area>

202.xx Paper Jam
<x> Pages Jammed

230.xx Paper Jam
Check <area>

230.xx Paper Jam
<x> Pages Jammed

A single page of media jam at the input
sensor.

Multiple pages of media are jammed at
the input sensor.

A single page of media is jammed
between the input and exit sensors.

Multiple pages of media are jammed
between the input and exit sensors.

A single page of media is jammed at
the exit sensors.

Multiple pages of media are jammed at
the exit sensor.

A single page of media is jammed at
the inner door.

Multiple pages of media are jammed at
the inner door.

Pull out tray 1, and then remove the
jammed page. See “200 paper jams” on

page 3-30.

Pull out tray 1 and open the front door to
remove all the jammed pages. See “200

paper jams” on page 3-30.

Open the front door and then remove the
jammed page. See “201 paper jam” on

page 3-30.

Open the front door, and then remove all
the jammed pages. See “201 paper jam”

on page 3-30.

Open the front door to access the jam
area. Remove the jammed page. See “202

paper jam” on page 3-31.

Open the front door to access the jam
area. Remove all the jammed pages. See

“202 paper jam” on page 3-31.

Open the front door, and then remove the
jammed page. See “230 paper jam” on

page 3-32.

Open the front door, and then remove all
the jammed pages. See “230 paper

on page 3-32.

jam”

24x.xx Paper Jam
Check <area>

24x.xx Paper Jam
<x> Pages Jammed

250.xx Paper Jam
Check Manual
Feeder

250.xx Paper Jam
<x> Pages Jammed

A single or multiple page media jam in
the 650-sheet duo drawer (tray 2).

Multiple pages of media are jammed in
the 650-sheet duo drawer (tray 2).

A single page of media is jammed in
the multipurpose feeder.

Multiple pages of media are jammed in
the multipurpose feeder.

See “24x paper jam” on page 3-32.

Pull the tray out and remove all the jams.
See “24x paper jam” on page 3-32.

Open tray 2 to access the jam area.
Remove the jammed page. See “250

paper jam” on page 3-32.

Open tray 2 to access the jam area.
Remove all the jammed pages. See “250

paper jam” on page 3-32.

Diagnostic information 2-11

5025-2xx, 4xx

Service error messages

Service error messages (1xx, 9xx)

Error code Description Action

106.xx Service
Yellow Printhead

106.01 Service
Yellow Printhead

106.02 Service
Yellow Printhead

106.03 Service
Yellow Printhead

106.04 Service
Yellow Printhead

106.05 Service
Yellow Printhead

106.06 Service
Yellow Printhead

106.07 Service
Yellow Printhead

Yellow printhead error. Perform a POR. If the problem persists, go

The yellow printhead lost HSYNC. Perform a POR. If the problem persists, go

The yellow printhead failed to complete
servo.

The yellow printhead mirror motors
failed to achieve lock.

The yellow printhead mirror motors lost
motor lock.

Failure reading NVRAM from
printhead.

The yellow printhead thermistor is
open.

The yellow printhead thermistor is
shorted to ground.

to “Printhead service check” on

page 2-51.

to “Printhead service check” on

page 2-51.

Perform a POR. If the problem persists, go
to “Printhead service check” on

page 2-51.

Perform a POR. If the problem persists, go
to “Printhead service check” on

page 2-51.

Perform a POR. If the problem persists, go
to “Printhead service check” on

page 2-51.

Perform a POR. If the problem persists, go
to “Printhead service check” on

page 2-51.

Perform a POR. If the problem persists, go
to “Printhead service check” on

page 2-51.

Perform a POR. If the problem persists, go
to “Printhead service check” on

page 2-51.

106.08 Service
Yellow Printhead

106.09 Service
Yellow Printhead

106.10 Service
Yellow Printhead

106.11 Service
Yellow Printhead

10

6.12 Service

Yellow Printhead

106.13 Service
Yellow Printhead

107.xx Cyan
Printhead Error

107.01 Service
Cyan Printhead

The yellow laser showed bad in testing. Perform a POR. If the problem persists, go

SOS/EOS measurement did not
complete.

Bad SOS/EOS measurement. Perform a POR. If the problem persists, go

Failure writing data tot he printhead. Perform a POR. If the problem persists, go

Failure reading data from the
printhead.

Printhead declared error. Perform a POR. If the problem persists, go

Cyan printhead error. Perform a POR. If the problem persists, go

The cyan printhead lost HSYNC. Perform a POR. If the problem persists, go

to “Printhead service check” on

page 2-51.

Perform a POR. If the problem persists, go
to “Printhead service check” on

page 2-51.

to “Printhead service check” on

page 2-51.

to “Printhead service check” on

page 2-51

Perform a POR. If the problem persists, go
to “Printhead service check” on

page 2-51.

to “Printhead service check” on

page 2-51.

to “Printhead service check” on

page 2-51.

to “Printhead service check” on

page 2-51.

.

2-12 Service Manual

5025-2xx, 4xx

Service error messages (1xx, 9xx) (continued)

Error code Description Action

107.02 Service
Cyan Printhead

107.03 Service
Cyan Printhead

107.04 Service
Cyan Printhead

107.05 Service
Cyan Printhead

107.06 Service
Cyan Printhead

107.07 Service
Cyan Printhead

107.08 Service
Cyan Printhead

107.09 Service
Cyan Printhead

The cyan printhead failed to complete
servo.

The cyan printhead mirror motors failed
to achieve lock.

The cyan printhead mirror motors lost
motor lock.

Failure reading NVRAM from the cyan
printhead.

The cyan printhead thermistor is open. Perform a POR. If the problem persists, go

The cyan printhead thermistor is
shorted to ground.

The cyan laser showed bad in testing. Perform a POR. If the problem persists, go

SOS/EOS measurement did not
complete.

Perform a POR. If the problem persists, go
to “Printhead service check” on

page 2-51.

Perform a POR. If the problem persists, go
to “Printhead service check” on

page 2-51.

Perform a POR. If the problem persists, go
to “Printhead service check” on

page 2-51.

Perform a POR. If the problem persists, go
to “Printhead service check” on

page 2-51.

to “Printhead service check” on

page 2-51.

Perform a POR. If the problem persists, go
to “Printhead service check” on

page 2-51.

to “Printhead service check” on

page 2-51.

Perform a POR. If the problem persists, go
to “Printhead service check” on

page 2-51.

107.10 Service
Cyan Printhead

107.11 Service
Cyan Printhead

107.12 Service
Cyan Printhead

107.13 Service
Cyan Printhead

108.

xx Se

Magenta Printhead

108.01 Service
Magenta Printhead

108.02 Service
Magenta Printhead

108.03 Service
Magenta Printhead

rvice

Bad SOS/EOS measurement. Perform a POR. If the problem persists, go

Failure writing data tot he printhead. Perform a POR. If the problem persists, go

Failure reading data from the
printhead.

Printhead declared error. Perform a POR. If the problem persists, go

Magenta printhead error. Perform a POR. If the problem persists, go

The magenta printhead lost HSYNC. Perform a POR. If the problem persists, go

The magenta printhead failed to
complete servo.

The magenta printhead mirror motors
failed to achieve lock.

to “Printhead service check” on

page 2-51.

to “Printhead service check” on

page 2-51.

Perform a POR. If the problem persists, go
to “Printhead service check” on

page 2-51.

to “Printhead service check” on

page 2-51.

to “Printhead service check” on

page 2-51.

to “Printhead service check” on

page 2-51.

Perform a POR. If the problem persists, go
to “Printhead service check” on

page 2-51.

Perform a POR. If the problem persists, go
to “Printhead service check” on

page 2-51.

Diagnostic information 2-13

5025-2xx, 4xx

Service error messages (1xx, 9xx) (continued)

Error code Description Action

108.04 Service
Magenta Printhead

108.05 Service
Magenta Printhead

108.06 Service
Magenta Printhead

108.07 Service
Magenta Printhead

108.08 Service
Magenta Printhead

108.09 Service
Magenta Printhead

108.10 Service
Magenta Printhead

108.11 Service
Magenta Printhead

The magenta printhead mirror motors
lost motor lock.

Failure reading NVRAM from the
magenta printhead.

The magenta printhead thermistor is
open.

The magenta printhead thermistor is
shorted to ground.

The magenta laser showed bad in
testing.

SOS/EOS measurement did not
complete.

Bad SOS/EOS measurement. Perform a POR. If the problem persists, go

Failure writing data tot he printhead. Perform a POR. If the problem persists, go

Perform a POR. If the problem persists, go
to “Printhead service check” on

page 2-51.

Perform a POR. If the problem persists, go
to “Printhead service check” on

page 2-51.

Perform a POR. If the problem persists, go
to “Printhead service check” on

page 2-51.

Perform a POR. If the problem persists, go
to “Printhead service check” on

page 2-51.

Perform a POR. If the problem persists, go
to “Printhead service check” on

page 2-51.

Perform a POR. If the problem persists, go
to “Printhead service check” on

page 2-51.

to “Printhead service check” on

page 2-51.

to “Printhead service check” on

page 2-51.

108.12 Service
Magenta Printhead

108.13 Service
Magenta Printhead

109.xx Service
Black Printhead

109.01 Service
Black Printhead

10

9.02 Service

Black Printhead

109.03 Service
Black Printhead

109.04 Service
Black Printhead

109.05 Service
Black Printhead

Failure reading data from the
printhead.

Printhead declared error. Perform a POR. If the problem persists, go

Black printhead error. Perform a POR. If the problem persists, go

The black printhead lost HSYNC. Perform a POR. If the problem persists, go

The black printhead failed to complete
servo.

The black printhead mirror motors
failed to achieve lock.

The black printhead mirror motors lost
motor lock.

Failure reading NVRAM from
printhead.

Perform a POR. If the problem persists, go
to “Printhead service check” on

page 2-51.

to “Printhead service check” on

page 2-51.

to “Printhead service check” on

page 2-51.

to “Printhead service check” on

page 2-51.

Perform a POR. If the problem persists, go
to “Printhead service check” on

page 2-51.

Perform a POR. If the problem persists, go
to “Printhead service check” on

page 2-51.

Perform a POR. If the problem persists, go
to “Printhead service check” on

page 2-51.

Perform a POR. If the problem persists, go
to “Printhead service check” on

page 2-51.

2-14 Service Manual

5025-2xx, 4xx

Service error messages (1xx, 9xx) (continued)

Error code Description Action

109.06 Service
Black Printhead

109.07 Service
Black Printhead

109.08 Service
Black Printhead

109.09 Service
Black Printhead

109.10 Service
Black Printhead

109.11 Service
Black Printhead

109.12 Service
Black Printhead

109.13 Service
Black Printhead

The black printhead thermistor is open. Perform a POR. If the problem persists, go

The black printhead thermistor is
shorted to ground.

The black laser showed bad in testing. Perform a POR. If the problem persists, go

SOS/EOS measurement did not
complete.

Bad SOS/EOS measurement. Perform a POR. If the problem persists, go

Failure writing data tot he printhead. Perform a POR. If the problem persists, go

Failure reading data from the
printhead.

Printhead declared error. Perform a POR. If the problem persists, go

to “Printhead service check” on

page 2-51.

Perform a POR. If the problem persists, go
to “Printhead service check” on

page 2-51.

to “Printhead service check” on

page 2-51.

Perform a POR. If the problem persists, go
to “Printhead service check” on

page 2-51.

to “Printhead service check” on

page 2-51.

to “Printhead service check” on

page 2-51.

Perform a POR. If the problem persists, go
to “Printhead service check” on

page 2-51.

to “Printhead service check” on

page 2-51.

122.xx Service
Fuser Error

122.01 Service
Fuser Error

122.02 Service
Fuser Error

122.03 Service
Fuser Error

122.04 Service
Fuser Error

122.05 Service
Fuser Error

122.06 Service
Fuser Error

122.11 Service
Fuser Error

122.12 Service
Fuser Error

122.13 Service
Fuser Error

122.14 Service
Fuser Error

Fuser error Go to “Fuser service check” on

Attempting to print with estimated
power at or below minimum power.

Fuser over temperature. Go to “Fuser service check” on

Fuser open thermistor check failed. Go to “Fuser service check” on

Fuser reached start temperature too
quickly.

Fu

ser failed to reach final temperature

in time.

Estimated power is at or below
minimum power.

Fuser under temperature error while in
standby.

Fuser under temperature error while
printing.

Fuser open thermistor check failed for
second thermistor.

Fuser shorted thermistor check failed
for hot roll thermistor.

page 2-32.

Go to “Fuser service check” on

page 2-32.

page 2-32.

page 2-32.

Go to “122.xx—Fuser temperature

incorrect” on page 2-24.

Go to “122.xx—Fuser temperature

incorrect” on page 2-24.

Go to “122.xx—Fuser temperature

incorrect” on page 2-24.

Go to “Fuser service check” on

page 2-32.

Go to “Fuser service check” on

page 2-32.

Go to “Fuser service check” on

page 2-32.

Go to “Fuser service check” on

page 2-32.

Diagnostic information 2-15

5025-2xx, 4xx

Service error messages (1xx, 9xx) (continued)

Error code Description Action

122.15 Service
Fuser Error

122.16 Service
Fuser Error

141.xx Service
Staging Motor

141.01 Service
Staging Motor

141.02 Service
Staging Motor

141.03 Service
Staging Motor

141.04 Service
Staging Motor

141.05 Service
Staging Motor

150.xx Service
Black/ITU cartridge
Motor

150.01 Service
Black/ITU cartridge
Motor

Fuser storted thermistor check failed
for second thermistor

Estimated power is at or above
maximum power.

Staging motor error. Go to “Autocompensator mechanism

Staging motor has exceeded the ramp
up table.

Staging motor has exceeded number
of encoders at minimum PWM.

Staging motor has exceeded number
of encoders at maximum PWM.

Motor encoder count did not change
between interrupts.

Staging motor has encountered a stall
timeout.

Black/ITU Cartridge Motor Go to “Main drive gear assembly (EP

Failed to achieve lock for motor within
allotted time.

Go to “Fuser service check” on

page 2-32.

Go to “Fuser service check” on

page 2-32.

service check” on page 2-27.

Go to “Autocompensator mechanism

service check” on page 2-27.

Go to “Autocompensator mechanism

service check” on page 2-27.

Go to “Autocompensator mechanism

service check” on page 2-27.

Go to “Autocompensator mechanism

service check” on page 2-27.

Go to “Autocompensator mechanism

service check” on page 2-27.

drive) service check” on page 2-35.

Go to “Main drive gear assembly (EP

drive) service check” on page 2-35.

150.02 Service
Black/ITU cartridge
Motor

150.03 Service
Black/ITU cartridge
Motor

15

0.04 Service
Black/ITU cartridge
Motor

150.05 Service
Black/ITU cartridge
Motor

150.06 Service
Black/ITU cartridge
Motor

150.07 Service
Black/ITU cartridge
Motor

152.xx Service
Cyan Cartridge Motor

152.01 Service
Cyan Cartridge Motor

152.02 Service
Cyan Cartridge Motor

Timeout waiting for SAP BLDC motor
to reach valid FG speed.

Timeout waiting for
MP_NUM_INITIAL_SAP_HALLS.

Timeout waiting for SAP BLDC motor
FG.

Lost lock for motor. Go to “Main drive gear assembly (EP

Excessive SAP BLDC PWM. Go to “Main drive gear assembly (EP

Motor stalled in time-based
commutation.

Failed to achieve lock for motor within
allotted time.

Timeout waiting for SAP BLDC motor
to reach valid FG speed.

Go to “Main drive gear assembly (EP

drive) service check” on page 2-35.

Go to “Main drive gear assembly (EP

drive) service check” on page 2-35.

Go to “Main drive gear assembly (EP

drive) service check” on page 2-35.

drive) service check” on page 2-35.

drive) service check” on page 2-35.

Go to “Main drive gear assembly (EP

drive) service check” on page 2-35.

Go to “Main drive gear assembly (EP

drive) service check” on page 2-35.

Go to “Main drive gear assembly (EP

drive) service check” on page 2-35.

Go to “Main drive gear assembly (EP

drive) service check” on page 2-35.

2-16 Service Manual

5025-2xx, 4xx

Service error messages (1xx, 9xx) (continued)

Error code Description Action

152.03 Service
Cyan Cartridge Motor

152.04 Service
Cyan Cartridge Motor

152.05 Service
Cyan Cartridge Motor

152.06 Service
Cyan Cartridge Motor

152.07 Service
Cyan Cartridge Motor

153.xx Service
Magenta Cartridge
Motor

153.01 Service
Magenta Cartridge
Motor

153.02 Service
Magenta Cartridge
Motor

153.03 Service
Magenta Cartridge
Motor

153.04 Service
Magenta Cartridge
Motor

Timeout waiting for
MP_NUM_INITIAL_SAP_HALLS.

Timeout waiting for SAP BLDC motor
FG.

Lost lock for motor. Go to “Main drive gear assembly (EP

Excessive SAP BLDC PWM. Go to “Main drive gear assembly (EP

Motor stalled in time-based
commutation.

Failed to achieve lock for motor within
allotted time.

Timeout waiting for SAP BLDC motor
to reach valid FG speed.

Timeout waiting for
MP_NUM_INITIAL_SAP_HALLS.

Timeout waiting for SAP BLDC motor
FG.

Go to “Main drive gear assembly (EP

drive) service check” on page 2-35.

Go to “Main drive gear assembly (EP

drive) service check” on page 2-35.

drive) service check” on page 2-35.

drive) service check” on page 2-35.

Go to “Main drive gear assembly (EP

drive) service check” on page 2-35.

Go to “Main drive gear assembly (EP

drive) service check” on page 2-35.

Go to “Main drive gear assembly (EP

drive) service check” on page 2-35.

Go to “Main drive gear assembly (EP

drive) service check” on page 2-35.

Go to “Main drive gear assembly (EP

drive) service check” on page 2-35.

Go to “Main drive gear assembly (EP

drive) service check” on page 2-35.

153.05 Service
Magenta Cartridge
Motor

153.06 Service
Magenta Cartridge
Motor

153.07 Service
Magenta Cartridge
Motor

154.xx Service
Yellow Cartridge
Motor

154.01 Service
Yellow Cartridge
Motor

154.02 Service
Yellow Cartridge
Motor

154.03 Service
Yellow Cartridge
Motor

Lost lock for motor. Go to “Main drive gear assembly (EP

Excessive SAP BLDC PWM. Go to “Main drive gear assembly (EP

Motor stalled in time-based
commutation.

Failed to achieve lock for motor within
allotted time.

Timeout waiting for SAP BLDC motor
to reach valid FG speed.

Timeout waiting for
MP_NUM_INITIAL_SAP_HALLS.

drive) service check” on page 2-35.

drive) service check” on page 2-35.

Go

to “Main drive gear assembly (EP

drive) service check” on page 2-35.

Go to “Main drive gear assembly (EP

drive) service check” on page 2-35.

Go to “Main drive gear assembly (EP

drive) service check” on page 2-35.

Go to “Main drive gear assembly (EP

drive) service check” on page 2-35.

Go to “Main drive gear assembly (EP

drive) service check” on page 2-35.

Diagnostic information 2-17

5025-2xx, 4xx

Service error messages (1xx, 9xx) (continued)

Error code Description Action

154.04 Service
Yellow Cartridge
Motor

154.05 Service
Yellow Cartridge
Motor

154.06 Service
Yellow Cartridge
Motor

154.07 Service
Yellow Cartridge
Motor

900.xx Service
RIP Software

902.xx Service
Engine Software

903.xx Service
Engine Software

904.xx Service
Engine Software

905.xx Service
Engine Software

906.xx Service
Engine Software

Timeout waiting for SAP BLDC motor
FG.

Lost lock for motor. Go to “Main drive gear assembly (EP

Excessive SAP BLDC PWM. Go to “Main drive gear assembly (EP

Motor stalled in time-based
commutation.

Unrecoverable RIP software error/
illegal trap.

A general engine software error. Go to “90x.xx error” on page 2-24.

A paperport link driver error. Go to “90x.xx error” on page 2-24.

An interface violation by RIP. Go to “90x.xx error” on page 2-24.

An interface violation by paperport
device.

A RIP interface driver error. Go to “90x.xx error” on page 2-24.

Go to “Main drive gear assembly (EP

drive) service check” on page 2-35.

drive) service check” on page 2-35.

drive) service check” on page 2-35.

Go to “Main drive gear assembly (EP

drive) service check” on page 2-35.

Go to “90x.xx error” on page 2-24.

Go to “90x.xx error” on page 2-24.

910.xx Service
DC Pick Motor

911.xx Service
DC Pick Motor

912.xx Service
DC Pi

ck Motor

913.xx Service
DC Pick Motor

914.xx Service
PC Pick Motor

917.xx Service
Transfer Roll

925.01 Service
Fan Stalled

927.xx Service
Fan Stalled

The DC pick motor stalled. Go to “Autocompensator mechanism

The DC pick motor has excessive
PWM.

The DC pick motor is below speed. Go to “Autocompensator mechanism

The DC pick motor over speed. Go to “Autocompensator mechanism

The DC pick has no encoder feedback. Go to “Autocompensator mechanism

There is a problem with the transfer
roll.

The printer fan has stalled. Go to “925.01—Fan error service check”

The printer fan has stalled.

service check” on page 2-27.

Go to “Autocompensator mechanism

service check” on page 2-27.

service check” on page 2-27.

service check” on page 2-27.

service check” on page 2-27.

Go to “Transfer roll service check” on

page 2-53.

on page 2-25.

2-18 Service Manual

5025-2xx, 4xx

Service error messages (1xx, 9xx) (continued)

Error code Description Action

929.xx Service
Toner Sensor

930.xx Service
LVPS Error

931.xx Service
Printhead Error

932.xx Service
Printhead Error

933.xx Service
Printhead Error

935.xx Service
Printhead Error

936.xx Service
Transport Motor

937.xx Service
Transport Motor

940.xx Service
LV Power Supply

The printer doesn't register a transition
on the toner sensor for a set period of
time. Either the printer's toner sensor is
faulty or its print cartridge is defective.

The LVPS did not detect zero crossing.

There is no first HSYNC. Go to “930.xx–935.xx—Printhead errors

The HSYNCs are lost. Go to “930.xx–935.xx—Printhead errors

Mirror motor is locked. No HSYNC
received.

Mirror motor is unable to reach
operating speed.

The transport motor had an initial lock
failure.

The transport motor lost lock. Go to “936.xx, 937.xx—Transport motor

A RIP to engine communication failure.
The zero crossing signal used for fuser
control in the low-voltage (LV) power
supply has failed, or the wrong low­voltage power supply has been
installed.

The Servicer should follow these steps to
resolve this problem:

• Use the base sensor test in
Diagnostics Menu to inspect the toner
sensor's operation.

• If the toner sensor is operating
correctly, then the problem is the print
cartridge.

service check” on page 2-25.

service check” on page 2-25.

Go to “930.xx–935.xx—Printhead errors

service check” on page 2-25.

Go to “930.xx–935.xx—Printhead errors

service check” on page 2-25.

Go to “936.xx, 937.xx—Transport motor

service check” on page 2-26.

service check” on page 2-26.

Replace the low-voltage power supply.
See “Low-voltage power supply (LVPS)

assembly removal” on page 4-37.

940.0x Service
Cyan TMC Sensor

94

1.0x Service
Magenta TMC
Sensor

942.0x Service
Yellow TMC Sensor

943.0x Service
Black TMC Sensor

948.xx Service
Engine Card

949.xx Service
Engine Card

The cyan cartridge toner meter cycle
(TMC) switch error.

The magenta cartridge toner meter
cycle (TMC) switch error.

The yellow cartridge toner meter cycle
(TMC) switch error.

The black cartridge toner meter cycle
(TMC) switch error.

The pel clock check failed. If this error message persists, replace the

Delay line calibration failure If this error message persists, replace the

Go to “Toner meter sensors (Y, C, M, K)

on TMC card” on page 2-52

Go to “Toner meter sensors (Y, C, M, K)

on TMC card” on page 2-52.

Go to “Toner meter sensors (Y, C, M, K)

on TMC card” on page 2-52.

Go “Toner meter sensors (Y, C, M, K) on

TMC card” on page 2-52.

controller board. See “Controller board

removal” on page 4-19.

controller board. See “Controller board

removal” on page 4-19.

Diagnostic information 2-19

.

5025-2xx, 4xx

Service error messages (1xx, 9xx) (continued)

Error code Description Action

950.xx Service
NVRAM Failure

951.xx Service
NVRAM Failure

952.xx Service
NVRAM Failure:n

953.xx Service
NVRAM Failure

954.xx Service
NVRAM Failure

955.xx Service
Code CRC <loc>

There is a mismatch between controller
EEPROM and mirror.

• 950.00 through 950.29 codes:
mismatch between controller and
mirror

• 950.30 through 950.60 codes:
mismatch between secure and
controller

Mismatch between controller EEPROM
and mirror.

• 951.00 through 951.29 codes:
mismatch between controller and
mirror

• 951.30 through 951.60: mismatch
between secure and controller

A recoverable MVRAM Cyclic
Redundancy Check (CRC) error
occurred. n is the offset at which the
error occurred.

NVRAM chip failure with mirror.

The NVRAM chip failure with controller
part.

The Code ROM or NAND flash failed
the Cyclic Redundancy Check (CRC)
check or the NAND experienced an
uncorrectable multi-bit failure. <loc>
indicates the source of the failure and
has one of the following values:

• CRC Failure: The source is a
failing package indicated by Pn
where n is the package number.
This error could occur on a
controller with ROM or NAND flash
and could occur as a result of the
CRC check done when the
machine is powered on. The range
of package numbers is from 0 to

15.

• Error Correction Code (ECC)
Failure: The source is a failing
page indicated by Bn where “n” is
the page number. This error occurs
only if a multi-bit failure is detected
during the ECC execution. Single
bit failures will be corrected
automatically and will not result in a
service error. The range of page
numbers is from 0 to 1023.

Go to “950.xx NVRAM Failure service

check” on page 2-26.

Performing a POR will clear this error.

956.00 Service
System Board

956.01 Service
System Board

2-20 Service Manual

Controller board failure. Processor

ilure.

fa

Processor over temperature. Replace the controller board. See

Replace the controller board. See

“Controller board removal” on
page 4-19.

“Controller board removal” on
page 4-19.

5025-2xx, 4xx

Service error messages (1xx, 9xx) (continued)

Error code Description Action

957.xx Service
System Board

958.xx Service
NAND Failure

959.01 Service
Invalid Firmware

959.02 Service
Invalid Firmware

959.03 Service
Invalid Firmware

959.04 Service
Invalid Firmware

959.05 Service
Invalid Firmware

959.20 Service
System Board

959.21 Service
System Board

Controller board failure. ASIC failure.

Printer has performed more than 100
“shift and reflash” operations as a
result of ECC bit corrections.

Controller verification failure of system
boot code

Failure to authenticate Signature
Verification Code.

Signature verification Code failure to
authenticate a code partition.

Jump to unverified address. Update firmware or replace the controller

Unknown Boot Failure. Update firmware or replace the controller

System hardware failure. Replace the controller board. See

System did not respond to command
request.

Update firmware or replace the controller
board. See “Controller board removal”

on page 4-19.

Update firmware or replace the controller
board. See “Controller board removal”

on page 4-19.

Update firmware or replace the controller
board. See “Controller board removal”

on page 4-19.

board. See “Controller board removal”

on page 4-19.

board. See “Controller board removal”

on page 4-19.

“Controller board removal” on
page 4-19.

Replace the controller board. See

“Controller board removal” on
page 4-19.

959.22 Service
System Board

959.23 Service
System Board

959.24 Service
System Board

959.25 Service
System Board

959.26 Service
System Board

959.27 Service
System Board

959.28 Service
System Board

Challenge Secret Failure. ASIC/SP mismatch. Replace the controller

System self test failure during
initialization.

EEPROM Retention Error (write
failure)

Insufficient device space during
hardware programming.

I

ncremental counter reset exceeds

maximum value.

Increment count failed due to
maximum value limit.

Invalid SP memory configuration. Replace the controller board. See

board. See “Controller board removal”

on page 4-19.

Replace the controller board. See

“Controller board removal” on
page 4-19.

Replace the controller board. See

“Controller board removal” on
page 4-19.

Replace the controller board. See

“Controller board removal” on
page 4-19.

Replace the controller board. See

“Controller board removal” on
page 4-19.

Replace the controller board. See

“Controller board removal” on
page 4-19.

“Controller board removal” on
page 4-19.

Diagnostic information 2-21

5025-2xx, 4xx

Service error messages (1xx, 9xx) (continued)

Error code Description Action

960.xx Service
Memory Error

961.xx Service
Memory Failure

962.xx Service
Memory Failure

964.xx Service
Emulation Error

975.xx Service
Standard Network

or

975.xx Service
Network Card x

976.xx Service
Standard Network

or

976.xx Service
Network Card x

RAM memory error: RAM soldered on
the board is bad.

RAM memory error: slot 1 RAM is bad. Replace the controller board. See

RAM memory error: slot 2 RAM is bad. Replace the controller board. See

Download emulation cyclic redundancy
check (CRC) failure has occurred. A
checksum failure detected in the
emulation header or emulation file.

Network error: unrecognizable network
port.

Unrecoverable software or error in
network or network card x.

Replace the controller board. See

“Controller board removal” on
page 4-19.

“Controller board removal” on
page 4-19.

“Controller board removal” on
page 4-19.

The following actions may be taken:

1. Disable the Download Emulation.

2. Program the download emulation into
the code overlay SIMM again.

3. If the problem is not resolved replace
the code overlay SIMM, and download
emulation again.

Replace the standard network card or the
card in the specified slot.

If unable to clear the error message, check
the following:

• If installed, check network card for
correct installation.

• If correctly installed, replace the
network card.

• If a network card is not installed,
replace the controller board.

978.xx Service
Standard Network

or

978.xx Service
Network Card x

979.xx Service
Standard Network

or

979.xx Service
Network Card x

2-22 Service Manual

Bad checksum while programming
Standard Network or Network Card x
port.

Flash parts failed while programming
the Standard Network or Network Card
x port.

Check the following:

• Make sure you have downloaded the
code in binary mode, not ASCII.

• Reprogram the Network card.

• If the problem persists, and if installed,
check the network card for correct
installation.

• If correctly installed, replace the
network card.

f a network card is not installed, replace

I
the controller board.

Check the following:

• If installed, check the network card for
correct installation.

• If correctly installed, replace the
network card.

• If a network card is not installed,
replace the controller board.

5025-2xx, 4xx

Service error messages (1xx, 9xx) (continued)

Error code Description Action

980.xx Service
<device> Comm.

981.xx Service
<device> Comm.

982.xx Service
<device> Comm.

983.xx Service
<device> Comm.

Engine is experiencing unreliable
communications with the specified
device.

Note: <device> can be one of the
following:

• Duplex unit.

•Tray 2.

Engine protocol violation detected by
the specified device.

Note: <device> can be one of the
following:

• Duplex unit.

•Tray 2.

Communications error detected by the
specified device.

Note: <device> can be one of the
following:

• Duplex unit.

•Tray 2.

Invalid command received by the
specified device.

Note: <device> can be one of the
following:

• Duplex unit.

•Tray 2.

984.xx Service
<device> Comm.

990.xx Service
<device>

991.xx Service
evice> Card

<d

Invalid command parameter received
by the specified device.

Note: <device> can be one of the
following:

• Duplex unit.

•Tray 2.

This error message indicates that an
equipment check condition has
occurred in the specified device, but
the device is unable to identify the
exact component failure.

Note: <device> can be one of the
following:

• Duplex unit.

•Tray 2.

The specified device has detected an
equipment check in its controller board.

Go to the service check for the device
indicated.

Diagnostic information 2-23

5025-2xx, 4xx

Service checks

122.xx—Fuser temperature incorrect

This service check covers fuser temperature errors, including 122.xx.

Step Questions / actions Yes No

1 Check the clearance around the printer. See

“Clearances” on page 1-5 or check the chart

below:

Description Dimensions

Rear 102 mm (4 in.)
Front 508 mm (20 in.)
Right side 152 mm (6 in.)
Left side 76 mm (3 in.)
Above 254 mm (10 in.)

Does the error clear?

Check the fuser connections on the fuser, at

2

JFUSES1 on the controller board, and the AC
connection at the LVPS.

Are the connections correct?

Turn the printer on, and then check the

3

following values at JFUSES1.

JFUSES1

Pin Value

5 Between +0.6 V dc and +3.28 V dc
6 Ground
8 Ground

9 +3.3 V dc
10 Between +0.6 V dc and +3.15 V dc
11 Ground

Problem resolved. Make sure the proper

Replace the fuser. See

“Fuser assembly
removal” on page 4-26.

Replace the fuser assembly.
See “Fuser assembly

removal” on page 4-26.

clearance is maintained.

Problem resolved.

Replace the controller
board. See “Controller

board removal” on
page 4-19.

Are these values approximately correct?

90x.xx error

Step Questions / actions Yes No

1 Turn the printer off, and remove the rear

shield. See “Rear shield removal” on

page 4-11. Check the cable connections.

Are all the cable connections secure?

Replace the controller
board. See “Controller

board removal” on
page 4-19.

Securely make all the
connections. POR the
printer.

2-24 Service Manual

5025-2xx, 4xx

925.01—Fan error service check

Step Questions / actions Yes No

1 Turn the printer off, and remove the rear

shield. See “Rear shield removal” on

page 4-11. Check the fan cable at JFAN1 for

the following values:

JFAN1

Pin Value

1 +3.3 V dc
2 Ground
3 0 (fan off)

Are the measured values correct?

Replace the top cover
(which includes the fan).
See “Top cover assembly

removal” on page 4-12.

Replace the controller
board. See “Controller

board removal” on
page 4-19.

930.xx–935.xx—Printhead errors service check

Step Questions / actions Yes No

1 Turn the printer off, and remove the rear

shield. See “Rear shield removal” on

page 4-11. Check the cables connected at

JMIRR1 and JPH1 on the controller board.
Check for damage.

Are the cables damaged?

Turn the printer on, and verify the following

2

values at JMIRR1:

JMIRR1

Pin Value

2 +3.3 V dc
4 Ground
5+24 V dc

Replace the printhead. See

“Printhead removal” on
page 4-49.

Replace the printhead. See

“Printhead removal” on
page 4-49.

Go to step 2.

Replace the controller
board. See “Controller

board removal” on
page 4-19.

Are the values approximately correct?

Diagnostic information 2-25

5025-2xx, 4xx

936.xx, 937.xx—Transport motor service check

Step Questions / actions Yes No

1 Turn the printer off, and remove the rear

shield. See “Rear shield removal” on

page 4-11. Check the cable at JCARB1 for

proper connection to the controller board.
Is the cable properly connected?

Turn the printer on, and ten measure the

2

values of the cable at JCARB1:

JCARB1

Pin Value

4 +24 V dc
6 +24 V dc
8 +24 V dc

9 Ground
12 Ground
13 +24 V dc
15 +24 V dc
17 +24 V dc

Are the values approximately correct?

950.xx NVRAM Failure service check

Reconnect the cable. Go to step 2.

Replace the main drive gear
assembly. See “Main drive

gear assembly removal”
on page 4-45.

Replace the controller
board. See “Controller

board removal” on
page 4-19.

Warning: Replace one of the following components, and perform a POR before replacing a second

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

• Controller board

Warning: Never install and remove components listed above as a method of troubleshooting components.

Once a component has been installed in a printer, and the printer is powered on, it cannot be
used in another printer. It must be returned to the manufacturer.

This error code indicates a mismatch between the memory on the operator panel assembly and the one on the
controller board.

Step Questions / actions Yes No

1 Have any updates been made to the firmware? Reload the firmware and try

Did reloading the firmware correct the

2

problem?

again.
Go to step 2.

Problem resolved. Replace the controller board

Replace the controller board
with a new, and not
previously installed
controller board. See

“Controller board
removal” on page 4-19.

with a new, and not
previously installed
controller board. See

“Controller board
removal” on page 4-19.

2-26 Service Manual

5025-2xx, 4xx

Autocompensator mechanism service check

Step Questions / actions Yes No

1 Turn the printer off, and then remove the rear

shield. See “Rear shield removal” on

page 4-11. Check the cable at JSP1 on the

controller board for proper connection.
Is the cable properly connected?

Did the printer function correctly after

2

reconnecting the cables?

Turn the printer on, and then verify the

3

following approximate values at JSP1:

JSP1

Pin Value Pin Value

2 +24 V dc 10 +5 V dc
4 +24 V dc 13 Ground
6 Ground 15 +5 V dc
7 Ground 16 Ground
8 Ground

Are the values approximately correct?

Go to step 3. Properly connect the cables,

Problem resolved. Go to step 3.

Replace the
autocompensator
mechanism. See

“Autocompensator
mechanism (ACM)
removal—standard tray”
on page 4-15.

and POR the printer.
Go to step 2.

Replace the controller
board. See “Controller

board removal” on
page 4-19.

Bin full sensor service check

Step Questions / actions Yes No

1 Is the bin full sensor dislodged or damaged? Repair or replace the bin full

Does the flag rotate freely and interrupt the

2

sensor beam when in normal position?

Turn the printer off, and remove the rear

3

shield. See “Rear shield removal” on

page 4-11. Turn the printer on, and then check

the values below at JBIN1:

JBIN1

Pin Value

1 > 0 V dc
2 +3.3 V dc beam blocked

0 V dc unblocked

3 Ground

Are the values correct?

sensor. See “Bin full

sensor removal” on
page 4-18.

Go to step 3. Reposition or replace the

Problem resolved. Replace the controller

Go to step 2.

flag.

board. See “Controller

board removal” on
page 4-19.

Diagnostic information 2-27

5025-2xx, 4xx

Dead printer service check

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. See “Operator panel display blank, five beeps”

on page 2-37.

If a 650-sheet duo drawer is installed, remove the option and check the base printer for correct operation. If the
base printer operates correctly, replace the 650-sheet duo drawer.

Warning: Observe all necessary ESD precautions when removing and handling the controller board or any

installed option cards or assemblies. See “Handling ESD-sensitive parts” on page 4-1.

CAUTION

When you see this symbol, there is a danger from hazardous voltage in the area of the product
where you are working. Unplug the product before you begin, or use caution if the product
must receive power in order to perform the task.

Remove any input paper-handling options from the printer.

Step Questions / actions Yes No

1 Check the AC line voltage.

Is the line voltage correct?

Is the AC line cord damaged? Replace the line cord. Go to step 3.

2

Is the LVPS cable correctly connected at

3

JLVPS1 on the controller board?

Turn the printer off, and then on.

4

Does the problem persist?

Warning: Damage to the printer is possible.

5

Be careful to touch only one conductor at a
time. Rest the probe against the connector to
steady it.

With the printer on, verify the following values
at JLVPS1:

JLVPS1 (exposed conductors)

Pin Value Pin Value

1 +5 V dc 7 +24 V dc
3 +5 V dc 9 +24 V dc
5 +5 V dc 11 +24 V dc

Are the values approximately correct?

Go to step 2. Inform the customer.

Go to step 5. Reconnect the cable at

Go to step 5. Problem resolved.

Replace the controller
board. See “Controller

board removal” on
page 4-19.

JLVPS1, and then go to
step 4.

Replace the LVPS. See

“Low-voltage power
supply (LVPS) assembly
removal” on page 4-37.

2-28 Service Manual

5025-2xx, 4xx

Duplex/manual feed sensor (S1) service check

Step Questions / actions Yes No

1 Is the printer setting on a hard, flat surface? Go to step 2. Make sure the printer is

Enter Diagnostics Menu (turn the printer off,

2

press and hold and , turn the printer on,
and then release the buttons when the
installed memory and processor speed
displays).

Perform the Base Sensor Test. See “Base

Sensor Test” on page 3-16.

1. Select Base Sensor Test, and press
Select ().

2. Select S1, and press Select ().

3. Install tray 1.

Does the display indicate InputS1—Media
Clear…?

Pull tray 1 out.

3

Does the display indicate InputS1—Media
Present…?

Remove the tray, and inspect the sensor.

4

Is there something obstructing the sensor?

Inspect the spring-loaded shaft/flag in the tray.

5

The flag portion of the shaft intercepts the
sensor, except when a sheet is being staged
for duplexing.

Does the shaft rotate freely and return to home
position (flag at top of rotation)?

Go to step 3. Go to step 5.

The sensor is functioning
correctly.

Remove the obstruction,
and restart the test.

Go to step 6. Replace the tray with a new

setting on a level, flat
surface.

Go to step 4.

Go to step 5.

one.

Is the flag on the shaft broken? Replace the tray. Go to step 7.

6

Verify the cable is correctly connected to

7

JFUSES1 on the controller board and to the
sensor.

Is the sensor cable properly connected?

Turn the printer off, and remove the rear

8

shield. See “Rear shield removal” on

page 4-11. Turn the printer on, and check the

values at JFUSES1:

JFUSES1

Pin Value

8 Ground
9 +3.3 V dc

Are the values approximately correct?

Go to step 8. Reconnect the cable.

If the problem persists, go to
step 8.

Replace the duplex sensor.
See “Duplex sensor

removal” on page 4-21.

Replace the controller
board. See “Controller

board removal” on
page 4-19.

Diagnostic information 2-29

5025-2xx, 4xx

Front door sensor or switches service check

Step Questions / actions Yes No

1 Enter Diagnostics Menu (turn the printer off,

press and hold and , turn the printer on,
and then release the buttons when the
installed memory and processor speed
displays).

Perform the Base Sensor Test. See “Base

Sensor Test” on page 3-16.

1. Select Base Sensor Test, and press
Select ().

2. Select Front Door, and press Select ().

3. Open and close the front door, and
observe the display.

Does the display indicate Value Closed with
the door closed and Value Opened with the
door opened?

Open the front door, and check the thin, tall,

2

plastic web (pivot plate) at the top right of the
printer. With the other covers in place and
closed, this web interacts with switches in the
door.

Open the toner cover, and check the motion of
the web. Is the web loose, damaged, or
missing?

Open the toner door, and inspect the vertical

3

web that pushes and rotates the pivot plate.
Is it damaged?

Sensor, toner door, and
right doors are OK.

Replace the right cover
assembly. See “Right

cover assembly removal”
on page 4-10.

Replace the top cover
assembly. See “Top cover

assembly removal” on
page 4-12.

Go to step 2.

Go to step 3.

Go to step 4.

With the front cover open, inspect the two

4

switches. Using a tool, such as a spring hook,
push the metal arms to check the movement.

Is there any damage to the switches or the
surrounding area?

Turn the printer off, and remove the rear

5

shield. See “Rear shield removal” on

page 4-11. Turn the printer on, and verify the

following values at JINT1 and JCVR1:

JINT1 JCVR1

Pin Value Pin Value

1 +5 V dc 1 +24 V dc
2 Ground

Are the values approximately correct?

Replace the right cover
assembly. See “Right

cover assembly removal”
on page 4-10.

Go to step 6. Replace the controller

Go to step 5.

board. See “Controller

board removal” on
page 4-19.

2-30 Service Manual

5025-2xx, 4xx

Step Questions / actions Yes No

Close the front cover and the toner door. Be

6

sure the right cover is in place. Turn the printer
off, and then disconnect the cables at JINT1
and JCVR1. Test continuity at the connector
under the following conditions:

• With front cover and toner door closed:

Test pin 1 and pin 3 at JINT1 cable end
and pin 1 and pin 2 at JCVR1 cable end.

• With one or both doors open:

Pin 2 and 3 at JINT1 cable end should
indicate continuity, but pins 1 and 2 at
JCVR1 should have no continuity.

Are the tests verified?

Contact your next level of
support.

Replace the front cover
assembly. See “Front

cover assembly removal”
on page 4-2.

Fuser exit sensor service check

Step Questions / actions Yes No

1 Enter Diagnostics Menu (turn the printer off,

press and hold and , turn the printer on,
and then release the buttons when the
installed memory and processor speed
displays).

Perform the Base Sensor Test. See “Base

Sensor Test” on page 3-16.

1. Select Base Sensor Test, and press
Select ().

2. Select Fuser Exit Sensor, and press
Select ().

3. Open and close the front door, and inspect
the fuser exit sensor located on the LVPS
shield.

Is the sensor dislodged or damaged?

Correct the sensor, or
replace it. See “Fuser exit

sensor removal” on
page 4-30.

Go to step 2.

Rotate the flag (paper diverter) in and out of

2

the sensor.
Does the display indicate Media Clear and

Media Present with the cycle?

Does the flag rotate freely, but return to block

3

the sensor?

Turn the printer off, and then remove the rear

4

shield. See “Rear shield removal” on

page 4-11.

Is the cable correctly connected to JBIN1 on
the controller board and to the sensor?

Sensor is good. Go to step 3.

Go to step 4. Replace the fuser. See

“Fuser assembly
removal” on page 4-26.

Go to step 5. Reconnect the cable.

Diagnostic information 2-31

5025-2xx, 4xx

Step Questions / actions Yes No

Turn the printer on, and check the values at

5

JBIN1:

JBIN1

Pin Value

4 +5 V dc
5 +0 V dc (no media), +3.3 V dc (media)
6 Ground

Are the values correct?

Replace the fuser exit
sensor. See “Fuser exit

sensor removal” on
page 4-30.

Replace the controller
board. See “Controller

board removal” on
page 4-19.

Fuser service check

Step Questions / actions Yes No

1 Some low-voltage power supply FRUs have a

voltage selector switch. If it does, the switch
needs to be set to the correct voltage for your
area.

Check the switch on the
side of the LVPS to verify
the correct voltage is set.

Go to step 2.

Has the LVPS been changed?

Turn the printer off, and remove the rear

2

shield. See “Rear shield removal” on

page 4-11. Check the cable at JFUSES1 for

proper connection to the controller board, the
cable for pinch points, and the cable or
connector for any other damage.

Is the cable damaged?

Check the connector JLVPS1 for proper

3

connection to the controller board, the cable
for pinch points, and the cable or connector for
any other damage.

Is the cable damaged?

Check the power cable on the left side of the

4

fuser and the thermistor cables and
connections on the right side of the fuser.

Are the cables or connectors damaged?

Replace the fuser cable. Go to step 3.

Repair or replace the LVPS
cable.

Repair the cables. If the
cables cannot be repaired,
replaced the fuser. See

“Fuser assembly
removal” on page 4-26.

Go to step 4.

Go to step 5.

2-32 Service Manual

5025-2xx, 4xx

Step Questions / actions Yes No

Check the following values at JFUSES1:

5

JFUSES1

Pin Value

5 +3.3 V dc
6 Ground

8 Ground
10 +2.7 V dc
11 Ground

Are the values approximately correct?

Replace the fuser. See “Fuser assembly

6

removal” on page 4-26.

Does the error clear?

Go to step 6. Replace the controller

board. See “Controller

board removal” on
page 4-19.

Problem resolved. Replace the controller

board. See “Controller

board removal” on
page 4-19.

Diagnostic information 2-33

5025-2xx, 4xx

Input sensor (S2) service check

The Input sensor (S2) is part of the ACM FRU.

Step Questions / actions Yes No

1 Enter Diagnostics Menu (turn the printer off,

press and hold and , turn the printer on,
and then release the buttons when the
installed memory and processor speed
displays).

Perform the Base Sensor Test. See “Base

Sensor Test” on page 3-16.

1. Select Base Sensor Test, and press
Select ().

2. Select S2, and press Select ().

3. Pull tray 1 out, and rotate the S2 sensor
flag (S2 is located in front of the center
autocompensator mechanism housing.) It
should rotate freely and return to its original
position.

Is the input (S2) sensor flag damaged?

Watch the display while rotating the flag.

2

Does the display indicate Media Clear and
Media Present?

Turn the printer off, and remove the rear

3

shield. See “Rear shield removal” on

page 4-11.

Is the JSP1 cable connector properly
connected to the controller board?

Turn the printer on, and check the voltage at

4

JSP1 pin 15.
Is the voltage approximately +5 V dc?

Replace the
autocompensator
mechanism. See

“Autocompensator
mechanism (ACM)
removal—standard tray”
on page 4-15.

Problem resolved. Go to step 3.

Go to step 4. Reseat the connector.

Replace the
autocompensator
mechanism. See

“Autocompensator
mechanism (ACM)
removal—standard tray”
on page 4-15.

Go to step 2.

Replace the controller
board. See “Controller

board removal” on
page 4-19.

2-34 Service Manual

5025-2xx, 4xx

Main drive gear assembly (EP drive) service check

Step Questions / actions Yes No

1 Turn the printer off, and remove the rear

shield. See “Rear shield removal” on

page 4-11. Check the cable at JCARTB1 for

proper connection to the controller board, the
cable for pinch points, and the cable or
connector for any other damage.

Is the cable damaged?

Verify the following values at JCARTB1 on the

2

controller board.

JCARTB1

Pin Value

4 +24 V dc
6 +24 V dc
8 +24 V dc

9 Ground
12 Ground
13 +24 V dc
15 +24 V dc
17 +24 V dc

Are the values approximately correct?

Replace the main drive assembly. See “Main

3

drive gear assembly removal” on
page 4-45.

Does the error clear?

Replace the JCARTB1
cable.

Go to step 3. Replace the controller

Problem resolved. Replace the controller

Go to step 2.

board. See “Controller

board removal” on
page 4-19.

board. See “Controller

board removal” on
page 4-19.

Diagnostic information 2-35

5025-2xx, 4xx

Operator panel service check

Warning: Replace one of the following components, and perform a POR before replacing a second

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

• Controller board

Warning: Never install and remove components listed above as a method of troubleshooting components.

Once a component has been installed in a printer, and the printer is powered on, it cannot be
used in another printer. It must be returned to the manufacturer.

One or more operator panel buttons fail

Step Questions / actions Yes No

1 Enter Diagnostics Menu (turn the printer off,

press and hold and , turn the printer on,
and then release the buttons when the
installed memory and processor speed
displays).

Perform the Panel Test. See “Panel Test” on

page 3-11. The Panel Test should show

alternating display of all pixels on, and all
pixels off. Press Stop to end the test.

Did the test show errors on the display?

Perform the Button Test. See “Button Test”

2

on page 3-12 in Diagnostics Menu.

Did any of the buttons fail the test?

Remove the rear shield. “Rear shield

3

removal” on page 4-11.

Turn the printer on, and verify the following
values at JOPP1:

JOPP1

Pin Value

2 +5 V dc
4 Ground
5 +5 V dc
6 +3.3 V dc
7 Ground

Replace the operator panel
assembly. See “Operator

panel removal” on
page 4-9.

Replace the operator panel
assembly. See “Operator

panel removal” on
page 4-9.

Replace the operator panel.
See “Operator panel

removal” on page 4-9.

If this does not fix the
problem, replace the front
cover assembly which
contains the operator panel
cables. See “Front cover

assembly removal” on
page 4-2.

Go to step 2.

Go to step 3.

Replace the controller
board. See “Controller

board removal” on
page 4-19.

Are the values approximately correct?

2-36 Service Manual

5025-2xx, 4xx

Operator panel display blank, five beeps

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.

Step Questions / actions Yes No

1 Is the operator panel assembly cable properly

installed at controller board JOPP1 and at the
operator panel assembly?

Turn the printer off, and remove the rear

2

shield. See “Rear shield removal” on

page 4-11.

Turn the printer on, and verify the following
values at JOPP1:

JOPP1

Pin Value

2 +5 V dc
4 Ground
5 +5 V dc
6 +3.3 V dc
7 Ground

Are the values approximately correct?

Check continuity of the operator panel

3

assembly cable.
Is there continuity?

Go to step 2. Reinstall the cable.

Go to step 3. Replace the controller

Replace the operator panel
assembly. See “Operator

panel removal” on
page 4-9.

board. See “Controller

board removal” on
page 4-19.

Replace the front cover
assembly. See “Front

cover assembly removal”
on page 4-2.

Diagnostic information 2-37

5025-2xx, 4xx

Operator panel display blank, printer beeps five times and pauses

Step Questions / actions Yes No

1 Turn the printer off, and remove the rear

shield. See “Rear shield removal” on

page 4-11.

Turn the printer on, and verify the following
values at JOPP1 on the controller board:

JOPP1

Pin Value

10 V dc
2 +5 V dc
30 V dc
4 Ground
5 +5 V dc
6 +3.3 V dc
7 Ground

Are all these values approximately correct?

Turn the printer off, and check for continuity in

2

the operator panel cable.
Note: Remove the three screws holding the

operator panel, and place it facedown on top of
the printer. The cable connector pins will be
exposed and easier to contact.

Do all the conductors indicate continuity?

Go to step 2. Replace the controller

Replace the operator panel.
See “Operator panel

removal” on page 4-9.

board. See “Controller

board removal” on
page 4-19.

Replace the front cover
assembly. See “Front

cover assembly removal”
on page 4-2.

2-38 Service Manual

5025-2xx, 4xx

Operator panel displays all diamonds, no beeps

Step Questions / actions Yes No

1 Turn the printer off, and remove the rear

shield. See “Rear shield removal” on

page 4-11.

Disconnect the cable at JOPP1 on the
controller board. Verify the following values:

JOPP1

Pin Value

10 V dc
2 +5 V dc
30 V dc
4 Ground
5 +5 V dc
6 +3.3 V dc
7 Ground

Are all these values approximately correct?

Check for continuity in the operator panel

2

cable connector.
Note: Remove the three screws holding the

operator panel, and place it facedown on top of
the printer. The cable connector pins will be
exposed and easier to contact.

Do all the conductors indicate continuity?

Go to step 2. Replace the controller

Replace the operator panel.
See “Operator panel

removal” on page 4-9.

board. See “Controller

board removal” on
page 4-19.

Replace the front cover
assembly. See “Front

cover assembly removal”
on page 4-2.

Diagnostic information 2-39

5025-2xx, 4xx

Operator panel displays all diamonds, five beeps

Step Questions / actions Yes No

1 Turn the printer off, and remove the rear

shield. See “Rear shield removal” on

page 4-11.

Turn the printer on, and verify the following
values at JOPP1:

JOPP1

Pin Value

10 V dc
2 +5 V dc
30 V dc
4 Ground
5 +5 V dc
6 +3.3 V dc
7 Ground

Are all these values approximately correct?

Check for continuity in the operator panel

2

cable connector.
Note: Remove the three screws holding the

operator panel, and place it facedown on top of
the printer. The cable connector pins will be
exposed and easier to contact.

Do all the conductors indicate continuity?

Go to step 2. Replace the controller

Replace the operator panel.
See “Operator panel

removal” on page 4-9.

board. See “Controller

board removal” on
page 4-19.

Replace the front cover
assembly. See “Front

cover assembly removal”
on page 4-2.

2-40 Service Manual

5025-2xx, 4xx

Operator panel display is dim and unchanging

Step Questions / actions Yes No

1 Turn the printer off, and remove the rear

shield. See “Rear shield removal” on

page 4-11.

Turn the printer on, and verify the following
values at JOPP1 on the controller board:

JOPP1

Pin Value

10 V dc
2 +5 V dc
30 V dc
4 Ground
5 +5 V dc
6 +3.3 V dc
7 Ground

Are all these values approximately correct?

Check for continuity in the operator panel

2

cable connector.
Note: Remove the three screws holding the

operator panel, and place it facedown on top of
the printer. The cable connector pins will be
exposed and easier to contact.

Do all the conductors indicate continuity?

Go to step 2. Replace the controller

Replace the operator panel.
See “Operator panel

removal” on page 4-9.

board. See “Controller

board removal” on
page 4-19.

Replace the front cover
assembly. See “Front

cover assembly removal”
on page 4-2.

Diagnostic information 2-41

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 the responsibility of the customer. With the customer's permission,
you may need to install a developer (toner) cartridge or photoconductor unit.

Service tip

Before troubleshooting any print quality problems, do the following:

1. Print a menu settings page, and check the life status of all supplies. Any supplies that are low should be

replaced.
To print a menu settings page:

a. Press Menu ( ) on the operator panel.
b. Select Reports from the Admin Menu, and press Select ().
c. Select Menu Settings, and press Select ().

Note: Be sure and keep the original menu page to restore the customer's custom settings if needed.

2. On the menu page, make sure the following is set to the default level:
– Color Correction: Set to Auto.
– Print Resolution: Set to 600 dpi (print quality problems should be checked at different resolution

settings).

– Toner Darkness: Set to 4 (default).
– Color Saver: Set to OFF.
– RGB Brightness, RGB Contrast, RGB Saturation: Set to 0.
– 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:

1. Inspect the imaging unit for damage, including the developers and toner cartridges. Replace if damaged.

2. If paper other than 20lb plain letter/A4 paper is being used, load 20lb plain letter/A4.

3. Print the Print Quality pages to see if the problem remains. Look for variations in the print from what is

expected.
To print the print Quality pages:

a. Enter Diagnostics (turn the printer off, press and hold Left ( ) and Select ( ), turn the printer on,

and release when the installed memory and processor speed displays).

b. Select PRINT TESTS, and press Select ( ).
c. Select Print Quality Pgs, and press Select ().

The message Printing Quality Test Pages is displayed.

An incorrect printer driver for the installed software can cause problems. Incorrect characters could print, and
the copy may not fit the page correctly.

Measure all voltages from the connector to the printer ground.

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5025-2xx, 4xx

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
occur by running a large amount of graphics in a humid environment.

Step Questions / actions Yes No

1 Read the current status of the imaging unit

from the customer menus.
To view the status of the photoconductor units:

1. In Ready mode, press Menus ().

2. Select Reports, and press Select ( ).

3. Select Device Statistics, and press
Select ().

It is possible a new imaging unit was installed,
but the counter was not reset.

Has the imaging unit been recently replaced?

Is the background only one of the primary

2

colors; yellow, cyan, magenta, or black?

Did replacing the developer unit correct the

3

problem?

Replace the photoconductor unit.

4

Does this fix the problem?

Check the high-voltage contact from the HVPS

5

to the image transfer unit (ITU).
Is a problem found?

Reset the value. To reset
this value:

1. In Ready mode, press

Menus ().

2. Select Supplies Menu,
and press Select ().

3. Select Replace Supply,
and press Select ().

4. Select the imaging unit ,
and press Select ().

5. Select Yes, and press
Select ().

If this does not fix the
problem, go to step 2.

Replace the developer unit
for the background color
and retest. See “Developer

unit removal” on
page 4-21.

Go to step 3.

Problem resolved. Go to step 4.

Problem resolved. Go to step 5.

Replace the failing part:

• Image transfer unit

(ITU). See “Image

transfer unit (ITU)
removal” on page 4-33.

• High-voltage power
supply (HVPS). See

“High-voltage power
supply (HVPS)
assembly removal” on
page 4-31.

Go to step 2.

Go to step 4.

Go to step 6.

Reseat the cable in the JHVPS1 connector.

6

Does this fix the problem?

Replace the HVPS. See “High-voltage power

7

supply (HVPS) assembly removal” on
page 4-31.

Does this fix the problem?

Clean the printhead.

8

Does this fix the problem?

Problem resolved. Go to step 7.

Problem resolved. Go to step 8.

Problem resolved. Replace the printhead. See

“Printhead removal” on
page 4-49.

Diagnostic information 2-43

5025-2xx, 4xx

Print quality—blank page

Step Questions / actions Yes No

1 Is all the packing material for the imaging unit

in question removed?

Print a document that requires all four colors

2

with just a few characters to verify if one
specific color is a problem. For example, print
the Print Quality Test Pages:

1. Enter Diagnostic mode. (Turn the printer

off, press and hold Left ( ) and
Select ( ), turn the printer on, and then
release the buttons when the installed
memory and processor speed displays.)

2. Select PRINT TESTS, and press
Select ().

3. Select Prt Qual Pgs, and press
Select ().

Is only one color missing?

Replace the imaging unit. See “Imaging unit

3

(IU) removal” on page 4-35.

Does this fix the problem?

Enter the Diagnostics Menu (turn the printer

4

off, press and hold and , turn the printer
on, and release the buttons when installed
memory and processor speed displays), and
run the appropriate cartridge drive motor test
for the missing color:

1. Select MISC TESTS in the Diag Menu, and
press Select ().

2. Select Motor Detect.
Remove Cartridge. Press Select appears.

Note: Do not press Select yet.

3. Remove all toner cartridges and the
imaging unit.

4. Close the front cover.
If you press Select before closing the front

cover, a message appears: Close Cover.
Press Select.

5. Press Select ().
Motor Detection In Progress… appears.

The motor detection process takes about
10 seconds, and stops automatically.

Detect Complete. Rebooting… appears,
and the printer performs a POR (Power On
Reset).

Did the motor run?

Go to step 2. Remove the packing

Replace the developer unit
for the missing color.

Problem resolved. Go to step 4.

Go to step 5. Replace the Main drive gear

material.

Go to step 3.

assembly. See “Main drive

gear assembly removal”
on page 4-45.

2-44 Service Manual

5025-2xx, 4xx

Step Questions / actions Yes No

Remove the developer unit. See “Developer

5

unit removal” on page 4-21. Check the

developer cartridge contacts from the HVPS to
the IU.

Are all the toner cartridge contacts clean on
both the pins and IU?

Are all the spring-loaded pins in the HVPS free

6

to move in and out with an equal amount of
spring force?

Turn the printer off, and remove the rear

7

shield. See “Rear shield removal” on

page 4-11. Check the continuity between the

spring-loaded pins and the JSC1 connector on
the controller board.

Are all conductors continuous?

Replace the printhead. See “Printhead

8

removal” on page 4-49.

Did this fix the problem?

Go to step 6. Clean the developer

Go to step 7. Replace the HVPS. See

Go to step 8. Replace the cable.

Problem resolved. Replace the controller

Print quality—blurred or fuzzy print

Run the automatic alignment. The TPS sensor may be damaged. To run Reset Color
Cal:

cartridge contacts. See

“Developer unit removal”
on page 4-21.

“High-voltage power
supply (HVPS) assembly
removal” on page 4-31.

board. See “Controller

board removal” on
page 4-19.

1. Enter the Diagnostics Menu. (Turn the printer off, press and hold and , turn

the printer on, and release the buttons when installed memory and processor
speed displays.

2. Select TPS Setup from Diag Menu, and press Select ().

3. Select Reset Color Cal, and press Select ().

Resetting appears. When the reset is complete, the screen is automatically
returned to TPS Setup.

Blurred or fuzzy print is usually caused by a problem in the main drive gear assembly or in the image transfer
unit (ITU). Check the main drive gear assembly and ITU for correct operation.

Blurred print can also be caused by incorrect feeding from one of the input paper sources, media trays, or
duplex paper path.

Check the high-voltage spring contacts to ensure they are not bent, corroded, or damaged. Replace the high­voltage power supply as necessary. See “High-voltage power supply (HVPS) assembly removal” on

page 4-31.

Print quality—half-color page

The imaging unit and developer units may not properly seated. Reseat the imaging unit. If that does not work,
remove the imaging unit and reseat each of the developer units.

Diagnostic information 2-45

5025-2xx, 4xx

Print quality—horizontal banding

Print the Print Defect Page:

1. At the Ready prompt, press Menu ().

2. Select Reports, and press Select ().

3. Select Print Defects, and press Select ().

Step Questions / actions Yes No

1 Measure the distance between repeating

bands.
Is the distance between bands either 34.6 or

94.2 mm?

Does the distance measure 95 mm or

2

108 mm?

Does the distance measure 37.7, 55, or

3

78.5 mm?

Does the distance measure 43.9 mm or 45.5? Replace the developers that

4

Replace the photoconductor
unit. 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 “Imaging unit (IU)

removal” on page 4-35.

Replace the fuser. See

“Fuser assembly
removal” on page 4-26.

Replace the ITU. See

“Image transfer unit (ITU)
removal” on page 4-33.

match the missing color
(black, cyan, magenta, or
yellow). See “Developer

unit removal” on
page 4-21.

Go to step 2.

Go to step 3.

Go to step 4.

Check the various rollers in
the printer for debris.

Print quality—horizontal line

Either the photoconductor unit or one of the developer units that make up the imaging unit is defective. Remove
and inspect the imaging unit. Replace the damaged part of the imaging unit. See “Imaging unit (IU) removal”

on page 4-35.

2-46 Service Manual

5025-2xx, 4xx

Print quality—insufficient fusing

Step Questions / actions Yes No

1 Is the printer setup to use the correct media? Go to step 2. Change the settings to

Check the fuser connections on the left and

2

right side of the printer.
Are the cables and connection correct?

Is the fuser properly installed? Go to step 4. Install the fuser properly.

3

Replace the fuser. See “Fuser assembly

4

removal” on page 4-26.

Does this fix the problem?

Go to step 3. Properly reconnect or

Problem resolved. Replace the LVPS. See

indicate the correct media.

replace the cables.

“Low-voltage power
supply (LVPS) assembly
removal” on page 4-37.

Print quality—missing image at edge

Remove and reseat the following:

• Toner cartridge

• Imaging unit

• Developer units.

Print quality—mottle (2–5mm speckles)

Keep running prints through, and the problem normally clears up. If the problem persists,
replace the developer.

Diagnostic information 2-47

5025-2xx, 4xx

Print quality—narrow vertical line

ABCDE
ABCDE
ABCDE

Step Questions / actions Yes No

1 Replace the photoconductor unit. See

“Imaging unit (IU) removal” on page 4-35.

Problem resolved. Replace the developer unit.

See “Developer unit

removal” on page 4-21.

Print quality—random marks

Service tip: The primary cause of random marks is loose material moving around inside the printer and attaching
to the photoconductor unit, developer roll, or transfer belt.

Step Questions / actions Yes No

1 Is there any loose or foreign material on the

imaging unit?

Is there any loose or foreign material on the

2

developer roll?

Is there any loose or foreign material on the

3

transfer belt?

Inspect the imaging unit by
looking at the individual
developers and photo
conductors. Clean or
replace the faulty unit. See

“Imaging unit (IU)
removal” on page 4-35.

Replace the developer unit. Go to step 3.

Replace the image transfer
unit. See “Image transfer

unit (ITU) removal” on
page 4-33.

Go to step 2.

Contact your next level of
support.

2-48 Service Manual

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Print quality—residual image

ABCDE
ABCDE
ABCDE

Step Questions / actions Yes No

1 Check the condition of the imaging unit using

the customer menus (administrative menus):

1. At the Ready prompt, press Menu ().

2. Select Supplies Menu, and press Select

().

3. Select Imaging Kit, and press Select ().

Does the display indicate OK?

Measure the distance from the original image

2

to the same point on the residual image.
Is the distance 43.9 mm?

Is the distance between the original image and

3

the residual image 94.2 mm?

Run the Menu Setting Page twice to clear any

4

debris.
To print a menu settings page:

1. Press Menu ( ) on the operator panel.

2. Select Reports from the Admin Menu, and
press Select ().

3. Select Menu Settings, and press
Select ().

Is there still any toner contamination on the
fuser assembly?

Go to step 2. Replace the imaging unit or

Replace the developer
corresponding to the color of
the image. See “Developer

unit removal” on
page 4-21.

Replace the
photoconductor. See

“Developer unit removal”
on page 4-21.

Replace the fuser. See

“Fuser assembly
removal” on page 4-26.

the photoconductor unit.
See “Imaging unit (IU)

removal” on page 4-35.

Replace the imaging unit or
the photoconductor unit.
See “Imaging unit (IU)

removal” on page 4-35.

Contact your next level of
support.

Diagnostic information 2-49

5025-2xx, 4xx

Print quality—solid color page

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.

Step Questions / actions Yes No

1 Replace the photoconductor unit (part of the

imaging unit). Remove the imaging unit and
remove the developers. Place the original
developers in the new photoconductor, and
then replace the imaging unit. See “Imaging

unit (IU) removal”.

Does this fix the problem?

A faulty printhead can cause the problem. To

2

test the printhead for solid colors, place a
narrow strip of paper over the gap between the
developers. Make sure the paper stays in
place when you replace the imaging unit. This
will block the laser from discharging the
photoconductors. Print a Quality Test Page.

Does the page have a white vertical band?

Check the high-voltage contact from the HVPS

3

to the photoconductor charge roll. Ensure the
contact springs are properly mounted and that
the charge roll contact spring is making good
contact with the HPVS spring that runs through
the left printer frame. See “Toner cartridge

contacts” on page 4-50 to view the proper

mounting and for removal procedures.
Are the spring(s) defective?

Turn the printer off, and check the continuity of

4

the HVPS cable.
Is there continuity?

Problem resolved. Go to step 2.

Replace the printhead. See

“Printhead removal” on
page 4-49.

Replace the transfer contact
assembly. See “Toner

cartridge contacts” on
page 4-50.

Go to step 5. Replace the cable

Go to step 3.

Go to step 4.

assembly.

Replace the HVPS. See “High-voltage power

5

supply (HVPS) assembly removal” on
page 4-31.

Did this solve the problem?

Print quality—vertical banding

Replace the developer unit.

2-50 Service Manual

Problem resolved. Replace the controller

board. See “Controller

board removal” on
page 4-19.

5025-2xx, 4xx

Printhead service check

This service check includes the following errors:

Error code Color

106.xx Yellow

107.xx Cyan

108.xx Magenta

109.xx Black

Step Questions / actions Yes No

1 Turn the printer off, and remove the rear

shield. See “Rear shield removal” on

page 4-11. Check the cable at JMIRR1 for

proper connection to the controller board, the
printhead cable for pinch points, and the cable
or connector for any other damage.

Is the cable damaged?

Turn the printer on, and then wait until the

2

printer posts an error. Using a voltmeter, check
the following values at JMIRR1:

JMIRR1

Pin Volt.

(V dc)

15

23.3
35
4GND
524

Are the values approximately correct?

Replace the printhead. See

“Printhead removal” on
page 4-49.

Replace the controller board
See “Controller board

removal” on page 4-19.

Go to step 2.

Replace the printhead. See

“Printhead removal” on
page 4-49.

Diagnostic information 2-51

5025-2xx, 4xx

Toner meter cycle (TMC) card

Step Questions / actions Yes No

1 Perform the Base Sensor Test:

1. Enter Diagnostics menu (turn the printer

off, press and hold and Select (), turn
the printer on, and release the buttons
when the installed memory and processor
speed displays).

2. Select Base Sensor Test, and press
Select ().

3. Select the sensor you want to test, open
the toner door, remove the corresponding
toner cartridge, and press Select ().

4. Note whether the operator panel shows a
change in state.

Note: If the reflective disk is not showing
on the cartridge, rotate the gear clockwise
to expose the reflective surface.

For additional information about the Base
Sensor Test, see “Base Sensor Test” on

page 3-16.

Does the operator panel display a change of
state?

Replace the toner cartridge. Replace the toner meter

cycle (TMC) card. See

“Toner meter cycle (TMC)
card removal” on
page 4-55.

Toner meter sensors (Y, C, M, K) on TMC card

Step Questions / actions Yes No

1 Remove the toner cartridge, and inspect the

lenses on the toner meter cycle (TMC) card.
Are the lenses blocked, damaged, or dirty?

Repair or replace the TMC
card. See “Toner meter

cycle (TMC) card removal”
on page 4-55.

Go to step 2.

Turn the printer off, and remove the rear

2

shield. See “Rear shield removal” on

page 4-11. Turn the printer on, and measure

the values below at JCTM1 during POR:

JCTM1

Pin Value

1 +5 V dc
2 +3.3 V dc
3 +3.3 V dc
4 +3.3 V dc
5 +3.3 V dc
6 Ground

Are any of the values incorrect?

Replace the controller
board. See “Controller

board removal” on
page 4-19.

Replace the TMC card. See

“Toner meter cycle (TMC)
card removal” on
page 4-55.

2-52 Service Manual

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Transfer roll service check

Step Questions / actions Yes No

1 Turn the printer off, and remove the rear

shield. See “Rear shield removal” on

page 4-11. Turn the printer on, and check the

cable at JHVPS1 connector on the controller
board without disconnecting it. Verify the
following values:

JHVPS1

Pin Value

7 +3.3 V dc
11 +3.3 V dc
13 +24 V dc
14 Ground
16 Ground

Are the values approximately correct?

Turn the printer off, and remove the ITU. See

2

“Image transfer unit (ITU) removal” on
page 4-33. Check the three spring-loaded

contacts between the HVPS and the ITU
located at the left rear of the printer and above
the HVPS.

Are the contact dirty?.

Tray 1 sensor service check

Replace the HVPS. See

“High-voltage power
supply (HVPS) assembly
removal” on page 4-31.

If the problem persists, go to
step 2.

Clean the contacts, and
reinstall the ITU.

Replace the controller
board. See “Controller

board removal” on
page 4-19.

Replace the ITU. See

“Image transfer unit (ITU)
removal” on page 4-33.

Step Questions / actions Yes No

1 When the printer is in Ready state, pull the

standard tray out. The display should indicate
Tray 1 Missing. Insert the tray.

Does the message remain on the display?

Check the vertical wall (or web) at the right

2

rear of the tray for damage.
Is the tray damaged?

Check for a dislodged sensor.

3

Is the sensor dislodged?

Does the message Tray 1 Missing fail to

4

appear when the tray is pulled out?

Go to step 2. Go to step 4.

Replace the tray. Go to step 3.

Replace the tray 1 sensor. Go to step 6.

Go to step 5. Problem resolved.

Diagnostic information 2-53

5025-2xx, 4xx

Step Questions / actions Yes No

Turn the printer off, and remove the rear

5

shield. See “Rear shield removal” on

page 4-11. Disconnect the cable at JTRAY1

connector on the controller board. Turn the
printer on, and measure the values below:

JTRAY1

Pin Value

1 +5 V dc
2 +5 V dc
3 Ground

Are the values approximately correct?

Test the continuity in the cable. See “Tray

6

present sensor removal” on page 4-57 to

access both ends of the cable.
Is the cable damaged?

Go to step 6. Replace the controller

Replace the cable
(Miscellaneous cables
FRU).

board. See “Controller

board removal” on
page 4-19.

Contact the next level of
support.

2-54 Service Manual

5025-2xx, 4xx

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
located to the left of the display and the navigation buttons are located below the display.

Menu

Indicator
light

USB Direct
interface

Stop/Cancel

Back

Operator panel buttons

Button or indicator Function

Select Press Select ( ) to initiate action on a menu item.

Indicator light Indicates the printer status:

Stop/Cancel Stops all printer activity.

Navigation buttons Press or to scroll through menu lists. Use the Select button in the center to

Navigation
button

Status Indicates

Off The power is off.
Blinking green The printer is warming up, processing data, or printing a job.
Solid green The printer is on, but idle.
Blinking red Operator intervention is needed.

A list of options is offered once Stopped appears on the display.

initiate action on a menu item.

Select button

Navigation
button

Back Returns the display to the previous screen.

Menu Opens the menu index.

USB Direct interface Note: The USB connector is available on some models.

Diagnostic information 2-55

5025-2xx, 4xx

Menu map

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
menu items may only be effective for a particular printer language. You can select these values at any time, but
they affect printer function only when you have the optional equipment, feature on your model, or the specified
printer language.

Supplies Menu

Cyan Cartridge
Magenta Cartridge
Yellow Cartridge
Black Cartridge
Imaging Kit
Waste Toner Bottle

Paper Menu

Default Source
Size/Type
Paper Texture
Paper Weight
Paper Loading
Custom Types
Universal Setup

Units of Measure
Portrait Width
Portrait Height
Feed Direction

Reports

Menu Settings Page
Device Statistics
Network Setup Page
Profiles List
Print Fonts
Print Directory
Print Defects
Print Demo

Demo Page
PPDS Info

Asset Report

Network/Ports

Active NIC
Network Menu

PCL Smartswitch
PS Smartswitch
NPA Mode
Network Buffer
Mac Binary PS
Network Setup

Reports
Network Card
TCP/IP
IPv6
Wireless
AppleTalk
SE Menu

USB Menu

PCL Smartswitch
PS Smartswitch
NPA Mode
USB Buffer
Mac Binary PS
USB With ENA

ENA Address
ENA Netmask
ENA Gateway
ENA Gateway

Settings

General Settings

Display Language
Eco-Mode
Quiet Mode
Run Initial Setup
Alarms
Timeouts
Print Recovery
Factory Defaults

Setup Menu

Printer Language
Print Area
Download Target
Resource Save

Finishing Menu

Sides (Duplex)
Duplex Bind
Copies
Blank Pages
Collate
Separator Sheets
Separator Source
N-up (Pages/Side)
N-up Ordering
Orientation
N-up Border

Quality Menu

Color Correction
Print Resolution
Toner Darkness
Enhance Fine Lines
Color Saver
RGB Brightness
RGB Contrast
RGB Saturation
Color Balance
Color Samples
Manual Color
Color Adjust

Utilities Menu

Format Flash
Defragment Flash
Hex Trace
Coverage Estimator

PDF Menu
PostScript Menu
PCL Emul Menu
PPDS Menu
Image Menu
PictBridge Menu
Flash Drive Menu

2-56 Service Manual

5025-2xx, 4xx

3. Diagnostic aids

Accessing service menus

There are different test menus that can be accessed during POR to identify problems with the printer.

Diagnostics Menu 1. Turn the printer off.

2. Press and hold Left ( ) and
Select ().

3. Turn the printer on.

4. Release the buttons when the
installed memory and
processor speed displays.

Configuration Menu 1. Turn the printer off.

2. Press and hold Select ()
and Right ().

3. Turn the printer on.

4. Release the buttons when the
installed memory and
processor speed displays.

The following menus do not require a POR:

Network SE Menu 1. From the Ready prompt, press

Menu ().

2. Select Customer Network/
Ports menu.

3. Press and hold Left ( ) and
Right ().

The Diagnostics menu group contains the settings
and operations used while manufacturing and
servicing the printer.

See “Diagnostics Menu (Diag Menu)” on

page 3-2 for more information.

The Configuration menu group contains a set of
menus, settings, and operations which are
infrequently required by a user. Generally, the
options made available in this menu group are
used to configure a printer for operation.

See “Configuration menu (Config Menu)” on

page 3-24 for more information.

4. Release the buttons when the
menu appears.

SE Menu In a browser, add /se to device’s

Additional error
message
information

Enter Invalid Engine
Mode (POR
Sequence)

To run the printer diagnostic tests described in this chapter, you must put the printer in Diagnostics Menu or in
the Configuration Menu.

IP address. For example, http://

158.183.3.2/se.
While the error displays on the

panel, press Back ( ) and
Right ().

Press Back ( ) and Left ( ). Load updated engine code.

Enters the SE menus online.

Access secondary debug information.

Diagnostic aids 3-1

5025-2xx, 4xx

Diagnostics Menu (Diag Menu)

Note: Tray 2 refers to the 550-sheet tray located in the 650-sheet duo drawer.

Diagnostics Menu structure

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
order shown. Any options that are referred to in the menus are displayed when the option is installed.

Available tests

The tests display on the operator panel in the order shown:

Diagnostics Menu

Registration (black registration)

Top Margin See “Registration” on page 3-4.
Bottom Margin
Left Margin
Right Margin
Skew See “Skew” on page 3-5.
Quick Test See “Quick Test” on page 3-5.

Alignment Menu (color alignment)

Cyan See “Alignment” on page 3-7.
Yellow
Magenta
Factory Scanner A summary page for all the color alignment settings: it can be used in
Factory Manual

PRINT TESTS

Tray 1 See “Input source tests” on page 3-10.
Tray 2 (if installed)
Manual Feeder (if installed)
MP Feeder (if installed)
Prt Quality Pgs See “Print quality test pages (Prt Quality Pgs)” on page 3-11.

Hardware Test

Panel Test See “Panel Test” on page 3-11.
Button Test See “Button Test” on page 3-12.
DRAM Test See “DRAM Test” on page 3-12.

DUPLEX TESTS (if installed)

Quick Test See “Quick Test (duplex)” on page 3-13.
Top Margin See “Top Margin (duplex)” on page 3-14.
Left Margin See “Left Margin (duplex)” on page 3-14.

INPUT TRAY TESTS

Feed Tests See “Feed Tests” on page 3-15.
Sensor Test See “Sensor Test” on page 3-15.

place of alignment pages for each individual color.

3-2 Service Manual

5025-2xx, 4xx

Diagnostics Menu (continued)

Base Sensor Test

Input See “Base Sensor Test” on page 3-16.
Standard Bin
S1
S2
Fuser exit Sensr
C-TMC Sensor
M-TMC Sensor
Y-TMC Sensor
K-TMC Sensor

MISC TESTS

Motor Detect See “Motor Detect” on page 3-16.

DEVICE TESTS

Flash Test (if flash memory is
installed)

Printer Setup

Defaults See “Defaults” on page 3-17.
Prt Color Pg Count See “Page counts” on page 3-17.
Prt Mono Pg Count
Perm Page Count
Serial Number See “Serial Number” on page 3-18.
Engine Setting 1 See “Engine Setting 1 through 4” on page 3-18.
Engine Setting 2
Engine Setting 3
Engine Setting 4
Model Name See “Model Name” on page 3-18.
Config ID (Configuration ID) See “Configuration ID” on page 3-18.
ITU Barcode See “ITU Barcode” on page 3-19.
Reset Fuser Cnt See “Reset Fuser Cnt” on page 3-19.

EP Setup

EP Defaults See “EP Defaults” on page 3-19.
Fuser Temp See “Fuser Temperature” on page 3-19.
DC Charge Adjust See “DC Charge Adjust, Dev Bias Adj, Transfer Adjust” on page 3-20.
Dev Bias Adjust
Transfer Adjust

TPS Setup

Right See “Right or Left TPS” on page 3-20.
Left
Cal Ref Adjust See “Cal Ref Adj” on page 3-20.
Reset Color Calibration See “Reset Color Cal” on page 3-21.

Reports

Menu Settings Page See “Menu Settings Page” on page 3-21.

See “Flash Test” on page 3-17.

Diagnostic aids 3-3

5025-2xx, 4xx

Diagnostics Menu (continued)

Event Log

Display Log See “Display Log” on page 3-21.
Print Log See “Print Log” on page 3-22.
Clear Log See “Clear Log” on page 3-22.

Exit Diags This selection exits the Diagnostics Menu. The printer performs a POR,

and returns to normal mode.

Registration

Print registration makes sure the black printing plane is properly aligned on the page. This is one of the steps in
aligning a new printhead. See “Alignment” on page 3-7. It is also the first step in aligning the duplex
registration. See “Quick Test (duplex)” on page 3-13.

To set print registration:

1. Select Registration from the Diag Menu, and press Select ().

2. Use or to select Print Quick Test, and press . See “Quick Test” on page 3-5 for additional

information.
The message Printing…, appears on the display, and the page prints.

Retain this page to determine the changes you need to make to the margin settings.

3. Press Select ( ) to enter the Registration.

4. Use or to select the margin setting you need to change, and press Select ().

5. Use to decrease or to increase the offset values, and press Select ( ) to confirm the value.

The message Submitting changes displays, and the original margin setting screen appears.
The print registration ranges are:

Description Value Direction of change

Top margin -50 to +50

Each increment corresponds to 8
scans at a 600 dpi scan rate (0.0133
inches or 0.339 mm)

The default is 0.

Bottom margin -25 to +25

Each increment causes
approximately 0.55 mm shift in the
bottom margin.

The default is 0.

Left margin -50 to +50

Each increment corresponds to 4
pixels at 600 dpi (0.00666 in. or

0.1693 mm).
The default is 0.

Right margin -50 to +50

Each increment corresponds to an
approximate shift of 4 pixels at 600
dpi.

The default is 0.

.

A positive change moves the image down the
page and increases the top margin. A negative
change moves the image up and decreases
the top margin. No compression or expansion
occurs.

A positive offset moves text down the page and
narrows the bottom margin, while a negative
offset moves text up the page and narrows the
bottom margin. The image is compressed or
expanded.

A positive change moves the image to the left,
and a negative change moves the image to the
right. No compression or expansion occurs.

A positive change moves the image to the left,
and a negative change moves the image to the
right.

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Description Value Direction of change

Skew -100 to +100

Each increment corresponds to
1/1200 of an inch.

The default is 0.

A positive value causes the left end of the scan
line to move down the page. A negative value
causes the left end of the scan line to move up
the page. The right end stays fixed. There is no
compression or expansion of the image.

6. Print another copy of the Quick Test to verify your changes.

7. Continue changing the settings by repeating steps 3 through 5.

To exit Registration, press Back (

) or Stop ( ).

Skew

One printhead houses the four color planes. The black plane is aligned to the printer, and the other color planes
are internally aligned to black. Electronic alignment fine tunes the alignment of the color planes to the black
plane once the printhead is installed. See “Alignment” on page 3-7 for instructions on setting printhead
alignment. This must be performed before color skew adjustment is attempted. The following illustration shows
proper alignment versus skewed alignment.

Straight Skewed

Quick Test

The Quick Test contains the following information:

• Print registration settings

• Alignment diamonds at the left, right, top, and bottom

• Horizontal lines to check for skew

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• General printer information, including current page count, installed memory, serial number, and code level.

To print the Quick Test page:

Note: Print the Quick Test Page on letter or A4 paper.

1. Select Registration from Diag Menu, and press Select ().

2. Select Quick Test Page, and press Select ( ).

The message Printing… appears on the display.
Once the Quick Test Page completes printing, the Registration screen displays again.

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Alignment

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.

To get started:

1. Select Alignment Menu from the Diag Menu, and press Select ( ).

2. Select a color (Cyan, Yellow, or Magenta), and press Select ().

Note: The yellow alignment page markings are more difficult to see, so you might not want to pick it first.

3. Select the Quick Test, and press Select ( ) to begin printing.

The message Printing… appears on the display. A page similar to the following prints:

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4. Select Top Margin, and press Select ().

5. 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.

6. Use or to enter the sum of the numbers, and press Select ().

Submitting changes… appears.
Print the Quick Test again to verify the observed value is the same as the current value (no change is

needed). If change is still needed, repeat steps 4–6. When the observed values and the current value are
the same, continue to the next step.

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7. Select the Skew value in the same way, enter the value, press Select ( ), and print the Quick Test to see

if the observed values and the current values are the same.

8. On the second page of the latest Quick Test you printed, proceed to Step 2; adjust the left, right, and bow

settings. Continue printing the Quick Test after each adjustment to verify your settings.

9. Continue on the other two colors in the same manner.

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Print Tests

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
source.

Check each Test Page from each source to assist in print quality and paper feed problems.

To run the Print Test Page:

1. Select PRINT TESTS from the Diag Menu, and press Select ().

2. Select the media source (Tray 1, Tray 2, Manual Feeder, or Multi-Purpose Feeder), and press

Select (),

3. Select Single or Continuous, and press Select ().

• If Single is selected, a single page is printed.

• If Continuous is selected, printing continues until Stop ( ) is pressed to cancel the test.

If a source is selected that contains envelopes, an envelope test pattern is printed. If Continuous is
selected, the test pattern is printed only on the first envelope.

Note: The Print Test Page always prints on one side of the paper, regardless of the duplex setting.

4. Press Back ( ) to return to PRINT TESTS.

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