Lexmark C540 Service Manual - Page 4

iv

Service Manual

5025-2xx, 4xx

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

Section	Page
Table of contents	3
Notices and safety information	9
Laser notice	9
Laser	9
Avis relatif à l’utilisation de laser	9
Avvertenze sui prodotti laser	10
Avisos sobre el láser	10
Declaração sobre Laser	10
Laserinformatie	10
Lasermeddelelse	10
Laserilmoitus	12
Huomautus laserlaitteesta	12
Laser-notis	12
Laser-melding	12
Avís sobre el Làser	13
Consignes de sécurité	15
Norme di sicurezza	15
Sicherheitshinweise	16
Pautas de Seguridad	16
Informações de Segurança	16
Informació de Seguretat	17
Preface	18
1. General information	19
Models	19
Options and features	19
Printer specifications	20
Memory	20
Print quality	20
Connectivity (network support)	21
Operating modes	21
Data streams	22
Dimensions	22
Clearances	23
Power and electrical specifications	24
Acoustics	25
Environment specifications	25
Media handling	26
Input and output sources	26
Duplex capability	26
Media input size specifications	27
Media input type specifications	28
Media output size and type	29
Media guidelines	30
Tools required for service	32
Acronyms	33
2. Diagnostic information	35
Start	35
POR (Power-On Reset) sequence	36
Symptom tables	37
Printer symptom table	37
Print quality symptom table	38
Error codes and messages	39
User status and customer attendance messages	39
Paper Jam messages	45
Service error messages	46
Service checks	58
122.xx-Fuser temperature incorrect	58
90x.xx error	58
925.01-Fan error service check	59
930.xx-935.xx-Printhead errors service check	59
936.xx, 937.xx-Transport motor service check	60
950.xx NVRAM Failure service check	60
Autocompensator mechanism service check	61
Bin full sensor service check	61
Dead printer service check	62
Duplex/manual feed sensor (S1) service check	63
Front door sensor or switches service check	64
Fuser exit sensor service check	65
Fuser service check	66
Input sensor (S2) service check	68
Main drive gear assembly (EP drive) service check	69
Operator panel service check	70
Print quality service check	76
Printhead service check	85
Toner meter cycle (TMC) card	86
Toner meter sensors (Y, C, M, K) on TMC card	86
Transfer roll service check	87
Tray 1 sensor service check	87
User operator panel and Administration menus	89
Printer operator panel	89
Operator panel buttons	89
Menu map	90
3. Diagnostic aids	91
Accessing service menus	91
Diagnostics Menu (Diag Menu)	92
Diagnostics Menu structure	92
Available tests	92
Registration	94
Alignment	97
Print Tests	100
Hardware Tests	101
Duplex Tests	103
Input Tray Tests	105
Base Sensor Test	106
Miscellaneous tests	106
Device Tests	107
Printer Setup	107
EP Setup	109
TPS Setup	110
Reports	111
Event Log	111
EXIT Diags	113
Configuration menu (Config Menu)	114
Available tests	114
Prt Quality Pgs	114
Color Trapping	114
Reports	115
Panel Menus	115
PPDS Emulation	115
Demo Mode	115
Factory Defaults	116
Energy Conserve	116
Auto Color Adj	117
Font Sharpening	117
Exit Config	117
Paper jams	118
Avoiding jams	118
Understanding jam numbers and locations	119
Theory of operation	123
Print engine theory	123
Paper path, transport components	132
Color theory	135
4. Repair information	139
Handling ESD-sensitive parts	139
Removal procedures	140
Front cover assembly removal	140
Left cover assembly removal	144
Operator panel bezel and name plate removal	146
Operator panel removal	147
Right cover assembly removal	148
Rear shield removal	149
Top cover assembly removal	150
Autocompensator mechanism (ACM) removal-standard tray	153
Bin full sensor removal	156
Bin full sensor flag and exit deflector removal	156
Controller board removal	157
Developer unit removal	159
Duplex sensor removal	159
Exit deflector and bin full sensor flag removal	162
Fuser assembly removal	164
Fuser drive motor assembly removal	167
Fuser exit sensor removal	168
High-voltage power supply (HVPS) assembly removal	169
Image transfer unit (ITU) removal	171
Imaging unit (IU) removal	173
Low-voltage power supply (LVPS) assembly removal	175
Lower frame removal, right and left	177
Main drive gear assembly removal	183
Pick tires removal-standard media tray	186
Printhead removal	187
Toner cartridge contacts	188
Toner density sensor (TDS) removal-left or right sensor	191
Toner meter cycle (TMC) card removal	193
Tray present sensor removal	195
USB port connector removal	197
Waste toner bottle removal	198
Wireless network antenna removal	199
Wireless network card	201
5. Connector locations	203
Locations	203
Connectors	204
Controller board diagram	204
High-voltage power supply (HVPS) diagram	212
Low-voltage power supply (LVPS) diagram	214
Toner meter cycle (TMC) card	215
Wireless network card	216
6. Preventive maintenance	217
Safety inspection guide	217
7. Parts catalog	219
How to use this parts catalog	219
Assembly 1: Covers	220
Assembly 2: Frames	222
Assembly 3: Electronics	224
Assembly 4: Cables	226
Assembly 5: Options and miscellaneous	227
Index	229

Lexmark C540 Service Manual - Page 4

Diagnostic aids, Toner meter sensors Y, C, M, K on TMC card - user manual

Page 4 highlights