Lexmark e330 Service Manual

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Lexmark E23x, E33x

Table of Contents

Safety and Notices

Start Diagnostics

Revised: 7/12/05


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Edition: July 2005

The following paragraph does not apply to any country where such provisions areinconsistent with local law: LEXMARK INTERNATIONAL, INC. PROVIDES THISPUBLICATION AS IS WITHOUT WARRANTY OF ANY KIND, EITHER EXPRESS ORIMPLIED, INCLUDING, BUT NOT LIMITED TO, THE IMPLIED WARRANTIES OFMERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. Some states do not allowdisclaimer of express or implied warranties in certain transactions; therefore, this statement maynot apply to you.

This publication could include technical inaccuracies or typographical errors. Changes areperiodically 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, 740West New Circle Road, Lexington, Kentucky 40550, U.S.A or e-mail at

[email protected]. Lexmark may use or distribute any of the informationyou supply in any way it believes appropriate without incurring any obligation to you. You canpurchase additional copies of publications related to this product by calling 1-800-553-9727. Inother countries, contact your point of purchase.

References in this publication to products, programs, or services do not imply that themanufacturer intends to make these available in all countries in which it operates. Any referenceto 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 thatdoes not infringe any existing intellectual property right may be used instead. Evaluation andverification of operation in conjunction with other products, programs, or services, except thoseexpressly designated by the manufacturer, are the users responsibility.

Lexmark, Lexmark with diamond design, and MarkVision are trademarks of LexmarkInternational, Inc., registered in the United States and/or other countries.

Optra Forms is a trademark of Lexmark International, Inc.

PCL

is a registered trademark of the Hewlett-Packard Company.PostScript is a registered trademark of Adobe Systems Incorporated.

Other trademarks are the property of their respective owners.

2004 Lexmark International, Inc.All rights reserved.


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Table of contents

Laser notices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . vii

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

Preface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xx

Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xxGeneral information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

Overview of the operator panel . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3Paper jamshow to clear. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4Tips on preventing jams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5

Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6Types of print media . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8

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

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

POST (poweron self test) . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1Overview of the operator panel . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2Understanding the operator panel lights . . . . . . . . . . . . . . . . . 2-3Common light sequences . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3Secondary errors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6

Operator panel codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8

Primary codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8Secondary error codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19

Service information with secondary and tertiary light patterns . 2-29Secondary error codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-30Tertiary service error codes 2 31


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Operator panel service check. . . . . . . . . . . . . . . . . . . . . . . . .2-59

Printhead service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-61Paper feed service checks . . . . . . . . . . . . . . . . . . . . . . . . . . .2-61Parallel port service check . . . . . . . . . . . . . . . . . . . . . . . . . . .2-65Print quality service checks . . . . . . . . . . . . . . . . . . . . . . . . . .2-66Using print quality test pages . . . . . . . . . . . . . . . . . . . . . . . . .2-66Transfer roll service check . . . . . . . . . . . . . . . . . . . . . . . . . .2-79

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

Configuration and diagnostic groups . . . . . . . . . . . . . . . . . . . . . .3-1Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1Diagnostic. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1PowerOn operations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-2

Configuration menu selections . . . . . . . . . . . . . . . . . . . . . . . . .3-6Diagnostics menu selections . . . . . . . . . . . . . . . . . . . . . . . . .3-12

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

Removals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-1Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-2

Fan removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-6Feed rollers (auto comp tires) removal. . . . . . . . . . . . . . . . . . .4-7Fuser idle gear links removal . . . . . . . . . . . . . . . . . . . . . . . . . .4-7Fuser power cable removal . . . . . . . . . . . . . . . . . . . . . . . . . . .4-8Fuser removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-8Input roller clutch and lever removal

(ACM clutch CBM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-9Input sensor #1 removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-9Input sensor #2 (manual) removal . . . . . . . . . . . . . . . . . . . . .4-10LVPS / HVPS card assembly removal . . . . . . . . . . . . . . . . . .4-10LVPS / HVPS to controller card cable removal 4-11


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

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

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

Part number index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .I-5


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Laser notices

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, andelsewhere is certified as a Class I laser product conforming to therequirements of IEC 60825-1.

Class I laser products are not considered to be hazardous. Theprinter contains internally a Class IIIb (3b) laser that is nominally a 5

milliwatt gallium arsenide laser operating in the wavelength region of770-795 nanometers. The laser system and printer are designed sothere is never any human access to laser radiation above a Class Ilevel during normal operation, user maintenance, or prescribedservice condition.

Laser

Der Drucker erfllt gem amtlicher Besttigung der USA dieAnforderungen der Bestimmung DHHS (Department of Health andHuman Services) 21 CFR Teil J fr Laserprodukte der Klasse I (1).In anderen Lndern gilt der Drucker als Laserprodukt der Klasse I,der die Anforderungen der IEC (International ElectrotechnicalCommission) 60825-1 gem amtlicher Besttigung erfllt.

L d kt d Kl I lt l hdli h I I d


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Avis relatif lutilisation de laser

Pour les Etats-Unis : cette imprimante est certifie conforme auxprovisions DHHS 21 CFR alina J concernant les produits laser deClasse I (1). Pour les autres pays : cette imprimante rpond auxnormes IEC 60825-1 relatives aux produits laser de Classe I.

Les produits laser de Classe I sont considrs comme des produitsnon dangereux. Cette imprimante est quipe dun laser de ClasseIIIb (3b) (arsniure de gallium dune puissance nominale de 5milliwatts) mettant sur des longueurs donde comprises entre 770et 795 nanomtres. Limprimante et son systme laser sont conus

pour impossible, dans des conditions normales dutilisation,dentretien par lutilisateur ou de rvision, lexposition desrayonnements laser suprieurs des rayonnements de Classe I .

Avvertenze sui prodotti laser

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

I prodotti laser di classe non sono considerati pericolosi. Lastampante contiene al suo interno un laser di classe IIIb (3b)allarseniuro di gallio della potenza di 5mW che opera sullalunghezza donda compresa tra 770 e 795 nanometri. Il sistemalaser e la stampante sono stati progettati in modo tale che le


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Avisos sobre el lser

Se certifica que, en los EE.UU., esta impresora cumple losrequisitos para los productos lser de Clase I (1) establecidos en elsubcaptulo J de la norma CFR 21 del DHHS (Departamento deSanidad y Servicios) y, en los dems pases, rene todas las

condiciones expuestas en la norma IEC 60825-1 para productoslser de Clase I (1).

Los productos lser de Clase I no se consideran peligrosos. Laimpresora contiene en su interior un lser de Clase IIIb (3b) dearseniuro de galio de funcionamiento nominal a 5 milivatios en una

longitud de onda de 770 a 795 nanmetros. El sistema lser y laimpresora estn diseados de forma que ninguna persona puedaverse afectada por ningn tipo de radiacin lser superior al nivel dela Clase I durante su uso normal, el mantenimiento realizado por elusuario o cualquier otra situacin de servicio tcnico.

Declarao sobre LaserA impressora est certificada nos E.U.A. em conformidade com osrequisitos da regulamentao DHHS 21 CFR Subcaptulo J para aClasse I (1) de produtos laser. Em outros locais, est certificadacomo um produto laser da Classe I, em conformidade com os

requisitos da norma IEC 60825-1.Os produtos laser da Classe I no so considerados perigosos.Internamente, a impressora contm um produto laser da Classe IIIb(3b), designado laser de arseneto de potssio, de 5 milliwatts


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Huomautus laserlaitteesta

Tm kirjoitin on Yhdysvalloissa luokan I (1) laserlaitteiden DHHS21 CFR Subchapter J -mrityksen mukainen ja muualla luokan Ilaserlaitteiden IEC 60825-1 -mrityksen mukainen.

Luokan I laserlaitteiden ei katsota olevan vaarallisia kyttjlle.Kirjoittimessa on sisinen luokan IIIb (3b) 5 milliwatingalliumarsenidilaser, joka toimii aaltoalueella 770 - 795 nanometri.Laserjrjestelm ja kirjoitin on suunniteltu siten, ett kyttj eialtistu luokan I mrityksi voimakkaammalle steilylle kirjoittimennormaalin toiminnan, kyttjn tekemien huoltotoimien tai muiden

huoltotoimien yhteydess.

VARO! Avattaessa ja suojalukitus ohitettaessa olet alttiinankymttmlle lasersteilylle. l katso steeseen.

VARNING! Osynlig laserstrlning nr denna del r ppnad ochsprren r urkopplad. Betrakta ej strlen.

Laser-notis

Denna skrivare r i USA certifierad att motsvara kraven i DHHS 21CFR, underparagraf J fr laserprodukter av Klass I (1). I andralnder uppfyller skrivaren kraven fr laserprodukter av Klass I enligtkraven i IEC 60825-1.


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Laser-melding

Skriveren er godkjent i USA etter kravene i DHHS 21 CFR,underkapittel J, for klasse I (1) laserprodukter, og er i andre landgodkjent som et Klasse I-laserprodukt i samsvar med kravene i IEC60825-1.

Klasse I-laserprodukter er ikke betrakte som farlige. Skrivereninneholder internt en klasse IIIb (3b)-laser, som bestr av engallium-arsenlaserenhet som avgir strling i blgelengdeomrdet770-795 nanometer. Lasersystemet og skriveren er utformet slik atpersoner aldri utsettes for laserstrling ut over klasse I-niv under

vanlig bruk, vedlikehold som utfres av brukeren, eller foreskrevneserviceoperasjoner.

Avs sobre el Lser

Segons ha estat certificat als Estats Units, aquesta impressoracompleix els requisits de DHHS 21 CFR, apartat J, pels producteslser de classe I (1), i segons ha estat certificat en altres llocs, s unproducte lser de classe I que compleix els requisits dIEC 60825-1.

Els productes lser de classe I no es consideren perillosos. Aquesta

impressora cont un lser de classe IIIb (3b) darsenir de gal.li,nominalment de 5 mil.liwats, i funciona a la regi de longitud donade 770-795 nanmetres. El sistema lser i la impressora han sigutconcebuts de manera que mai hi hagi exposici a la radiaci lserper sobre dun nivell de classe I durant una operaci normal durant


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Japanese Laser Notice

Chinese Laser Notice


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Korean Laser Notice


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Safety information

The safety of this product is based on testing and approvals ofthe original design and specific components. The manufactureris not responsible for safety in the event of use of unauthorizedreplacement parts.

The maintenance information for this product has beenprepared for use by a professional service person and is notintended to be used by others.

There may be an increased risk of electric shock and personalinjury during disassembly and servicing of this product.

Professional service personnel should understand this and takenecessary precautions.

CAUTION: When you see this symbol, there is adanger from hazardous voltage in the area of theproduct where you are working. Unplug the productbefore you begin, or use caution if the product must

receive power in order to perform the task.

Consignes de scurit

La scurit de ce produit repose sur des tests et desagrations portant sur sa conception d'origine et sur descomposants particuliers. Le fabricant n'assume aucuneresponsabilit concernant la scurit en cas d'utilisation depices de rechange non agres.


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Norme di sicurezza

La sicurezza del prodotto si basa sui test e sull'approvazionedel progetto originale e dei componenti specifici. Il produttorenon responsabile per la sicurezza in caso di sostituzione nonautorizzata delle parti.

Le informazioni riguardanti la manutenzione di questo prodottosono 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 pielevato. Il personale di assistenza autorizzato deve, quindi,adottare le precauzioni necessarie.

ATTENZIONE: Questo simbolo indica la presenzadi tensione pericolosa nell'area del prodotto.Scollegare il prodotto prima di iniziare o usarecautela se il prodotto deve essere alimentato pereseguire l'intervento.

Sicherheitshinweise

Die Sicherheit dieses Produkts basiert auf Tests undZulassungen des ursprnglichen Modells und bestimmter

Bauteile. Bei Verwendung nicht genehmigter Ersatzteile wirdvom Hersteller keine Verantwortung oder Haftung fr dieSicherheit bernommen.

Die Wartungsinformationen fr dieses Produkt sindausschlielich fr die Verwendung durch einen


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Pautas de Seguridad

La seguridad de este producto se basa en pruebas yaprobaciones del diseo original y componentes especficos.El fabricante no es responsable de la seguridad en caso de usode piezas de repuesto no autorizadas.

La informacin sobre el mantenimiento de este producto estdirigida exclusivamente al personal cualificado demantenimiento.

Existe mayor riesgo de descarga elctrica y de daospersonales durante el desmontaje y la reparacin de lamquina. El personal cualificado debe ser consciente de este

peligro y tomar las precauciones necesarias. PRECAUCIN: este smbolo indica que el voltaje

de la parte del equipo con la que est trabajando espeligroso. Antes de empezar, desenchufe el equipoo tenga cuidado si, para trabajar con l, debeconectarlo.

Informaes de Segurana

A segurana deste produto baseia-se em testes e aprovaes

do modelo original e de componentes especficos. O fabricanteno responsvel pela segunrana, no caso de uso de peasde substituio no autorizadas.

As informaes de segurana relativas a este produtodestinam se a profissionais destes servios e no devem ser


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Informaci de Seguretat

La seguretat d'aquest producte es basa en l'avaluaci iaprovaci del disseny original i els components especfics.El fabricant no es fa responsable de les qestions deseguretat si s'utilitzen peces de recanvi no autoritzades.

La informaci pel manteniment daquest producte estorientada exclusivament a professionals i no est destinadaa ning que no ho sigui.

El risc de xoc elctric i de danys personals pot augmentardurant el procs de desmuntatge i de servei daquest producte.El personal professional ha destar-ne assabentat i prendre

les mesures convenients. PRECAUCI: aquest smbol indica que el voltatge

de la part de l'equip amb la qual esteu treballant sperills. Abans de comenar, desendolleu l'equipo extremeu les precaucions si, per treballar ambl'equip, l'heu de connectar.


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Preface

This manual contains maintenance procedures for servicepersonnel. 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. Specialtools and test equipment are listed in this chapter, as well asgeneral environmental and safety instructions.

2. Diagnostic information contains an error indicator table,symptom tables, and service checks used to isolate failing fieldreplaceable units (FRUs (field replaceable unit)).

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

4. Repair information provides instructions for making printeradjustments and removing and installing field replaceable units(FRUs).

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

6. Preventive maintenance contains the lubrication specificationsand recommendations to prevent problems.

7. Parts catalog contains illustrations and part numbers forindividual FRUs.

Definitions


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1. General information

The Lexmark E23x, E33x printers are monochrome laser printersdesigned for single users or small workgroups. There are fourmodels:

E230, 8MB memory standard, a USB (universal serial bus) port,a parallel port, and prints 18 pages per minute.Note: The optional 550-sheet tray is not supported.

E232, 16MB of memory standard, a parallel port, a USB port,and prints 22 pages per minute.


E332n, 32MB of memory standard, an integrated Ethernetadapter, a parallel port, a USB port, and prints 27 pages perminute.


E234n, 32MB of memory standard, an integrated Ethernetadapter, a parallel port, a USB port, and prints 27 pages perminute.


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The differences between the models are listed in the following table.

Item4505-100Lexmark

E230

4505-200Lexmark

E232

4505-300Lexmark E330

4505-310Lexmark

E332n

Base memory 8MB 16MB 32MB

Maximummemory 8MB 80MB 160MB

Paper inputs 250sheettray

Singlesheetmanual

feeder

250sheet tray Singlesheet manual feeder Optional 550sheet drawer

Emulations HBP (hostbasedprinting), PCL(printer controllanguage) 5e,and Windows/Macintosh/Linuxcompatibility

HBP, PCL 6,and Windows/Macintosh/Linuxcompatibility

HBP, PostScript 3, PCL 6, PPDS(personal printer data stream)and Windows/Macintosh/Linuxcompatibility

Connectivity USB and Parallel USB, Parallel,and 10/100Base-TXEthernet

Toner cartridgeyield 1,500 pages*(starter toner cartridge) 2,500 pages

Photoconductorkit yield

30,000 pages*


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Overview of the operator panel

The operator panel has six lights and two buttons. SeeOperator panel codes on page 2-8 for more information.

Continue

Cancel

Ready

Toner Low /Replace PC Kit

Load Paper

Paper Jam


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Paper jamshow to clear

When a paper jam occurs, the printer stops operating and the

operator panels and lights come on. Press and release

twice quickly to display the specific secondary error paper

jam light sequence. See Secondary errors on page 2-6 formore information.

We recommend the entire paper path be cleared when a paperjam occurs.

To clear a paper jam:

1. If the paper is feeding from a tray, remove the tray, andthen remove any jams.

2. Open the front cover and remove the print cartridgeassembly.

3. Remove any jams located in the area behind the printcartridge assembly.

4. Lift the flap at the front of the printer and remove any jamslocated beneath the flap.

5. Open the rear exit and remove any jams.6. After you have cleared the jams, reinstall the print cartridge

assembly, make sure all printer covers and trays are closed, andthen press the button to resume printing.


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Tips on preventing jams

You can avoid most paper jams by correctly loading paper andspecialty media.

The following hints can help you avoid paper jams:

Do not load wrinkled, creased, or damp paper. Never mix media types within a tray. Flex, fan, and straighten paper before you load it. Do not exceed the maximum stack height.

Push all trays firmlyinto the printer after loading them. Make sure the guides in the trays are positioned snugly againstthe paper or specialty media.

Do not remove paper trays while a job is printing. Wait for aLoad Paper light sequence before you remove the tray.

Before loading transparencies, fan the stack to prevent sheetsfrom sticking together. Do not use envelopes that:

Have excessive curl Are stuck together

Are damaged in any way Contain windows, holes, perforations, cutouts, or embossing Use metal clasps, string ties, or metal folding bars Have postage stamps attached


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Tools

The removal and adjustment procedures require the following toolsand equipment:

Magnetic tip Phillips screwdrivers, large and small Volt ohmmeter


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Types of print media

Ensure trays are properly loaded. Never mix media typeswithin a tray.

Source Sizes Types WeightCapacity

(sheets)

Tray 1

(250-sheettray)

A4, A5,JIS B5,letter, legal,executive,folio,

statement,Universal

Plain paper,transparencies,labels

6090 g/m2

(1624 lb) 250 paper labels 50 trans-

parencies

Tray 2

(550-sheettray)

A4, A5,JIS B5,letter, legal,executive,

folio,statement,Universal

Plain paper,transparencies,labels

60163 g/m2

(1643 lb) 550 paper labels 50

transpar-encies

card stock

Manualfeeder

A4, A5,JIS B5,letter, legal,

executive,folio,statement,Universal

Plain paper,transparencies,labels, card

stock

60163 g/m2

(1643 lb)1


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Abbreviations

ACM Auto Comp Mechanism (or paper feed)ASIC Application Specific Integrated CircuitCBM Complete Bill Of MaterialDIMM Dual In-Line Memory Module

ENA External Network AdapterFRU Field Replaceable UnitHBP Host Based PrintingHV High VoltageHVPS High Voltage Power SupplyINTL InternationalLVPS Low Voltage Power SupplyNVRAM Nonvolatile Random Access MemoryPCL Printer Control LanguagePOR Power-On ResetPOST Power-On Self Test

PPDS Personal Printer Data StreamPRC Peoples' Republic of ChinaPSO Participating Standards OrganizationRIP Raster Image ProcessorSDR Synchronous Dynamic RAM

USB Universal Serial BusV ac Volts alternating currentV dc Volts direct current


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2. Diagnostic information

Start

POST (poweron self test)

When you turn the printer on, it performs a POST. Check for correctPOST functioning of the base printer by observing the followingprocess:

1. All operator panel lights flash irregularly for approximately

10 seconds.2. If there is a problem in the printer such as a paper jam, the

panel lights indicate the problem. See Common lightsequences on page 2-3 for more information.

3. Otherwise, the light flashes until the fuser comes up to

temperature (520 additional seconds depending on the initialtemperature of the fuser).

Note: The operator panel has six lights and two buttons. Thebutton has a light in it.

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Overview of the operator panel

Continue

Cancel

Ready

Toner Low /

Replace PC Kit

Load Paper

Paper Jam

Error

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Understanding the operator panel lights

The operator panel lights mean different things, depending on theirsequence. Lights that are off, on, and/or blinking indicate printerconditions such as printer status, intervention, or service.

The following tables show the most common light sequences.

Note: See Primary codes on page 2-8 for more information.

Common light sequences

See Overview of the operator panel on page 2-2 for iconinformation.

Light on

Light is off

Light blinking

x Light blinking slow

Printer condition

Ready / PowerSaver

Busy

4505


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4505

Load manualfeeder

Print side two ofduplex job

Toner low

Replacephotoconductorkit

Replacephotoconductorkit (printer hardstop)

Missing ordefective toner

cartridge Unsupported

toner cartridge

Change cartridge,invalid refill

Invalid enginecode /Invalid networkcode

Printer condition

4505


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4505

Service error (seeServiceinformation withsecondary andtertiary light

patterns onpage 2-29 formore information).

Printer error (seeSecondaryerror codes on

page 2-19 formore information).

Printer condition

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4505

Secondary errors

When the and lights are both on, a secondary error hasoccurred. Press and release twice quickly to display thesecondary error code light sequence. The following table showswhat these light sequences mean.

Printercondition

Printer error /Secondaryerror code

Paper jams inthe manualfeeder

Paper jams asit exits the trayinto the printer

Paper jams asa printed jobexits the printer

Complex page

Insufficientprinter memory

Insufficientcollation area

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4505

Short paper

Unformattedflash

Flash full

Invalid enginecode

Invalid networkcode

Paper jam secondary codes

200 Paper jaminput sensor

201 Paper jam

between inputand exitsensors

202 Paper jamexit sensor

241 Paper jamTray 1 jam

242 Paper JamTray 2 jam

Printer

condition

4505


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4505

Operator panel codes

The following tables explain the primary light sequences, or codes,and secondary error codes, what they mean and how to clear them.

Primary codes

Ready / Power Saver

Light sequence Meaning Action:

Printer ready to receiveand process data.

Printer is in PowerSaver mode.

Send a print job. Press to print the

menu settings pagesfor a list of currentprinter settings.

Press and hold toreset the printer.

Note: To change the

Power Saver setting, usethe Local Printer SetupUtility. See UsersReferencefor moreinformation.

4505


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Busy


Printer is busyreceiving andprocessing data orprinting.

Printer isdefragmenting the flashmemory to reclaimstorage spaceoccupied by deletedresources.

Printer is formatting theflash memory. Printer is storing

resources, such asfonts or macros, inflash memory.

Printer is printing a

directory, font list,menu settings pages,or Print Quality TestPages.

Busy: Wait for message to

clear. Press and release

to cancel printjob. Press and hold to

reset printer. Defragmenting flash,

formatting flash, orprogramming flash: Wait for message to

clear. Warning: Do not turn

the printer off whilethis message isdisplayed.

Printing a directory, afont list, menu settings

pages, or Print QualityTest Pages: Wait for the pages to

print. TheBusymessage is displayedas the pages print.The light is onwhen printing stops.

Press and releaseto cancelprinting.

Press and hold toreset printer.

Receiving/processing

4505


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Hex Trace Ready

Waiting


Printer is in the Readymode and Hex Trace isactive.

Hex Trace helpstroubleshoot printingproblems. Afterresolving the problem,

turn off the printer toexit Hex Trace.

Or, press and holdto reset the printer.


Printer is waiting until aprint timeout occurs, oruntil it receives additionaldata.

Press and releaseto print contents of theprint buffer.

Press and release

to cancel the print job. Press and hold to

reset the printer.

4505


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Flushing / Resolution reduced

Not ready


Printer is flushingcorrupted print data.

Printer is processingdata or printing pages,but the resolution of apage in the currentprint job is reducedfrom 600 dots per inch(dpi) to 300 dpi toprevent a memory fullerror.

Wait until isdisplayed to print otherjobs.

Press and releaseto cancel print job.

Press and hold toreset printer.


Printer is not ready toreceive or process data,or the printer ports are

offline.

Press to return toor Busy state.

Press and release

to cancel print job. Press and hold to

reset printer.

4505


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Close door / Insert cartridge

Load media


The printer door is open. Close the door.


The printer is out ofmedia, or the media didnot feed properly.

Load media into tray 1or the optional550-sheet tray and

press to resumeprinting. Check that the media is

loaded correctly intray 1 or the optional

4505


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Load manual feeder

Print side two of duplex job


Printer prompts to load asingle sheet of media inthe manual feeder.

Load media, with theside to be printedfacing the front of theprinter, into the manual

feeder. Press to resume

printing. Press and hold to

reset printer.


Print the other side ofduplex print job.

Reinsert print job intray 1 using theinstructions in thedriver pop-up menu to

orient the pagescorrectly.

Press to resumeprinting.

4505


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Toner low

Replace photoconductor kit


Printer is ready toreceive and processdata.

The toner in the tonercartridge is getting low.

Send a print job. Press to print the

menu settings page fora list of currentsettings.

Remove the tonercartridge and shake itto extend the life of thecartridge.

Replace the toner

cartridge. Press and hold toreset printer.

Note: The lightmay not come on if thestarter toner cartridge isinstalled in a base printer

model.


The photoconductor kitsdrum is full and needsreplacing.

Press to resumeprinting.

Replace thephotoconductor kit

4505


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Replace photoconductor kit (printer hard stop)

Toner cartridge error / Toner cartridge is not installed


The photoconductor kitsdrum is full and needsreplacing. No pages printuntil the photoconductor

kit is replaced.

Replace thephotoconductor kit.


The toner cartridge is notinstalled, or the printerdetects a toner cartridge

error.

If the toner cartridge isnot installed, install it.

If the toner cartridge is

installed, remove it andinstall a new tonercartridge.

4505


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Change invalid toner cartridge

Invalid engine code / Invalid network code


The toner cartridge beingused is not designed forthis printer.

Install a toner cartridgecompatible to printer.


The code in an internalprint server has not beenprogrammed, or the

programmed code is notvalid.

Download validnetwork code to theinternal print server.

Press twicequickly to see thesecondary error code.

4505


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Programming engine code / Programming system code

Cancel job / Reset printer


New code is beingprogrammed into theengine or firmware codeflash.

Wait for the message toclear. When the printerhas finished programmingthe code, it performs a

soft reset.


The current print job iscanceled.

The printer is resettingto the user defaultsettings. Any active print jobs

are canceled. A user default setting

Wait for the message toclear.

4505


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Service error

Printer error


The printer has a serviceerror and printing hasstopped.

Turn the printer off andback on.

If the lights are stillblinking, contact the placewhere printer waspurchased.


The printer has one of thefollowing errors:

Memory is full,

insufficient to savewhat is in the buffer, orinsufficient todefragment flashmemory

Press twicequickly to see thesecondary error code.

See Secondary errorcodes on page 2-19for more information.

Press to clear thesecondary message.

4505


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Secondary error codes

When the and lights are both on, a secondary error hasoccurred. Press and release twice quickly to display thesecondary error code light sequence.

When the and lights are both on, a paper jamsecondary error has occurred.

Press and release twice to display the secondary error codelight sequence.

The following tables show what these light sequences mean andwhat to do.

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Paper jam in the manual feeder

Paper jams as it exits the tray into the printer


A paper jam has occurredin the manual feeder.

Clear the paper jam.


A paper jam has occurredas the paper is exiting thepaper tray and enteringthe printer.


4505


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Paper jams as a printed job exits the printer

Complex page


A paper jam has occurredas the paper is exiting theprinter.



The page may not printcorrectly because theprint information on thepage is too complex (that

is, too large for theprinters memory).

Press to clear themessage and continueprocessing the print job(some of the print data

may be lost). To avoid this error in

the future: Reduce the

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Insufficient printer memory

Insufficient collation area


The printer does not haveenough memory to savethe data in the buffer.

Install additionalmemory.

Press to continueprinting the job.

Press to cancelthe print job.


The printer memory doesnot have the free spacenecessary to collate theprint job. This may

happen due to one ofthese errors:

Memory is full. A page is too complex

Press to clear themessage and continueprinting the job (the jobmay not print correctly.)

Press and releaseto cancel the print job.


4505


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Font error

Defective flash


The printer has receiveda request for a PPDS fontwhich is not installed.



Press and releaseto clear the messageand continue printing.


The printer detectsdefective flash memory.

Press to clear themessage and continueprinting. Downloaded fonts

and macros notpreviously stored inflash memory aredeleted.

4505


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Insufficient defrag memory

Network interface errors


The printer hasinsufficient memory tofree unused space inflash memory.

Delete fonts, macros,and other data in RAM.

Install additional printermemory.


The printer cannotestablish communicationwith the network.

Press to clear themessage and continueprinting (the job may notprint correctly).

4505


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Error communicating with host computer

Memory full


The printer has lost theconnection to an externalprint server (also calledan external network

adapter or externalnetwork adapter (ENA)).

This light sequence isdisplayed if your printer isconnected to the network,but it cannot detect theprint server when you turnon the printer.

Make sure the cableconnecting the ENAand the printer issecurely attached.

Turn the printer off andthen on to reset theprinter.



The printer is processingdata, but the memoryused to store pages is full.

Press to clear themessage and continueprinting the job (the jobmay not print correctly).



4505

S


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Short paper

Flash full


The paper length is tooshort to print theformatted data. Thisoccurs when the printer

does not know the mediasize loaded in the tray, orthere is a problem feedingthe media.

Make sure the printmedia you loaded islarge enough.

Open the front cover,

clear the paper pathand close the cover toresume printing.

Press to clear themessage and continueprinting the job.

Press to cancelthe print job.


There is not enough freespace in the flashmemory to store the datayou are trying to

download.

Delete fonts, macros,and other data storedon the flash memory tofree up space.

Press to clear themessage and continueprinting. Downloaded fonts

4505

U f tt d fl h


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Unformatted flash

Invalid engine code


The printer detectsunformatted flashmemory.

Press to clear themessage and continueprinting. The job maynot print correctly.

Reformat the flashmemory. Refer to theTechnical ReferenceonLexmarks Web site formore information.

If the error messageremains, the flashmemory may bedefective and shouldbe replaced.


The code in an internalprint server has not beenprogrammed, or theprogrammed code is not

valid.

Download valid enginecode to the internal printserver.

4505

Invalid network code


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Invalid network code


The code in an internalprint server has not beenprogrammed, or theprogrammed code is not

valid.

Download valid networkcode to the internal printserver.

4505


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Service information with secondary and tertiary

light patternsAll service errors are indicated by all lights flashing as the primarynotification or code. The secondary code indicates an area orfunction which has the error. Tertiary codes (shown on the followingpages) indicate specific device errors. Double click to see the

secondary code. Double click again to see the tertiary code.

DoubleClick

DoubleClick

DoubleClick

Double Click

PrimaryCodes

SecondaryCodes

TertiaryCodes

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Secondary codes

Lights Primarycode

90x

91x

92x

93x

94x

95x

96x

97x

98x

99x

Continue

Ready

Toner Low

/

Replace

PC Kit

Load

Paper

Paper Jam

E

4505

Tertiary service error codes


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Tertiary service error codes

Service error codes are generally non-recoverable except in anintermittent condition when you can POR (power-on reset) theprinter to temporarily recover from the error.

Note: All service errors are initially communicated by all lightsflashing which is the primary indication or code. For brevity, this

indication is not repeated in the following codes.

1. Controller software error/illegal trap (90x)

Call the next level of support for a 900 error.

For the other errors, which indicate a faulty programming

process or faulty component on the controller card, replace thecontroller card.

4505

Controller software


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Controller software

Tertiary codes

Lights900

901

902

903

904

905

906

Continue

Ready

Toner Low /

Replace PC

Kit

Load Paper

Paper Jam

Error

RIPS d d

4505

Transfer roll


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Transfer roll

CAUTION: When you see this symbol, there is adanger from hazardous voltage in the area of theproduct where you are working. Unplug the productbefore you begin, or use caution if the product mustreceive power in order to perform the task.

Code 917 indicates a problem in the transfer roll circuit. Check thecontinuity from the cable connection on the HVPS (high voltagepower supply) to the right side of the transfer roll.

Tertiary code

Lights917

Continue

Ready

Toner Low /

Replace PCKit

4505

Fuser, fan, or toner sensor error


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, ,

Codes 920 through 929 indicate a problem in the fuser (see Fuserservice check on page 2-53 for more information), a stalled fan motoror a faulty toner sensor or toner cartridge.

Tertiary codes

Lights920

921

922

923

924

925

926

927

928

929

Continue

Ready

Toner Low /

Replace PCKit

Load Paper

Paper Jam

4505

Printhead, transport motor or RIP/engine communication error


63/161

, p g

Codes 930 through 935 indicate a problem with the printhead.Check cables to the printhead. Replace the printhead as necessary.

Codes 936 and 937 indicate a problem in the drive system.

4505

Code 939 indicates a communication failure between the RIP and


64/161

engine processors.

Tertiary codes

Code930

931

932

933

934

935

936

937

939

Continue

Ready

Toner Low /

Replace PC

Kit

Load Paper

Paper Jam

Error

4505

RIP to engine communication failure (controller card).


65/161

This indicates fuser control in the LVPS has failed or the wrong LVPShas been installed.

Tertiary

codes

Code 940

Continue

Ready

Toner Low /

Replace PC

Kit

Load Paper

Paper Jam

4505

NVRAM failure


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Error codes 950954 indicate a problem in the NVRAM (nonvolatilerandom access memory). Replace the operator panel assembly.Codes 955959 indicate a failed controller card assembly. Replacethe controller card.

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Tertiary codes

Code950

951

952

954

955

956

957

958

959

Continue

Ready

Toner Low /

Replace PC

Kit

Load Paper

Paper Jam

Error

S d d SRAM

4505

Note: NVRAM is on the operator panel printed circuit board (PCB)hil NVRAM i th t ll PCB Ch k m gi


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while secure NVRAM is on the controller PCB. Check margin

alignments after replacing the operator panel assembly. SeePrinthead service check on page 2-61 for more information. Ifmargin errors are unacceptable, corrections can only be madethrough software. Contact the next level of support or Lexmark at1-800-539-6275.

4505

RAM memory error


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This error indicates RAM failure. Remove DIMM(s) and POR theprinter. If the error persists, replace the card. If the error subsides,check each DIMM independently. Replace faulty DIMM.

Tertiary codes

Code960

961

962

963

Continue

Ready

Toner Low /

Replace PCKit

Load Paper

Paper Jam

4505

Network error


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Indicates an error in the network circuitry. Replace the controllercard assembly.

Tertiary codes

Code970

971

972

973

974

975

976

978

979

Continue

Ready

Toner Low /

Replace PC

Kit

Load Paper

Paper Jam

4505

Paper port communication failure


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Indicates an error communicating with Tray 2, if installed. RemoveTray 2 and recheck. If the error does not recur, replace Tray 2. If theerror recurs, replace the controller card assembly

Tertiary codes

Code980

981

982

983

984

Continue

Ready

Toner Low /

Replace PC

Kit

Load Paper

Paper Jam

4505

Symptom tables


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POST symptom table

Symptom Action

The main motor, cooling fan,

and fuser do not come on.

See Cover interlock switch service

check on page 2-51.

POST completes except one ormore lights do not come on.

See Operator panel service checkon page 2-59.

None of the lights come on. See Operator panel service checkon page 2-59.

Main motor does not come on. See Main motor service check onpage 2-58.

Fan does not come on. See Cooling fan service check onpage 2-48.

Fuser lamp does not come on. See Cold fuser service check onpage 2-47.

Fuser lamp never turns off. See Hot fuser service check onpage 2-56.

The paper feed picks and triesto feed paper.

See Paper feed service checks onpage 2-61.

4505

Printer symptom table


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Symptom Action

Dead machine (no power) See Dead machine service checkon page 2-52.

Fan noisy or not working See Cooling fan service check on

page 2-48.Fuser parts melted See Hot fuser service check on

page 2-56.

Fuser lamp doesnt light See Cold fuser service check onpage 2-47.

Toner not fused to the paper SeeCold fuser service check onpage 2-47.

Paper jams See Paper feed service checks onpage 2-61.

Main motor noisy or not moving See Main motor service check on

page 2-58.

Paper skew See Paper feed service checks onpage 2-61.

Printer not communicating withhost

See Parallel port service check onpage 2-65.

Front access cover will notclose

See Cover interlock switch servicecheck on page 2-51.

O t l b tt t S O t l i h k

4505

Symptom Action


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White or black lines or bands See White or black lines or bandson page 2-72.

Toner on back of page See Toner on back of page onpage 2-72.

Paper never picks See Paper never picks on

page 2-63.

Paper feeds continuously See Paper picks during POST and/orcontinuously on page 2-62.

Paper wrinkled or bent See Paper trees, wrinkles, stackspoorly or curls on page 2-65.

4505

Service checks


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Service checks which involve measuring voltages onthe LVPS/HVPS (low voltage power supply/high voltagepower supply board) should be performed with the printerpositioned on its back side.

Note: When you make voltage readings, always use frame groundunless another ground is specified. See Wiring diagram onpage 5-4 for more information.

Cold fuser service check

Make sure the correct voltage lamp is installed. The voltage rating isstamped on one of the lamp contacts.

FRU Action

Fuser AC cablesLVPS/HVPS

Fuser

If the fuser lamp comes on and a

fuser failure light error code displays,be sure the thermistor is contactingthe hot roll and the thermistor cableis firmly seated in connector J15 onthe controller card.

Check for excessive toner buildup on

the surface of the thermistor. Cleanas necessary.

With the printer unplugged,disconnect the thermistor cable from

4505

Cooling fan service check


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FRU Action

Cooling fan Make sure the fan cable plug isproperly seated at J19 (controllercard).

Turn the printer off and disconnect

the cooling fan cable from thecontroller card.

Turn the printer on. Within a fewseconds the controller cardassembly should apply between+24 V dc to pin 2. See Controller

board on page 5-3 for moreinformation.

If voltage is present and the fan isnot turning, replace the coolingfan. If the fan still doesnt function,replace the controller card.

Note: The fan speed is controlled bya module on the PCB.Between +8 V and +24 V dcare constantly supplied atpin 2 (J19). Pin 1 is groundwhile pin 3 receives feedbackfrom the fan motor.

If voltage is not present, seeController board on page 5-3for more information.

4505

Controller card service check


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FRU Action

Controller card assembly Verify +24 V dc input from theLVPS/HVPS.

Turn the printer off. Disconnect the LVPS/HVPS

cable from the controller card atJ7. See Controller board onpage 5-3 for more information.

Turn the printer on.

Verify +24 V dc from the cableconnector of J9, pin 8.

Verify that pin 7 on both the cableand the card connectors is ground.

If voltage is correct, check thecontinuity in the cable. If thecable is good, see theController board on

page 5-3 for more information. If grounds are not correct on thecable, first check it for continuityand then the LVPS/HVPS.

If the grounds are not correct onthe controller card, replace thecontroller card. (Check with one

probe on the connector pin andthe other on the cards groundplane found at each screwhead.)

4505

Controller card service check (continued)


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FRU Action

Controller card assembly Note: With all cables connected, theprinter should completePOST within approximately1215 seconds in thefollowing sequence:

1. All operator panel lights on solidmomentarily.

2. Lights then flash on and offsequentially.

After lights quit flashing, thelight turns on solid.

3. The cooling fan comes on.4. The fuser lamp comes on.5. The drive motor runs.6. The printhead motor runs.7. The printer cycles down into

standby mode/ready.

If immediately following poweronthe operator panel lights are activebut the printer does not go throughsteps 1 and 2 above, replace thecontroller card assembly.

Note: Settings for U.S. versusnonU.S. and the printerconfiguration ID can bechanged. SeeConfiguration and

4505

Cover interlock switch service check


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Note: Make sure a print cartridge assembly is installed and thecover closes all the way, engaging the cover open switchlever.

FRU Action

Cover interlock switch Disconnect the cover interlock cablefrom the controller card at J13.

Verify continuity between cablepin 1 and pin 2 with the door closedbut not open.

Verify continuity between cablepin 1 and pin 3 with the door openbut not closed.

If either fail continuity, replace thecover interlock switch.

If both pass continuity, turn theprinter on and verify +5 V dc on

pin 2 at J6 on the controller card. Verify pins 1 and 3 are ground. If voltage or ground is not present,

see Controller card servicecheck on page 2-49 for moreinformation.

Verify discontinuity between pins 2and 3 whether the door is open orclosed.

Replace the cover interlock switch if

4505

Dead machine service check


80/161

CAUTION: Check the AC line voltage. The voltage should bewithin the following limits:

100 V ac (volts alternating current) 127 V ac for the 110 Vprinter

200 V ac 240 V ac for the 220 V printer

FRU Action

LVPS/HVPS

Unplug the printer and check thefuses on the LVPS/HVPS board for

continuity. If open, replace the LVPS/HVPS

board. If fuse opens again, see LVPS/

HVPS service check onpage 2-57 for more information

If not open, unplug the cables atCN102 and CN201 (fuser andcontroller card respectively).

Plug LVPS/HVPS board to sourceand turn switch on.

Verify 24 V dc on pin 8 at connector

CN201.Verify line voltage (110 or 220 V ac)across pins 1 and 2 of CN102.

4505

Fuser service check


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When toner is partially fused to the paper, it is usually caused by lowfuser temperature.

Warning: Avoid handling the lamp as much as possible as it iseasily broken. Be careful not to touch the glass housingwith bare hands because skin acids can weaken theglass. The lamp is not a service part.

The line voltage to the printer must be within the following limits:

100 V ac127 V ac for the 110 V model printer 200 V ac240 V ac for the 220 V model printer

Turn the printer off and wait a few minutes for the fuser lamp to cool.Turn the printer on and observe the lamp turning on during POST.

You can see the light from the lamp by opening the leftside cover and observing the upper opening throughwhich the fuser power cables pass.

4505

Fuser service check (continued)


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FRU Action

Lamp cableLVPS/HVPSFuser

Unplug the printer and disconnectthe fuser lamp cable plug from theLVPS/HVPS board connectorCN102.

Check for continuity across the fuserlamp by checking across theconnector pins.

If there is continuity, go to Step 1:Continuity.

If there is no continuity, go to

Step 2: No continuity.Step 1: Continuity

Turn the printer on with only thefuser power disconnected.

Measure the voltage at connectorCN2 on the LVPS/HVPS. It shouldmatch the line voltage.

If line voltage is not present, seeLVPS/HVPS service check onpage 2-57 for more information.

Make sure the fuser thermistor iscorrectly connected to the controller

board. If the problem persists,disconnect the thermistor cable atJ15 and check for less than +5 V dcon pin 1. Pin 2 should be ground.

4505

Fuser service check (continued)


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FRU Action

Fuser (continued)

Disconnect the thermistor cable fromJ15 on the controller card.

Measure the resistance across theends of the thermistor cable. See

Connector locations onpage 5-1 for more information.

Replace the fuser assembly if theresistance is lower than 1K ohm orshorted.

Note: Resistance measures

approximately 240K ohmswhen cool and 1.4K ohmshot.

4505

Hot fuser service check


84/161

Note: Ensure correct lamp is installed.

FRU Action

Fuser AC cablesLVPS/HVPSFuser

Measure the resistance of thethermistor. The resistance measures

from approximately 1K ohmsimmediately after printing or POR toapproximately 240K ohms whenthermistor reaches roomtemperature. (It may take 30 minutesto cool.)

Replace the fuser assembly asnecessary.

4505

LVPS/HVPS service check


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FRU Action

LVPS/HVPS

LVPS portion of board

Fuses that open typically indicate afaulty LVPS/HVPS.

Use the voltage meter to verify theappropriate voltage at the printerend of the power cable.

Remove the LVPS/HVPS assemblyfrom the printer.

Check continuity on the fuses.

If either fuse has opened, replacethe card.

Ensure the switch is off and plug thepower cord into the card.

Turn the switch on.

CAUTION: The card has severalpoints where AC voltage isexposed.

Carefully verify the AC voltagebetween pins 1 and 2 matches thepower cable (wall) voltage.

If voltage is incorrect, replace thecard assembly.

Verify +24 V dc from pin 8 at CN201.

4505

Main motor service check


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FRU Action

Main motor cableLVPS/HVPSController card

Warning: Do notreplacethe operator panel and

controller card at the sametime. Each card containsthe printer settings. Wheneither of these cards isnew, it obtains the settingsfrom the other card.Settings are lost when bothare new and replaced atthe same time.

Verify +24 V dc at J9, pin 8 and+5 V dc at pin 1 (controller card).

Verify ground at pins 2 and 7 for boththe card and cable.

If these voltages are correct,check the main motor cable forcontinuity. Remove rear cover to access

connector on motor. If continuity exists on each wire,

call next level of service. If continuity does not exist onone or more of the wires,replace the motor cable.

If these voltages are not correct,see the LVPS/HVPS servicecheck on page 2-57 or replace

the controller card.Note: The main motor is not aservice part.

4505

Operator panel service check


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Inspect the operator panel cable for damage. Make sure the cable isplugged in securely.

Run POST and check each light for proper operation.

Operator panel service check

FRU Action

Operator panel Buttons

Open controller card cage andlocate the operator panel connector

at J16.Check for continuity between pins 1and 2 of the cable as you press theContinue button.

Similarly, check the continuitybetween pins 1 and 6 of the cable

while pressing Cancel . If continuity is not present, replace

the operator panel.Note: Check margin alignments

after replacing the operatorpanel assembly. If marginerrors are unacceptable,corrections can only be madethrough software. Contact thenext level of support orLexmark at

4505

Operator panel service check (continued)

FRU A ti


88/161

FRU Action

Operator panelController card

Warning: Do notreplace theoperator panel andcontroller card at thesame time. Each cardcontains the printersettings. When eitherof these cards is new,it obtains the settings

from the other card.Settings are lost whenboth are new andreplaced at the sametime.

Lights

If none of the lights come on, makesure the cable is properly connectedto the controller card and the

controller card has input voltage to it.Verify +24 V dc on cable pin 8 at J7.

Check for +5 V dc at J16, pin 5See Controller card servicecheck on page 2-49or page 5-3for more information.

If these voltages are not correct,replace the controller card. If these voltages are correct,

replace the operator panel.If more than one light does not turnon or an individual light stays onsolid during POST, replace theoperator panel.

If all lights are dim and operateerratically during POST or all lightscome on and stay on solid duringPOST, replace the FRUs in thefollowing order one at a time:

Controller card Operator panel

4505

Printhead service check

FRU Action


89/161

Paper feed service checks

Paper jam error indication during POST

FRU Action

Printhead

Unplug the printer.

Disconnect the printhead cablesfrom J11 and J12 on the controllercard.

Turn the printer on.

On the controller card, verify+24 V dc on pin 5 at J11 and+5 V dc on pin 7 at J12.

Verify grounds on pin 4 at J11 andon pins 2, 6, and 8 at J12.

If voltages or grounds areincorrect, check the controllercard. See Controller cardservice check on page 2-49 formore information.

If voltages are correct, replace the

printhead (comes with cables).

FRU Action

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Paper picks during POST and/or continuously

FRU Action


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Paper picks but stops half way through the printer

FRU Action

ACM (auto comp mechanism orpaper feed) clutchManual feed clutch

Check the ACM clutch for wear. Thesolenoid interacts with the clutch tocontrol the motion of the pick tires.

If the ratchet teeth of the ACM clutch

assembly are worn or broken, thesolenoid may not stop the ACM fromrotating. Replace the ACM clutchassembly if necessary.

Check the manual feed clutch for thesame damage.

FRU Action

Input sensor #1 (under printcartridge assembly) andInput sensor #2 (manual)

Make sure the input sensors areworking properly.

Check for a broken or stuck flag onthe input sensors.

Make sure the cables are seated onthe controller card at J20 (Tray 1input) and J18 (manual input).

Check for less than +5 V dc on pin 3at J20 (Tray 1 input) and pin 1 at J18(manual input sensor).

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Paper never picks

FRU Action


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FRU Action

Paper feed (pick tires) Open the left cover and verify thesolenoid and clutch are functioningwhen an attempt is made to feed thepaper.

Make sure the rubber tires areinstalled and clean.

Replace if necessary.

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Paper occasionally picks or picks multiple sheets at once

FRU Action


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FRU Action

Tray 1Tray 2 (option)

Check tray for paper catch points.

If the sheet being fed stopsmomentarily, the ACM appliesadditional vertical force causing

additional sheets to feed.Do not mix paper types.

Paper pick tires Check the tires in the ACM assemblyfor signs of wear or damage.

Replace the tires as necessary.

ACM clutch complete bill ofmaterial (CBM)Manual feed clutch CBM

Open left cover and observe thesolenoid and clutch actions at theACM and manual feed shafts as aprint job is attempted.

Replace the faulty part.

Controller card Disconnect the solenoid cable at J5on the controller card.

Measure the resistance across cablepins 1 and 2 and then pins 3 and 4.

The resistance should be180210 ohms.

If it is not, call the next level ofservice.

If the resistance is 180210 ohms,h k th t ll d S

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Paper trees, wrinkles, stacks poorly or curls

FRU Action


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Parallel port service check

1. Perform a print test to make sure the printer prints correctly.

Verify is on, press to print menu settings.2. Be sure the printer cable is designed for bidirectional printing.

3. Be sure the user Program is set up correctly.

4. If the internal print test page prints correctly, the userProgram/printer driver is set up correctly and the correct

bidirectional parallel cable is installed, but the printer still fails toprint on command from the host computer, replace thecontroller card.

FRU Action

Fuser This problem is most likely due to aworn backup roll. It causes theprinter to run hotter than required forthe media being printed. Excessiveheat can cause paper treeing

problems, poor stacking, or curl.

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Print quality service checks

Note: Ensure cover is closed tightly. A gap in the opening may allowlight to expose the photoconductor resulting in a dirty print


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light to expose the photoconductor resulting in a dirty print.

Using print quality test pages

To help isolate print quality problems, like streaking, print test pages

using the print quality test pages setting:1. Turn the printer on with pressed and the front door open.

2. When light stays on, close cover.

3. Wait (approximately 7 seconds) until the printer drive activates.

4. Enter the configuration menu. See Configuration anddiagnostic groups on page 3-1 for more information.

5. Slowly press and release three times until the andlights come on.

6. Press and hold until all the lights flash to initiate print quality

test pages.Three pages print to help you evaluate print quality. The firstpage has various fonts, the second page is gray, and the thirdpage is black. Once the paper exits into the output bin, theprinter returns to the homestate (four top lights on).

7. Use the test pages to isolate problems such as light or tonerstreaks. See Symptom tables on page 2-44 for solutions tothese problems.

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Blank page

FRU Action


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Toner cartridge (not a FRU) Remove the toner cartridge andgently shake it to evenly distributethe toner.

Check for cartridge damage.

Printhead

LVPS/HVPSController cardToner electrodes (cableassembly)

Blank pages can be caused by adefective printhead assembly,LVPS/HVPS, or controller card.

Printhead errors typically result inprinter service errors.

Blank pages typically are causedby the PC roll not being properlycharged. Try a different PC kit.

Unplug the printer and checkcontinuity between the LVPS/HVPSconnection pads marked OPC andthe corresponding pin inside the

printer. If there is not continuity, call the

next level of service.Try a different toner cartridge andPC kit.

If those fail, replace the

LVPS/HVPS.

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Black page

Note: Incorrect laser exposure or incorrect charging of thephotoconductor causes an all black page. Always verify the


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photoconductor causes an all black page. Always verify thesame results from a different print cartridge assembly anddeveloper before proceeding.

FRU Action

Toner electrodes (not a FRU) Check the electrodes below the printcartridge assembly forcontamination or damage. Correctas necessary.

Check continuity between the cableconnections on the contact tipsbelow the print cartridge assembly.

If continuity fails, call the next levelof service.

LVPS/HVPS boardController card

With the printer off, disconnect theLVPS/HVPS cable from J7 on the

controller card.Turn the printer on and verify+24 V dc on pin 8 of the cable.

Verify ground on pin 7.

If the voltage is incorrect, replaceLVPS/HVPS board.

If voltage is correct and the tonerelectrodes are good, replace thecontroller card.

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Heavy background

Poor development or poorly charged toner particles cause excessivebackground. This is more noticeable as the toner cartridge nears


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bac g ou d s s o e ot ceab e as t e to e ca t dge ea sendoflife.

FRU Action

Toner cartridge (not a FRU)PC Kit (not a FRU) Make sure the toner cartridge andPC Kit are correctly installed and thehigh voltage contacts are clean.

If the toner cartridge and PC Kit areinstalled correctly, try a new PC Kitfirst and then toner cartridge.

LVPS/HVPS

Controller card

Check the contacts for correctinstallation and contamination wherecontact is made between the printcartridge assembly, and LVPS/HVPSboard. Clean as necessary.

If this does not correct the problem,

replace the following FRUs one at atime in the order shown:

LVPS/HVPS board Controller card

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Partial blank image/white spots (no periodic pattern)

FRU Action


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Variation in image density horizontally across page

Toner cartridge (not a FRU) Remove the toner cartridgeassembly and gently shake theassembly to evenly distribute thetoner.

If toner cartridge is low, try a newone.

Paper (not a FRU) Make sure recommended paper isbeing used.

FRU Action

PC Kit (not a FRU) The charge roll may have anunbalanced pressure against the

Photoconductor (PC) drum.Try a new PC Kit.

Transfer roll Check the springs in the left andright transfer roll bearings. Thebearing assemblies should supportthe transfer roll, applying even

pressure to the PC drum.Replace the transfer roll assembly ifthe springs or bearing show signs of

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Poor fusing of image

FRU Action


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Light print

Fuser The fuser may not be operating atthe proper temperature to fuse thetoner to the paper. SeeHot fuserservice check on page 2-56 formore information.

Paper (not a FRU) Make sure recommended paper isbeing used.

FRU Action

Toner cartridge (not a FRU) Make sure the toner cartridge andPC Kit are installed correctly andthat the toner cartridge is not low ontoner.

If the problem continues, install anew toner cartridge.

Recheck condition before replacingPC Kit, if necessary.

Check the transfer roll for signs of

toner buildup and contamination.Inspect the HVPS contact (transferroll) for contamination.

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White or black lines or bands

FRU Action


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Toner on back of page

Print cartridge assembly (not aFRU)

Developer drive couplingassembly

Banding appears as light or darkhorizontal lines on a uniformly graypage or on a page with a large areaof graphics. Banding is primarily dueto a variation in the speed of the

paper as it feeds through the printerespecially in the developer andtransfer process.

Inspect the toner cartridge andpaper feed components, especiallythe drive coupler and drive gears for

debris, binds or damage.

FRU Action

PC Kit (not a FRU) Inspect the overall paper path forsigns of spilled toner.

Gently clean the contaminated areaswith a soft cloth or compressed air.

Fuser The fuser hot roll can cause toner

deposits on the back of the paper iftoner is building up on the hot roll.This buildup may transfer to thebackup roll later transferring to the

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Solving print quality problems

Problem Action


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Light or blurred characters. Light print

The toner cartridge may be gettinglow on toner:

Remove the toner cartridge and

print cartridge assembly. Shake it from side to side to

redistribute the toner. Reinstall it and recheck for

condition. Make sure you are using

recommended print media (seemedia types and sizes in theUsers Reference.)

Use MarkVision to define thecustom type setting for mediatype, media texture, or mediaweight.

The toner cartridge or PC Kit maybe defective. Replace the PC Kitfirst and recheck.

Blurred characters

Blurred images, including

characters, are usually caused by adefective printhead. See Lightprint on page 2-71.

4505

Vertical or horizontal streaksappear on the page. Replace the toner cartridge forvertical black streaks.

Problem Action


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Wipe the glass lens clean with a softtissue for vertical white streaks.

For horizontal streaks, see Whiteor black lines or bands on

page 2-72 for more information.

Toner smears or rubs off thepage.

Replace the fuser. The toner is notbeing fused. See Cold fuserservice check on page 2-47 formore information.

Try a different kind of paper. Paperdesigned for copiers gives thebest quality fusing.

If you are printing on specialmedia, such as card stock orlabels, be sure you select thecorrect paper type in the printerdriver.

Change the media texture setting.

If the setting is not in your driver,you can download the correctLexmark setup utility from theLexmark Web site at

4505

Solid black areas ontransparencies or white streaks Choose a different fill pattern inyour software Program.

Problem Action


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on paper. Try a different type of paper. Paperdesigned for copiers gives thebest quality.

Remove the toner cartridge andgently shake it from side to side to

redistribute the toner. Replace the toner cartridge.

Faint images or repetitive spotsappear on the page.

Select a different media type orform type setting from your printerdriver.

Try a different type of paper. Paperdesigned for copiers gives thebest quality.

Replace the toner cartridge.

Pages are blank. The print cartridge may be out oftoner or defective. Replace the

cartridge. You may have a software error. Tryturning the printer off and back on.

Check the printhead. See Paperfeed service checks onpage 2-61 for more information.

4505

The printer is on, but nothingprints. Make sure the toner cartridgeassembly is installed properly.

Problem Action


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Make sure the parallel or USBcable is not damaged and is firmlyplugged into the connector on theback of the printer.

Press and release to print a

menu settings page just to savespace. If you cannot print a menu

settings page, call the next levelof support.

If you can print a menu settingspage, the problem is one of thefollowing: Computer Software program Cable (USB only) failed ASIC or

controller card. Replace card.

Note: Test by unplugging USBand replugging it with theprinter on. If the computerindicates unknown device,replace the card.

Toner Low light is on and printing

stops.

If you are using a 3000 or 6000 toner

cartridge and the Toner Low alarm isset to on, the printer stops printinguntil you replace the toner cartridge.

Download the correct Lexmark

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The media skews or buckles. Dont overfill Tray 1 or the optionalTray 2 (see media capacities inthe media types and sizes table in

Problem Action


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the media types and sizes table inthe Users Reference).

Make sure the paper guides areflush against the edges of themedia.

The paper sticks together/printerfeeds multiple sheets of paper.

Remove the paper from Tray 1 orthe optional Tray 2 and fan it.

Dont overfill Tray 1 or the optionalTray 2 (see media capacities inthe media types and sizes chart inthe Users Reference).

The paper fails to feed fromTray 1.

Remove the paper from Tray 1and fan the paper.

Make sure Tray 1 is selected fromthe printer driver.

Do not overfill the tray.

Check the condition of the rubberon the paper feed rolls. Verify clutch for ACM is not

slipping.

The paper fails to feed from theoptional Tray 2.

Make sure the optional Tray 2 isselected from the printer driver.

Make sure the tray is pushed allthe way in. Remove the paper from the

ti l T 2 d f it

4505

The printer does not print after apaper jam has been cleared. Clear all jams. Press and release or opend l th i t t

Problem Action


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and close the printer cover torestart the printer.

Make sure the print cartridgeassembly is installed properly.

Unexpected characters print orcharacters are missing.

Ensure correct printer driver isbeing used.

Press and hold until all lightscome on to reset printer to userdefault settings.

Select hex trace mode todetermine what the problem is.

Restore factory defaults. Make sure the parallel cable or

USB cable is firmly plugged in atthe back of the printer.

Jobs are not printing and the Error

light is on solid.

Make sure the print cartridge

assembly is installed properly. Make sure the printer top cover is

closed.

While in PostScript 3 emulation,the printer is flushing data(Ready/Data and Error lights are

blinking).

Ensure the correct PostScriptdriver is being used.

The printer doesnt have enough

memory to print the job. Installmore memory.

While using manual duplex the A paper jam interrupts the duplex

4505

Transfer roll service check

FRU Action

C


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Transfer roll

Check transfer roll area for debrisand clean as necessary.

Verify continuity between the springbelow the left side bearing and the

transfer roll shaft.Verify continuity in the spring and thecable connection on theLVPS/HVPS.

Inspect the roll for signs of wearor damage and replace if

necessary.

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3. Diagnostic aids

Configuration and diagnostic groups


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g g g p

Configuration

The configuration group contains a set of menus, settings, andoperations which are not used by an end user. Generally, the optionsmade available in this menu group are used to configure a printer.

Access to the configuration group is gained by way of a POR keysequence. See Accessing the configuration and diagnosticgroups on page 3-2 for more information.

Diagnostic

The diagnostic group contains menu settings and operations thatare useful in the manufacturing of the printer. It also features otheraids in diagnosing problems. See Accessing the configurationand diagnostic groups on page 3-2 for more information.

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Accessing the configuration and diagnostic groups

PowerOn operations

To access printer operations:


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1. Turn off the printer.

2. Open the front cover.

3. Press and hold the buttons in the following table for theoperation needed.

4. Turn on the printer. Hold the selected button until the lights cycleon the operator panel

Operation Poweron action

Enterconfigurationmenu mode

1. Power on with cover open andpressed.

2. Close cover once the light isdisplayed.

Enterdiagnosticsmode

1. Power on with top cover open andpressed.


Reset NVRAMand enternormal mode

1. Power on with top cover open andboth and buttons pressed.


4505

Moving around the menu

Printer settings configuration on page 3-4 and Printer

diagnostics on page 3-5, are similar to the instructions printed byfollowing steps 1-6 on page 3-2. These menu items are designated


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by the nonindented items listed along the left edge of the page.(Bottom as printed from printer.) These items are also unshaded.

Press and release to move sequentially from one menuitem to another.

Press and hold to jump to home state (top four lights on). Press and release to move through the menu settings

(indicated by and lights).

This action rotates only through the possible settings of the

selected menu item.

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Printer settings configuration


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Printer diagnostics


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Configuration menu selections

Utilities

Use the Utilities menu to troubleshoot printer problems.


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Setting Use setting to: Values

Reset FactoryDefaults

Return the printer settings to factory default values.

Sometimes resetting the printer to the original settingssolves formatting problems.

All menu items are reset to the factory default valuesexcept:

Display Language.

All settings in the Parallel menu, Network menu,LocalTalk menu, and USB menu.

All downloaded resources (fonts, macros, and symbolsets) in printer memory (RAM) are deleted.

Resources in flash memory are unaffected.

Hex Trace Help isolate printingproblems whenunexpected charactersprint or characters aremissing.

Hex Trace helpsdetermine if there is a

problem with the languageinterpreter or the cable byproviding information

b t h t th i t i

Off*

On

4505

ResetPhotoconductorCounter

Return the photoconductor counter to zero.The replace photoconductor message should becleared onlywhen the photoconductor kit has been

Setting Use setting to: Values


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Setup

Use the Setup menu to configure how the printer formats theend of a line depending on the computer system being used.

y preplaced.

* Factory default

Menu item Use setting to: Values

Demo mode Put printer into demomode where internalsheets prints with eachpress of .

To deactivate, turn theprinter off and re-enterconfiguration group. Set todeactivate.

Deactivate*

Activate

Auto CR after LF Specify whether theprinter automatically

performs a carriage returnafter a line feed controlcommand.

Off*

On

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Parallel

Use the Parallel menu to change printer settings on jobs sent

throu

Documents

Lexmark e330 Service Manual