LEXMARK E23x, E33x Service Manual

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Lexmark ™ E23x, E33x

• Table of Contents

• Start Diagnostics

• Safety and Notices

4505-100 4505-200 4505-300 4505-310 4505-400 4505-410

• Trademarks

• Index

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

Edition: June 2004

The following paragraph does not apply to any country where such provisions are inconsistent with local law: LEXMARK INTERNATIONAL, INC. PROVIDES THIS

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

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

Comments may be addressed to Lexmark International, Inc., Department D22A/032-2, 740 West New Circle Road, Lexington, Kentucky 40550, U.S.A or e-mail at ServiceInfoAndTraining@Lexmark.com. Lexmark ma y use or distribute any of the information you supply in any way it believes appropriate without incurring any obligation to you. You can purchase additional copies of publications related to this product by calling 1-800-553-9727. In other countries, contact your point of purchase.

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

Lexmark, Lexmark with diamond design, and MarkVision are trademarks of Lexmark International, 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.

UNITED STATES GOVERNMENT RIGHTS

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

U.S.A. P/N 12G9399

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

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

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

Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .xx

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

Overview of the operator panel . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

Paper jams–how to clear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

Tips on preventing jams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5

Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6

Types of print media . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7

Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8

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

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

POST (power–on self test) . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

Overview of the operator panel . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

Understanding the operator panel lights. . . . . . . . . . . . . . . . . 2-3

Common light sequences . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

Secondary errors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6

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

Primary codes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8

Secondary error codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19

Service information with secondary and tertiary light patterns . 2-29

Secondary error codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-30

Tertiary service error codes . . . . . . . . . . . . . . . . . . . . . . . . . 2-31

Symptom tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-44

POST symptom table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-44

Printer symptom table. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-45

Service checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-47

Cold fuser service check. . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-47

Cooling fan service check . . . . . . . . . . . . . . . . . . . . . . . . . . 2-48

Controller card service check . . . . . . . . . . . . . . . . . . . . . . . . 2-49

Cover interlock switch service check . . . . . . . . . . . . . . . . . . 2-51

Dead machine service check . . . . . . . . . . . . . . . . . . . . . . . . 2-52

Fuser service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-53

Hot fuser service check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-56

LVPS/HVPS service check . . . . . . . . . . . . . . . . . . . . . . . . . 2-57

Main motor service check . . . . . . . . . . . . . . . . . . . . . . . . . . 2-58

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

Printhead service check. . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-61

Paper feed service checks. . . . . . . . . . . . . . . . . . . . . . . . . . .2-61

Parallel port service check . . . . . . . . . . . . . . . . . . . . . . . . . . .2-65

Print quality service checks . . . . . . . . . . . . . . . . . . . . . . . . . .2-66

Using print quality test pages. . . . . . . . . . . . . . . . . . . . . . . . .2-66

Transfer roll service check . . . . . . . . . . . . . . . . . . . . . . . . . .2-79

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

Configuration and diagnostic groups . . . . . . . . . . . . . . . . . . . . . .3-1

Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1

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

Power–On operations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-2

Configuration menu selections. . . . . . . . . . . . . . . . . . . . . . . . .3-6

Diagnostics menu selections . . . . . . . . . . . . . . . . . . . . . . . . .3-12

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

Removals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-1

Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-2

Fan removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-6

Feed rollers (auto comp tires) removal. . . . . . . . . . . . . . . . . . .4-7

Fuser idle gear links removal . . . . . . . . . . . . . . . . . . . . . . . . . .4-7

Fuser power cable removal . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8

Fuser removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-8

Input roller clutch and lever removal

(ACM clutch CBM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-9

Input sensor #1 removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-9

Input sensor #2 (manual) removal . . . . . . . . . . . . . . . . . . . . .4-10

LVPS / HVPS card assembly removal . . . . . . . . . . . . . . . . . .4-10

LVPS / HVPS to controller card cable removal . . . . . . . . . . .4-11

Manual feed clutch assembly removal. . . . . . . . . . . . . . . . . .4-11

Operator panel removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-11

Paper exit guide assembly removal . . . . . . . . . . . . . . . . . . . .4-12

Printhead removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-12

Toner level sensor cable removal . . . . . . . . . . . . . . . . . . . . .4-12

Toner level sensor removal . . . . . . . . . . . . . . . . . . . . . . . . . .4-13

Transfer roll removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-13

Transport motor cable removal . . . . . . . . . . . . . . . . . . . . . . .4-14

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

Front and rear views . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1

Power supply board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-2

Controller board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-3

Wiring diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-4

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

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

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

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

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

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vi Service Manual

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, and elsewhere is certified as a Class I laser product conforming to the requirements of IEC 60825-1.

Class I laser products are not considered to be hazardous. The printer contains internally a Class IIIb (3b) laser that is nominally a 5 milliwatt gallium arsenide laser operating in the wav elength region of 770-795 nanometers. The laser system and printer are designed so there is never any human access to laser radiation above a Class I level during normal operation, user maintenance, or prescribed service condition.

Laser

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

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Laserprodukte der Klasse I gelten als unschädlich. Im Inneren des Druckers befindet sich ein Laser der Klasse IIIb (3b), bei dem es sich um einen Galliumarsenlaser mit 5 Milliwatt handelt, der Wellen der Länge 770-795 Nanometer ausstrahlt. Das Lasersystem und der Drucker sind so konzipiert, daß im Normalbetrieb, bei der Wartung durch den Benutzer oder bei ordnungsgemäßer Wartung durch den Kundendienst Laserbestrahlung, die die Klasse I übersteigen würde, Menschen keinesfalls erreicht.

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Avis relatif à l’utilisation de laser

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

Les produits laser de Classe I sont considérés comme des produits non dangereux. Cette imprimante est équipée d’un laser de Classe IIIb (3b) (arséniure de gallium d’une puissance nominale de 5 milliwatts) émettant sur des longueurs d’onde comprises entre 770 et 795 nanomètres. L’imprimante et son système laser sont conçus pour impossible, dans des conditions normales d’utilisation, d’entretien par l’utilisateur ou de révision, l’exposition à des rayonnements laser supérieurs à des rayonnements de Classe I .

Avvertenze sui prodotti laser

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

I prodotti laser di classe non sono considerati pericolosi. La stampante contiene al suo interno un laser di classe IIIb (3b) all’arseniuro di gallio della potenza di 5mW che opera sulla lunghezza d’onda compresa tra 770 e 795 nanometri. Il sistema laser e la stampante sono stati progettati in modo tale che le persone a contatto con la stampante, durante il normale funzionamento, le operazioni di servizio o quelle di assistenza tecnica, non ricevano radiazioni laser superiori al livello della classe 1.

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Avisos sobre el láser

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

Los productos láser de Clase I no se consideran peligrosos. La impresora contiene en su interior un láser de Clase IIIb (3b) de arseniuro de galio de funcionamiento nominal a 5 milivatios en una longitud de onda de 770 a 795 nanómetros. El sistema láser y la impresora están diseñados de forma que ninguna persona pueda verse afectada por ningún tipo de radiación láser superior al niv el de la Clase I durante su uso normal, el mantenimiento realizado por el usuario o cualquier otra situación de servicio técnico.

Declaração sobre Laser A impressora está certificada nos E.U.A. em conformidade com os

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

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Os produtos laser da Classe I não são considerados perigosos. Internamente, a impressora contém um produto laser da Classe IIIb (3b), designado laser de arseneto de potássio, de 5 milliwatts ,operando numa faixa de comprimento de onda entre 770 e 795 nanómetros. O sistema e a impressora laser foram concebidos de forma a nunca existir qualquer possiblidade de acesso humano a radiação laser superior a um nível de Classe I durante a operação normal, a manutenção feita pelo utilizador ou condições de assistência prescritas.

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Huomautus laserlaitteesta

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

Luokan I laserlaitteiden ei katsota olevan vaarallisia käyttäjälle. Kirjoittimessa on sisäinen luokan IIIb (3b) 5 milliwatin galliumarsenidilaser, joka toimii aaltoalueella 770 - 795 nanometriä. Laserjärjestelmä ja kirjoitin on suunniteltu siten, että käyttäjä ei altistu luokan I määrityksiä voimakkaammalle säteilylle kirjoittimen normaalin toiminnan, käyttäjän tekemien huoltotoimien tai muiden huoltotoimien yhteydessä.

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

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

Laser-notis

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

Laserprodukter i Klass I anses ej hälsovådliga. Skrivaren har en inbyggd laser av Klass IIIb (3b) som består av en laserenhet av gallium-arsenid på 5 milliwatt som arbetar i våglängdsområdet 770- 795 nanometer. Lasersystemet och skrivaren är utf ormade så att det aldrig finns risk för att någon person utsätts för laserstrålning över Klass I-nivå vid normal användning, underhåll som utförs av användaren eller annan föreskriven serviceåtgärd.

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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 land godkjent som et Klasse I-laserprodukt i samsvar med kravene i IEC 60825-1.

Klasse I-laserprodukter er ikke å betrakte som farlige. Skriveren inneholder internt en klasse IIIb (3b)-laser, som består av en gallium-arsenlaserenhet som avgir stråling i bølgelengdeområdet 770-795 nanometer. Lasersystemet og skriveren er utformet slik at personer aldri utsettes for laserstråling ut over klasse I-nivå under vanlig bruk, vedlikehold som utføres av brukeren, eller foreskrevne serviceoperasjoner.

Avís sobre el Làser

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

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Els productes làser de classe I no es consideren perillosos. Aquesta impressora conté un làser de classe IIIb (3b) d’arseniür de gal.li, nominalment de 5 mil.liwats, i funciona a la regió de longitud d’ona de 770-795 nanòmetres. El sistema làser i la impressora han sigut concebuts de manera que mai hi hagi exposició a la radiació làser per sobre d’un nivell de classe I durant una operació normal, durant les tasques de manteniment d’usuari ni durant els serveis que satisfacin les condicions prescrites.

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Japanese Laser Notice

Chinese Laser Notice

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Korean Laser Notice

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Laser notices xiii

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Safety information

• The safety of this product is based on testing and approvals of

the original design and specific components. The manufacturer is not responsible for safety in the event of use of unauthorized replacement parts.

• The maintenance information for this product has been

prepared for use by a professional service person and is not intended to be used by others.

• There may be an increased risk of electric shock and personal

injury during disassembly and servicing of this product. Professional service personnel should understand this and take necessary precautions.

• CAUTION: When you see this symbol, there is a

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

Consignes de sécurité

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

agréations portant sur sa conception d'origine et sur des composants particuliers. Le fabricant n'assume aucune responsabilité concernant la sécurité en cas d'utilisation de pièces de rechange non agréées.

• Les consignes d'entretien et de réparation de ce produit

s'adressent uniquement à un personnel de maintenance qualifié.

• Le démontage et l'entretien de ce produit pouvant présenter

certains risques électriques, le personnel d'entretien qualifié devra prendre toutes les précautions nécessaires.

• ATTENTION : Ce symbole indique la présence

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

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Norme di sicurezza

• La sicurezza del prodotto si basa sui test e sull'approvazione

del progetto originale e dei componenti specifici. Il produttore non è responsabile per la sicurezza in caso di sostituzione non autorizzata delle parti.

• Le informazioni riguardanti la manutenzione di questo prodotto

sono indirizzate soltanto al personale di assistenza autorizzato.

• Durante lo smontaggio e la manutenzione di questo prodotto,

il rischio di subire scosse elettriche e danni alla persona è più elevato. Il personale di assistenza autorizzato deve, quindi, adottare le precauzioni necessarie.

• ATTENZIONE: Questo simbolo indica la presenza

di tensione pericolosa nell'area del prodotto. Scollegare il prodotto prima di iniziare o usare cautela se il prodotto deve essere alimentato per eseguire l'intervento.

Sicherheitshinweise

• Die Sicherheit dieses Produkts basiert auf Tests und

Zulassungen des ursprünglichen Modells und bestimmter Bauteile. Bei Verwendung nicht genehmigter Ersatzteile wird vom Hersteller keine Verantwortung oder Haftung für die Sicherheit übernommen.

• Die Wartungsinformationen für dieses Produkt sind

ausschließlich für die Verwendung durch einen Wartungsfachmann bestimmt.

• Während des Auseinandernehmens und der Wartung des

Geräts besteht ein zusätzliches Risiko eines elektrischen Schlags und körperlicher Verletzung. Das zuständige Fachpersonal sollte entsprechende Vorsichtsmaßnahmen treffen.

• ACHTUNG: Dieses Symbol weist auf eine

gefährliche elektrische Spannung hin, die in diesem Bereich des Produkts auftreten kann. Ziehen Sie vor den Arbeiten am Gerät den Netzstecker des Geräts, bzw. arbeiten Sie mit g roßer Vorsicht, wenn das Produkt für die Ausführung der Arbeiten an den Strom angeschlossen sein muß.

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Pautas de Seguridad

• La seguridad de este producto se basa en pruebas y

aprobaciones del diseño original y componentes específicos. El fabricante no es responsable de la seguridad en caso de uso de piezas de repuesto no autorizadas.

• La información sobre el mantenimiento de este producto está

dirigida exclusivamente al personal cualificado de mantenimiento.

• Existe mayor riesgo de descarga eléctrica y de daños

personales durante el desmontaje y la reparación de la máquina. El personal cualificado debe ser consciente de este peligro y tomar las precauciones necesarias.

• PRECAUCIÓN: este símbolo indica que el voltaje

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

Informações de Segurança

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• A segurança deste produto baseia-se em testes e aprovações

do modelo original e de componentes específicos. O fabricante não é responsável pela segunrança, no caso de uso de peças de substituição não autorizadas.

• As informações de segurança relativas a este produto

destinam-se a profissionais destes serviços e não devem ser utilizadas por outras pessoas.

• Risco de choques eléctricos e ferimentos graves durante a

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

• CUIDADO: Quando vir este símbolo, existe a

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

Safety information xvii

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Informació de Seguretat

• La seguretat d'aquest producte es basa en l'avaluació i

aprovació del disseny original i els components específics. El fabricant no es fa responsable de les qüestions de seguretat si s'utilitzen peces de recanvi no autoritzades.

• La informació pel manteniment d’aquest producte està

orientada exclusivament a professionals i no està destinada a ningú que no ho sigui.

• El risc de xoc elèctric i de danys personals pot augmentar

durant el procés de desmuntatge i de servei d’aquest producte. El personal professional ha d’estar-ne assabentat i prendre les mesures convenients.

• PRECAUCIÓ: aquest símbol indica que el voltatge

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

xviii Service Manual

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Safety information xix

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Preface

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

1. General information contains a general description of the printer and the maintenance approach used to repair it. Special tools and test equipment are listed in this chapter, as well as general environmental and safety instructions.

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

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

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

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

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

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

Definitions

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

product hardware or software. CAUTION: A caution identifies something that might cause a

servicer harm.

CAUTION: When you see this symbol, there is a danger from hazardous voltage in the area of the product where you are working. Unplug the product before you begin, or use caution if the product must receive power in order to perform the task.

xx Service Manual

1. General information

The Lexmark™ E23x, E33x printers are monochrome laser printers designed for single users or small workgroups. There are four models:

• 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.

• E330, 32MB of memory standard, a parallel port, a USB port,

and prints 27 pages per minute.

• E332n, 32MB of memory standard, an integrated Ethernet

adapter, a parallel port, a USB port, and prints 27 pages per minute.

• E234, 32MB of memory standard, a parallel port, a USB port,

and prints 25 pages per minute.

• E234n, 32MB of memory standard, an integrated Ethernet

adapter, a parallel port, a USB port, and prints 27 pages per minute.

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General information 1-1

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

Item

Base memory 8MB 16MB 32MB Maximum

memory Paper inputs • 250–sheet

Emulations HBP (host–

Connectivity USB and Parallel USB, Parallel,

Toner cartridge yield

4505-100 Lexmark

E230

8MB 80MB 160MB

tray

• Single– sheet manual feeder

based printing), PCL (printer control language) 5e, and Windows/ Macintosh/ Linux compatibility

1,500 pages* (starter toner cartridge)

4505-200 Lexmark

E232

• 250–sheet tray

• Single–sheet manual feeder

• Optional 550–sheet drawer

HBP, PCL 6, and Windows/ Macintosh/ Linux compatibility

4505-300

Lexmark E330

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

2,500 pages

4505-310 Lexmark

E332n

and 10/100 Base-TX Ethernet

Photoconductor kit yield

* Yield based on approximately 5% coverage of pages.

30,000 pages*

1-2 Service Manual

Overview of the operator panel

The operator panel has six lights and two buttons. See

“Operator panel codes” on page 2-8 for more information.

Continue

Cancel

Ready

Toner Low /

Replace PC Kit

4505

Load Paper

Paper Jam

Error

• Press and release to resume printing.

• Press and release twice quickly to display a secondary

error code following an error.

• Press and release to cancel the job currently printing.

• Press and hold until all of the lights come on to reset the

printer.

General information 1-3

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Paper jams–how to clear

When a paper jam occurs, the printer stops operating and the operator panel’s 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 for more information.

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

To clear a paper jam:

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

2. Open the front cover and remove the print cartridge assembly.

3. Remove any jams located in the area behind the print cartridge assembly.

4. Lift the flap at the front of the printer and remove any jams located 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, and then press the button to resume printing.

Note: Pages caught in the paper jam will reprint.

1-4 Service Manual

Tips on preventing jams

You can avoid most paper jams by correctly loading paper and specialty media.

The following hints can help yo u 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 firmly into the printer after loading them.

• Make sure the guides in the trays are positioned sn ugly against

the paper or specialty media.

• Do not remove paper trays while a job is printing. Wait for a

Load Paper light sequence before you remove the tray.

• Before loading transparencies, fan the stack to prevent sheets

from 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 – Have any exposed adhesive when the flap is in the sealed

position

4505

• Use only recommended paper. Refer to the Card Stock & Label

Guide available on the Lexmark Web site at www.lexmark.com for

more information about which paper provides optimum results for current printing environment.

General information 1-5

4505

Tools

The removal and adjustment procedures require the following tools and equipment:

• Magnetic tip Phillips screwdrivers, large and small

• Volt ohmmeter

1-6 Service Manual

Types of print media

Ensure trays are properly loaded. Never mix media types within a tray.

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Capacity (sheets)

• 250 paper

• labels

• 50 trans-

Source Sizes Types Weight

Tray 1 (250-sheet

tray)

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

Plain paper, transparencies, labels

60–90 g/m (16–24 lb)

folio,

Tray 2 (550-sheet

tray)

statement, Universal

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

‡

Plain paper, transparencies, labels

60–163 g/m (16–43 lb)

• 550 paper

• labels

• 50

folio,

Manual feeder

statement, Universal

‡

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

Plain paper, transparencies, labels, card

†

stock

60–163 g/m (16–43 lb)

• card stock

folio, statement, Universal

7¾, 9, 10,

‡

Envelopes DL, C5, B5, other

†

Card stock up to 90# Index. Grain short is recommended.

‡

Universal size range: 76–216 x 127–356 mm (3.0–8.5 x 5.0–

14.0 in.) (includes 3 x 5 in. cards).

parencies

transparencies

General information 1-7

4505

Abbreviations

ACM Auto Comp Mechanism (or paper feed) ASIC Application Specific Integrated Circuit CBM Complete Bill Of Material DIMM Dual In-Line Memory Module ENA External Network Adapter FRU Field Replaceable Unit HBP Host Based Printing HV High Voltage HVPS High Voltage Power Supply INTL International LVPS Low Voltage Power Supply NVRAM Nonvolatile Random Access Memory PCL Printer Control Language POR Power-On Reset POST Power-On Self Test PPDS Personal Printer Data Stream PRC Peoples' Republic of China PSO Participating Standards Organization RIP Raster Image Processor SDR Synchronous Dynamic RAM USB Universal Serial Bus V ac Volts alternating current V dc Volts direct current

1-8 Service Manual

2. Diagnostic information

Start

POST (power–on self test)

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

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 light

sequences” on page 2-3 for more information.

3. Otherwise, the light flashes until the fuser comes up to temperature (5–20 additional seconds depending on the initial temperature of the fuser).

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

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Diagnostic information 2-1

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Overview of the operator panel

Continue

Cancel

Ready

Toner Low /

Replace PC Kit

Load Paper

Paper Jam

Error

• Press and release to resume printing.

• Press and release twice quickly to display a secondary

error code (following an error -

and lights on).

• Press and release to cancel the job currently printing.

• Press and hold until all of the lights come on to reset the

printer.

2-2 Service Manual

Understanding the operator panel lights

The operator panel lights mean different things, depending on their sequence. Lights that are off, on, and/or blinking indicate printer conditions 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.

● Light on Light is off

✷ Light blinking

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Light blinking slow

Common light sequences

See “Overview of the operator panel” on page 2-2 for icon information.

Printer condition

● Ready / Power Saver

✷ Busy

● ● Waiting

✷✷Flushing /

● Not ready (printer

Hex Trace Ready

Resolution reduced

offline)

● Close door / Insert cartridge

● ● Load media

Diagnostic information 2-3

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Printer condition

●

✷●Print side two of

● Toner low

●✷ Replace

●✷ ✷Replace

✷●Missing or

●●Unsupported

●✷Change cartridge,

●●Invalid engine

✷ Load manual

feeder

duplex job

photoconductor kit

photoconductor kit (printer hard stop)

defective toner cartridge

toner cartridge

invalid refill

code / Invalid network code

●●● Programming

● ● ● ●●●Cancel job /

2-4 Service Manual

engine code / Programming system code

Reset printer

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Printer condition

✷ ✷ ✷ ✷✷✷Service error (see

✷●Printer error (see

“Service information with secondary and tertiary light patterns” on page 2-29 for

more information).

“Secondary error codes” on page 2-19 for

more information).

Diagnostic information 2-5

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Secondary errors

When the and lights are both on, a secondary error has occurred. Press and release twice quickly to display the secondary error code light sequence. The following table shows what these light sequences mean.

Printer condition

●●Printer error /

Secondary error code

● ✷ ● Paper jams in

the manual feeder

●●●Paper jams as

it exits the tray into the printer

●●●Paper jams as

a printed job exits the printer

●● ●Complex page

● ✷ ● Insufficient

printer memory

●● ●Insufficient

collation area

● ✷ ● Font error

●●●Defective flash

● ✷ ● Insufficient

defrag memory

●●●Network

● ✷ ● Error

●●● ●Memory full

2-6 Service Manual

interface errors

communicating with host computer

Printer condition

4505

●● ● ●

Short paper

●●●●Unformatted

flash

●● ●●Flash full

●●●Invalid engine

code

● ✷ ● Invalid network

code

Paper jam secondary codes

●● ● 200 Paper jam

input sensor

●●●201 Paper jam

between input and exit sensors

●●●202 Paper jam

exit sensor

●●●●241 Paper jam

Tray 1 jam

●● ●● 242 Paper Jam

Tray 2 jam

● ✷ ● 251 Paper jam

manual feeder

Diagnostic information 2-7

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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 receive and process data.

• Printer is in Power Saver mode.

• Send a print job.

• Press to print the

menu settings pages for a list of current printer settings.

• Press and hold to reset the printer.

Note: To change the Power Saver setting, use the Local Printer Setup Utility. See User’s Reference for more information.

2-8 Service Manual

Busy

Light sequence Meaning Action:

4505

• Printer is busy receiving and processing data or printing.

• Printer is defragmenting the flash memory to reclaim storage space occupied by deleted resources.

• Printer is formatting the flash memory.

• Printer is storing resources, such as fonts or macros, in flash memory.

• Printer is printing a directory, font list, menu settings pages, or Print Quality Test Pages.

• Busy: –Wait for message to

clear.

–Press and release

to cancel print

job.

–Press and hold to

reset printer.

• Defragmenting flash,

formatting flash, or programming flash:

–Wait for message to

clear.

–Warning: Do not turn

the printer off while this message is displayed.

• Printing a directory, a

font list, menu settings pages, or Print Quality Test Pages:

–Wait for the pages to

print. The Busy message is displayed as the pages print. The light is on when printing stops.

–Press and release

to cancel

printing.

–Press and hold to

reset printer.

• Receiving/processing

data from a host interface:

–Wait for message to

clear.

–Press and release

to stop

processing.

–Press and hold

to reset printer.

Diagnostic information 2-9

4505

Hex Trace Ready

Light sequence Meaning Action:

Printer is in the Ready mode and Hex Trace is active.

• Hex Trace helps troubleshoot printing problems. After resolving the problem, turn off the printer to exit Hex Trace.

• Or , press and hold to reset the printer.

Waiting

Light sequence Meaning Action:

Printer is waiting until a print timeout occurs, or until it receives additional data.

• Press and release to print contents of the print buffer.

• Press and release to cancel the print job.

• Press and hold to reset the printer.

2-10 Service Manual

Flushing / Resolution reduced

Light sequence Meaning Action:

4505

• Printer is flushing corrupted print data.

• Printer is processing data or printing pages, but the resolution of a page in the current print job is reduced from 600 dots per inch (dpi) to 300 dpi to prevent a memory full error.

• Wait until is displayed to print other jobs.

• Press and release to cancel print job.

• Press and hold to reset printer.

Not ready

Light sequence Meaning Action:

Printer is not ready to receive or process data, or the printer ports are offline.

• Press to return to

• Press and release

to cancel print job.

• Press and hold to reset printer.

or Busy state.

Diagnostic information 2-11

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Close door / Insert cartridge

Light sequence Meaning Action:

The printer door is open. Close the door.

Load media

Light sequence Meaning Action:

2-12 Service Manual

The printer is out of media, or the media did not feed properly.

• Load media into tray 1 or the optional 550-sheet tray and press to resume printing.

• Check that the media is loaded correctly in tray 1 or the optional 550-sheet tray.

• Press to cancel the print job.

Load manual feeder

Light sequence Meaning Action:

4505

Printer prompts to load a single sheet of media in the manual feeder.

• Load media, with the side to be printed facing the front of the printer, into the manual feeder.

• Press to resume printing.

• Press and hold to reset printer.

Print side two of duplex job

Light sequence Meaning Action:

Print the other side of duplex print job.

• Reinsert print job in tray 1 using the instructions in the driver pop-up menu to orient the pages correctly.

• Press to resume printing.

• Press and hold to reset printer.

Diagnostic information 2-13

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Toner low

Light sequence Meaning Action:

• Printer is ready to receive and process data.

• The toner in the toner cartridge is getting low.

• Send a print job.

• Press to print the

menu settings page for a list of current settings.

• Remove the toner cartridge and shake it to extend the life of the cartridge.

• Replace the toner cartridge.

• Press and hold to reset printer.

Note: The light may not come on if the starter toner cartridge is installed in a base printer model.

Replace photoconductor kit

Light sequence Meaning Action:

The photoconductor kit’s drum is full and needs replacing.

• Press to resume printing.

• Replace the photoconductor kit.

2-14 Service Manual

Replace photoconductor kit (printer hard stop)

Light sequence Meaning Action:

4505

The photoconductor kit’s drum is full and needs replacing. No pages print until the photoconductor kit is replaced.

• Replace the photoconductor kit.

Toner cartridge error / Toner cartridge is not installed

Light sequence Meaning Action:

The toner cartridge is not installed, or the printer detects a toner cartridge error.

• If the toner cartridge is not installed, install it.

• If the toner cartridge is installed, remove it and install a new toner cartridge.

Diagnostic information 2-15

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Change invalid toner cartridge

Light sequence Meaning Action:

The toner cartridge being used is not designed for this printer.

Install a toner cartridge compatible to printer.

Invalid engine code / Invalid network code

Light sequence Meaning Action:

The code in an internal print server has not been programmed, or the programmed code is not valid.

• Download valid network code to the internal print server.

• Press twice quickly to see the secondary error code.

2-16 Service Manual

Programming engine code / Programming system code

Light sequence Meaning Action:

4505

New code is being programmed into the engine or firmware code flash.

Wait for the message to clear. When the printer has finished programming the code, it performs a soft reset.

Cancel job / Reset printer

Light sequence Meaning Action:

• The current print job is canceled.

• The printer is resetting to the user default settings.

–Any active print jobs

are canceled.

–A user default setting

remains in effect until changed or until restored to factory default settings.

Wait for the message to clear.

Diagnostic information 2-17

4505

Service error

Light sequence Meaning Action:

The printer has a service error and printing has stopped.

Turn the printer off and back on.

If the lights are still blinking, contact the place where printer was purchased.

Printer error

Light sequence Meaning Action:

The printer has one of the following errors:

• Memory is full, insufficient to save what is in the buffer, or insufficient to defragment flash memory.

• A page is too complex to print or is shorter than the set page margins.

• Resolution of a formatted page is reduced to 300 dpi.

• A font error occurred.

• Communication with

the host computer is lost.

• Press twice quickly to see the secondary error code. See “Secondary error

codes” on page 2-19

for more information.

• Press to clear the secondary message.

2-18 Service Manual

Secondary error codes

• When the and lights are both on, a secondary error has

occurred. Press and release twice quickly to display the secondary error code light sequence.

• When the and lights are both on, a paper jam

secondary error has occurred.

Press and release twice to display the secondary error code

light sequence.

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

4505

Diagnostic information 2-19

4505

Paper jam in the manual feeder

Light sequence Meaning Action:

A paper jam has occurred in the manual feeder.

Clear the paper jam.

Paper jams as it exits the tray into the printer

Light sequence Meaning Action:

A paper jam has occurred as the paper is exiting the paper tray and entering the printer.

Clear the paper jam.

2-20 Service Manual

Paper jams as a printed job exits the printer

Light sequence Meaning Action:

4505

A paper jam has occurred as the paper is exiting the printer.

Clear the paper jam.

Complex page

Light sequence Meaning Action:

The page may not print correctly because the print information on the page is too complex (that is, too large for the printer’s memory).

• Press to clear the message and continue processing the print job (some of the print data may be lost).

• To avoid this error in the future:

• Install additional printer memory.

–Reduce the

complexity of the page by reducing the amount of text or graphics on the page and deleting unnecessary downloaded fonts or macros.

–Set Page Protect to

on in the Local Printer Setup Utility.

Diagnostic information 2-21

4505

Insufficient printer memory

Light sequence Meaning Action:

The printer does not have enough memory to save the data in the buffer.

• Install additional memory.

• Press to continue printing the job.

• Press to cancel the print job.

Insufficient collation area

Light sequence Meaning Action:

The printer memory does not have the free space necessary to collate the print job. This may happen due to one of these errors:

• Memory is full.

• A page is too complex

to print.

• A page is shorter than the set page margins.

• Memory is insufficient to save what is in the buffer.

• Press to clear the message and continue printing the job (the job may not print correctly.)

• Press and release to cancel the print job.

• Press and hold to reset the printer.

• To avoid this error in the future:

–Simplify the print job.

• Install additional printer

memory.

Reduce the complexity of the page by reducing the amount of text or graphics on the page and deleting unnecessary downloaded fonts or macros.

2-22 Service Manual

Font error

Light sequence Meaning Action:

4505

The printer has received a request for a PPDS font which is not installed.

• Press and release to cancel the print job.

• Press and hold to reset the printer.

• Press and release to clear the message and continue printing.

Defective flash

Light sequence Meaning Action:

The printer detects defective flash memory.

• Press to clear the message and continue printing.

• Install flash memory.

–Downloaded fonts

and macros not previously stored in flash memory are deleted.

Diagnostic information 2-23

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Insufficient defrag memory

Light sequence Meaning Action:

The printer has insufficient memory to free unused space in flash memory.

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

• Install additional printer memory.

Network interface errors

Light sequence Meaning Action:

The printer cannot establish communication with the network.

Press to clear the message and continue printing (the job may not print correctly).

2-24 Service Manual

Error communicating with host computer

Light sequence Meaning Action:

4505

The printer has lost the connection to an external print server (also called an external network adapter or external network adapter (ENA)).

This light sequence is displayed if your printer is connected to the network, but it cannot detect the print server when you turn on the printer.

• Make sure the cable connecting the ENA and the printer is securely attached.

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

• Press and hold to reset the printer.

Memory full

Light sequence Meaning Action:

The printer is processing data, but the memory used to store pages is full.

• Press to clear the message and continue printing the job (the job may not print correctly).

• Press and release to cancel the print job.

• Press and hold to reset the printer.

• To avoid this error in the future:

• Install additional printer memory.

–Simplify the print job.

Reduce the complexity of the page by reducing the amount of text or graphics on the page and deleting unnecessary downloaded fonts or macros.

Diagnostic information 2-25

4505

Short paper

Light sequence Meaning Action:

The paper length is too short to print the formatted data. This occurs when the printer does not know the media size loaded in the tray, or there is a problem feeding the media.

• Make sure the print media you loaded is large enough.

• Open the front cover, clear the paper path and close the cover to resume printing.

• Press to clear the message and continue printing the job.

• Press to cancel the print job.

Flash full

Light sequence Meaning Action:

There is not enough free space in the flash memory to store the data you are trying to download.

• Delete fonts, macros, and other data stored on the flash memory to free up space.

• Press to clear the message and continue printing.

–Downloaded fonts

• Install flash memory

with more storage capacity.

• Press and release to cancel the print job.

• Press and hold to reset the printer.

and macros not previously stored in flash memory are deleted.

2-26 Service Manual

Unformatted flash

Light sequence Meaning Action:

4505

The printer detects unformatted flash memory.

• Press to clear the message and continue printing. The job may not print correctly.

• Reformat the flash memory. Refer to the T echnical Reference on Lexmark’s Web site for more information.

• If the error message remains, the flash memory may be defective and should be replaced.

Invalid engine code

Light sequence Meaning Action:

The code in an internal print server has not been programmed, or the programmed code is not valid.

Download valid engine code to the internal print server.

Diagnostic information 2-27

4505

Invalid network code

Light sequence Meaning Action:

The code in an internal print server has not been programmed, or the programmed code is not valid.

Download valid network code to the internal print server.

2-28 Service Manual

4505

Service information with secondary and tertiary light patterns

All service errors are indicated by all lights flashing as the primary notification or code. The secondary code indicates an area or function which has the error. Tertiary codes (shown on the following pages) indicate specific device errors. Double click to see the secondary code. Double click again to see the tertiary code.

Double

Click

Primary

Codes

Note: All lights flashing simultaneously, as a result of sending data to the printer, may indicate a code problem. Call the next level of support.

Double

Click

Secondary

Codes

● Light on Light off

Double

Click

Tertiary

Codes

✷

Light blinking Light blinking slow

Diagnostic information 2-29

4505

Secondary error codes

Secondary codes

Lights

Continue

Ready

Toner Low

Replace

PC Kit

Load

Paper

Paper Jam

Error

Primary code

901

91x

92x

93x

94x

95x

96x

97x

98x

99x

✷ ✷✷✷✷✷✷✷✷✷✷

✷

✷✷✷

✷✷✷✷✷

✷ ✷✷✷✷✷

Software

DC motor or transfer roll

Fuser or toner sensor

Printhead, drive motor, RIP to engine

RIP to engine communication, engine

electronics

Controller card, specifically, NVRAM, ROM or

Paper port communications

2-30 Service Manual

NAND

RAM memory

Network

Device system card

Tertiary service error codes

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

Note: All service errors are initially communicated by all lights flashing 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 the controller card.

4505

Diagnostic information 2-31

4505

Controller software

Tertiary codes

Lights

Continue

Ready

Toner Low / Replace PC

Kit

Load Paper

Paper Jam

Error

Secondary code

900

901

902

903

904

905

906

✷

● ✷✷✷✷✷✷✷

●

●✷✷✷

RIP interface driver error

2-32 Service Manual

General engine software error

Faulty engine code flash or programming failed

Contact next level of support or 1-800-539-6275

Transfer roll

CAUTION: When you see this symbol, there is a

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

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

Tertiary code

4505

Lights

Continue

Ready

Toner Low / Replace PC

Kit

Load Paper

Paper Jam

Error

Secondary code

917

✷

●✷

●

●✷

✷✷

Diagnostic information 2-33

4505

Fuser, fan, or toner sensor error Codes 920 through 929 indicate a problem in the fuser (see “Fuser

service check” on page 2-53 f or more inf ormation), a stalled fan motor

or a faulty toner sensor or toner cartridge.

Tertiary codes

Lights

Continue

Ready

Toner Low / Replace PC

Kit

Load Paper

Paper Jam

Error

Secondary

code

Fuser below

temperature when

printing

Fuser below standby

temperature at idle

920

921

922

923

924

925

926

927

928

929

✷

● ✷✷✷✷✷✷✷✷✷✷

●✷✷

●✷✷✷✷

✷✷✷✷✷

● ✷✷✷✷✷

Fan stalled

Toner sensor or toner cartridge

Incorrect fuser lamp installed

Open circuit in thermistor path

Fuser too hot during printing or idle

Fuser failed to reach standby temperature

2-34 Service Manual

Printhead, transport motor or RIP/engine communication error

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

Diagnostic information 2-35

4505

Code 939 indicates a communication failure between the RIP and engine processors.

Tertiary codes

Code

Continue

Ready

Toner Low / Replace PC

Kit

Load Paper

Paper Jam

Error

930

931

932

933

934

935

936

937

939

✷

● ✷✷✷✷✷✷✷✷✷

●✷

●✷✷✷✷

✷✷✷✷✷

✷✷✷✷✷✷

Secondary

code

Wrong printhead

Printhead - no first hsync.

(Verify interlock switch is

plugged in at J13.)

Printhead - lost hsync

Mirror motor locked

Mirror motor not at opening speed.

(Verify +24 V dc on pin #5 of J11.)

2-36 Service Manual

Mirror motor lost lock

RIP/engine communication error

Transport motor lost lock

Transport motor initial lock failure

RIP to engine communication failure (controller card).

This indicates fuser control in the L VPS has f ailed or the wrong LVPS has been installed.

Tertiary

codes

4505

Code

Continue

Ready

Toner Low / Replace PC

Kit

Load Paper

Paper Jam

Error

Secondary

code

940

✷

●✷

●

✷

●

Diagnostic information 2-37

4505

NVRAM failure

Error codes 950–954 indicate a problem in the NVRAM (nonvolatile random access memory). Replace the operator panel assembly. Codes 955–959 indicate a failed controller card assembly. Replace the controller card.

2-38 Service Manual

Tertiary codes

4505

Code

Continue

Ready

Toner Low / Replace PC

Kit

Load Paper

Paper Jam

Error

950

951

952

954

955

956

957

958

959

✷

● ✷✷✷✷✷✷✷✷✷

●✷✷

✷✷✷✷✷

●✷✷✷

✷ ✷ ✷✷✷

Secondary code

NVRAM data does not match secure NVRAM

RIP firmware cannot

communicate with secure

NVRAM chip failure

NVRAM CRC failure

NVRAM

SRAM

failure

NAND failure

ASIC failure

Processor failure

Code ROM or NAND failed cyclic redundancy check (CRC)

Diagnostic information 2-39

4505

Note: NVRAM is on the operator panel printed circuit board (PCB)

while secure NVRAM is on the controller PCB. Check margin alignments after replacing the operator panel assembly. See

“Printhead service check” on page 2-61 for more information. If

margin errors are unacceptable, corrections can only be made through software. Contact the next level of support or Lexmark at 1-800-539-6275.

2-40 Service Manual

RAM memory error

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

Tertiary codes

4505

Code

Continue

Ready

Toner Low / Replace PC

Kit

Load Paper

Paper Jam

Error

960

961

962

963

✷

●✷✷✷✷

●

✷

✷✷✷

●✷ ✷

Secondary

code

RAM in slot 1 is bad

RAM soldered on the board is bad

Diagnostic information 2-41

4505

Network error

Indicates an error in the network circuitry. Replace the controller card assembly.

Tertiary codes

Code

Continue

Ready

Toner Low / Replace PC

Kit

Load Paper

Paper Jam

Error

Secondary code

970

971

972

973

974

975

976

978

979

✷

● ✷✷✷✷✷✷✷✷✷

●✷✷

✷✷✷✷

✷✷✷✷ ✷

Unrecognizable

network port

Unrecoverable software error in network port

2-42 Service Manual

Bad checksum while programming port

Flash parts failed while programming port

Paper port communication failure

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

Tertiary codes

4505

Code

Continue

Ready

Toner Low / Replace PC

Kit

Load Paper

Paper Jam

Error

980

981

982

983

984

✷

●✷✷✷✷✷

✷

●✷

●✷✷

●✷ ✷

Secondary code

Engine experiencing

unreliable communications

to specified device

Engine protocol violation detected by

the specified device

Invalid command parameter received by specified device

Invalid command received by specified device

Communications error detected by specified device

Diagnostic information 2-43

4505

Symptom tables

POST symptom table

Symptom Action

The main motor, cooling f a n, and fuser do not come on.

POST completes except one or more lights do not come on.

None of the lights come on. See “Operator panel service check”

Main motor does not come on. See “Main motor service check” on

Fan does not come on. See “Cooling fan service check” on

Fuser lamp does not come on. See “Cold fuser service check” on

Fuser lamp never turns off. See “Hot fuser service check” on

The paper feed picks and tries to feed paper.

See “Cover interlock switch service

check” on page 2-51.

See “Operator panel service check”

on page 2-59.

page 2-58.

page 2-48.

page 2-47.

page 2-56.

See “Paper feed service checks” on

page 2-61.

2-44 Service Manual

Printer symptom table

Symptom Action

4505

Dead machine (no power) See “Dead machine service check”

Fan noisy or not working See “Cooling fan service check” on

Fuser parts melted See “Hot fuser service check” on

Fuser lamp doesn’t light See “Cold fuser service check” on

Toner not fused to the paper See“Cold fuser service check” on

Paper jams See “Paper feed service checks” on

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

Paper skew See “Paper feed service checks” on

Printer not communicating with host

Front access cover will not close

on page 2-52.

page 2-48.

page 2-56.

page 2-47.

page 2-61.

page 2-58.

page 2-61.

See “Parallel port service check” on

page 2-65.

See “Cover interlock switch service

check” on page 2-51.

Operator panel button not responding

Operator panel lights are off or very dim

Blank page See “Blank page” on page 2-67. Black page See “Black page” on page 2-68. Heavy background See “Heavy background” on

Light print See “Light print” on page 2-71.

See “Operator panel service check”

on page 2-59 or “Controller card service check” on page 2-49.

See “Controller card service check”

on page 2-49.

page 2-69.

Diagnostic information 2-45

4505

Symptom Action

White or black lines or bands See “White or black lines or bands”

Toner on back of page See “Toner on back of page” on

Paper never picks See “Paper never picks” on

Paper feeds continuously See “Paper picks during POST and/or

Paper wrinkled or bent See “Paper “trees,” wrinkles, stacks

on page 2-72.

page 2-72.

page 2-63.

continuously” on page 2-62.

poorly or curls” on page 2-65.

2-46 Service Manual

Service checks

Service checks which involve measuring voltages on the LVPS/HVPS (

power supply

positioned on its back side.

Note: When you make voltage readings, always use frame ground unless another ground is specified. See “Wiring diagram” on

page 5-4 for more information.

Cold fuser service check

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

FRU Action

Fuser AC cables LVPS/HVPS Fuser

low voltage power supply/high voltage

board) should be performed with the printer

If the fuser lamp comes on and a fuser failure light error code displays , be sure the thermistor is contacting the hot roll and the thermistor cable is firmly seated in connector J15 on the controller card.

Check for e xcessive toner b uildup on the surface of the thermistor. Clean as necessary.

With the printer unplugged, disconnect the thermistor cable from J15 on the controller card.

Measure the resistance of the thermistor. The resistance measures from approximately 1K ohms immediately after printing or POR to approximately 240K ohms when thermistor reaches room temperature. (It may tak e 30 minutes to cool.)

Replace the fuser assembly as necessary.

4505

Diagnostic information 2-47

4505

Cooling fan service check

FRU Action

Cooling fan Make sure the fan cable plug is

properly seated at J19 (controller card).

Turn the printer off and disconnect the cooling fan cable from the controller card.

Turn the printer on. Within a few seconds the controller card assembly should apply between +24 V dc to pin 2. See “Controller

board” on page 5-3 for more

information.

• If voltage is present and the fan is not turning, replace the cooling fan. If the fan still doesn’t function, replace the controller card.

Note: The fan speed is controlled by

a module on the PCB. Between +8 V and +24 V dc are constantly supplied at pin 2 (J19). Pin 1 is ground while pin 3 receives feedback from the fan motor.

• If voltage is not present, see

“Controller board” on page 5-3

for more information.

2-48 Service Manual

Controller card service check

FRU Action

4505

Controller card assembly Verify +24 V dc input from the

LVPS/HVPS.

• Turn the printer off.

• Disconnect the LVPS/HVPS

cable from the controller card at J7. See “Controller board” on

page 5-3 for more information.

• Turn the printer on.

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

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

• If voltage is correct, check the continuity in the cable. If the cable is good, see the

“Controller board” on page 5-3 for more information.

• If grounds are not correct on the cable, first check it for continuity and then the LVPS/HVPS.

• If the grounds are not correct on the controller card, replace the controller card. (Check with one probe on the connector pin and the other on the card’s ground plane found at each screw head.)

Diagnostic information 2-49

4505

Controller card service check (continued)

FRU Action

Controller card assembly Note: With all cables connected, the

printer should complete POST within approximately 12–15 seconds in the following sequence:

1. All operator panel lights on solid momentarily.

2. Lights then flash on and off sequentially.

After lights quit flashing, the

light 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 power–on the operator panel lights are active but the printer does not go through steps 1 and 2 above, replace the controller card assembly.

Note: Settings for U.S. versus

non–U.S. and the printer configuration ID can be changed. See

“Configuration and diagnostic groups” on page 3-1 for more

information.

If some lights are on or flashing, see “Common light sequences”

on page 2-3 to determine action

required.

2-50 Service Manual

Cover interlock switch service check

Note: Make sure a print cartridge assembly is installed and the

cover closes all the way, engaging the cover open switch lever.

FRU Action

Cover interlock switch Disconnect the cover interlock cable

from the controller card at J13. Verify continuity between cable

pin 1 and pin 2 with the door closed but not open.

Verify continuity between cable pin 1 and pin 3 with the door open but not closed.

• If either fail continuity, replace the cover interlock switch.

• If both pass continuity, turn the printer 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 g round is not present,

see “Controller card service

check” on page 2-49 for more

information.

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

Replace the cover interlock s witch if faulty.

4505

Diagnostic information 2-51

4505

Dead machine service check

CAUTION: Check the AC line voltage. The voltage should be

within the following limits:

• 100 V ac (volts alternating current) – 127 Vac for the 110 V

printer

• 200 V ac – 240 Vac for the 220 V printer

FRU Action

Unplug the printer and check the fuses on the LVPS/HVPS board for continuity.

• If open, replace the LVPS/HVPS

LVPS/HVPS

board.

–If fuse opens again, see “LVPS/

HVPS service check” on page 2-57 for more information

• If not open, unplug the cables at CN102 and CN201 (fuser and controller card respectively).

Plug LVPS/HVPS board to source and 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.

• If either voltage is not correct, replace the LVPS/HVPS board.

• If both voltages are correct, chec k the controller card. See

“Controller board” on page 5-3

for more information.

Verify grounds.

2-52 Service Manual

Fuser service check

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

Warning: Avoid handling the lamp as much as possible as it is

easily broken. Be careful not to touch the glass housing with bare hands because skin acids can weaken the glass. The lamp is not a service part.

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

• 100 V ac–127 V ac for the 110 V model printer

• 200 V ac–240 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 left side cover and observing the upper opening through which the fuser power cables pass.

4505

Diagnostic information 2-53

4505

Fuser service check (continued)

FRU Action

Unplug the printer and disconnect the fuser lamp cable plug from the LVPS/HVPS board connector CN102.

Lamp cable LVPS/HVPS Fuser

Check for continuity across the fuser lamp by checking across the connector pins.

• If there is continuity, go to Step 1:

• If there is no continuity, go to

Step 1: Continuity

Turn the printer on with only the fuser power disconnected.

Measure the voltage at connector CN2 on the LVPS/HVPS. It should match the line voltage.

• If line voltage is not present, see

Make sure the fuser thermistor is correctly connected to the controller board. If the problem persists, disconnect the thermistor cable at J15 and check for less than +5 V dc on pin 1. Pin 2 should be ground.

• If line voltage is incorrect on pin1,

Continuity. Step 2: No continuity.

“LVPS/HVPS service check” on page 2-57 for more information.

see “Controller card service

check” on page 2-49 for more

information.

2-54 Service Manual

Step 2: No continuity

Check the lamp cable for continuity.

• If correct, replace the fuser.

• If incorrect, replace the lamp

cable.

Fuser service check (continued)

FRU Action

Disconnect the thermistor cable from J15 on the controller card.

Measure the resistance across the ends of the thermistor cable. See

Fuser (continued)

“Connector locations” on page 5-1 for more information.

Replace the fuser assembly if the resistance is lower than 1K ohm or shorted.

Note: Resistance measures

4505

approximately 240K ohms when cool and 1.4K ohms hot.

Diagnostic information 2-55

4505

Hot fuser service check

Note: Ensure correct lamp is installed.

FRU Action

Measure the resistance of the thermistor. The resistance measures from approximately 1K ohms immediately after printing or POR to approximately 240K ohms when

Fuser AC cables LVPS/HVPS Fuser

thermistor reaches room temperature. (It may take 30 min utes to cool.)

Replace the fuser assembly as necessary.

2-56 Service Manual

LVPS/HVPS service check

FRU Action

LVPS portion of board

Fuses that open typically indicate a faulty LVPS/HVPS.

Use the voltage meter to verify the

LVPS/HVPS

appropriate voltage at the printer end of the power cable.

Remove the LVPS/HVPS assembly from the printer.

Check continuity on the fuses. If either fuse has opened, replace

the card. Ensure the switch is off and plug the

power cord into the card. Turn the switch on.

4505

CAUTION: The card has several

points where AC voltage is exposed.

Carefully verify the AC voltage between pins 1 and 2 matches the power cable (wall) voltage.

• If voltage is incorrect, replace the card assembly.

V erify +24 V dc from pin 8 at CN201.

• If voltage is incorrect, replace the card assembly.

HVPS portion of board

Problems with the HVPS are exhibited in the print quality. See

“Print quality service checks” on page 2-66 for more information.

Diagnostic information 2-57

4505

Main motor service check

FRU Action

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

V erify ground at pins 2 and 7 for both the card and cable.

Main motor cable LVPS/HVPS Controller card

Warni ng: Do not replace the operator panel and controller card at the same time. Each card contains the printer settings. When either of these cards is new, it obtains the settings from the other card. Settings are lost when both are new and replaced at the same time.

• If these voltages are correct,

• If these voltages are not correct,

Note: The main motor is not a service par t.

check the main motor cable for continuity.

–Remove rear cover to access

connector on motor.

–If continuity exists on each wire,

call next level of service.

–If continuity does not exist on

one or more of the wires, replace the motor cable.

see the “LVPS/HVPS service

check” on page 2-57 or replace

the controller card.

2-58 Service Manual

Operator panel service check

Inspect the operator panel cable for damage . Mak e sure the cab le is plugged in securely.

Run POST and check each light for proper operation.

Operator panel service check

FRU Action

Operator panel Buttons

Open controller card cage and locate the operator panel connector at J16.

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

Similarly, check the continuity between 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 operator panel assembly. If margin errors are unacceptable, corrections can only be made through software. Contact the next level of support or Lexmark at 1–800–539–6275.

4505

Diagnostic information 2-59

4505

Operator panel service check (continued)

FRU Action

Operator panel Controller card

Warning: Do not replace the

operator panel and controller card at the same time. Each card contains the printer settings. When either of these cards is new, it obtains the settings from the other card. Settings are lost when both are new and replaced at the same time.

Lights

If none of the lights come on, make sure the cable is properly connected to 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 5 See “Controller card service

check” on page 2-49 or page 5-3

for 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 turn on or an individual light stays on solid during POST, replace the operator panel.

If all lights are dim and operate erratically during POST or all lights come on and stay on solid during POST, replace the FRUs in the following order one at a time:

• Controller card

• Operator panel

2-60 Service Manual

Printhead service check

FRU Action

Unplug the printer. Disconnect the printhead cables

from J11 and J12 on the controller card.

Printhead

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 and on pins 2, 6, and 8 at J12.

• If voltages or grounds are

• If voltages are correct, replace the

4505

incorrect, check the controller card. See “Controller card

service check” on page 2-49 for

more information. printhead (comes with cables).

Paper feed service checks

Paper jam error indication during POST

FRU Action

Exit sensor If the exit sensor flag is not resting

within the paper exit sensor during POST, the printer displays a paper jam message. Make sure the flag is operating freely and is correctly installed.

Input sensor Input sensor #1 (under print cartridge assembly) and Input sensor #2 (manual)

Make sure the input paper feed sensors are working properly. A stuck or incorrectly installed sensor causes this error.

Diagnostic information 2-61

4505

Paper picks during POST and/or continuously

FRU Action

ACM (auto comp mechanism or paper feed) clutch Manual feed clutch

Check the ACM clutch for wear. The solenoid interacts with the clutch to control the motion of the pick tires.

If the ratchet teeth of the ACM clutch assembly are worn or broken, the solenoid may not stop the ACM from rotating. Replace the ACM clutch assembly if necessary.

Check the manual feed clutch f or the same damage.

Paper picks but stops half way through the printer

FRU Action

Input sensor #1 (under print cartridge assembly) and Input sensor #2 (manual)

Make sure the input sensors are working properly.

Check for a broken or stuck flag on the input sensors.

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

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

• If correct, replace the input paper feed sensor.

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

2-62 Service Manual

Paper never picks

FRU Action

Paper feed (pick tires) Open the left cover and verify the

solenoid and clutch are functioning when an attempt is made to feed the paper.

Make sure the rubber tires are installed and clean.

Replace if necessary.

4505

Diagnostic information 2-63

4505

Paper occasionally picks or picks multiple sheets at once

FRU Action

Tray 1 Tray 2 (option)

Paper pick tires Check the tires in the A CM assembly

ACM clutch complete bill of material (CBM) Manual feed clutch CBM

Controller card Disconnect the solenoid cable at J5

Check tray for paper catch points. If the sheet being fed stops

momentarily, the ACM applies additional vertical force causing additional sheets to feed.

Do not mix paper types.

for signs of wear or damage. Replace the tires as necessary.

Open left cover and observe the solenoid and clutch actions at the ACM and manual feed shafts as a print job is attempted.

Replace the faulty part.

on the controller card. Measure the resistance across cable

pins 1 and 2 and then pins 3 and 4.

• The resistance should be 180–210 ohms.

• If it is not, call the next level of service.

• If the resistance is 180–210 ohms, check the controller card. See

“Controller card service check” on page 2-49 for more

information.

Replace controller card as necessary.

2-64 Service Manual

Paper “trees,” wrinkles, stacks poorly or curls

FRU Action

Fuser This problem is most likely due to a

worn backup roll. It causes the printer to run hotter than required for the media being printed. Excessive heat can cause paper treeing problems, poor stacking, or curl.

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 user Program/printer driver is set up correctly and the correct bidirectional parallel cable is installed, but the printer still fails to print on command from the host computer, replace the controller card.

4505

Diagnostic information 2-65

4505

Print quality service checks

Note: Ensure cover is closed tightly. A gap in the opening may allow

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

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

4. Enter the configuration menu. See “Configuration and

diagnostic groups” on page 3-1 for more information.

5. Slowly press and release three times until the and lights 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 first page has various fonts, the second page is gray, and the third page is black. Once the paper exits into the output bin, the printer returns to the home state (four top lights on).

7. Use the test pages to isolate problems such as light or toner streaks. See “Symptom tables” on page 2-44 for solutions to these problems.

8. To exit print quality test pages, turn the printer off.

light stays on, close cover.

2-66 Service Manual

Blank page

FRU Action

Toner cartridge (not a FRU) Remove the toner cartridge and

gently shake it to evenly distribute the toner.

Check for cartridge damage. Blank pages can be caused by a

defective printhead assembly, LVPS/HVPS, or controller card.

• Printhead errors typically result in

Printhead LVPS/HVPS Controller card Toner electrodes (cable assembly)

printer service errors.

• Blank pages typically are caused by the PC roll not being properly charged. Try a different PC kit.

Unplug the printer and check continuity between the LVPS/HVPS connection pads marked OPC and the corresponding pin inside the printer.

• If there is not continuity, call the next level of service.

Try a different toner cartridge and PC kit.

• If those fail, replace the LVPS/HVPS.

4505

Diagnostic information 2-67

4505

Black page

Note: Incorrect laser exposure or incorrect charging of the

photoconductor causes an all black page. Always verify the same results from a different print cartridge assembly and developer before proceeding.

FRU Action

Toner electrodes (not a FRU) Check the electrodes below the print

cartridge assembly for contamination or damage. Correct as necessary.

Check continuity between the cable connections on the contact tips below the print cartridge assembly.

• If continuity f ails, call the ne xt lev el of service.

With the printer off, disconnect the LVPS/HVPS cable from J7 on the controller card.

Turn the printer on and verify

LVPS/HVPS board Controller card

+24 V dc on pin 8 of the cable. Verify ground on pin 7.

• If the voltage is incorrect, replace LVPS/HVPS board.

• If voltage is correct and the toner electrodes are good, replace the controller card.

2-68 Service Manual

Heavy background

Poor de velopment or poorly charged toner particles cause excessive background. This is more noticeable as the toner cartridge nears end–of–life.

FRU Action

4505

Toner cartridge (not a FRU) PC Kit (not a FRU)

LVPS/HVPS Controller card

Make sure the toner cartridge and PC Kit are correctly installed and the high voltage contacts are clean.

If the toner cartridge and PC Kit are installed correctly, try a new PC Kit first and then toner cartridge.

Check the contacts for correct installation and contamination where contact is made between the print cartridge assembly, and LVPS/HVPS board. Clean as necessary.

If this does not correct the problem, replace the following FRUs one at a time in the order shown:

• LVPS/HVPS board

• Controller card

Diagnostic information 2-69

4505

Partial blank image/white spots (no periodic pattern)

FRU Action

Toner cartridge (not a FRU) Remove the toner cartridge

Paper (not a FRU) Make sure recommended paper is

assembly and gently shake the assembly to evenly distribute the toner.

If toner cartridge is low, try a new one.

being used.

Variation in image density horizontally across page

FRU Action

PC Kit (not a FRU) The charge roll may have an

Transfer roll Check the springs in the left and

unbalanced pressure against the Photoconductor (PC) drum.

Try a new PC Kit.

right transfer roll bearings. The bearing assemblies should support the transfer roll, applying even pressure to the PC drum.

Replace the transfer roll assembly if the springs or bearing show signs of damage or fatigue.

Inspect the transfer roll for signs of wear, damage or contamination.

Replace as necessary.

2-70 Service Manual

Poor fusing of image

FRU Action

Fuser The fuser may not be operating at

the proper temperature to fuse the toner to the paper. See“Hot fuser

service check” on page 2-56 for

more information.

4505

Paper (not a FRU) Make sure recommended paper is

being used.

Light print

FRU Action

Toner cartridge (not a FRU) Make sure the toner cartridge and

Transfer roll LVPS/HVPS board

PC Kit are installed correctly and that the toner cartridge is not low on toner.

If the problem continues, install a new toner cartridge.

Recheck condition before replacing PC Kit, if necessary.

Check the transfer roll for signs of toner buildup and contamination.

Inspect the HVPS contact (transfer roll) for contamination.

Verify the high voltage cable is plugged into the LVPS/HVPS.

If all components appear free of contamination, replace the following FRUs one at a time in the order shown:

• Transfer roll

• LVPS/HVPS board

Diagnostic information 2-71

4505

White or black lines or bands

FRU Action

Print cartridge assembly (not a FRU)

Developer drive coupling assembly

Banding appears as light or dark horizontal lines on a uniformly gray page or on a page with a large area of graphics. Banding is primarily due to a variation in the speed of the paper as it feeds through the printer especially in the developer and transfer process.

Inspect the toner cartridge and paper feed components, especially the drive coupler and drive gears for debris, binds or damage.

Toner on back of page

FRU Action

PC Kit (not a FRU) Inspect the overall paper path for

signs of spilled toner. Gently clean the contaminated areas

with a soft cloth or compressed air.

Fuser The fuser hot roll can cause toner

deposits on the back of the paper if toner is building up on the hot roll. This buildup may transfer to the backup roll, later transferring to the back of the paper.

Inspect the hot roll and backup roller for signs of contamination.

Replace the fuser as necessary.

Transfer roll A transfer roll contaminated with

toner can cause toner to transfer to the back of printed pages.

Inspect the transfer roll for contamination and replace as necessary.

2-72 Service Manual

LEXMARK E23x, E33x Service Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Table of contents

Laser notices

Safety information

Preface

Definitions

1. General information

Overview of the operator panel

Paper jams–how to clear

Tips on preventing jams

Tools

Types of print media

Abbreviations

2. Diagnostic information

Start

POST (power–on self test)

Overview of the operator panel

Understanding the operator panel lights

Common light sequences

Secondary errors

Operator panel codes

Primary codes

Ready / Power Saver

Busy

Hex Trace Ready

Waiting

Flushing / Resolution reduced

Not ready

Close door / Insert cartridge

Load media

Load manual feeder

Print side two of duplex job

Toner low

Replace photoconductor kit

Replace photoconductor kit (printer hard stop)

Toner cartridge error / Toner cartridge is not installed

Change invalid toner cartridge

Invalid engine code / Invalid network code

Programming engine code / Programming system code

Cancel job / Reset printer

Service error

Printer error

Secondary error codes

Paper jam in the manual feeder

Paper jams as it exits the tray into the printer

Paper jams as a printed job exits the printer

Complex page

Insufficient printer memory

Insufficient collation area

Font error

Defective flash

Insufficient defrag memory

Network interface errors

Error communicating with host computer

Memory full

Short paper

Flash full

Unformatted flash

Invalid engine code

Invalid network code

Service information with secondary and tertiary light patterns

Secondary error codes

Tertiary service error codes

Controller software

Transfer roll

Fuser, fan, or toner sensor error Codes 920 through 929 indicate a problem in the fuser (see “Fuser

Printhead, transport motor or RIP/engine communication error

RIP to engine communication failure (controller card).

NVRAM failure

RAM memory error

Network error

Paper port communication failure

Symptom tables

POST symptom table

Printer symptom table

Service checks

Cold fuser service check