Page 1 4505-200 4505-300 4505-310 4505-400 4505-410 • Table of Contents • Start Diagnostics • Safety and Notices • Trademarks • Index Lexmark and Lexmark with diamond design are trademarks of Lexmark International, Inc., registered in the United States and/or other countries.
Page 2 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.
Page 3: Table Of Contents
4505 Table of contents Laser notices ......... . . vii Safety information.
Page 4 4505 Operator panel service check......2-59 Printhead service check ......2-61 Paper feed service checks .
Page 5 4505 Preventive maintenance ....... . 6-1 Parts catalog ......... . 7-1 How to use this parts catalog .
Page 6 4505 Service Manual...
Page 7: Laser Notices
4505 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.
Page 8 4505 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.
Page 9 4505 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).
Page 10 4505 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.
Page 11 4505 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.
Page 12 4505 Japanese Laser Notice Chinese Laser Notice Service Manual...
Page 13 4505 Korean Laser Notice xiii Laser notices...
Page 14 4505 Service Manual...
Page 15: Safety Information
4505 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.
Page 16 4505 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.
Page 17 4505 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. •...
Page 18 4505 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. •...
Page 19 4505 Safety information...
Page 20: Preface
4505 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.
Page 21: General Information
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.
Page 22: Service Manual
4505 The differences between the models are listed in the following table. 4505-100 4505-200 4505-310 4505-300 Item Lexmark Lexmark Lexmark Lexmark E330 E230 E232 E332n Base memory 16MB 32MB Maximum 80MB 160MB memory Paper inputs • 250–sheet • 250–sheet tray tray •...
Page 23: Overview Of The Operator Panel
4505 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 Load Paper Paper Jam Error • Press and release to resume printing.
Page 24: Paper Jams-How To Clear
4505 Paper jams–how to clear When a paper jam occurs, the printer stops operating and the operator panel’s 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 more information.
Page 25: Tips On Preventing Jams
– Have any exposed adhesive when the flap is in the sealed position • 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...
Page 26: Tools
4505 Tools The removal and adjustment procedures require the following tools and equipment: • Magnetic tip Phillips screwdrivers, large and small • Volt ohmmeter Service Manual...
Page 27: Types Of Print Media
4505 Types of print media Ensure trays are properly loaded. Never mix media types within a tray. Capacity Source Sizes Types Weight (sheets) Tray 1 A4, A5, Plain paper, 60–90 g/m • 250 paper JIS B5, transparencies, (16–24 lb) • labels (250-sheet letter, legal, labels...
Page 28: Abbreviations
4505 Abbreviations Auto Comp Mechanism (or paper feed) ASIC Application Specific Integrated Circuit Complete Bill Of Material DIMM Dual In-Line Memory Module External Network Adapter Field Replaceable Unit Host Based Printing High Voltage HVPS High Voltage Power Supply INTL International LVPS Low Voltage Power Supply NVRAM...
Page 29: Diagnostic Information
4505 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.
Page 30: Overview Of The Operator Panel
4505 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 - lights on).
Page 31: Understanding The Operator Panel Lights
4505 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”...
Page 32 4505 Printer condition ● ✷ Load manual feeder ✷ ● Print side two of duplex job ● Toner low ● ✷ Replace photoconductor ● ✷ ✷ Replace photoconductor kit (printer hard stop) ✷ ● Missing or defective toner cartridge ● ●...
Page 33 4505 Printer condition ✷ ✷ ✷ ✷ ✷ ✷ Service error (see “Service information with secondary and tertiary light patterns” on page 2-29 more information). ✷ ● Printer error (see “Secondary error codes” on page 2-19 more information). Diagnostic information...
Page 34: Secondary Errors
4505 Secondary errors When the 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...
Page 35 4505 Printer condition ● ● ● ● Short paper ● ● ● ● Unformatted flash ● ● ● ● Flash full ● ● ● Invalid engine code ● ● ✷ Invalid network code Paper jam secondary codes ● ● ● 200 Paper jam input sensor ●...
Page 36: Operator Panel Codes
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 receive •...
Page 37 4505 Busy Light sequence Meaning Action: • Busy: • Printer is busy – Wait for message to receiving and clear. processing data or – Press and release printing. to cancel print • Printer is job. defragmenting the flash – Press and hold memory to reclaim reset printer.
Page 38: Hex Trace Ready
4505 Hex Trace Ready Light sequence Meaning Action: Printer is in the Ready • Hex Trace helps mode and Hex Trace is troubleshoot printing active. problems. After resolving the problem, turn off the printer to exit Hex Trace. • Or, press and hold to reset the printer.
Page 39: Not Ready
4505 Flushing / Resolution reduced Light sequence Meaning Action: • Wait until • Printer is flushing corrupted print data. displayed to print other jobs. • Printer is processing data or printing pages, • Press and release but the resolution of a to cancel print job.
Page 40: Close Door / Insert Cartridge
4505 Close door / Insert cartridge Light sequence Meaning Action: The printer door is open. Close the door. Load media Light sequence Meaning Action: The printer is out of • Load media into tray 1 media, or the media did or the optional not feed properly.
Page 41: Load Manual Feeder
4505 Load manual feeder Light sequence Meaning Action: Printer prompts to load a • Load media, with the single sheet of media in side to be printed the manual feeder. facing the front of the printer, into the manual feeder. •...
Page 42: Toner Low
4505 Toner low Light sequence Meaning Action: • Printer is ready to • Send a print job. receive and process • Press to print the data. menu settings page for • The toner in the toner a list of current cartridge is getting low.
Page 43 4505 Replace photoconductor kit (printer hard stop) Light sequence Meaning Action: • Replace the The photoconductor kit’s drum is full and needs photoconductor kit. replacing. No pages print until the photoconductor kit is replaced. Toner cartridge error / Toner cartridge is not installed Light sequence Meaning Action:...
Page 44: Change Invalid Toner Cartridge
4505 Change invalid toner cartridge Light sequence Meaning Action: The toner cartridge being Install a toner cartridge used is not designed for compatible to printer. this printer. Invalid engine code / Invalid network code Light sequence Meaning Action: The code in an internal •...
Page 45: Cancel Job / Reset Printer
4505 Programming engine code / Programming system code Light sequence Meaning Action: Wait for the message to New code is being programmed into the clear. When the printer engine or firmware code has finished programming flash. the code, it performs a soft reset.
Page 46: Service Error
4505 Service error Light sequence Meaning Action: The printer has a service Turn the printer off and error and printing has back on. stopped. If the lights are still blinking, contact the place where printer was purchased. Printer error Light sequence Meaning Action: •...
Page 47: Secondary Error Codes
4505 Secondary error codes • When the lights are both on, a secondary error has occurred. Press and release twice quickly to display the secondary error code light sequence. • lights are both on, a paper jam When the secondary error has occurred. twice to display the secondary error code Press and release light sequence.
Page 48 4505 Paper jam in the manual feeder Light sequence Meaning Action: A paper jam has occurred Clear the paper jam. in the manual feeder. Paper jams as it exits the tray into the printer Light sequence Meaning Action: A paper jam has occurred Clear the paper jam.
Page 49: Complex Page
4505 Paper jams as a printed job exits the printer Light sequence Meaning Action: A paper jam has occurred Clear the paper jam. as the paper is exiting the printer. Complex page Light sequence Meaning Action: The page may not print •...
Page 50: Insufficient Printer Memory
4505 Insufficient printer memory Light sequence Meaning Action: The printer does not have • Install additional enough memory to save memory. the data in the buffer. • Press to continue printing the job. • Press to cancel the print job. Insufficient collation area Light sequence Meaning...
Page 51: Font Error
4505 Font error Light sequence Meaning Action: The printer has received • Press and release a request for a PPDS font to cancel the print job. which is not installed. • Press and hold reset the printer. • Press and release to clear the message and continue printing.
Page 52: Insufficient Defrag Memory
4505 Insufficient defrag memory Light sequence Meaning Action: • Delete fonts, macros, The printer has insufficient memory to and other data in RAM. free unused space in • Install additional printer flash memory. memory. Network interface errors Light sequence Meaning Action: The printer cannot Press...
Page 53: Memory Full
4505 Error communicating with host computer Light sequence Meaning Action: • Make sure the cable The printer has lost the connection to an external connecting the ENA print server (also called and the printer is an external network securely attached. adapter or external •...
Page 54: Short Paper
4505 Short paper Light sequence Meaning Action: • Make sure the print The paper length is too short to print the media you loaded is formatted data. This large enough. occurs when the printer • Open the front cover, does not know the media clear the paper path size loaded in the tray, or and close the cover to...
Page 55: Unformatted Flash
The job may not print correctly. • Reformat the flash memory. Refer to the Technical Reference on Lexmark’s Web site for more information. • If the error message remains, the flash memory may be defective and should be replaced.
Page 56: Invalid Network Code
4505 Invalid network code Light sequence Meaning Action: Download valid network The code in an internal print server has not been code to the internal print programmed, or the server. programmed code is not valid. 2-28 Service Manual...
Page 57: Service Information With Secondary And Tertiary Light Patterns
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.
Page 58: Secondary Error Codes
4505 Secondary error codes Secondary codes Lights Primary code ✷ ✷ ✷ ✷ ✷ ✷ ✷ ✷ ✷ ✷ ✷ Continue ✷ Ready ✷ ✷ ✷ Toner Low Replace PC Kit ✷ ✷ ✷ ✷ ✷ Load Paper ✷ ✷ ✷...
Page 59: Tertiary Service Error Codes
4505 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.
Page 60 4505 Controller software Tertiary codes Lights ✷ Continue ✷ ✷ ✷ ✷ ✷ ✷ ✷ Ready Toner Low / Replace PC ✷ ✷ ✷ Load Paper ✷ ✷ ✷ Paper Jam ✷ ✷ ✷ Error Secondary code interface driver error General engine software error Faulty engine code flash or...
Page 61 4505 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.
Page 62 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 for more information), a stalled fan motor or a faulty toner sensor or toner cartridge. Tertiary codes Lights ✷...
Page 63 4505 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. 2-35 Diagnostic information...
Page 64 4505 Code 939 indicates a communication failure between the RIP and engine processors. Tertiary codes Code ✷ Continue ✷ ✷ ✷ ✷ ✷ ✷ ✷ ✷ ✷ Ready ✷ Toner Low / Replace PC ✷ ✷ ✷ ✷ Load Paper ✷...
Page 65 4505 RIP to engine communication failure (controller card). This indicates fuser control in the LVPS has failed or the wrong LVPS has been installed. Tertiary codes Code ✷ Continue ✷ Ready Toner Low / Replace PC ✷ Load Paper Paper Jam Error Secondary code...
Page 66 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...
Page 67 4505 Tertiary codes Code ✷ Continue ✷ ✷ ✷ ✷ ✷ ✷ ✷ ✷ ✷ Ready ✷ ✷ Toner Low / Replace PC ✷ ✷ ✷ ✷ ✷ Load Paper ✷ ✷ ✷ Paper Jam ✷ ✷ ✷ ✷ ✷ Error SRAM Secondary code...
Page 68 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...
Page 69 4505 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 Code ✷ Continue ✷ ✷ ✷...
Page 70 4505 Network error Indicates an error in the network circuitry. Replace the controller card assembly. Tertiary codes Code ✷ Continue ✷ ✷ ✷ ✷ ✷ ✷ ✷ ✷ ✷ Ready ✷ ✷ Toner Low / Replace PC ✷ ✷ ✷ ✷...
Page 71 4505 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 Code ✷...
Page 72: Symptom Tables
4505 Symptom tables POST symptom table Symptom Action The main motor, cooling fan, “Cover interlock switch service and fuser do not come on. check” on page 2-51. POST completes except one or “Operator panel service check” more lights do not come on. on page 2-59.
Page 73: Printer Symptom Table
4505 Printer symptom table Symptom Action Dead machine (no power) “Dead machine service check” on page 2-52. Fan noisy or not working “Cooling fan service check” on page 2-48. Fuser parts melted “Hot fuser service check” on page 2-56. Fuser lamp doesn’t light “Cold fuser service check”...
Page 74 4505 Symptom Action White or black lines or bands “White or black lines or bands” on page 2-72. Toner on back of page “Toner on back of page” on page 2-72. Paper never picks “Paper never picks” on page 2-63. Paper feeds continuously “Paper picks during POST and/or continuously”...
Page 75: Service Checks
4505 Service checks Service checks which involve measuring voltages on the LVPS/HVPS ( low voltage power supply/high voltage board) should be performed with the printer power supply positioned on its back side. Note: When you make voltage readings, always use frame ground unless another ground is specified.
Page 76: Cooling Fan Service Check
4505 Cooling fan service check 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.
Page 77: Controller Card Service Check
4505 Controller card service check Action 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. •...
Page 78 4505 Controller card service check (continued) 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.
Page 79: Cover Interlock Switch Service Check
4505 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. 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.
Page 80: Dead Machine Service Check
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 V ac for the 110 V printer • 200 V ac – 240 V ac for the 220 V printer Action Unplug the printer and check the fuses on the LVPS/HVPS board for...
Page 81: Fuser Service Check
4505 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.
Page 82 4505 Fuser service check (continued) Action Unplug the printer and disconnect the fuser lamp cable plug from the LVPS/HVPS board connector CN102. Check for continuity across the fuser Lamp cable lamp by checking across the LVPS/HVPS connector pins. Fuser • If there is continuity, go to Step 1: Continuity.
Page 83 4505 Fuser service check (continued) Action Disconnect the thermistor cable from J15 on the controller card. Measure the resistance across the ends of the thermistor cable. See “Connector locations” on Fuser (continued) page 5-1 for more information. Replace the fuser assembly if the resistance is lower than 1K ohm or shorted.
Page 84: Hot Fuser Service Check
4505 Hot fuser service check Note: Ensure correct lamp is installed. Action 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 Fuser AC cables temperature.
Page 85: Lvps/Hvps Service Check
4505 LVPS/HVPS service check Action LVPS portion of board Fuses that open typically indicate a faulty LVPS/HVPS. Use the voltage meter to verify the appropriate voltage at the printer LVPS/HVPS end of the power cable. Remove the LVPS/HVPS assembly from the printer. Check continuity on the fuses.
Page 86: Main Motor Service Check
4505 Main motor service check Action 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 both the card and cable. • If these voltages are correct, Main motor cable check the main motor cable for LVPS/HVPS...
Page 87: Operator Panel Service Check
• 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. 2-59 Diagnostic information...
Page 88 4505 Operator panel service check (continued) Action Lights Operator panel Controller card If none of the lights come on, make sure the cable is properly connected Warning: Do not replace the to the controller card and the operator panel and controller card has input voltage to it.
Page 89: Printhead Service Check
4505 Printhead service check Action Unplug the printer. Disconnect the printhead cables from J11 and J12 on the controller card. Turn the printer on. Printhead 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.
Page 90 4505 Paper picks during POST and/or continuously Action ACM (auto comp mechanism or Check the ACM clutch for wear. The paper feed) clutch solenoid interacts with the clutch to Manual feed clutch 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.
Page 91: Paper Never Picks
4505 Paper never picks 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. 2-63 Diagnostic information...
Page 92 4505 Paper occasionally picks or picks multiple sheets at once Action Tray 1 Check tray for paper catch points. Tray 2 (option) If the sheet being fed stops momentarily, the ACM applies additional vertical force causing additional sheets to feed. Do not mix paper types.
Page 93: Parallel Port Service Check
4505 Paper “trees,” wrinkles, stacks poorly or curls 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.
Page 94: Print Quality Service Checks
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.
Page 95: Blank Page
4505 Blank page 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. •...
Page 96: Black Page
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. Action Toner electrodes (not a FRU) Check the electrodes below the print cartridge assembly for contamination or damage.
Page 97: Heavy Background
4505 Heavy background Poor development or poorly charged toner particles cause excessive background. This is more noticeable as the toner cartridge nears end–of–life. Action Toner cartridge (not a FRU) Make sure the toner cartridge and PC Kit (not a FRU) PC Kit are correctly installed and the high voltage contacts are clean.
Page 98 4505 Partial blank image/white spots (no periodic pattern) Action Toner cartridge (not a FRU) Remove the toner cartridge assembly and gently shake the assembly to evenly distribute the toner. If toner cartridge is low, try a new one. Paper (not a FRU) Make sure recommended paper is being used.
Page 99: Poor Fusing Of Image
4505 Poor fusing of image 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 more information. Paper (not a FRU) Make sure recommended paper is being used.
Page 100: Toner On Back Of Page
4505 White or black lines or bands Action Print cartridge assembly (not a Banding appears as light or dark FRU) horizontal lines on a uniformly gray page or on a page with a large area Developer drive coupling of graphics. Banding is primarily due assembly to a variation in the speed of the paper as it feeds through the printer...
Page 101 4505 Solving print quality problems Problem Action Light or blurred characters. Light print The toner cartridge may be getting low on toner: • Remove the toner cartridge and print cartridge assembly. • Shake it from side to side to redistribute the toner. •...
Page 102 • Change the media texture setting. If the setting is not in your driver, you can download the correct Lexmark setup utility from the Lexmark Web site at www.lexmark.com. The print is getting light but the • The light does not come light is not on.
Page 103 4505 Problem Action Solid black areas on • Choose a different fill pattern in transparencies or white streaks your software Program. on paper. • Try a different type of paper. Paper designed for copiers gives the best quality. • Remove the toner cartridge and gently shake it from side to side to redistribute the toner.
Page 104 Toner Low alarm is set to on, the printer stops printing until you replace the toner cartridge. – Download the correct Lexmark setup utility from the Lexmark Web site at www.lexmark.com to change the Toner Low alarm.
Page 105 4505 Problem Action The media skews or buckles. • Don’t overfill Tray 1 or the optional Tray 2 (see media capacities in the media types and sizes table in the User’s Reference). • Make sure the paper guides are flush against the edges of the media.
Page 106 4505 Problem Action The printer does not print after a • Clear all jams. paper jam has been cleared. • Press and release or open and close the printer cover to restart the printer. • Make sure the print cartridge assembly is installed properly.
Page 107: Transfer Roll Service Check
4505 Transfer roll service check Action Check transfer roll area for debris and clean as necessary. Verify continuity between the spring below the left side bearing and the transfer roll shaft. Transfer roll Verify continuity in the spring and the cable connection on the LVPS/HVPS.
Page 108 4505 2-80 Service Manual...
Page 109: Diagnostic Aids
4505 3. Diagnostic aids Configuration and diagnostic groups Configuration The configuration group contains a set of menus, settings, and operations which are not used by an end user. Generally, the options made available in this menu group are used to configure a printer. Access to the configuration group is gained by way of a POR key sequence.
Page 110: Power-On Operations
4505 Accessing the configuration and diagnostic groups Power–On operations To access printer operations: 1. Turn off the printer. 2. Open the front cover. 3. Press and hold the buttons in the following table for the operation needed. Operation Power–on action Enter 1.
Page 111 4505 Moving around the menu “Printer settings configuration” on page 3-4 “Printer diagnostics” on page 3-5, are similar to the instructions printed by following steps 1-6 on page 3-2. These menu items are designated by the non–indented items listed along the left edge of the page. (Bottom as printed from printer.) These items are also un–shaded.
Page 112 4505 Printer settings configuration Service Manual...
Page 113 4505 Printer diagnostics Diagnostic aids...
Page 114: Configuration Menu Selections
4505 Configuration menu selections Utilities Use the Utilities menu to troubleshoot printer problems. Setting Use setting to: Values Reset Factory Return the printer settings to factory default values. Defaults Sometimes resetting the printer to the original settings solves formatting problems. All menu items are reset to the factory default values except: •...
Page 115 4505 Setting Use setting to: Values Reset Return the photoconductor counter to zero. Photoconductor The replace photoconductor message should be Counter cleared only when the photoconductor kit has been replaced. * Factory default Setup Use the Setup menu to configure how the printer formats the end of a line depending on the computer system being used.
Page 116 4505 Parallel Use the Parallel menu to change printer settings on jobs sent through a parallel port. Menu item Use setting to: Values NPA Mode Send print jobs to the printer and query printer status information simultaneously. Auto* Protocol Receive information at a Standard much higher transmission Fastbytes*...
Page 117 4505 Use the USB menu to change printer settings on jobs sent through a USB port. Menu item Use setting to: Values NPA Mode Send print jobs to the printer and query printer status information simultaneously. Auto* MAC Binary PS Configure the printer to Off—The printer filters process Macintosh binary...
Page 118 4505 Network Use the network menu to change printer settings on jobs sent through a network port (either standard network or network opt <x>). Menu item Use setting to: Values NPA Mode Send print jobs to the printer and query printer Auto* status information simultaneously.
Page 119 4505 Network (continued) Menu item Use setting to: Values Auto* – the printer detects Set card speed Automatically detect the connection speed of your current network speed. network. 10Mbps, half duplex– This setting can be forces the printer to try to disabled to set the speed connect to the network manually.
Page 120: Diagnostics Menu Selections
4505 Diagnostics menu selections Development Menu item Use setting to: Value Edge–to–edge Allow a shift of all four Off* margins (top, bottom, right and left) to the physical edge of the page (printable area of supported paper). Setting ignored by PPDS interpreter.
Page 121 4505 Parallel Menu item Use setting to: Value Par S strobe Adjust for an unusually long adjustment parallel cable. (Parallel mode 2 only is supported and can be turned off in the configuration group.) * Factory default Network Menu item Use setting to: Value Mark history...
Page 122 4505 3-14 Service Manual...
Page 123: Repair Information
4505 4. Repair information Removals Note: 1. Remove the toner cartridge and paper tray before removing other printer parts. The toner cartridge should be protected from light while out of the printer. 2. We recommend all external cables be disconnected from the printer to prevent damage during service.
Page 124: Covers
4505 Covers Access cover removal (See “Covers” on page 7-2.) 1. Open the front access cover. 2. Place thumbs on the inside of the respective hinge. 3. Force the left hinge out of its socket and relax it above the socket.
Page 125 4505 Left side cover removal (See “Covers” on page 7-2.) 1. Open the access cover to expose a screw and the two left side cover latches. 2. Remove the screw, which fastens the side cover. 3. Open the rear door (output tray). 4.
Page 126: Controller Card Removal
4505 Top cover removal (See “Covers” on page 7-2.) 1. Open the access cover. 2. Open the left cover. 3. Open the right cover. 4. Remove two screws at the top rear corners of the top cover. 5. Remove two screws at the front of the top cover just behind the access door.
Page 127: Cover Open Sensor Removal
4505 Cover open sensor removal (See “Electronics” on page 7-4.) 1. Remove the right side cover. See “Right side cover removal” on page 4-3 for more information. 2. Remove the controller card cover (two screws). 3. Disconnect the cover open switch at J13 on the controller card and extract the cable.
Page 128: Fan Removal
4505 Exit sensor removal (on the fuser) (See “Electronics” on page 7-4.) 1. Remove the paper exit guide assembly. See “Paper exit guide assembly removal” on page 4-12 for more information. 2. Remove the controller card cover. See “Controller card removal”...
Page 129: Feed Rollers (Auto Comp Tires) Removal
4505 Feed rollers (auto comp tires) removal (See “Frame” on page 7-6.) 1. Remove the paper tray. 2. Remove the toner cartridge. 3. Tilt the printer onto its back. 4. Remove old tires. 5. Ensure the new tires are captured between the rims of the plastic hub.
Page 130: Fuser Power Cable Removal
4505 Fuser power cable removal (See “Electronics” on page 7-4.) 1.Remove the LVPS/HVPS card. See “LVPS / HVPS card assembly removal” on page 4-10 more information. Note: The cable can be reached without fully removing the card. 2. Remove the rear cover. See “Rear cover removal”...
Page 131: Input Roller Clutch And Lever Removal (Acm Clutch Cbm)
4505 Input roller clutch and lever removal (ACM clutch CBM) (See “Frame” on page 7-6.) 1. Remove the left side cover. 2. Place the printer on its right side. Protect the cover from being marred. 3. Remove four screws in the gear train metal cover. 4.
Page 132: Input Sensor #2 (Manual) Removal
4505 Input sensor #2 (manual) removal (See “Electronics” on page 7-4.) 1. Open the right side cover. See “Right side cover removal” on page 4-3 for more information. 2. Remove the controller card cover. 3. Disconnect the sensor cable at J18 on the controller card (front, top of card).
Page 133: Lvps / Hvps To Controller Card Cable Removal
4505 LVPS / HVPS to controller card cable removal (See “Electronics” on page 7-4.) 1. Remove the LVPS/HVPS card. See “LVPS / HVPS card assembly removal” on page 4-10 for more information. 2. Remove the controller card cover. See “Controller card removal”...
Page 134: Paper Exit Guide Assembly Removal
4505 Paper exit guide assembly removal (see “Frame” on page 7-6.) 1. Remove the rear cover. See “Rear cover removal” on page 4-3 for more information. 2. Remove the three screws holding the exit guide. 3. Remove the paper exit guide assembly. Reinstallation note: It may be necessary to rotate the gears to mesh with the fuser and drive gear.
Page 135: Toner Level Sensor Removal
4505 Toner level sensor removal (See “Electronics” on page 7-4.) 1. Open the right side cover. See “Right side cover removal” on page 4-3 for more information. 2. Unplug the cable from the sensor. 3. Unsnap the toner level sensor from the frame and remove through the inside of the printer.
Page 136: Transport Motor Cable Removal
4505 Transport motor cable removal (See “Electronics” on page 7-4.) 1.Remove the right cover. See “Right side cover removal” on page 4-3 for more information. 2.Remove the controller card cover. See “Controller card removal” on page 4-4 for more information. 3.Unplug the transport motor cable (XPRT) at J9.
Page 137: Connector Locations
4505 5. Connector locations Front and rear views Connector locations...
Page 138: Power Supply Board
4505 Power supply board Service Manual...
Page 139: Controller Board
4505 Controller board Connector locations...
Page 140: Wiring Diagram
4505 Wiring diagram Note: See the fold out wiring diagram in the back of this book for a larger view. MMRef-C MMStart-C MMLock-C +24V only) (H/Hr LPOW_C VDO_ADJ_C Video_C LDEN_C +5V_LD HSYNC_C VREF +5V_LD +24V <5V Paper_Out_C +24V Feedback Button1_C LED_CLK_C LED_Data_C Button2_C...
Page 141: Preventive Maintenance
4505 6. Preventive maintenance The Lexmark E23x, E33x do not require preventive maintenance. Preventive maintenance...
Page 142 4505 Service Manual...
Page 143: Parts Catalog
4505 7. Parts catalog How to use this parts catalog SIMILAR ASSEMBLIES: If two assemblies contain a majority of identical parts, they are shown on the same list. Common parts are shown by one index number. Parts peculiar to one or the other of the assemblies are listed separately and identified by description.
Page 144 4505 Assembly 1: Covers Service Manual...
Page 145: Index
56P1833 Cover, logo plate E230 56P2086 Cover, logo plate (plain) 56P2628 Cover, logo plate (white) E230 56P2096 Cover, logo plate (white) E330 56P2097 Cover, logo plate (white) E232 56P2629 Cover, logo plate (white) E332 56P2703 Cover, logo plate E234 56P1816...
Page 146 4505 Assembly 2: Electronics Service Manual...
Page 147 Fuser assembly, 100 V 56P1826 Sensor, exit 56P2077 Cable assemblies, miscellaneous • Toner sensor • LVPS/HVPS to controller • Main drive motor (E23x/E330) • Main drive motor (E234n/E332n) • Fuser power 56P1824 Sensor, input #1 56P1827 Sensor, cover open 56P2072...
Page 148 4505 Assembly 3: Frame Service Manual...
Page 149 4505 Assembly 3: Frame Index Units Description 56P2078 Guide assembly, paper exit 56P1823 Transfer, roll, bearings, gear 56P1822 Cover, legal extender 56P2094 Cover, legal extender (white) 56P2646 Screws, miscellaneous (actual size) TP2NC-3.0+6P-Ni (quantity 2) M3.0*0.5+6P-Ni,2 Washer (quantity 2) MT3.0*0.5+6PF-Ni (quantity 5) TP2NC-3.0+6PF-Ni (quantity 4) 56P1820 Paper feed, rubber tires...
Page 150 4505 Assembly 4: Miscellaneous This page intentionally left blank. Service Manual...
Page 151 4505 Assembly 4: Miscellaneous Index Units Description 56P1232 Adapter, US 802.11B wireless print 56P1233 Adapter, INTL 802.11B wireless print 56P1431 Adapter, MarkNet X2011E external 56P1432 Adapter, MarkNet X2012E external 56P1433 Adapter, MarkNet X2031E external 56P1434 Adapter, MarkNet X2030 Token Ring external 56P1435 Adapter, external serial 1038693...
Page 152 4505 7-10 Service Manual...
Page 153 4505 Index abbreviations diagnostic aids auto CR after LF (setup menu) accessing configuration group auto LF after CR (setup menu) accessing diagnostic group configuration menu diagnostic menu power-on operations buttons diagnostic menu moving around the menu printer diagnostics configuration menu printer setting configuration moving around the menu diagnostic menu selections...
Page 154 2-17 E230 lights E232 overview E234 primary codes E234n busy E330 cancel job / reset printer 2-17 E332n change invalid toner cartridge 2-16 close door / insert cartridge NPA mode 2-12 parallel menu 3-10 3-11 flushing/resolution...
Page 155 4505 secondary codes print media 2-19 manual feed complex page 2-21 Tray 1 defective flash 2-23 Tray 2 error communicating with types host 2-25 print quality problems flash full 2-26 solving 2-73 font error 2-23 print quality test pages insufficient collation area using...
Page 156 4505 paper exit guide asm. 4-12 service checks 2-47 printhead 4-12 controller card 2-49 toner level sensor 4-13 cooling fan 2-48 toner level sensor cable 4-12 cover interlock 2-51 reset factory defaults (utilities menu) dead machine 2-52 fuser 2-53 cold 2-47 2-56 LVPS/HVPS...
Page 157: Part Number Index
4505 Part number index Description Page 1038693 Cable, serial, 50 foot (PSO) ......7-9 11D0330 Power cord, Argentina .
Page 158 Cover, left .........7-3 56P2081 Cover, logo plate E330 .......7-3 56P2082 Latch CBM, access cover .
Page 159 Card, controller E232 ....... 7-5 56P3088 Card, controller E330, E234 ......7-5 56P3089 Card, controller E332n, E234n .
Page 160 4505 Service Manual...

This manual is also suitable for:

E23 series E33 series

Lexmark E330 Service Manual

Laser Notices

Safety Information

Preface

General Information

Diagnostic Information

Diagnostic Aids

Repair Information

Preventive Maintenance

Parts Catalog

Index

Part Number Index

Quick Links

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Summary of Contents for Lexmark E330

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Table of Contents