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Lexmark E23x and E33x

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1. IN ge O 5 2 Service Manual 4505 Controller board lt A 4 LS m 4M Jg P d e ei ae 11913 we Bis L 3 E ieee Eo Era TE E J19 S ri 6 C i e J18 J20 at 4197 1s Connector locations 5 3 Note See the fold out wiring diagram in the back of this book for a larg
2. 7 3 Cover legal extender white 7 7 Cover left white 7 8 Cover logo plate white E330 7 3 Cover logo plate white E232 7 3 Cover assembly rear white 7 3 Card assembly Korean font 7 9 Cover logo plate white E230 7 3 Cover logo plate white E332 7 3 Screws miscellaneous 7 7 Springs front door and ACM 7 3 7 7 Rings plastic Snap casas ERR A ex mn 7 7 Cover logo plate E234 7 3 Card controller E230 7 5 Card controller E232 7 5 Card controller E330 E234 7 5 Card controller E332n E234n 7 5 Software Optra Forms 7 9 Software Optra Forms director 7 9 Package assembly field relocation 7 9 4505 l 8 Service Manual
3. 7 9 Power cord Brazil 6 foot straight 7 9 Cable 20 foot parallel cable with pack 7 9 Power cord PRC 1 77M straight 7 9 DIMM 16MB PC100 SDR DIMM 79 DIMM 32MB PC100 SDR DIMM 79 DIMM 64MB PC100 SDR DIMM 79 DIMM 128MB PC100 SDR DIMM 79 Adapter US 802 11B wireless print 79 Adapter INTL 802 11B wireless print 7 9 Card assembly 16MB flash 7 9 Card assembly 32MB flash 7 9 Card assembly OptraForms 32MB flash 7 9 Card assembly OptraForms 16MB flash 7 9 Card assembly simplified Chinese font 7 9 Card assembly traditional Chinese font 7 9 Adapter MarkNet X2011E external 7 9 Adapter MarkNet X2012E external 7 9 Adapter MarkNet X2031E external 7 9 Adapter MarkNet X2030 Token Ring external 7 9 Adapter external serial 7 9 Fuser assembly 110 V 7 5 Fuser assembly 220 V 7 5 4505 56P1812 56P1816 56P1817 56P1818 56P1819 56P1820 56P1821 56P1822 56P1823 56P1824 56P1825 56P1826 56P1827 56P1829 56P1830 56P1832 56P1833 56P1834 56P2070 56
4. 2 14 Service Manual 4505 Replace photoconductor hit printer hard stop Light sequence Meaning Action 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 If the toner cartridge is installed or the printer not installed install it detects a toner cartridge If the toner cartridge is error installed remove it and install a new toner cartridge o E O o D o Diagnostic information 2 15 4505 Change invalid toner cartridge Light sequence Meaning Action M TE DE x 0 0600 Invalid engine code Invalid network code Light sequence The toner cartridge being used is not designed for this printer Meaning Install a toner cartridge compatible to printer Action 0006 2DE The code in an internal print server has not been programmed or the programmed code is not valid 2 16 Service Manual Download valid network code to the internal print server e Press amp twice quickly to see the secondary error code 4505 Programming engine code Programming system code Light sequence Meaning Action 00 2D E N
5. Fuser lamp never turns off See Hot fuser service check on page 2 56 The paper feed picks and tries to feed paper See Paper feed service checks on page 2 61 2 44 Service Manual Printer symptom table 4505 Symptom Action Dead machine no power See Dead machine service check on page 2 52 Fan noisy or not working See Cooling fan service check on page 2 48 Fuser parts melted Fuser lamp doesn t light See Hot fuser service check on page 2 56 See Cold fuser service check on page 2 47 Toner not fused to the paper See Cold fuser service check on page 2 47 Paper jams See Paper feed service checks on page 2 61 Main motor noisy or not moving See Main motor service check on page 2 58 Paper skew See Paper feed service checks on page 2 61 Printer not communicating with host See Parallel port service check on page 2 65 Front access cover will not close See Cover interlock switch service check on page 2 51 Operator panel button not responding See Operator panel service check on page 2 59 or Controller card service check on page 2 49 Operator panel lights are off or very dim See Controller card service check on page 2 49 Blank page See Blank page on page 2 67 Black page See Black page on p
6. Verify 24 V de 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 Ifthe 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 dovvn into standby mode ready If immediately following power on the operator panel
7. Index P N Units Description NS 56P1232 1 Adapter US 802 11B wireless print NS 56P1233 1 Adapter INTL 802 11B wireless print NS 56P1431 1 Adapter MarkNet X2011E external NS 56P1432 1 Adapter MarkNet X2012E external NS 56P1433 1 Adapter MarkNet X2031E external NS 56P1434 1 Adapter MarkNet X2030 Token Ring external NS 56P1435 1 Adapter external serial NS 1038693 1 Cable serial 50 foot PSO NS 12A2405 1 Cable packaged USB NS 1329605 1 Cable packaged parallel NS 1427498 1 Cable 20 foot parallel cable with pack NS 56P1417 1 Card assembly 16MB flash NS 56P1418 1 Card assembly 32MB flash NS 56P1427 1 Card assembly OptraForms 32MB flash NS 56P1428 1 Card assembly OptraForms 16MB flash NS 56P1429 1 Card assembly simplified Chinese font NS 56P1430 1 Card assembly traditional Chinese font NS 56P2231 1 Card assembly Korean font NS 56P0696 1 DIMM 16MB PC100 SDR DIMM NS 56P0697 1 DIMM 32MB PC100 SDR DIMM NS 56P0698 1 DIMM 64MB PC100 SDR DIMM NS 56P0699 1 DIMM 128MB PC100 SDR DIMM NS 7372839 1 Package assembly field relocation NS 1339520 1 Power cord Spain 8 foot straight NS 11D0330 1 Power cord Argentina NS 1339528 1 Power cord United Kingdom 6 foot NS 1339529 1 Power cord Austria HV 6 foot straight NS 1339530 1 Power cord Israel 6 foot straight NS 1339531 1 Power cord Switzerland 6 foot NS 1339532 1 Power cord South Africa 6 foot NS 1339533 1 Power cord Italy 6 foot straight NS 1339534 1 Power cord Danis
8. 1 Remove the right side cover See Right side cover removal on page 4 3 for more information Remove the left side cover See Left side cover removal on page 4 3 for more information Open the rear door rear exit tray and remove the two screws holding the cover Lift the rear cover unhook it from the frame at the bottom and remove Right side cover removal See Covers on page 7 2 Remove the right side cover the same way as the left side cover except use the opposite hand See Left side cover removal on page 4 3 for more information Note There is no screw holding the right cover Repair information 4 3 4505 Top cover removal See Covers on page 7 2 c oco m co T Open the access cover Open the left cover Open the right cover Remove two screws at the top rear corners of the top cover Remove two screws at the front of the top cover just behind the access door Release the top cover latch which is about 40 mm behind the access cover latch on the left side Lift and remove the top cover Access cover logo removal See Covers on page 7 2 1 2 3 Open the access cover Remove the screw holding the logo cover in place Remove the logo cover from the access cover Controller card removal See Electronics on page 7 4 Warning gt WO N Always touch a ground before touching the card Handle the card by the edges
9. 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 4505 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 E33
10. e 202 Paper jam exit sensor e e e e 241 Paper jam Tray 1 jam e e e e 242 Paper Jam Tray 2 jam e e 251 Paper jam manual feeder Diagnostic information 2 7 4505 Operator panel codes The follovving 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 000060 S De 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 e Press and hold to reset the printer Note To change the Povver Saver setting use the Local Printer Setup Utility See Users Reference for more information 2 8 Service Manual 4505 Busy Light sequence Meaning Action e Printer is busy e Busy receiving and Wait for message to processing data or clear y 5 CEDE WV 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 Press and release to cancel print job Pres
11. secondary codes 2 19 complex page 2 21 defective flash 2 23 error communicating with host 2 25 flash full 2 26 font error 2 23 insufficient collation area 2 22 insufficient defrag memory 2 24 insufficient printer memory 2 22 invalid engine code 2 27 invalid network code 2 28 memory full 2 25 network interface errors 2 24 paper jams as it exits tray 2 20 paper jams as printed job ex its 2 21 short paper 2 26 unformatted flash 2 27 secondary errors 2 6 service check 2 59 understanding lights 2 3 overview operator panel P paper jams clearing 1 4 tips on preventing part number index i 5 parts catalog covers 7 2 electronics 7 4 frame 7 6 how to use 7 1 POST 2 1 POST symptoms 2 44 power on self test POST 2 1 preventive maintenance 6 1 1 3 1 5 4505 print media manual feed 1 7 Tray 1 1 7 Tray 2 1 7 types 1 7 print quality problems solving 2 73 print quality test pages using 2 66 print quality test pages utilities menu 3 6 printer symptom table 2 45 protocol parallel menu 3 8 R removals 4 1 controller card 4 4 cover open sensor covers 4 2 access 4 2 access coverlogo 4 4 extender 4 2 left side 4 3 rear 4 3 right side 4 3 top 4 4 developer drive coupling asm 4 5 door latch asm 4 5 exit sensor 4 6 fan 4 6 feed rollers 4 7 fuser 4 8 fuser idle gear links 4 7 fuser power cable 4 8 input roller clutch and lever input sensor 1 4 9 input sensor 2 4 10 LVPS H
12. 1 Remove the paper exit guide assembly See Paper exit guide assembly removal on page 4 12 for more information 2 Remove the two screws one on each side from the lower corners of the fuser 3 Remove the controller card cover two screws A Disconnect the thermistor at J15 and exit sensor at J10 on the controller card 5 Slide the fuser out far enough to expose and disconnect the AC cable connections 6 Carefully extract the fuser with thermistor and sensor cables 4 8 Service Manual 4505 Input roller clutch and lever removal ACM clutch CBM See Frame on page 7 6 1 Remove the left side cover Place the printer on its right side Protect the cover from being marred 3 Remove four screws in the gear train metal cover 4 Remove the clip from the shaft of the input roller clutch assembly Remove the screw and lever pawl Remove the clutch assembly If the pieces come apart they can be easily reassembled if necessary Input sensor 1 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 3 Disconnect the sensor cable at J20 on the controller card front near top of card Carefully place the printer on its top 5 Using a small shank screwdriver remove the screw behind the paper pick pivot which holds the paper sensor in pl
13. 7 7 Clutch GBM ACM Aare ae ew 7 7 Sensor toner level 7 5 Cable assemblies miscellaneous 7 5 Cable assembly misc fuser power 7 5 Cable assembly misc LVPS HVPS to controller 7 5 Cable assembly misc main drive motor 7 5 Cable assembly misc toner sensor 7 5 Fuser power u une es ra eat 7 5 Guide assembly paper exit 7 7 Cover assembly top 7 3 Cover left es ai se duane men aes Co mars actes 7 3 Cover logo plate E330 7 3 Latch CBM access COVer 7 1 Link CBM door fuser idle gear 7 7 Tray 2 optional white 7 3 Cover logo plate E232 7 3 Cover logo plate plain 7 3 Cover assembly rear 7 3 TAV Ma SE aan 7 3 Drawer optional mE 23 200 me RR aaa 7 3 Tray 2 optional umm pie di a 7 3 Cover assembly front access white 7 3 Operator panel assembly operator panel vvith PCB assembly 1 6 Service Manual 56P2093 56P2094 56P2095 56P2096 56P2097 56P2098 56P2231 56P2628 56P2629 56P2646 56P2647 56P2648 56P2703 56P3086 56P3087 56P3088 56P3089 56P9926 56P9927 7372839 Cover right white
14. Clean as necessary LVPS HVPS If this does not correct the problem Controller card replace the following FRUs one at a time in the order shown e 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 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 Variation in image density horizontally across page FRU Action PC Kit not a FRU The charge roll may have an unbalanced pressure against the Photoconductor PC drum Try a new PC Kit Transfer roll Check the springs in the left and 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 4505 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 Paper not a FRU Make sure recommended paper
15. Remove the paper from Tray 1 and fan the paper Make sure Tray 1 is selected from the printer driver Do not overfill the tray Check the condition of the rubber on the paper feed rolls Verify clutch for ACM is not slipping The paper fails to feed from the optional Tray 2 Make sure the optional Tray 2 is selected from the printer driver Make sure the tray is pushed all the way in Remove the paper from the optional Tray 2 and fan it Check the rubber on the paper feed tires Check the paper path in the tray for burrs or debris that may hinder paper movement Make sure the paper does not exceed the stack height indicator The Load Paper light is on even though there is paper loaded in the optional Tray 2 Make sure the tray is pushed all the way in Press Diagnostic information 2 77 4505 Problem Action The printer does not print after a paper jam has been cleared Clear all jams Press and release lt or open and close the printer cover to restart the printer Make sure the print cartridge assembly is installed properly Unexpected characters print or characters are missing Ensure correct printer driver is being used Press and hold lt until all lights come on to reset printer to user default settings Select hex trace mode to determine what the problem is Restore factory defaults Make sure the parallel cable or USB cable is fir
16. See Frame on page 7 6 a A N gt Remove the paper tray Remove the toner cartridge Tilt the printer onto its back Remove old tires Ensure the new tires are captured between the rims of the plastic hub Fuser idle gear links removal See Frame on page 7 6 1 Remove the access cover See Access cover removal on page 4 2 for more information 2 Remove the left side cover 3 Place printer on its right side Protect the cover from being marred 4 Remove the metal plate covering the gear train 5 Grasp the rear link with your index fingers and thumb on each side of the shaft and unsnap the link from the shaft Disconnect front link from coupler and remove links Repair information 4 7 4505 Fuser povver cable removal See Electronics on page 7 4 1 Remove the LVPS HVPS card See LVPS A HVPS card assembly removal on page 4 10 for more information Note The cable can be reached vvithout fully removing the card 2 Remove the rear cover See Rear cover removal on page 4 3 for more information 3 Remove the exit guide assembly See Paper exit guide assembly removal on page 4 12 for more information 4 Remove the two screws one on each side from the lower corners of the fuser 5 Slide the fuser out far enough to expose and disconnect the AC cable connections 6 Extract the fuser power cable Fuser removal See Electronics on page 7 4
17. white or black lines 2 72 transfer roll 2 79 drive motor or transfer roll Service error lights 2 18 2 33 engine communication 2 35 fuser fan or toner sensor 2 34 network error 2 42 symptom tables 2 44 POST 2 44 printer 2 45 paper port communication tools 1 6 failure 2 43 printhead transport motor or RIP 2 35 RAM memory error 2 41 1 4 Service Manual 4505 Part number index P N 1038693 11D0330 12A2405 1329605 1339520 1339528 1339529 1339530 1339531 1339532 1339533 1339534 1339548 1427498 43H5545 56P0696 56P0697 56P0698 56P0699 56P1232 56P1233 56P1417 56P1418 56P1427 56P1428 56P1429 56P1430 56P1431 56P1432 56P1433 56P1434 56P1435 56P1810 56P1811 Description Page Cable serial 50 foot PSO 79 Power cord Argentina 7 9 Cable packaged USB 7 9 Cable packaged parallel 7 9 Power cord Spain 8 foot straight 7 9 Power cord United Kingdom 6 foot 79 Power cord Austria HV 6 foot straight 7 9 Power cord Israel 6 foot straight 7 9 Power cord Switzerland 6 foot 7 9 Power cord South Africa 6 foot 79 Power cord Italy 6 foot straight 7 9 Power cord Danish 6 foot straight
18. 4505 Light sequence Meaning Action Printer is flushing corrupted print data Printer is processing but the resolution of a page in the current print job is reduced dpi to 300 dpi to prevent a memory full error Not ready Light sequence Meaning data or printing pages from 600 dots per inch e Wait until x is displayed to print other jobs Press and release 9 to cancel print job Press and hold to reset printer Action Printer is not ready to receive or process data or the printer ports are offline 7 REDE lt Press 4 to return to or Busy state Press and release 9 to cancel print job Press and hold to reset printer Diagnostic information 2 11 4505 Close door Insert cartridge Light sequence Meaning Action 00000 lt The printer door is open Close the door Load media Light seguence Meaning Action 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 4 to resume printing e Check thatthe media is loaded correctly in tray 1 or the optional 550 sheet tray Press to cancel the print job 2 12 Service Manual Load manual feeder 4505 Light sequence Meaning Action Printer prompts to load a s
19. 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 4505 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 45 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 incorrect check the controller card See Controller card service check on page 2 49 for more information If voltages are correct replace the 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 Make sure the input pa
20. Error communicating with host computer Light sequence Meaning Action The printer has lost the Make sure the cable connection to an external connecting the ENA print server also called and the printer is an external network securely attached adapter or external e Turn the printer off and network adapter ENA then on to reset the This light sequence is printer x displayed if your printer is Press and hold to connected to the network reset the printer 9 11 8 but it cannot detect the o D print server when you turn A on the printer Memory full Light sequence Meaning Action The printer is processing Press amp to clear the data but the memory message and continue used to store pages is full printing the job the job may not print correctly Press and release 9 to cancel the print job e Pressandhold to reset the printer 2 To avoid this error in D the future o Simplify the print job v Reduce the complexity of the page by reducing the amount of text or graphics on the page and deleting unnecessary downloaded fonts or macros Install additional printer memory Diagnostic information 2 25 4505 Short paper Light sequence Meaning Action The paper length is too short to print the formatted data This Make sure the print media you loaded is large enough occurs when the printer Open the front cover
21. 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 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 e Reinstall it and recheck for condition Make sure you are using recommended print media see media types and sizes in the User s Reference Use MarkVision to define the custom type setting for media type media texture or media weight e The toner cartridge or PC Kit may be defective Replace the PC Kit first and recheck Blurred characters Blurred images including characters are usually caused by a defective printhead See Light print on page 2 71 Toner smudges appear on the Make sure the paper is straight front or back of the page and unwrinkled Replace the PC Kit and
22. does not know the media clear the paper path size loaded in the tray or and close the cover to thereisa problem feeding resume printing x the media Press to clear the message and continue O we printing the job D e Press to cancel o XV the print job Flash full Light sequence Meaning Action 000060 TUE There is not enough free space in the flash memory to store the data you are trying to download 2 26 Service Manual 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 and macros not previously stored in flash memory are deleted Install flash memory with more storage capacity Press and release to cancel the print job Press and hold to reset the printer Unformatted flash 4505 Light sequence Meaning Action The printer detects unformatted flash Press to clear the message and continue memory printing The job may not print correctly Reformat the flash memory Refer to the Technical Reference on Y Lexmark s Web site for more information WA f the error message o D remains the flash Ar memory may be defective and should i be replaced Invalid engine code Light sequence Meaning Action es 2D0 E The code in an internal print server has not been programmed or the pr
23. for the printers memory Press amp 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 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 Install additional printer memory 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 e 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 X G to print A page is shorter than the set page margins Memory is insufficient to save what is in the buffer 00000 TE DE 2 22 Service Manual e Press to clear the message and continue printing the job the job may not print correctiy Press and release to cancel the print job e Press and hold to reset the printer To avoid this error in the future Simplify the print job Reduce the complexit
24. functioning when an attempt is made to feed the paper Make sure the rubber tires are installed and clean Replace if necessary Diagnostic information 2 63 4505 Paper occasionally picks or picks multiple sheets at once FRU Action Tray 1 Tray 2 option 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 Paper pick tires Check the tires in the ACM assembly for signs of wear or damage Replace the tires as necessary ACM clutch complete bill of material CBM Manual feed clutch CBM 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 Controller card Disconnect the solenoid cable at J5 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 itis not call the next level of service Ifthe 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 4505 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 ru
25. 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 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 To exit print quality test pages turn the printer off 2 66 Service Manual 4505 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 e Printhead errors typically result in TM printer service errors rinthea Blank pages typically are caused LVPS HVPS by the PC roll not being properly Controller card charged Try a different PC kit Toner electrodes cable assembly 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 Diagnostic information 2 67 4505 Black page Note Incorrect laser exposure or incorrect charging of the photoconductor c
26. is being used Light print FRU Action Toner cartridge not a FRU Make sure the toner cartridge and 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 Transfer roll Verify the high voltage cable is LVPS HVPS board 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
27. level of support f you can print a menu settings page the problem is one of the following Computer Software program Cable USB only failed ASIC or controller card Replace card Note Test by unplugging USB and replugging it with the printer on If the computer indicates unknown device replace the card If you are using a 3000 or 6000 toner cartridge and the 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 The Error light is on Make sure the printer cover is closed The Toner Low light is blinking and the Error light is on Make sure the toner cartridge is installed correctly Install a new toner cartridge 2 76 Service Manual 4505 Problem Action The media skews or buckles The paper sticks together printer feeds multiple sheets of paper 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 Remove the paper from Tray 1 or the optional Tray 2 and fan it Don t overfill Tray 1 or the optional Tray 2 see media capacities in the media types and sizes chart in the User s Reference The paper fails to feed from Tray 1
28. page 2 8 for more information Continue Cancel Ready O Xf ur uM Load Paper Q Paper Jam Q Ala Error O e Press and release lt gt to resume printing e Press and release lt gt twice quickly to display a secondary error code following an error e Press and release to cancel the job currently printing e Press and hold until all of the lights come on to reset the printer General information 1 3 4505 Paper jams how to clear When a paper jam occurs the printer stops operating and the operator panel s s and lt gt lights come on Press and release lt gt 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 Ifthe paper is feeding from a tray remove the tray and then remove any jams Open the front cover and remove the print cartridge assembly Remove any jams located in the area behind the print cartridge assembly 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 lt gt button to resume printing Note Pages caught in the paper jam wi
29. recheck before replacing the toner cartridge See Toner on back of page on page 2 72 for more information Diagnostic information 2 73 4505 Problem Action Vertical or horizontal streaks appear on the page BCDEN BCDE BCDE Replace the toner cartridge for vertical black streaks Wipe the glass lens clean with a soft tissue for vertical white streaks For horizontal streaks see White or black lines or bands on page 2 72 for more information Toner smears or rubs off the page Replace the fuser The toner is not being fused See Cold fuser service check on page 2 47 for more information Try a different kind of paper Paper designed for copiers gives the best quality fusing If you are printing on special media such as card stock or labels be sure you select the correct paper type in the printer driver 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 amp amp light is not on The x light does not come on if the standard 1 500 page toner cartridge is installed Remove the toner cartridge and gently shake it from side to side to redistribute the toner Replace the toner cartridge The x light is on Remove the toner cartridge and gently shake it from side to side to redis
30. 2n 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 General information 1 1 4505 The differences between the models are listed in the following table 4505 100 4505 200 4505 310 Item Lexmark Lexmark ee Lexmark E230 E232 E332n Base memory 8MB 16MB 32MB Maximum 8MB 80MB 160MB memory Paper inputs 250 sheet 250 sheet tray tray Single sheet manual feeder Single Optional 550 sheet drawer sheet manual feeder Emulations HBP host HBP PCL 6 HBP PostScript 3 PCL 6 PPDS based and Windows personal printer data stream printing PCL Macintosh and Windows Macintosh Linux printercontrol Linux compatibility language 5e compatibility and Windows Macintosh Linux compatibility Connectivity USB and Parallel USB Parallel Toner cartridge yield 1 500 pages starter toner cartridge 2 500 pages and 10 100 Base TX Ethernet Photoconductor Rit yield 30 000 pages Yield based on approximately 5 coverage of pages 1 2 Service Manual 4505 Overview of the operator panel The operator panel has six lights and two buttons See Operator panel codes on
31. 6P2072 1 Fan cooling 8 56P2076 1 Sensor toner level 9 56P3087 1 Card controller E232 9 56P3088 1 Card controller E330 E234 9 56P3089 1 Card controller E332n E234n 9 56P3086 1 Card controller E230 10 56P1817 1 Operator panel assembly operator panel with PCB assembly 10 56P2092 1 Operator panel assembly operator panel with PCB assembly white 11 56P1818 1 Card assembly LVPS HVPS 110 V 11 56P1819 1 Card assembly LVPS HVPS 220 V 12 56P1825 1 Sensor input 2 manual Parts catalog 7 5 4505 Assembly 3 Frame 7 6 Service Manual Assembly 3 Frame 4505 Index P N Units Description 3 1 56P2078 1 Guide assembly paper exit 2 56P1823 1 Transfer roll bearings gear 3 56P1822 1 Cover legal extender 3 56P2094 1 Cover legal extender white 4 56P2646 N A Screws miscellaneous actual size TP2NC 3 0 6P Ni quantity 2 Q fm M3 0 0 5 6P Ni 2 Washer quantity 2 qu MT3 0 0 5 6PF Ni quantity 5 dom TP2NC 3 0 6PF Ni quantity 4 5 56P1820 2 Paper feed rubber tires 6 56P2647 1 Springs front door and ACM 7 56P2075 1 Clutch CBM ACM 8 56P2083 1 Link CBM door fuser idle gear 9 56P2074 1 Clutch CBM manual feed 10 56P2648 2 Rings plastic snap 11 56P2073 1 Coupling assembly developer drive 12 56P2082 1 Latch CBM access cover Parts catalog 7 7 4505 Assembly 4 Miscellaneous This page intentionally left blank 7 8 Service Manual 4505 Assembly 4 Miscellaneous
32. Bad checksum while programming port Flash parts failed while programming port 2 42 Service Manual 4505 Paper port communication failure Indicates an error communicating with Tray 2 if installed Remove Tray 2 and recheck Ifthe error does not recur replace Tray 2 Ifthe error recurs replace the controller card assembly Tertiary codes co eo co co ceo o o o o o S Continue e Toner Low Replace PC Kit E e Load Paper e Paper Jam e x Secondary Invalid command parameter received by Engine experiencing specified device unreliable communications to specified device Invalid command received by specified device Engine protocol Who Specs dec Communications error detected by specified device Diagnostic information 2 43 4505 Symptom tables POST symptom table Symptom Action The main motor cooling fan and fuser do not come on See Cover interlock switch service check on page 2 51 POST completes except one or more lights do not come on See Operator panel service check on page 2 59 None of the lights come on See Operator panel service check on page 2 59 Main motor does not come on See Main motor service check on page 2 58 Fan does not come on Fuser lamp does not come on See Cooling fan service check on page 2 48 See Cold fuser service check on page 2 47
33. EC 60825 1 m rityksen mukainen Luokan laserlaitteiden ei katsota olevan vaarallisia k ytt j lle Kirjoittimessa on sis inen luokan Illb 3b 5 milliwatin galliumarsenidilaser joka toimii aaltoalueella 770 795 nanometri Laserj rjestelm ja kirjoitin on suunniteltu siten ett k ytt j ei altistu luokan maarityksia voimakkaammalle s teilylle kirjoittimen normaalin toiminnan k ytt j n tekemien huoltotoimien tai muiden huoltotoimien yhteydess VARO Avattaessa ja suojalukitus ohitettaessa olet alttiina n kym tt m lle lasers teilylle Al katso s teeseen VARNINGI Osynlig laserstralning nar denna del ar ppnad och sparren ar urkopplad Betrakta ej stralen Laser notis Denna skrivare ar i USA certifierad att motsvara kraven i DHHS 21 CFR underparagraf J f r laserprodukter av Klass 1 andra lander uppfyller skrivaren kraven f r laserprodukter av Klass enligt kraven i IEC 60825 1 Laserprodukter i Klass anses ej halsovadliga Skrivaren har en inbyggd laser av Klass Illb 3b som best r av en laserenhet av gallium arsenid pa 5 milliwatt som arbetar i vaglangdsomradet 770 795 nanometer Lasersystemet och skrivaren ar utformade sa att det aldrig finns risk f r att n gon person uts tts f r laserstr lning ver Klass I niv vid normal anv ndning underh ll som utf rs av anvandaren eller annan f reskriven service tg rd x Service Manual 4505 Laser melding Skriveren er god
34. IIIb 3b de arseniuro de galio de funcionamiento nominal a 5 milivatios en una longitud de onda de 770 a 795 nan metros El sistema l ser y la impresora est n disefiados de forma que ninguna persona pueda verse afectada por ning n tipo de radiaci n l ser superior al nivel de la Clase I durante su uso normal el mantenimiento realizado por el usuario o cualquier otra situaci n de servicio t cnico Declara o sobre Laser A impressora est certificada nos E U A em conformidade com os requisitos da regulamenta o DHHS 21 CFR Subcap tulo J para a Classe 1 de produtos laser Em outros locais esta certificada como um produto laser da Classe em conformidade com os requisitos da norma IEC 60825 1 Os produtos laser da Classe n o s o considerados perigosos Internamente a impressora cont m um produto laser da Classe Illb 3b designado laser de arseneto de pot ssio de 5 milliwatts operando numa faixa de comprimento de onda entre 770 e 795 nan metros O sistema e a impressora laser foram concebidos de forma a nunca existir qualquer possiblidade de acesso humano a radiac o laser superior a um nivel de Classe durante a operac o normal a manutenc o feita pelo utilizador ou condic es de assist ncia prescritas Laser notices IX 4505 Huomautus laserlaitteesta T m kirjoitin on Yhdysvalloissa luokan 1 laserlaitteiden DHHS 21 CFR Subchapter J m rityksen mukainen ja muualla luokan laserlaitteiden I
35. Open the right cover Remove the metal controller card cover two screws Disconnect all the cables to the controller card Remove three screws at the back of the printer which secure the USB and parallel ports to the metal frame 5 Remove five screws holding the card to the metal side frame Carefully lift the card and remove 4 4 Service Manual 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 5 and extract the cable Use a small Phillips screwdriver to remove the screw holding the sensor Slide the sensor from the positioning post Developer drive coupling assembly removal See Frame on page 7 6 1 Remove the left side cover Carefully place the printer on its right side Protect the cover from marring Remove four screws in the gear train metal cover 4 Remove the developer gear the conical spring and the coupling assembly Door latch assembly removal See Frame on page 7 6 1 Open access cover 2 Open left side cover 3 Locate the opening on the backside of the button The opening is partially covered by the front left edge of the printhead metal frame 4 Use a small shank Phillips screwdriver to extract the
36. P2072 56P2073 56P2074 56P2075 56P2076 56P2077 56P2077 56P2077 56P2077 56P2077 56P2077 56P2078 56P2079 56P2080 56P2081 56P2082 56P2083 56P2084 56P2085 56P2086 56P2087 56P2088 56P2089 56P2090 56P2091 56P2092 white Print assembly laser mirror E232 7 5 Cover assembly front access no logo 7 3 Operator panel assembly operator panel with PCB assembly 7 5 Card assembly LVPS HVPS 110 V 7 5 Card assembly LVPS HVPS 220 V 7 5 Paper feed rubber tires 7 7 Gover right escis aus ee ens a ua ee a ee 7 3 Cover legal extender 7 7 Transfer roll bearings gear 7 7 Sensor INPUT ATUA ER US 7 5 Sensor input 2 manual 7 5 SENSOR OXIME seo cue aeos ese tt ie ste 7 5 Sensor cover open 7 5 Print assembly laser mirror E330 E332n 7 5 Print assembly laser mirror E230 7 5 Cover logo plate E332n 7 3 Cover logo plate E230 7 3 Tray main white 7 3 Fuser assembly 1O00V 7 5 Fanongo Mar Et SR EA RE ED AU a ES Sa 7 5 Coupling assembly developer drive 7 7 Clutch CBM manualfeed
37. 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 Vac Volts alternating current V de Volts direct current 1 8 Service Manual 4505 2 Diagnostic information Start POST povver 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 x 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 0 button has a light in it Diagnostic information 2 1 4505 Overview of the operator panel Continue Cancel Ready Toner Low Q Replace PC Kit Load Paper Q Paper Jam Q Error O ly P J EX ee e Press and release lt to resume printing e Press andrelease amp twice quickly to display a secondary error code following an error 1 and lights on e Press and release to cancel the job currently printing e Press and h
38. SIC failure communicate with secure NVRAM Processor failure NVRAM chip failure Code ROM or NAND NVRAM CRC failure 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 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 961 962 963 amp Continue Toner Low Replace PC Kit E Load Paper Paper Jam 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 975 976 978 979 Continue Toner Low Replace PC Kit E Load Paper Paper Jam Secondary code Unrecognizable network port Unrecoverable software error in network port
39. Use setting to Values Reset Return the photoconductor counter to zero Photoconductor Counter The replace photoconductor message should be 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 Menu item Use setting to Values Demo mode Put printer into demo mode where internal sheets prints with each press of SG To deactivate turn the printer off and re enter configuration group Set to deactivate Deactivate Activate Auto CR after LF Specify whether the printer automatically performs a carriage return after a line feed control command Off Auto LF after CR Specify whether the printer automatically performs a line feed after a Carriage return control command Factory default Diagnostic aids 3 7 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 Off printer and query printer On status information simultaneously Auto Protocol Receive information at a Standard much higher transmission rate if your printer is set to Fastbytes Fastbytes if your computer supports Fastbytes or receive information at a normal transmission rate if your printer is set to Standard Pa
40. VPS card asm 4 10 LVPS HVPStocontrollercard cable 4 11 manual feed clutch asm 4 11 operator panel 4 11 4 5 4 9 l 3 4505 paper exit guide asm 4 12 printhead 4 12 toner level sensor 4 13 toner level sensor cable 4 12 reset factory defaults utilities menu 3 6 S safety information xv secondary error codes complex page 2 21 defective flash 2 23 error communicating with the host computer 2 25 flash full 2 26 font error 2 23 insufficient collation area 2 22 insufficient defrag memory 2 24 insufficient printer memory 2 22 invalid engine code 2 27 invalid network code 2 28 memory full 2 25 network interface errors 2 24 PPDS font error 2 23 short paper 2 26 unformatted flash 2 27 service information 2 29 secondary error codes 2 30 secondary light patterns 2 29 tertiary error codes 2 31 controller software 2 32 service checks 2 47 controller card 2 49 cooling fan 2 48 cover interlock 2 51 dead machine 2 52 fuser 2 53 cold 2 47 hot 2 56 LVPS HVPS 2 57 main motor 2 58 operator panel 2 59 operator panel button 2 59 paper feed 2 61 paper jam during POST 2 61 paper never picks 2 63 paper picks but stops 2 62 paper picks during POST 2 62 paper picks sheets 2 64 paper trees curls 2 65 parallel port 2 65 print quality 2 66 black page 2 68 blank page 2 67 heavy background 2 69 image density 2 70 light print 2 71 partial blank image 2 70 poor fusing ofimage 2 71 toner on back of page 2 72
41. ace Remove the sensor and the attached cable flag and spring 7 Re install the sensor so that the flag is spring loaded against the pages as it advances in its path Verify the cable is captured and out of the paper path Repair information 4 9 4505 Input sensor 2 manual removal See Electronics on page 7 4 1 e p gx Ov 8 Open the right side cover See Right side cover removal on page 4 3 for more information Remove the controller card cover Disconnect the sensor cable at J18 on the controller card front top of card Carefully place the printer on its top with the front facing you Remove the screw beside the left pick tire Remove the sensor and its attached cable Re install the new sensor in the same orientation as the old The flag should be spring loaded against the leading edge of an advancing sheet Verify the cable is captured and away from the paper path LVPS HVPS card assembly removal See Electronics on page 7 4 e no a 1 Remove the cover extender if installed and the A rear cover See Rear cover removal on page 4 3 for more information Place the printer onto its top with the back and bottom in view Remove two screws one left ofthe power switch and the other at the opposite side of the panel Remove the foot brackets 2x above the power supply cover Remove four screws in the bottom of the metal cover Move the cover so the connec
42. age 2 68 Heavy background See Heavy background on page 2 69 Light print See Light print on page 2 71 Diagnostic information 2 45 4505 Symptom Action White or black lines or bands See White or black lines or bands on page 2 72 Toner on back of page See Toner on back of page on page 2 72 Paper never picks Paper feeds continuously See Paper never picks on page 2 63 See Paper picks during POST and or continuously on page 2 62 Paper wrinkled or bent See Paper trees wrinkles stacks poorly or curls on page 2 65 2 46 Service Manual 4505 Service checks Service checks which involve measuring voltages on the LVPS HVPS low voltage power supply high voltage power supply board should be performed with the printer 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 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 Fuser AC cables LVPS HVPS Chec
43. agnostics Printer Diagnostics This page explains how to access the printer menus and change values Menus are represented by Continue Ready Data Toner Lou and Load Remove Paper Light sequences Menu items and their values are indicated by Paper Jam and Error light sequences Use the illustration to help you find the menu and value you want to change The Paper Jam and Error lights show the current value of the menu item 1 Press and release Cancel to advance through the menus and menu items to the one you need 2 Press and release Continue to advance to the value you need 3 Press and hold Continue until all of the lights cycle to perform the function or to save the value 4 Press and hold Cancel until all of the lights cycle to return to the Home menu 5 Turn the printer off to exit the menus Menus menu items and values Light on Light off amp Light Blinking Value Development Parallel Network Press Continue e e cece e oe o eoe o Ready Data Y o 0000 e oo e eoo e Toner Low 4 8 o ooee e oo o cee e Load Paper D oO 0000 o e eee o Paper Jam Mr 069600006 000080 ooeoeeococecoeo Error 00800000800 000008 oeoeooeooeoeeoce x a a E T E Es E gt 3 M E 5 S o 5s 8 se I n 3 ros t f 3 S s Ss 8 3 2 aS 82 5 x o go B 2 fi B E a TREES 5 gt Eop zl 8 E 502 05 rs s v 3081 fins 5 LB e 7 do i Suns HH E NER n NE Eo Hu e E er Sf2fubsas d a
44. alth and Human Services 21 CFR Teil J f r Laserprodukte der Klasse I 1 In anderen L ndern gilt der Drucker als Laserprodukt der Klasse I der die Anforderungen der IEC International Electrotechnical Commission 60825 1 gem amtlicher Best tigung erf llt Laserprodukte der Klasse gelten als unsch dlich Im Inneren des Druckers befindet sich ein Laser der Klasse Illb 3b bei dem es sich um einen Galliumarsenlaser mit 5 Milliwatt handelt der Wellen der L nge 770 795 Nanometer ausstrahlt Das Lasersystem und der Drucker sind so konzipiert da im Normalbetrieb bei der Wartung durch den Benutzer oder bei ordnungsgem er Wartung durch den Kundendienst Laserbestrahlung die die Klasse bersteigen w rde Menschen keinesfalls erreicht Laser notices Vii 4505 Avis relatif l utilisation de laser Pour les Etats Unis cette imprimante est certifi e conforme aux provisions DHHS 21 CFR alin a J concernant les produits laser de Classe 1 Pour les autres pays cette imprimante r pond aux normes IEC 60825 1 relatives aux produits laser de Classe l Les produits laser de Classe sont consid r s comme des produits non dangereux Cette imprimante est quip e d un laser de Classe lb 3b ars niure de gallium d une puissance nominale de 5 milliwatts mettant sur des longueurs d onde comprises entre 770 et 795 nanom tres L imprimante et son syst me laser sont con us pour impossible dans des conditions normal
45. an a no caso de uso de pecas de substitui o n o autorizadas As informac es de seguran a relativas a este produto destinam se a profissionais destes servicos e n o devem ser utilizadas por outras pessoas Risco de choques el ctricos e ferimentos graves durante a desmontagem e manutenc o deste produto Os profissionais destes servicos devem estar avisados deste facto e tomar os cuidados necessarios CUIDADO Quando vir este s mbolo existe a A possivel presenca de uma potencial tens o perigosa na zona do produto em que est a trabalhar Antes de come ar desligue o produto da tomada el ctrica ou seja cuidadoso caso o produto tenha de estar ligado corrente el ctrica para realizar a tarefa necess ria Safety information xvii 4505 Informaci de Seguretat e La seguretat d aquest producte es basa en l avaluaci i aprovaci del disseny original i els components espec fics El fabricant no es fa responsable de les questions de seguretat si s utilitzen peces de recanvi no autoritzades e La informaci pel manteniment d aquest producte est orientada exclusivament a professionals i no est destinada a ning que no ho sigui e El risc de xoc el ctric i de danys personals pot augmentar durant el proc s de desmuntatge i de servei d aquest producte El personal professional ha d estar ne assabentat i prendre les mesures convenients PRECAUCIO aguest simbol indica gue el voltatge de la par
46. ance si l ex cution de la t che exige que le produit reste sous tension Safety information XV 4505 Norme di sicurezza e La sicurezza del prodotto si basa sui test e sull approvazione del progetto originale e dei componenti specifici Il produttore non 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 pi elevato Il personale di assistenza autorizzato deve quindi adottare le precauzioni necessarie ATTENZIONE Questo simbolo indica la presenza A 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 Sicherheitshinvveise e Die Sicherheit dieses Produkts basiert auf Tests und Zulassungen des urspr nglichen Modells und bestimmter Bauteile Bei Verwendung nicht genehmigter Ersatzteile wird vom Hersteller keine Verantwortung oder Haftung f r die Sicherheit bernommen e Die Wartungsinformationen f r dieses Produkt sind ausschlie lich f r die Verwendung durch einen Wartungsfachmann bestimmt e W hrend des Auseinandernehmens und der Wartung des Ger ts besteht ein zus tzliches Risiko eines elektrischen Schla
47. auses 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 A LVPS HVPS board Controller card 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 fails call the next level of service With the printer off disconnect the LVPS HVPS cable from J7 on the controller card Turn the printer on and verify 24 V dc on pin 8 of the cable Verify ground on pin 7 If the voltage is incorrect replace LVPS HVPS board If voltage is correct and the toner electrodes are good replace the controller card 2 68 Service Manual 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 FRU 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 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
48. condition Service error see Service information vvith secondary and tertiary light patterns on page 2 29 for more information Printer error see Secondary error codes on page 2 19 for more information Diagnostic information 2 5 4505 Secondary errors When the and lights are both on a secondary error has occurred Press and release 4 twice quickly to display the secondary error code light sequence The follovving table shovvs what these light sequences mean Printer Ar condition o Les E M D e o Printer error Secondary error code e e Paper jams in the manual feeder e e e Paper jams as it exits the tray into the printer e e e Paper jams as a printed job exits the printer e e e Complex page e e Insufficient printer memory e e 8 Insufficient collation area o e Font error e e e Defective flash e e Insufficient defrag memory e e e Network interface errors e e Error communicating with host computer e e e e Memory full 2 6 Service Manual 4505 Printer condition cx Ea LJ gt 8 e e e Short paper e e e e Unformatted flash e e e Flash full e e e Invalid engine code e e Invalid network code Paper jam secondary codes e 200 Paper jam input sensor e 201 Paper jam between input and exit sensors
49. d 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 See Accessing the configuration and diagnostic groups on page 3 2 for more information Diagnostic The diagnostic group contains menu settings and operations that are useful in the manufacturing of the printer It also features other aids in diagnosing problems See Accessing the configuration and diagnostic groups on page 3 2 for more information Diagnostic aids 3 1 4505 Accessing the configuration and diagnostic groups Povver 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 Power on with cover open and configuration pressed menu mode 2 Close cover once the light is displayed Enter 1 Power on with top cover open and diagnostics pressed mode 2 Close cover once the 1 lightis displayed Reset NVRAM 1 Power on with top cover open and and enter both and buttons pressed normal mode 2 Close cover once the lightis displayed 4 Turn on the printer Hold the selected button until the lights cycle on the operator panel 5 Close the cover and wait for the printer to activate the drive 6 Print menus by pressing and holding 4 unt
50. ead FelOoVal 3 5532 aaa 4 12 Toner level sensor cable removal 4 12 Toner level sensor removal 4 13 Transter toll MWA 4 34 33 ei 4 13 Transport motor cable removal 4 14 Connector locations 5 1 Front and rear VIEWS re 5 1 POWER supply BOSE sais ass nie 5 2 Controller board IKAWA 5 3 RC OA gs ea 5 4 iv Service Manual Preventive maintenance 6 1 Parts Catalog nei ossadas idos ee 7 1 How to us IE PIE catalog rin 7 1 INDEX C trn l 1 l 5 Part number index IIIA hh hh 4505 vi Service Manual 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 1 laser products and elsewhere is certified as a Class laser product conforming to the requirements of IEC 60825 1 Class laser products are not considered to be hazardous The printer contains internally a Class IIIb 3b laser that is nominally a 5 milliwatt gallium arsenide laser operating in the wavelength region of 770 795 nanometers The laser system and printer are designed so there is never any human access to laser radiation above a Class level during normal operation user maintenance or prescribed service condition Laser Der Drucker erf llt gem amtlicher Best tigung der USA die Anforderungen der Bestimmung DHHS Department of He
51. eceive 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 Continue Tertiary code W Toner Low Replace PC Kit a Load Paper Paper Jam Secondary code 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 for more information a stalled fan motor or a faulty toner sensor or toner cartridge a u S S S S9 S 2 ZE Toner Low Replace PC Kit a Load Paper Paper Jam Fan stalled Secondary Toner sensor or code toner cartridge Fuser below Incorrect fuser lamp temperature when installed printing Open circuit in thermistor path Fuser below standby Fuser too hot during temperature at idle printing or idle Fuser failed to reach standby temperature 2 34 Service Manual 4505 Printhead transport motor or RIP engine communication error Codes 930 through 935 indicate a problem vvith the printhead Check cables to the printhead Replace the printhead as necessary Codes 936 and 937 indicate a problem in the drive system Diagnostic information 2 35 4505 Code 939 indicates a communication failure betvveen the RIP and engine pr
52. el service check Inspect the operator panel cable for damage Make sure the cable 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 4 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 Diagnostic information 2 59 4505 Operator panel service check continued FRU Action Operator panel Controller card Warning Do notreplace the operator panel and controller card at the same time Each card contains the printer settings VVhen 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
53. er Notice L 3X icBiy 328054 CoSTJrs ti RETRDHHS 21 CFRYTFFrTF I 07241 1 Okumu F RATBS ERGENS Atos EAIKEBEACRIECS82950E88tWNIULZZT RIOU FN CG SC E NI AA KA NE je 225AX1I0v VY W amp iifsl amp tEd7vcxxoncoxzv CO TII RV 5205 3b OL P AARMELTOEF CO Li RROT70 T957JX4 Y OURTC BH 5387y FORY YAEY aL TH TOL YVAFREFUVI H BORE 2 FOAVFPVY ALE ES ICC BO Tl AMI FALTOVANVELELOL V ik HiMsNSZCLOMWEABHANTHET Chinese Laser Notice dT EN OL ae 32 EIU GEA S DHHS 21 CFR Subchapter I Xj 2 28 I 1 RIT im ES tn E TMAH Hb X MI SEGA UE amp IEC 825 ES AR HE DE I HIT dh IR LN TR ROG Ee Ek X TIED DLA SB amp ASH NI 3b AS ROC EREHE NS CES ENS CURRO EG HKEE 770 795 nm z ABOGRA RI EN LE RT EMI VE ME RE REU A HE A RUA TEOLT AA EA KB fh JE T D ES RASES Xii Service Manual 4505 Rorean Laser Notice auge 158 dI0JX ASSO CHSt DHHS 21 CFR Subchapter 3 TAS Bsa Ves ai Roja CIS So A 319 9 Leola E IEC 825 Tas tte 158 lA HECEA OSS SS UC 158 dlojx ABSES CHS AOS desert HES 5 delste dE ofato AOIMEAM 770 795 Loje tacho A SSE Class ill 3b AOIME go zi SUC 2 alo x AAMT DAE AA AS SOL Fr BS S ES HAE MHA AEA 712 Class TES HoH HEA Ao cl 28 BES HAHA QSUCH Laser notices Xiii 4505 xiv Service Manual 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 respon
54. er supply board 5 2 wiring diagram 5 4 l 1 4505 MAC binary PS parallel menu 3 8 3 10 USB menu 3 9 mode 2 parallel menu 3 8 models 1 1 differences 1 2 E230 1 1 E232 1 1 E234 1 1 E234n 1 1 E330 1 1 E332n 1 1 N NPA mode parallelmenu 3 8 3 10 3 11 USB menu 3 9 O operator panel buttons 1 3 common light sequences 2 3 light sequences canceling job 2 17 change invalid toner cartridge 2 16 Hex Trace ready 2 10 Invalid network code 2 16 Load Tray 1 or 550 sheet tray 2 12 notready 2 11 offline 2 11 printing a directory 2 9 printing a font list 2 9 printing menu settings pag es 2 9 printing print quality test pag es 2 9 1 2 Service Manual programming engine code 2 17 programming flash 2 9 programming system code 2 17 resetting printer 2 17 restoring factory defaults 2 17 1 3 2 3 overview 2 2 primary codes busy 2 9 cancel job reset printer 2 17 change invalid toner cartridge 2 16 close door insert cartridge 2 12 flushing resolution reduced 2 11 hex trace ready 2 10 invalid engine code 2 16 invalid network code 2 16 load manual feeder 2 13 load media 2 12 notready 2 11 print side two of duplex job 2 13 printer error 2 18 programming engine code 2 17 programming system code 2 17 ready power saver 2 8 replace photoconductor kit 2 14 service error 2 18 toner cartridge error 2 15 toner cartridge not installed 2 15 toner low 2 14 waiting 2 10
55. er view Wiring diagram 4505 EK C Tomo N Plouejos FEIN o ol S Eh EE Ale E ir OE Heer 4 sn tds neI t e a fe ee Tojonpuosdjoyd dE ss We Hose e peddinbo ji 1 HE 6nid vr 1 aie j MOmjoN 000 2892 E ES x EEE ee Eu du er seas eo ss o o o D wo V Me E m O ww O T 5 A o e PAR BBBB T il SdA1 e e BO nz Sd H El E ER to ci oe cor TT m S Anl EI La I tis o ued O ns idi doo Puri o BC wesBeiq GUUIM OS O X 3 X ca 5 4 Service Manual 4505 6 Preventive maintenance The Lexmark E23x E33x do not require preventive maintenance Preventive maintenance 6 1 4505 6 2 Service Manual 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 e NS Not Shown in the Asm Index column indicates that the part is procurable but is not pictured in the illustration Parts catalog 7 1 4505 Assembly 1 Covers 7 2 Service Manual Assembly 1 Covers 4505 Index P N Units Description 1 1 56P2079 1 Cover assembly top 2 56P2087 1 Cover assembly rear 2 56P2098 1 Cover assembly rear white 3 56P1821 1 C
56. es d utilisation d entretien par l utilisateur ou de r vision l exposition des rayonnements laser sup rieurs des rayonnements de Classe Avvertenze sui prodotti laser Questa stampante certificata negli Stati Uniti per essere conforme ai requisiti del DHHS 21 CFR Sottocapitolo J per i prodotti laser di classe 1 ed certificata negli altri Paesi come prodotto laser di classe 1 conforme ai requisiti della norma CEI 60825 1 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 viil Service Manual 4505 Avisos sobre el l ser Se certifica que en los EE UU esta impresora cumple los requisitos para los productos laser de Clase 1 establecidos en el subcapitulo J de la norma CFR 21 del DHHS Departamento de Sanidad y Servicios y en los dem s pa ses re ne todas las condiciones expuestas en la norma IEC 60825 1 para productos l ser de Clase I 1 Los productos l ser de Clase no se consideran peligrosos La impresora contiene en su interior un l ser de Clase
57. ew 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 2DE 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 Printer error Light sequence The printer has a service error and printing has stopped Meaning Turn the printer off and back on If the lights are still blinking contact the place where printer was purchased Action S 00000 gt DE lt 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 e Press amp twice quickly to see the secondary error code See Secondary error codes on page 2 19 for mo
58. fault Diagnostic aids 3 11 4505 Diagnostics menu selections Development Menu item Use setting to Value Edge to edge Allow a shift of all four margins top bottom right and left to the physical edge of the page printable area of supported paper Setting ignored by PPDS interpreter Off Print quality test pages Help isolate print quality problems such as streaking Three pages print A text page with printer information cartridge information current margin settings anda graphic Two pages with graphics Note Cartridge lockout function disabled Continuous print simplex Tray 1 Continuously print pages containing cross lines printer information and margin settings Press to stop Print history Print history of errors Defaults Configuration ID Change sizes and designations to metric Allow the printer s ID to match the label s ID after the controller card is replaced U S Non U S 000101 000189 Factory default 3 12 Service Manual 4505 Parallel Menu item Use setting to Value Par S strobe Adjust for an unusually long 1 adjustment parallel cable Parallel 0 mode 2 only is supported 1 and can be turned off in the 2 configuration group 3 Factory default Network Menu item Use setting to Value Mark history Append a tag to the history report to indicate t
59. gine communication engine electronics Controller card specifically NVRAM ROM or NAND RAM memory Network Paper port communications Device system card 2 30 Service Manual 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 vvhich is the primary indication or code For brevity this indication is not repeated in the follovving codes 1 Controller softvvare error illegal trap 90x Call the next level of support for a 900 error For the other errors vvhich indicate a faulty programming process or faulty component on the controller card replace the controller card Diagnostic information 2 31 4505 Controller softvvare Tertiary codes Lights Ki Continue Toner Low Replace PC Kit L Load Paper Paper Jam Secondary code n interface driver error General engine software error Faulty engine code flash or programming failed Contact next level of support or 1 800 539 6275 2 32 Service Manual 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 r
60. gs und k rperlicher Verletzung Das zust ndige Fachpersonal sollte entsprechende Vorsichtsma nahmen treffen ACHTUNG Dieses Symbol weist auf eine A gef hrliche elektrische Spannung hin die in diesem Bereich des Produkts auftreten kann Ziehen Sie vor den Arbeiten am Ger t den Netzstecker des Ger ts bzw arbeiten Sie mit gro er Vorsicht wenn das Produkt f r die Ausf hrung der Arbeiten an den Strom angeschlossen sein mu Xvi Service Manual 4505 Pautas de Seguridad La seguridad de este producto se basa en pruebas y aprobaciones del disefio original y componentes espec ficos El fabricante no es responsable de la seguridad en caso de uso de piezas de repuesto no autorizadas La informaci n sobre el mantenimiento de este producto est dirigida exclusivamente al personal cualificado de mantenimiento Existe mayor riesgo de descarga el ctrica y de dafios personales durante el desmontaje y la reparaci n de la m quina El personal cualificado debe ser consciente de este peligro y tomar las precauciones necesarias PRECAUCI N este s mbolo indica que el voltaje A de la parte del equipo con la que est trabajando es peligroso Antes de empezar desenchufe el equipo o tenga cuidado si para trabajar con l debe conectarlo Informac es de Seguranca A seguranca deste produto baseia se em testes e aprovac es do modelo original e de componentes especificos O fabricante n o respons vel pela segunr
61. h 6 foot straight NS 1339548 1 Power cord Brazil 6 foot straight NS 43H5545 1 Power cord PRC 1 77M straight NS 56P9926 1 Software Optra Forms NS 56P9927 1 Software Optra Forms director Parts catalog 7 9 4505 7 10 Service Manual Index A abbreviations 1 8 auto CR after LF setup menu 3 7 auto LF after CR setup menu 3 7 B buttons 1 3 C configuration menu 3 1 moving around the menu 3 3 printer diagnostics 3 5 printer setting configuration 3 4 configuration menu selections network 3 10 parallel 3 8 setup 3 7 USB 3 9 utilities 3 6 configuration menus parallel MAC binary PS 3 8 3 10 mode2 3 8 NPA mode 3 8 3 10 3 11 protocol 3 8 setup auto CR after LF 3 7 auto LF after CR 3 7 USB MAC binary PS 3 9 NPA mode 3 9 utilities Hex Trace 3 6 print quality test pages 3 6 reset factory defaults 3 6 4505 D diagnostic aids accessing configuration group 3 2 accessing diagnostic group 3 2 configuration menu 3 1 diagnostic menu 3 1 power on operations 3 2 diagnosticmenu 3 1 moving around the menu 3 3 printer diagnostics 3 5 printer setting configuration 3 4 diagnostic menu selections development 3 12 network 3 13 parallel 3 13 E error light 2 16 2 18 G general information 1 1 H Hex Trace utilities menu 3 6 L laser notices vii lights 1 3 2 3 load paper light Tray 1 or 550 sheet tray 2 12 locations 5 1 controller board 5 3 front and rear views 5 1 pow
62. he lights cycle to perform the function or to save the value E Press and hold Cancel until all of the Lights cycle to return to the Home menu u Turn the printer off to exit the menus Menus menu items and values Light On O Light off Light Blinking Value Utilities Setup Parallel USB Network Press Continue e eo eoe o e o e e Ready Data e oe eo o e e o o o Toner Low 4 8 e oo ce e e e o o e Load Paper D e oo oo o o o e e e Paper Jam O 006000 e6006000600600 e Error tl o 000800 008008008008 e Oeo eecee Ooeeceeooeeoc 2 2 5 a 5 2 5 2 c 2 So E x x 8 82 2 852 8 q DO Tico e e a8 2 8 RS 9g 2 t c o 0888 8 ow o 5 2 E E 9 E 2 3333 s 3 ss 8 6 2 2 E 5 ad 5 BE El 5 5 5 El S 2 25 s n 2 2 2 53 5 9 u Uo a x B S233 a 8e Pa gs 5 8 E Ba u 2 n 2 522 E SE E co 80 g 3 E 2 y 2 5 x pS 52 88 ic 5 29 o 5 o 6 El ue a 2 BS Seo ees 5 2 obs 2 2 2 a S ida 9 Gn 8 222 8222 223 goha D Sense SRE gt x u gt 8883 E Se go 2599535 5 sa E E 2 g288 5 88 S 3028802 2 o EB El 9 g es 8 g 85 epeoee a pyet D 528055tc5tc Bee SBS SPE chek S Bet sect Ss BESE 5550088 2 uoe 227454055755 2562852 2562652 26620652 25225652829 222 2 ES 20 Eg 7 E e E Ba ES B Bp 5 8 lt Bi B ro lt o a o 2 85 TES 5 3 El amp Pis 2 amp 2 p m S E e2 GE amp 23 2 El Papa E DE 3 4 Service Manual 4505 Printer di
63. he most recent crashes Mark Do not mark History mode Post the 976 error code to the user each time it occurs The default modified internally resets the posting but records it in the crash history A substantial number of consecutive errors result in posting 976 Modified Every time Optra Form mode Dump NVRAM Print a hex dump if the network NVRAM partition Reinit NVRAM Rest the network NVRAM to factory defaults Treat all print jobs as Optra Forms jobs Meditech mode Prevent the network card from accepting more than one 9100 mode connections at a time Factory default Diagnostic aids 3 13 4505 3 14 Service Manual 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 vvhile out of the printer 2 We recommend all external cables be disconnected from the printer to prevent damage during service 3 Unless othenvise stated re install the parts in reverse order of removal 4 When re installing a part held with several screws start all screws before final tightening Repair information 4 1 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 4 F
64. heck We 2 58 4505 Operator panel service check 2 59 Printhead service Check sues uns m mm mnn 2 61 Paper feed service checks 2 61 Parallel port service check 2x sana esa era a mmn 2 65 Print quality service CHECKS ie aci 0 00 aa 2 66 Using print quality test pages 2 66 Transfer roll service check 2 79 Diagnostic aids III deine 3 1 Configuration and diagnostic groups 3 1 II RE LT T CELA C LS 3 1 Bier c LUTTE 3 1 Power OM OporIONS assadas ads E 3 2 Configuration menu selections 3 6 Diagnostics menu selections 3 12 Repair information 4 1 REMOVAIS ss rams ve naar 4 1 CT TI T E T 4 2 Fahnen ae een 4 6 Feed rollers auto comp tires removal 4 7 Fuser idle gear links removal 4 7 Fuser power cable removal 4 8 FUS T I MONAl ss T P ER 4 8 Input roller clutch and lever removal ADM clutch CE MEELA 4 9 Input sensor 41 removal ss ieee oni ier Rm Rum mns 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 III 4 11 Paper exit guide assembly removal 4 12 Prinih
65. il the lights flash see menu samples on page 3 4 and page 3 5 3 2 Service Manual 4505 Moving around the menu Printer settings configuration on page 3 4 and Printer diagnostics on page 3 5 are similar to the instructions printed 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 e Press and release to move sequentially from one menu item to another e Press and hold amp to jump to home state top four lights on e Press and release lt to move through the menu settings indicated by s and 1 lights This action rotates only through the possible settings of the selected menu item Diagnostic aids 3 3 4505 Printer settings configuration Printer Settings Configuration This page explains how to access the printer menus and change values Menus are represented by Continue Ready Data Toner Low and Load Remove Paper Light sequences Menu items and their values are indicated by Paper Jam and Error light sequences Use the illustration to help you find the menu and value you want to change The Paper Jam and Error Lights show the current value of the menu item Press and release Cancel to advance through the menus and menu items to the one you need v gt Press and release Continue to advance to the value you need w Press and hold Continue until all of t
66. ingle sheet of media in the manual feeder 00 00 TEE V Load media with the side to be printed facing the front of the printer into the manual feeder e Press 4 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 O x D r Reinsert print job in tray 1 using the instructions in the driver pop up menu to orient the pages correctly Press 4 toresume printing Press and hold to reset printer Diagnostic information 2 13 4505 Toner low Light sequence Meaning Action Printer is ready to receive and process data The toner in the toner CORDE x 0 cartridge is getting low Send a print job Press lt 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 e Press and hold to reset printer Note The x 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 Y WA o D O HX e Press amp to resume printing Replace the photoconductor kit
67. ings on jobs sent through a network port either standard network or network opt lt x gt MAC Binary PS status information simultaneously Configure the printer to process Macintosh binary PostScript print jobs Menu item Use setting to Values NPA Mode Send print jobs to the Off printer and query printer Auto Off The printer filters PostScript print jobs using Standard protocol On The printer processes raw binary PostScript print jobs from computers using the Macintosh operating system This setting often causes Windows print jobs to fail Auto The printer processes print jobs from computers using either Windows or Macintosh operating systems 3 10 Service Manual Network continued 4505 Menu item Use setting to Values Set card speed Automatically detect the connection speed of your network This setting can be disabled to set the speed manually Auto the printer detects current network speed 10Mbps half duplex forces the printer to try to connect to the network only at 10Mbps half duplex 10Mbps full duplex forces the printer to try to connect to the network only at 10Mbps full duplex 100Mbps half duplex forces the printer to try to connect to the network only at 100Mbps half duplex 100Mbps full duplex forces the printer to try to connect to the network only at 100Mbps full duplex Factory de
68. k for excessive toner buildup on Fuser 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 take 30 minutes to cool Replace the fuser assembly as necessary 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 4505 Controller card service check FRU Action Controller card assembly
69. kjent i USA etter kravene i DHHS 21 CFR underkapittel J for klasse 1 laserprodukter og er i andre land godkjent som et Klasse l laserprodukt i samsvar med kravene i IEC 60825 1 Klasse l laserprodunter er ikke a betrakte som farlige Skriveren inneholder internt en klasse IIIb 3b laser som best r av en gallium arsenlaserenhet som avgir str ling i balgelengdeomradet 770 795 nanometer Lasersystemet og skriveren er utformet slik at personer aldri utsettes for laserstr ling ut over klasse I niva under vanlig bruk vedlikehold som utfgres av brukeren eller foreskrevne serviceoperasjoner Av s sobre el L ser Segons ha estat certificat als Estats Units aquesta impressora compleix els requisits de DHHS 21 CFR apartat J pels productes laser de classe 1 i segons ha estat certificat en altres llocs s un producte l ser de classe que compleix els requisits d IEC 60825 1 Els productes l ser de classe no es consideren perillosos Aquesta impressora cont un l ser de classe Illb 3b d arseni r de gal li nominalment de 5 mil liwats i funciona a la regi de longitud d ona de 770 795 nan metres El sistema l ser i la impressora han sigut concebuts de manera que mai hi hagi exposici a la radiaci l ser per sobre d un nivell de classe durant una operaci normal durant les tasques de manteniment d usuari ni durant els serveis que satisfacin les condicions prescrites Laser notices Xi 4505 Japanese Las
70. 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 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 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 f voltage or ground 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 switch if faulty Diagnostic information 2 51 4505 Dead machine service check CAUTION Check the AC line voltage The v
71. ll reprint 1 4 Service Manual 4505 Tips on preventing jams You can avoid most paper jams by correctly loading paper and specialty media The following hints can help you avoid paper jams Do not load wrinkled creased or damp paper Never mix media types within a tray Flex fan and straighten paper before you load it Do not exceed the maximum stack height Push all trays firmly into the printer after loading them Make sure the guides in the trays are positioned snugly against the paper or specialty media Do not remove paper trays while a job is printing Wait fora 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 Use only recommended paper Refer to the Card Stock amp 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 follovving tools and equipment e Magnetic tip Phillips screwdri
72. mly plugged in at the back of the printer Jobs are not printing and the Error light is on solid Make sure the print cartridge assembly is installed properly Make sure the printer top cover is closed While in PostScript 3 emulation the printer is flushing data Ready Data and Error lights are blinking Ensure the correct PostScript driver is being used The printer doesn t have enough memory to print the job Install more memory While using manual duplex the printer gets a paper jam A paper jam interrupts the duplex process As a result the information on the page that jammed is lost Press and release to cancel the print job Press and hold 9 approximately 3 seconds to reset the printer Resend the print job 2 78 Service Manual 4505 Transfer roll service check FRU 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 f NR Verify continuity in the spring and the cable connection on the LVPS HVPS Inspect the roll for signs of wear or damage and replace if necessary Diagnostic information 2 79 4505 2 80 Service Manual 4505 3 Diagnostic aids Configuration and diagnostic groups Configuration The configuration group contains a set of menus settings and operations which are not use
73. n 1 1 Overview of the operator panel 1 3 Paper jams how Io Clear nis 1 4 Tips on preventing jams 22 ccm mm ERR 1 5 ri O Pr E TT aiaee VER 1 6 TYPES Of print media sur en 1 7 AbDHeviatlbil nisse 1 8 Diagnostic information 2 1 vict P Pr eT 2 1 POST power on self test 2 1 Overview of the operator panel 2 2 Understanding the operator panel lights 2 3 Common ligh sequences sauer 2 3 Secondary COS asma amena nenn 2 6 Operator panel codes 222 22 a awe a dds 2 8 PRE EOS are 2 8 Secondaly emor Ehlers 2 19 Service information with secondary and tertiary light patterns 2 29 Secondary error COMES sus di cede eee eden ges na 2 30 Tertiary service error codes 2 31 Oym OM Tables PPP 2 44 POST symptom table ss anne Gaim mano Ran 2 44 Printer Symplomtable es 22 asas sus e essere een 2 45 Service Cie KS us 2 47 Cold fuser service check run ed 2 47 Cooling fan service Check asse scars ae are 2 48 Controller card service check 2 49 Cover interlock switch service check 2 51 Dead machine service check 2 52 F sel service CHECK ioo d aa wes e adia Reb Re Eus 2 53 Hot fuser service check uiuos o ew eevee eee ea 2 56 LVPS IHVPS Service check are 2 57 Main motor service C
74. n 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 x ison press lt 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 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 gt U N Turn the printer on with amp pressed and the front door open When t light stays on close cover Wait approximately 7 seconds until the printer drive activates Enter the configuration menu See Configuration and diagnostic groups on page 3 1 for more information Slowly press and release amp three times until the and lights come on Press and hold amp until all the lights flash to
75. ntinued 4505 FRU Action A Fuser continued Disconnect the thermistor cable from J15 on the controller card Measure the resistance across the ends of the thermistor cable See 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 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 A Fuser AC cables LVPS HVPS Fuser Measure the resistance of the thermistor The resistance measures from approximately 1R ohms immediately after printing or POR to approximately 240R ohms when thermistor reaches room temperature It may take 30 minutes to cool Replace the fuser assembly as necessary 2 56 Service Manual 4505 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 CAUTION The card has several points where AC voltage is exposed Ca
76. ocessors Tertiary codes amp Continue Toner Low Replace PC Kit E Load Paper Paper Jam Secondary RIP engine code communica Wrong printhead tion error Printhead no first hsync Verify interlock switch is plugged in at J13 lock Printhead lost hsync Transport Mirror motor locked motor initial lock failure Mirror motor lost lock Mirror motor not at opening speed Verify 24 V dc on pin 5 of J11 2 36 Service Manual 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 mm T o O Continue e I Toner Low Replace PC Kit E Load Paper ya Paper Jam e Secondary J code 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 4505 Tertiary codes Ki Continue w Toner Low Replace PC Kit E X Load Paper Paper Jam ES i Secondary E L SRAM failure NVRAM data does not NAND match secure NVRAM failure RIP firmware cannot A
77. oe Lexmark E23x E33x Service Manual 4505 100 4505 200 4505 300 4505 310 4505 400 4505 410 Table of Contents e Start Diagnostics e Safety and Notices e Trademarks e Index LEXMARK 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 MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE Some states do not allow disclaimer of express or implied warranties in certain transactions therefore this statement may not apply to you This publication could include technical inaccuracies or typographical errors Changes are periodically made to the information herein these changes will be incorporated in later editions Improvements or changes in the products or the programs described may be made at any time Comments may be addressed to Lexmark International Inc Department D22A 032 2 740 West New Circle Road Lexington Kentucky 40550 U S A or e mail at ServicelnfoAndTraining Lexmark com Lexmark may 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 purcha
78. ogrammed 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 0 0 De 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 vvith 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 lt gt again to see the tertiary code Primary Secondary Tertiary Codes Codes 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 e Light on Light off Light blinking x Light blinking slow Diagnostic information 2 29 4505 Secondary error codes Lights Primary code m Continue Secondary codes Toner Low Replace PC Kit Paper Jam Software 1 DC motor or transfer roll Fuser or toner sensor Printhead drive motor RIP to engine RIP to en
79. old amp until all of the lights come on to reset the printer 2 2 Service Manual Understanding the operator panel lights 4505 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 e Light on Light is off Light blinking x 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 Hex Trace Ready Waiting x e x x Flushing Resolution reduced Not ready printer offline Close door Insert cartridge Load media Diagnostic information 2 3 4505 Printer condition Load manual feeder Print side tvvo of duplex job Toner low Replace photoconductor kit Replace photoconductor kit printer hard stop Missing or defective toner cartridge Unsupported toner cartridge Change cartridge invalid refill Invalid engine code Invalid network code Programming engine code Programming system code Cancel job Reset printer 2 4 Service Manual 4505 Printer
80. older is unlatched Atthe left side of the transfer roll squeeze the holder arms with the right hand while lifting with the left hand Stop when the left holder is unlatched With a hand at each end lift the transfer roll out The springs should remain in place Re installation note Verify the springs are inserted into the bearings when re installing Repair information 4 13 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 4 Remove the LVPS HVPS card assembly See LVPS HVPS card assembly removal on page 4 10 for more information 5 Extract the cable through the side frame leaving it free at the opening above the LVPS HVPS 6 Remove the fuser See Fuser removal on page 4 8 for more information 7 Extract the cable through the hole and from its retainers 8 Unplug the cable at the motor and install the new cable 4 14 Service Manual 4505 5 Connector locations Front and rear views Front paper support 150 Sheet output bin Front cover Manual feeder Tray 1 Optional 550 sheet drawer Power button Connector locations 5 1 4505 Power supply board
81. oltage should be AA within the following limits 100 V ac volts alternating current 127 V ac for the 110 V printer e 200 V ac 240 V ac 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 board LVPS HVPS f 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 check the controller card See Controller board on page 5 3 for more information Verify grounds 2 52 Service Manual 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 The lamp is not a service part The line voltage to the printer must be within the following limits e 100 V ac 127 V ac for the 110 V model printer e 200 V ac 240 V ac for the 220 V model printer Turn the printer off and wait a few minu
82. orce the right hinge out of its socket and lift it above the socket CAUTION Do not pull the fuser link out of the printer any farther than when the door is fully open Otherwise the link extension may cause the cartridge coupler to become dislodged 5 Carefully lift the cover free from the printer frame 6 Use your left hand to hold the fuser link at the cover joint while rotating the right side of the cover slightly away from the printer to disengage the link 7 Remove the access cover Reinstallation note If the access cover is being replaced remove the logo plate and use it on the new cover Extender cover removal See Frame on page 7 6 1 Locate the latches on the left and right sides of the extender cover 2 Push the latches and pull the cover away from the rear of the printer 4 2 Service Manual 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 Release the latches with the right hand while applying opening force with the left hand Swing the cover open To remove the cover position the printer with the left rear corner hanging over the edge of the table Lift the top rear of the cover over the pivot point and drop the cover away from the printer Rear cover removal See Covers on page 7 2
83. over right 3 56P2093 1 Cover right white 4 56P2089 1 Drawer optional 5 56P2090 1 Tray 2 optional 5 56P2084 1 Tray 2 optional white 6 56P2088 1 Tray main 6 56P 1834 1 Tray main white 7 56P 1832 1 Cover logo plate E332n 7 56P2081 1 Cover logo plate E330 7 56P2085 1 Cover logo plate E232 7 56P 1833 1 Cover logo plate E230 7 56P2086 1 Cover logo plate plain 7 56P2628 1 Cover logo plate white E230 7 56P2096 1 Cover logo plate white E330 7 56P2097 1 Cover logo plate white E232 7 56P2629 1 Cover logo plate white E332 7 56P2703 1 Cover logo plate E234 8 56P1816 1 Cover assembly front access no logo 8 56P2091 1 Cover assembly front access white 9 56P2647 1 Springs front door and ACM 10 56P2080 1 Cover left 10 56P2095 1 Cover left white Parts catalog 7 3 4505 Assembly 2 Electronics 7 4 Service Manual Assembly 2 Electronics 4505 Index P N Units Description 2 1 56P1812 1 Print assembly laser mirror E232 1 56P1829 1 Print assembly laser mirror E330 E332n E234 E234n 1 56P1830 1 Print assembly laser mirror E230 2 56P1810 1 Fuser assembly 110 V 2 56P1811 1 Fuser assembly 220 V 2 56P2070 1 Fuser assembly 100 V 3 56P1826 1 Sensor exit 4 56P2077 1 Cable assemblies miscellaneous Toner sensor e LVPS HVPS to controller Main drive motor E23x E330 Main drive motor E234n E332n Fuser power 5 56P1824 1 Sensor input 1 6 56P1827 1 Sensor cover open 7 5
84. per feed Input sensor 1 under print sensors are working properly A cartridge assembly and stuck or incorrectly installed sensor Input sensor 2 manual 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 for 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 de 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 4505 Paper never picks FRU Action Paper feed pick tires Open the left cover and verify the solenoid and clutch are
85. r 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 Printhead removal See Electronics on page 7 4 1 Remove the top cover See Top cover removal on page 4 4 for more information 2 Remove the controller card cover two screws Note Notice the alignment of the printhead at each screw 3 Unplug the printhead cables at locations J11 and J12 4 Remove three screws securing the printhead to the cross brace and lift the printhead out Toner level sensor cable 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 two screws 3 Unplug the sensor at J17 and extract the cable 4 12 Service Manual 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 Transfer roll removal See Frame on page 7 6 1 Open the access cover 2 At the right side of the transfer roll squeeze the holder arms with the left hand while lifting with the right Stop when the h
86. rallel Mode 2 Determine whether the Off parallel port data is On sampled on the leading On or trailing Off edge of strobe MAC Binary PS Configure the printer to process Macintosh binary PostScript print jobs Off The printer filters PostScript print jobs using Standard protocol On The printer processes raw binary PostScript print jobs from computers using the Macintosh operating system This setting often causes Windows print jobs to fail Auto The printer processes print jobs from computers using either Windows or Macintosh operating systems Factory default 3 8 Service Manual USB 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 Off printer and query printer On status information simultaneously Auto MAC Binary PS Configure the printer to process Macintosh binary PostScript print jobs Off The printer filters PostScript print jobs using Standard protocol On The printer processes raw binary PostScript print jobs from computers using the Macintosh operating system This setting often causes Windows print jobs to fail Auto The printer processes print jobs from computers using either Windows or Macintosh operating systems Factory default Diagnostic aids 3 9 4505 Network Use the network menu to change printer sett
87. re information e Press amp to clear the secondary message 2 18 Service Manual 4505 Secondary error codes e Whenthe and 4 lights are both on a secondary error has occurred Press and release amp twice quickly to display the secondary error code light sequence e When the and 4 lights are both on a paper jam secondary error has occurred Press andrelease amp twice to display the secondary error code light sequence The following tables show what these light sequences mean and what to do Diagnostic information 2 19 4505 Paper jam in the manual feeder Light sequence Meaning Action A paper jam has occurred Clear the paper jam in the manual feeder Gv O x o D O NY Paper jams as it exits the tray into the printer Light sequence Meaning Action A paper jam has occurred Clear the paper jam as the paper is exiting the paper tray and entering the printer O x 4 o D ne 2 20 Service Manual Paper jams as a printed job exits the printer 4505 Light sequence Meaning Action 72DE X 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 correctly because the print information on the page is too complex that is too large
88. refully verify the AC voltage between pins 1 and 2 matches the power cable wall voltage f voltage is incorrect replace the card assembly Verify 24 V dc from pin 8 at CN201 f 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 A Main motor cable LVPS HVPS 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 Verify 24 V dc at J9 pin 8 and 5 V de at pin 1 controller card Verify ground at pins 2 and 7 for both the card and cable If these voltages are correct 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 If these voltages are not correct see the LVPS HVPS service check on page 2 57 or replace the controller card Note The main motor is nota service part 2 58 Service Manual 4505 Operator pan
89. s 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 andhold to reset printer Diagnostic information 2 9 4505 Hex Trace Ready Light sequence Meaning Action 00006 CORDE lt Printer is in the Ready mode and Hex Trace is active e Hex Trace helps troubleshoot printing problems After resolving the problem turn off the printer to exit Hex Trace Or press andhold to reset the printer VVaiting Light sequence Meaning Action e 0000 2DE lt Printer is waiting until a print timeout occurs or until it receives additional data e Press and release amp to print contents of the print buffer e Press and release 9 to cancel the print job Press and hold to reset the printer 2 10 Service Manual Flushing Resolution reduced
90. screw 5 Contain the spring as the latch is removed Repair information 4 5 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 Remove the controller card cover See Controller card removal on page 4 4 for more information 3 Unplug the exit sensor at J10 on the controller card 4 Locate the long shaft just above the exit sensor and two flats on the shaft just inside the bearing support at the gear Push the shaft to the right using your right thumb against the inside gear surface and the left index finger against the opposite end of the shaft Align the two flats with the opening of the bearing support and lift the right end of the shaft through the support 7 Swing the shaft away from the printer to expose the sensor flag 8 Remove the two lower outermost screws holding the fuser 9 Slide the fuser out just enough to access the screw holding the 10 11 sensor Remove the sensor and its attached cable Observe the orientation of the flag and spring before replacing units Fan removal See Electronics on page 7 4 1 2 3 Open the right side cover Unplug the fan from the controller card at J19 Remove two screws holding the fan to the metal side frame 4 6 Service Manual 4505 Feed rollers auto comp tires removal
91. se References in this publication to products programs or services do not imply that the manufacturer intends to make these available in all countries in which it operates Any reference to a product program or service is not intended to state or imply that only that product program or service may be used Any functionally equivalent product program or service that does not infringe any existing intellectual property right may be used instead Evaluation and verification of operation in conjunction with other products programs or services except those expressly designated by the manufacturer are the user s responsibility Lexmark 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 2004 Lexmark International Inc All rights reserved UNITED STATES GOVERNMENT RIGHTS This software and any accompanying documentation provided under this agreement are commercial computer software and documentation developed exclusively at private expense U S A P N 12G9399 4505 Table of contents KISASI se vii Safety informatio se IIIA ei me XV PIGIaCE Gm XX Denon Rere een xx General informatio
92. sible 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 s curit La s curit de ce produit repose sur des tests et des agr ations portant sur sa conception d origine et sur des composants particuliers Le fabricant n assume aucune responsabilit concernant la s curit en cas d utilisation de pi ces de rechange non agr es Les consignes d entretien et de r paration de ce produit s adressent uniquement un personnel de maintenance qualifi Le d montage et l entretien de ce produit pouvant pr senter certains risques lectriques le personnel d entretien qualifi devra prendre toutes les pr cautions n cessaires ATTENTION Ce symbole indique la pr sence A d une tension dangereuse dans la partie du produit sur laquelle vous travaillez D branchez le produit avant de commencer ou faites preuve de vigil
93. t 265872 255 Be RS So ee z 255922333288 uTo nm G2 8852472555232 E good ed ee gt E e opii PO sto PEL E tits Bg s sos NER 3 Be IBSIR 8 OE 23 3886 H Diagnostic aids 3 5 4505 Configuration menu selections Utilities Use the Utilities menu to troubleshoot printer problems Setting Use setting to Values Reset Factory Defaults Return the printer settings to factory default values Sometimes resetting the printer to the original settings solves formatting problems All menu items are reset to the factory default values except Display Language All settings in the Parallel menu Network menu LocalTalk menu and USB menu All downloaded resources fonts macros and symbol sets in printer memory RAM are deleted Resources in flash memory are unaffected Hex Trace Help isolate printing Off problems when On unexpected characters print or characters are missing Hex Trace helps determine if there is a problem with the language interpreter or the cable by providing information about what the printer is receiving To exit Hex Trace turn off the printer Print Quality Test Pages Help isolate print quality problems such as streaking Three pages print to help evaluate print quality A text page with printer information cartridge information current margin settings and a graphic Two pages with graphics 3 6 Service Manual 4505 Setting
94. t de l equip amb la qual esteu treballant s perill s Abans de comen ar desendolleu l equip o extremeu les precaucions si per treballar amb l equip l heu de connectar r9 ra gt of Sp lee Te WA Se Ta eae MARS TS al S eT AU IE T T T 2 Tas TS tc 3 Te MEYA 729 p I s BEA d Ee Wap Oo ee a eA At Ai El H H Mete AT Bat A 9 A LI 1 0 L A L L SET HH G e EIES TITS TAL Sa A as VII PENA TSE WATS ales A ee ques Ares suae Top ele ea A ee ee 9 51 HA Ol L E A At Ai Ol LISE ESA Lt Tl n H IL El Bu Te ed 79T xviii Service Manual 4505 LIRE AR UT PT Y ES JF EIN DT fi NE Vic SEABRA SIN UNES NERI im PER HIER RATE TETE TEMA RE I TA Ta m B FE UE X DA NET AA UR RITE SAT JM Safety information xix 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 vvell 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
95. tes 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 Diagnostic information 2 53 4505 Fuser service check continued 2 54 Service Manual FRU 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 If there is no continuity go to Step 2 No continuity 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 LVPS HVPS service check on page 2 57 for more information Make sure the fuser thermistor is correctly connected to the controller board Ifthe 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 pin 1 see Controller card service check on page 2 49 for more information Step 2 No continuity Check the lamp cable for continuity If correct replace the fuser If incorrect replace the lamp cable Fuser service check co
96. ting cables can be unplugged Remove the LVPS HVPS card and cover 4 10 Service Manual 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 Remove the controller card cover See Controller card removal on page 4 4 for more information Unplug the cable at J7 and extract the cable Note The card may not have to be completely removed to disconnect the cable Manual feed clutch assembly removal See Frame on page 7 6 1 Remove the left side cover N O q A C Place the printer on its right side Protect the cover from being marred Remove the four screws in the gear train metal cover Remove the clip from the shaft of the pick up clutch assembly Remove the screw and lever pawl Remove the clutch assembly If the pieces come apart they can be easily reassembled if necessary Operator panel removal See Electronics on page 7 4 a A O N Open access door Open the right cover Remove the controller card cover Unplug the operator panel from the controller card at J16 Remove two screws at the front top and bottom of the operator panel Remove the operator panel Repair information 4 11 4505 Paper exit guide assembly removal see Frame on page 7 6 1 Remove the rear cover See Rear cove
97. tribute the toner Replace the toner cartridge 2 74 Service Manual 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 Replace the toner cartridge Faint images or repetitive spots Select a different media type or appear on the page form type setting from your printer driver Try a different type of paper Paper designed for copiers gives the best quality Replace the toner cartridge Pages are blank The print cartridge may be out of toner or defective Replace the cartridge You may have a software error Try turning the printer off and back on Check the printhead See Paper feed service checks on page 2 61 for more information Diagnostic information 2 75 4505 Problem Action The printer is on but nothing prints Toner Low light is on and printing stops Make sure the toner cartridge assembly is installed properly Make sure the parallel or USB cable is not damaged and is firmly plugged into the connector on the back of the printer Press and release amp to print a menu settings page just to save space f you cannot print a menu settings page call the next
98. vers large and small Volt ohmmeter 1 6 Service Manual 4505 Types of print media Ensure trays are properly loaded Never mix media types within a tray Source Sizes Types Weight Capacity sheets Tray 1 A4 A5 Plain paper 60 90 g m 250 paper 250 sheet es a ce ee 16 24 Ib e labels tray etter egal abels 50 trans ne parencies statement Universal Tray 2 A4 A5 Plain paper 60 163 g m 550 paper 550 sheet JIS B5 transparencies 16 43 Ib labels letter legal labels tray 50 executive transpar folio encies statement Universalt Card stock Manual A4 A5 Plain paper 60 163 g m 1 feeder JIS B5 transparencies 16 43 Ib letter legal labels card executive stock folio statement Universal 73A 9 10 Envelopes DL C5 B5 other T 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 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
99. y of the page by reducing the amount of text or graphics on the page and deleting unnecessary downloaded fonts or macros Install additional printer memory Font error 4505 Light sequence Meaning Action 0060 DE Les The printer has received a request for a PPDS font which is not installed Press and release 9 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 Ee 7 LJ En The printer detects defective flash memory Press amp to clear the message and continue printing Downloaded fonts and macros not previously stored in flash memory are deleted Install flash memory Diagnostic information 2 23 4505 Insufficient defrag memory Light sequence Meaning Action x 0 00 DE 73 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 CORDE The printer cannot establish communication with the network Press 4 to clear the message and continue printing the job may not print correctly 2 24 Service Manual 4505

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