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· Table of Contents · Start Diagnostics · Safety and Notices · Trademarks · Index

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

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 [email protected]. 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 purchase. 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

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Table of contents
Laser notices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . vii Safety information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xv Preface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xx Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xx General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 Overview of the operator panel . . . . . . . . . . . . . . . . . . . . . . . . . . Paper jams­how to clear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tips on preventing jams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Types of print media . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3 1-4 1-5 1-6 1-7 1-8

Diagnostic information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 POST (power­on self test) . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 Overview of the operator panel . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 Understanding the operator panel lights . . . . . . . . . . . . . . . . . 2-3 Common light sequences . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 Secondary errors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6 Operator panel codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8 Primary codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8 Secondary error codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19 Service information with secondary and tertiary light patterns . 2-29 Secondary error codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-30 Tertiary service error codes . . . . . . . . . . . . . . . . . . . . . . . . . 2-31 Symptom tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-44 POST symptom table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-44 Printer symptom table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-45 Service checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-47 Cold fuser service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-47 Cooling fan service check . . . . . . . . . . . . . . . . . . . . . . . . . . 2-48 Controller card service check . . . . . . . . . . . . . . . . . . . . . . . . 2-49 Cover interlock switch service check . . . . . . . . . . . . . . . . . . 2-51 Dead machine service check . . . . . . . . . . . . . . . . . . . . . . . . 2-52 Fuser service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-53 Hot fuser service check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-56 LVPS/HVPS service check . . . . . . . . . . . . . . . . . . . . . . . . . 2-57 Main motor service check . . . . . . . . . . . . . . . . . . . . . . . . . . 2-58

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4505 Operator panel service check. . . . . . . . . . . . . . . . . . . . . . . . .2-59 Printhead service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-61 Paper feed service checks . . . . . . . . . . . . . . . . . . . . . . . . . . .2-61 Parallel port service check . . . . . . . . . . . . . . . . . . . . . . . . . . .2-65 Print quality service checks . . . . . . . . . . . . . . . . . . . . . . . . . .2-66 Using print quality test pages . . . . . . . . . . . . . . . . . . . . . . . . .2-66 Transfer roll service check . . . . . . . . . . . . . . . . . . . . . . . . . .2-79 Diagnostic aids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1 Configuration and diagnostic groups . . . . . . . . . . . . . . . . . . . . . .3-1 Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1 Diagnostic. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1 Power­On operations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-2 Configuration menu selections . . . . . . . . . . . . . . . . . . . . . . . . .3-6 Diagnostics menu selections . . . . . . . . . . . . . . . . . . . . . . . . .3-12 Repair information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-1 Removals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-1 Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-2 Fan removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-6 Feed rollers (auto comp tires) removal. . . . . . . . . . . . . . . . . . .4-7 Fuser idle gear links removal . . . . . . . . . . . . . . . . . . . . . . . . . .4-7 Fuser power cable removal . . . . . . . . . . . . . . . . . . . . . . . . . . .4-8 Fuser removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-8 Input roller clutch and lever removal (ACM clutch CBM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-9 Input sensor #1 removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-9 Input sensor #2 (manual) removal . . . . . . . . . . . . . . . . . . . . .4-10 LVPS / HVPS card assembly removal . . . . . . . . . . . . . . . . . .4-10 LVPS / HVPS to controller card cable removal . . . . . . . . . . .4-11 Manual feed clutch assembly removal . . . . . . . . . . . . . . . . . .4-11 Operator panel removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-11 Paper exit guide assembly removal . . . . . . . . . . . . . . . . . . . .4-12 Printhead removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-12 Toner level sensor cable removal . . . . . . . . . . . . . . . . . . . . .4-12 Toner level sensor removal . . . . . . . . . . . . . . . . . . . . . . . . . .4-13 Transfer roll removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-13 Transport motor cable removal . . . . . . . . . . . . . . . . . . . . . . .4-14 Connector locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1 Front and rear views . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1 Power supply board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-2 Controller board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-3 Wiring diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-4

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4505 Preventive maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 Parts catalog . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1 How to use this parts catalog . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1 Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I-1 Part number index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I-5

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Laser notices
Laser notice
The printer is certified in the U.S. to conform to the requirements of DHHS 21 CFR Subchapter J for Class I (1) laser products, and elsewhere is certified as a Class I laser product conforming to the requirements of IEC 60825-1. Class I laser products are not considered to be hazardous. The printer contains internally a Class IIIb (3b) laser that is nominally a 5 milliwatt gallium arsenide laser operating in the 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 I level during normal operation, user maintenance, or prescribed service condition.

Laser
Der Drucker erfüllt gemäß amtlicher Bestätigung der USA die Anforderungen der Bestimmung DHHS (Department of Health and Human Services) 21 CFR Teil J für Laserprodukte der Klasse I (1). In anderen Ländern gilt der Drucker als Laserprodukt der Klasse I, der die Anforderungen der IEC (International Electrotechnical Commission) 60825-1 gemäß amtlicher Bestätigung erfüllt. Laserprodukte der Klasse I gelten als unschädlich. Im Inneren des Druckers befindet sich ein Laser der Klasse IIIb (3b), bei dem es sich um einen Galliumarsenlaser mit 5 Milliwatt handelt, der Wellen der Länge 770-795 Nanometer ausstrahlt. Das Lasersystem und der Drucker sind so konzipiert, daß im Normalbetrieb, bei der Wartung durch den Benutzer oder bei ordnungsgemäßer Wartung durch den Kundendienst Laserbestrahlung, die die Klasse I übersteigen würde, Menschen keinesfalls erreicht.

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Avis relatif à l'utilisation de laser
Pour les Etats-Unis : cette imprimante est certifiée conforme aux provisions DHHS 21 CFR alinéa J concernant les produits laser de Classe I (1). Pour les autres pays : cette imprimante répond aux normes IEC 60825-1 relatives aux produits laser de Classe I. Les produits laser de Classe I sont considérés comme des produits non dangereux. Cette imprimante est équipée d'un laser de Classe IIIb (3b) (arséniure de gallium d'une puissance nominale de 5 milliwatts) émettant sur des longueurs d'onde comprises entre 770 et 795 nanomètres. L'imprimante et son système laser sont conçus pour impossible, dans des conditions normales d'utilisation, d'entretien par l'utilisateur ou de révision, l'exposition à des rayonnements laser supérieurs à des rayonnements de Classe I .

Avvertenze sui prodotti laser
Questa stampante è certificata negli Stati Uniti per essere conforme ai requisiti del DHHS 21 CFR Sottocapitolo J per i prodotti laser di classe 1 ed è certificata negli altri Paesi come prodotto laser di classe 1 conforme ai requisiti della norma CEI 60825-1. I prodotti laser di classe non sono considerati pericolosi. La stampante contiene al suo interno un laser di classe IIIb (3b) all'arseniuro di gallio della potenza di 5mW che opera sulla lunghezza d'onda compresa tra 770 e 795 nanometri. Il sistema laser e la stampante sono stati progettati in modo tale che le persone a contatto con la stampante, durante il normale funzionamento, le operazioni di servizio o quelle di assistenza tecnica, non ricevano radiazioni laser superiori al livello della classe 1.

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Avisos sobre el láser
Se certifica que, en los EE.UU., esta impresora cumple los requisitos para los productos láser de Clase I (1) establecidos en el subcapítulo J de la norma CFR 21 del DHHS (Departamento de Sanidad y Servicios) y, en los demás países, reúne todas las condiciones expuestas en la norma IEC 60825-1 para productos láser de Clase I (1). Los productos láser de Clase I no se consideran peligrosos. La impresora contiene en su interior un láser de Clase IIIb (3b) de arseniuro de galio de funcionamiento nominal a 5 milivatios en una longitud de onda de 770 a 795 nanómetros. El sistema láser y la impresora están diseñados de forma que ninguna persona pueda verse afectada por ningún tipo de radiación láser superior al nivel de la Clase I durante su uso normal, el mantenimiento realizado por el usuario o cualquier otra situación de servicio técnico. Declaração sobre Laser A impressora está certificada nos E.U.A. em conformidade com os requisitos da regulamentação DHHS 21 CFR Subcapítulo J para a Classe I (1) de produtos laser. Em outros locais, está certificada como um produto laser da Classe I, em conformidade com os requisitos da norma IEC 60825-1. Os produtos laser da Classe I não são considerados perigosos. Internamente, a impressora contém um produto laser da Classe IIIb (3b), designado laser de arseneto de potássio, de 5 milliwatts ,operando numa faixa de comprimento de onda entre 770 e 795 nanómetros. O sistema e a impressora laser foram concebidos de forma a nunca existir qualquer possiblidade de acesso humano a radiação laser superior a um nível de Classe I durante a operação normal, a manutenção feita pelo utilizador ou condições de assistência prescritas.

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Huomautus laserlaitteesta
Tämä kirjoitin on Yhdysvalloissa luokan I (1) laserlaitteiden DHHS 21 CFR Subchapter J -määrityksen mukainen ja muualla luokan I laserlaitteiden IEC 60825-1 -määrityksen mukainen. Luokan I laserlaitteiden ei katsota olevan vaarallisia käyttäjälle. Kirjoittimessa on sisäinen luokan IIIb (3b) 5 milliwatin galliumarsenidilaser, joka toimii aaltoalueella 770 - 795 nanometriä. Laserjärjestelmä ja kirjoitin on suunniteltu siten, että käyttäjä ei altistu luokan I määrityksiä voimakkaammalle säteilylle kirjoittimen normaalin toiminnan, käyttäjän tekemien huoltotoimien tai muiden huoltotoimien yhteydessä.

VARO! Avattaessa ja suojalukitus ohitettaessa olet alttiina näkymättömälle lasersäteilylle. Älä katso säteeseen. VARNING! Osynlig laserstrålning när denna del är öppnad och spärren är urkopplad. Betrakta ej strålen.

Laser-notis
Denna skrivare är i USA certifierad att motsvara kraven i DHHS 21 CFR, underparagraf J för laserprodukter av Klass I (1). I andra länder uppfyller skrivaren kraven för laserprodukter av Klass I enligt kraven i IEC 60825-1. Laserprodukter i Klass I anses ej hälsovådliga. Skrivaren har en inbyggd laser av Klass IIIb (3b) som består av en laserenhet av gallium-arsenid på 5 milliwatt som arbetar i våglängdsområdet 770795 nanometer. Lasersystemet och skrivaren är utformade så att det aldrig finns risk för att någon person utsätts för laserstrålning över Klass I-nivå vid normal användning, underhåll som utförs av användaren eller annan föreskriven serviceåtgärd.

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Laser-melding
Skriveren er godkjent i USA etter kravene i DHHS 21 CFR, underkapittel J, for klasse I (1) laserprodukter, og er i andre land godkjent som et Klasse I-laserprodukt i samsvar med kravene i IEC 60825-1. Klasse I-laserprodukter er ikke å betrakte som farlige. Skriveren inneholder internt en klasse IIIb (3b)-laser, som består av en gallium-arsenlaserenhet som avgir stråling i bølgelengdeområdet 770-795 nanometer. Lasersystemet og skriveren er utformet slik at personer aldri utsettes for laserstråling ut over klasse I-nivå under vanlig bruk, vedlikehold som utføres av brukeren, eller foreskrevne serviceoperasjoner.

Avís sobre el Làser
Segons ha estat certificat als Estats Units, aquesta impressora compleix els requisits de DHHS 21 CFR, apartat J, pels productes làser de classe I (1), i segons ha estat certificat en altres llocs, és un producte làser de classe I que compleix els requisits d'IEC 60825-1. Els productes làser de classe I no es consideren perillosos. Aquesta impressora conté un làser de classe IIIb (3b) d'arseniür de gal.li, nominalment de 5 mil.liwats, i funciona a la regió de longitud d'ona de 770-795 nanòmetres. El sistema làser i la impressora han sigut concebuts de manera que mai hi hagi exposició a la radiació làser per sobre d'un nivell de classe I durant una operació normal, durant les tasques de manteniment d'usuari ni durant els serveis que satisfacin les condicions prescrites.

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Japanese Laser Notice

Chinese Laser Notice

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Korean Laser Notice

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Safety information
· The safety of this product is based on testing and approvals of
the original design and specific components. The manufacturer is not responsible for safety in the event of use of unauthorized replacement parts. The maintenance information for this product has been prepared for use by a professional service person and is not intended to be used by others. There may be an increased risk of electric shock and personal injury during disassembly and servicing of this product. Professional service personnel should understand this and take necessary precautions. CAUTION: When you see this symbol, there is a danger from hazardous voltage in the area of the product where you are working. Unplug the product before you begin, or use caution if the product must receive power in order to perform the task.

· ·

·

Consignes de sécurité
· La sécurité de ce produit repose sur des tests et des
agréations portant sur sa conception d'origine et sur des composants particuliers. Le fabricant n'assume aucune responsabilité concernant la sécurité en cas d'utilisation de pièces de rechange non agréées. Les consignes d'entretien et de réparation de ce produit s'adressent uniquement à un personnel de maintenance qualifié. Le démontage et l'entretien de ce produit pouvant présenter certains risques électriques, le personnel d'entretien qualifié devra prendre toutes les précautions nécessaires. ATTENTION : Ce symbole indique la présence d'une tension dangereuse dans la partie du produit sur laquelle vous travaillez. Débranchez le produit avant de commencer ou faites preuve de vigilance si l'exécution de la tâche exige que le produit reste sous tension.

· · ·

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Norme di sicurezza
· La sicurezza del prodotto si basa sui test e sull'approvazione
del progetto originale e dei componenti specifici. Il produttore non è responsabile per la sicurezza in caso di sostituzione non autorizzata delle parti. Le informazioni riguardanti la manutenzione di questo prodotto sono indirizzate soltanto al personale di assistenza autorizzato. Durante lo smontaggio e la manutenzione di questo prodotto, il rischio di subire scosse elettriche e danni alla persona è più elevato. Il personale di assistenza autorizzato deve, quindi, adottare le precauzioni necessarie. ATTENZIONE: Questo simbolo indica la presenza di tensione pericolosa nell'area del prodotto. Scollegare il prodotto prima di iniziare o usare cautela se il prodotto deve essere alimentato per eseguire l'intervento.

· ·

·

Sicherheitshinweise
· Die Sicherheit dieses Produkts basiert auf Tests und
Zulassungen des ursprünglichen Modells und bestimmter Bauteile. Bei Verwendung nicht genehmigter Ersatzteile wird vom Hersteller keine Verantwortung oder Haftung für die Sicherheit übernommen. Die Wartungsinformationen für dieses Produkt sind ausschließlich für die Verwendung durch einen Wartungsfachmann bestimmt. Während des Auseinandernehmens und der Wartung des Geräts besteht ein zusätzliches Risiko eines elektrischen Schlags und körperlicher Verletzung. Das zuständige Fachpersonal sollte entsprechende Vorsichtsmaßnahmen treffen. ACHTUNG: Dieses Symbol weist auf eine gefährliche elektrische Spannung hin, die in diesem Bereich des Produkts auftreten kann. Ziehen Sie vor den Arbeiten am Gerät den Netzstecker des Geräts, bzw. arbeiten Sie mit großer Vorsicht, wenn das Produkt für die Ausführung der Arbeiten an den Strom angeschlossen sein muß.

· ·

·

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Pautas de Seguridad
· La seguridad de este producto se basa en pruebas y
aprobaciones del diseño original y componentes específicos. El fabricante no es responsable de la seguridad en caso de uso de piezas de repuesto no autorizadas. La información sobre el mantenimiento de este producto está dirigida exclusivamente al personal cualificado de mantenimiento. Existe mayor riesgo de descarga eléctrica y de daños personales durante el desmontaje y la reparación de la máquina. El personal cualificado debe ser consciente de este peligro y tomar las precauciones necesarias. PRECAUCIÓN: este símbolo indica que el voltaje de la parte del equipo con la que está trabajando es peligroso. Antes de empezar, desenchufe el equipo o tenga cuidado si, para trabajar con él, debe conectarlo.

· ·

·

Informações de Segurança
· A segurança deste produto baseia-se em testes e aprovações
do modelo original e de componentes específicos. O fabricante não é responsável pela segunrança, no caso de uso de peças de substituição não autorizadas. As informações de segurança relativas a este produto destinam-se a profissionais destes serviços e não devem ser utilizadas por outras pessoas. Risco de choques eléctricos e ferimentos graves durante a desmontagem e manutenção deste produto. Os profissionais destes serviços devem estar avisados deste facto e tomar os cuidados necessários. CUIDADO: Quando vir este símbolo, existe a possível presença de uma potencial tensão perigosa na zona do produto em que está a trabalhar. Antes de começar, desligue o produto da tomada eléctrica ou seja cuidadoso caso o produto tenha de estar ligado à corrente eléctrica para realizar a tarefa necessária.

· ·

·

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Informació de Seguretat
· La seguretat d'aquest producte es basa en l'avaluació i
aprovació del disseny original i els components específics. El fabricant no es fa responsable de les qüestions de seguretat si s'utilitzen peces de recanvi no autoritzades. La informació pel manteniment d'aquest producte està orientada exclusivament a professionals i no està destinada a ningú que no ho sigui. El risc de xoc elèctric i de danys personals pot augmentar durant el procés de desmuntatge i de servei d'aquest producte. El personal professional ha d'estar-ne assabentat i prendre les mesures convenients. PRECAUCIÓ: aquest símbol indica que el voltatge de la part de l'equip amb la qual esteu treballant és perillós. Abans de començar, desendolleu l'equip o extremeu les precaucions si, per treballar amb l'equip, l'heu de connectar.

· ·

·

xviii Service Manual

4505

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 well as general environmental and safety instructions. 2. Diagnostic information contains an error indicator table, symptom tables, and service checks used to isolate failing field replaceable units (FRUs (field replaceable unit)). 3. Diagnostic aids contains tests and checks used to locate or repeat symptoms of printer problems. 4. Repair information provides instructions for making printer adjustments and removing and installing field replaceable units (FRUs). 5. Connector locations uses illustrations to identify the connector locations and test points on the printer. 6. Preventive maintenance contains the lubrication specifications and recommendations to prevent problems. 7. Parts catalog contains illustrations and part numbers for individual FRUs.

Definitions
Note: A note provides additional information. Warning: A warning identifies something that might damage the product hardware or software. CAUTION: A caution identifies something that might cause a servicer harm. CAUTION: When you see this symbol, there is a danger from hazardous voltage in the area of the product where you are working. Unplug the product before you begin, or use caution if the product must receive power in order to perform the task.

xx Service Manual

4505

1. General information
The LexmarkTM E23x, E33x printers are monochrome laser printers designed for single users or small workgroups. There are four models:

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

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

· E330, 32MB of memory standard, a parallel port, a USB port,
and prints 27 pages per minute.

· E332n, 32MB of memory standard, an integrated Ethernet
adapter, a parallel port, a USB port, and prints 27 pages per minute.

· E234, 32MB of memory standard, a parallel port, a USB port,
and prints 25 pages per minute.

· E234n, 32MB of memory standard, an integrated Ethernet
adapter, a parallel port, a USB port, and prints 27 pages per minute.

General information 1-1

4505 The differences between the models are listed in the following table.
4505-100 Lexmark E230 8MB 8MB · 250­sheet tray · Single­ sheet manual feeder HBP (host­ based printing), PCL (printer control language) 5e, and Windows/ Macintosh/ Linux compatibility USB and Parallel 4505-200 Lexmark E232 16MB 80MB 4505-310 Lexmark E332n

Item

4505-300 Lexmark E330 32MB 160MB

Base memory Maximum memory Paper inputs

· 250­sheet tray · Single­sheet manual feeder · Optional 550­sheet drawer

Emulations

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

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

Connectivity

USB, Parallel, and 10/100 Base-TX Ethernet 2,500 pages

Toner cartridge yield Photoconductor kit yield

1,500 pages* (starter toner cartridge) 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 page 2-8 for more information.

Continue

Cancel

Ready

Toner Low / Replace PC Kit Load Paper

Paper Jam

Error

· Press and release · Press and release

to resume printing.

twice quickly to display a secondary error code following an error.

· Press and release to cancel the job currently printing. · Press and hold until all of the lights come on to reset the
printer.

General information 1-3

4505

Paper jams­how to clear
When a paper jam occurs, the printer stops operating and the operator panel's and lights come on. Press and release twice quickly to display the specific secondary error paper jam light sequence. See "Secondary errors" on page 2-6 for more information. We recommend the entire paper path be cleared when a paper jam occurs. To clear a paper jam: 1. If the paper is feeding from a tray, remove the tray, and then remove any jams. 2. Open the front cover and remove the print cartridge assembly. 3. Remove any jams located in the area behind the print cartridge assembly. 4. Lift the flap at the front of the printer and remove any jams located beneath the flap. 5. Open the rear exit and remove any jams.
6. After you have cleared the jams, reinstall the print cartridge assembly, make sure all printer covers and trays are closed, and then press the button to resume printing. Note: Pages caught in the paper jam will reprint.

1-4 Service Manual

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. Load Paper light sequence before you remove the tray.

· Do not remove paper trays while a job is printing. Wait for a · 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 & Label Guide available on the Lexmark Web site at www.lexmark.com for more information about which paper provides optimum results for current printing environment.

General information 1-5

4505

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

· Magnetic tip Phillips screwdrivers, large and small · Volt ohmmeter

1-6 Service Manual

4505

Types of print media
Ensure trays are properly loaded. Never mix media types within a tray.
Source Tray 1 (250-sheet tray) Sizes A4, A5, JIS B5, letter, legal, executive, folio, statement, Universal A4, A5, JIS B5, letter, legal, executive, folio, statement, Universal A4, A5, JIS B5, letter, legal, executive, folio, statement, Universal 7¾, 9, 10, DL, C5, B5, other


Types Plain paper, transparencies, labels

Weight 60­90 g/m2 (16­24 lb)

Capacity (sheets) · 250 paper · labels · 50 transparencies

Tray 2 (550-sheet tray)

Plain paper, transparencies, labels

60­163 g/m2 (16­43 lb)

· 550 paper · labels · 50 transparencies · card stock 1

Manual feeder

Plain paper, transparencies, labels, card stock

60­163 g/m2 (16­43 lb)

Envelopes

Card stock up to 90# Index. Grain short is recommended. Universal size range: 76­216 x 127­356 mm (3.0­8.5 x 5.0­ 14.0 in.) (includes 3 x 5 in. cards).

General information 1-7

4505

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

1-8 Service Manual

4505

2. Diagnostic information
Start
POST (power­on self test)
When you turn the printer on, it performs a POST. Check for correct POST functioning of the base printer by observing the following process: 1. All operator panel lights flash irregularly for approximately 10 seconds. 2. If there is a problem in the printer such as a paper jam, the panel lights indicate the problem. See "Common light sequences" on page 2-3 for more information. 3. Otherwise, the light flashes until the fuser comes up to temperature (5­20 additional seconds depending on the initial temperature of the fuser). Note: The operator panel has six lights and two buttons. The button has a light in it.

Diagnostic information 2-1

4505

Overview of the operator panel

Continue

Cancel

Ready

Toner Low / Replace PC Kit Load Paper Paper Jam

Error

· Press and release · Press and release

to resume printing.

twice quickly to display a secondary error code (following an error and lights on).

· Press and release to cancel the job currently printing. · Press and hold until all of the lights come on to reset the
printer.

2-2 Service Manual

4505

Understanding the operator panel lights
The operator panel lights mean different things, depending on their sequence. Lights that are off, on, and/or blinking indicate printer conditions such as printer status, intervention, or service. The following tables show the most common light sequences. Note: See "Primary codes" on page 2-8 for more information. G Light on Light is off


Light blinking Light blinking slow

x

Common light sequences
See "Overview of the operator panel" on page 2-2 for icon information.

Printer condition G Ready / Power Saver Busy Hex Trace Ready Waiting Flushing / Resolution reduced Not ready (printer offline) G Close door / Insert cartridge Load media

x
G
G

G

G

G

Diagnostic information 2-3

4505

Printer condition

G
G G

G

Load manual feeder Print side two 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 G G Cancel job / Reset printer

G





G

G G G

G G

G

G

G

G

G

G

G

2-4 Service Manual

4505

Printer condition Service error (see "Service information with 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).



G

Diagnostic information 2-5

4505

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

G

G

Printer error / Secondary error code Paper jams in the manual feeder Paper jams as it exits the tray into the printer Paper jams as a printed job exits the printer

G



G

G

G

G

G

G

G

G G G G G G G G

G


G G G


Complex page Insufficient printer memory Insufficient collation area Font error Defective flash Insufficient defrag memory Network interface errors Error communicating with host computer Memory full

G G G


G G G


G G

G

G

G

G

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4505
Printer condition

G G G

G G G G G

G G G G


G G G G G

Short paper Unformatted flash Flash full Invalid engine code Invalid network code

Paper jam secondary codes

G G

G G

G G

200 Paper jam input sensor 201 Paper jam between input and exit sensors 202 Paper jam exit sensor 241 Paper jam Tray 1 jam 242 Paper Jam Tray 2 jam 251 Paper jam manual feeder

G G G G G


G G G G

G G G G

Diagnostic information 2-7

4505

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

Primary codes
Ready / Power Saver
Light sequence Meaning · Printer ready to receive and process data. · Printer is in Power Saver mode. Action: · Send a print job. · Press to print the menu settings pages for a list of current printer settings. · Press and hold to reset the printer. Note: To change the Power Saver setting, use the Local Printer Setup Utility. See User's Reference for more information.

2-8 Service Manual

4505 Busy
Light sequence Meaning · Printer is busy receiving and processing data or printing. · Printer is defragmenting the flash memory to reclaim storage space occupied by deleted resources. · Printer is formatting the flash memory. · Printer is storing resources, such as fonts or macros, in flash memory. · Printer is printing a directory, font list, menu settings pages, or Print Quality Test Pages. Action:
· Busy: ­ Wait for message to clear. ­ Press and release to cancel print job. ­ Press and hold to reset printer. · Defragmenting flash, formatting flash, or programming flash: ­ Wait for message to clear. ­ Warning: Do not turn the printer off while this message is displayed. · Printing a directory, a font list, menu settings pages, or Print Quality Test Pages: ­ Wait for the pages to print. The Busy message is displayed as the pages print. The light is on when printing stops. ­ Press and release to cancel printing. ­ Press and hold to reset printer. · Receiving/processing data from a host interface: ­ Wait for message to clear. ­ Press and release to stop processing. ­ Press and hold to reset printer.

Diagnostic information 2-9

4505 Hex Trace Ready
Light sequence Meaning Printer is in the Ready mode and Hex Trace is active. Action: · Hex Trace helps troubleshoot printing problems. After resolving the problem, turn off the printer to exit Hex Trace. · Or, press and hold to reset the printer.

Waiting
Light sequence Meaning Printer is waiting until a print timeout occurs, or until it receives additional data. Action: · Press and release to print contents of the print buffer. · Press and release to cancel the print job. · Press and hold to reset the printer.

2-10 Service Manual

4505 Flushing / Resolution reduced
Light sequence Meaning · Printer is flushing corrupted print data. · Printer is processing data or printing pages, but the resolution of a page in the current print job is reduced from 600 dots per inch (dpi) to 300 dpi to prevent a memory full error. Action: · Wait until is displayed to print other jobs. · Press and release to cancel print job. · Press and hold to reset printer.

Not ready
Light sequence Meaning Printer is not ready to receive or process data, or the printer ports are offline. Action: · Press to return to or Busy state. · Press and release to cancel print job. · Press and hold to reset printer.

Diagnostic information 2-11

4505 Close door / Insert cartridge
Light sequence Meaning The printer door is open. Action: Close the door.

Load media
Light sequence Meaning The printer is out of media, or the media did not feed properly. Action: · Load media into tray 1 or the optional 550-sheet tray and press to resume printing. · Check that the media is loaded correctly in tray 1 or the optional 550-sheet tray. · Press to cancel the print job.

2-12 Service Manual

4505 Load manual feeder
Light sequence Meaning Printer prompts to load a single sheet of media in the manual feeder. Action: · Load media, with the side to be printed facing the front of the printer, into the manual feeder. · Press to resume printing. · Press and hold to reset printer.

Print side two of duplex job
Light sequence Meaning Print the other side of duplex print job. Action: · Reinsert print job in tray 1 using the instructions in the driver pop-up menu to orient the pages correctly. · Press to resume printing. · Press and hold to reset printer.

Diagnostic information 2-13

4505 Toner low
Light sequence Meaning · Printer is ready to receive and process data. · The toner in the toner cartridge is getting low. Action: · Send a print job. · Press to print the menu settings page for a list of current settings. · Remove the toner cartridge and shake it to extend the life of the cartridge. · Replace the toner cartridge. · Press and hold to reset printer. Note: The light may not come on if the starter toner cartridge is installed in a base printer model.

Replace photoconductor kit
Light sequence Meaning The photoconductor kit's drum is full and needs replacing. Action: · Press to resume printing. · Replace the photoconductor kit.

2-14 Service Manual

4505 Replace photoconductor kit (printer hard stop)
Light sequence Meaning The photoconductor kit's drum is full and needs replacing. No pages print until the photoconductor kit is replaced. Action: · Replace the photoconductor kit.

Toner cartridge error / Toner cartridge is not installed
Light sequence Meaning The toner cartridge is not installed, or the printer detects a toner cartridge error. Action: · If the toner cartridge is not installed, install it. · If the toner cartridge is installed, remove it and install a new toner cartridge.

Diagnostic information 2-15

4505 Change invalid toner cartridge
Light sequence Meaning The toner cartridge being used is not designed for this printer. Action: Install a toner cartridge compatible to printer.

Invalid engine code / Invalid network code
Light sequence Meaning The code in an internal print server has not been programmed, or the programmed code is not valid. Action: · Download valid network code to the internal print server. · Press twice quickly to see the secondary error code.

2-16 Service Manual

4505 Programming engine code / Programming system code
Light sequence Meaning New code is being programmed into the engine or firmware code flash. Action: 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 · 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. Action: Wait for the message to clear.

Diagnostic information 2-17

4505 Service error
Light sequence Meaning The printer has a service error and printing has stopped. Action: Turn the printer off and back on. If the lights are still blinking, contact the place where printer was purchased.

Printer error
Light sequence Meaning 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. Action: · Press twice quickly to see the secondary error code. See "Secondary error codes" on page 2-19 for more information. · Press to clear the secondary message.

2-18 Service Manual

4505

Secondary error codes · When the
and lights are both on, a secondary error has occurred. Press and release twice quickly to display the secondary error code light sequence. and lights are both on, a paper jam secondary error has occurred.

· When the

Press and release

twice to display the secondary error code

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

Diagnostic information 2-19

4505 Paper jam in the manual feeder
Light sequence Meaning A paper jam has occurred in the manual feeder. Action: Clear the paper jam.

Paper jams as it exits the tray into the printer
Light sequence Meaning A paper jam has occurred as the paper is exiting the paper tray and entering the printer. Action: Clear the paper jam.

2-20 Service Manual

4505 Paper jams as a printed job exits the printer
Light sequence Meaning A paper jam has occurred as the paper is exiting the printer. Action: Clear the paper jam.

Complex page
Light sequence Meaning The page may not print correctly because the print information on the page is too complex (that is, too large for the printer's memory). Action: · Press to clear the message and continue processing the print job (some of the print data may be lost). · To avoid this error in the future: ­ 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 The printer does not have enough memory to save the data in the buffer. Action: · Install additional memory. · Press to continue printing the job. · Press to cancel the print job.

Insufficient collation area
Light sequence Meaning The printer memory does not have the free space necessary to collate the print job. This may happen due to one of these errors: · Memory is full. · A page is too complex to print. · A page is shorter than the set page margins. · Memory is insufficient to save what is in the buffer. Action: · Press to clear the message and continue printing the job (the job may not print correctly.) · Press and release to cancel the print job. · Press and hold to reset the printer. · To avoid this error in the future: ­ Simplify the print job. 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.

2-22 Service Manual

4505 Font error
Light sequence Meaning The printer has received a request for a PPDS font which is not installed. Action: · Press and release to cancel the print job. · Press and hold to reset the printer. · Press and release to clear the message and continue printing.

Defective flash
Light sequence Meaning The printer detects defective flash memory. Action: · Press 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 The printer has insufficient memory to free unused space in flash memory. Action: · Delete fonts, macros, and other data in RAM. · Install additional printer memory.

Network interface errors
Light sequence Meaning The printer cannot establish communication with the network. Action: Press to clear the message and continue printing (the job may not print correctly).

2-24 Service Manual

4505 Error communicating with host computer
Light sequence Meaning The printer has lost the connection to an external print server (also called an external network adapter or external network adapter (ENA)). This light sequence is displayed if your printer is connected to the network, but it cannot detect the print server when you turn on the printer. Action: · Make sure the cable connecting the ENA and the printer is securely attached. · Turn the printer off and then on to reset the printer. · Press and hold to reset the printer.

Memory full
Light sequence Meaning The printer is processing data, but the memory used to store pages is full. Action: · Press to clear the message and continue printing the job (the job may not print correctly). · Press and release to cancel the print job. · Press and hold to reset the printer. · To avoid this error in the future: ­ Simplify the print job. 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 The paper length is too short to print the formatted data. This occurs when the printer does not know the media size loaded in the tray, or there is a problem feeding the media. Action: · Make sure the print media you loaded is large enough. · Open the front cover, clear the paper path and close the cover to resume printing. · Press to clear the message and continue printing the job. · Press to cancel the print job.

Flash full
Light sequence Meaning There is not enough free space in the flash memory to store the data you are trying to download. Action: · 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.

2-26 Service Manual

4505 Unformatted flash
Light sequence Meaning The printer detects unformatted flash memory. Action: · Press to clear the message and continue printing. The job may not print correctly. · Reformat the flash memory. Refer to the Technical Reference on Lexmark's Web site for more information. · If the error message remains, the flash memory may be defective and should be replaced.

Invalid engine code
Light sequence Meaning The code in an internal print server has not been programmed, or the programmed code is not valid. Action: Download valid engine code to the internal print server.

Diagnostic information 2-27

4505 Invalid network code
Light sequence Meaning The code in an internal print server has not been programmed, or the programmed code is not valid. Action: Download valid network code to the internal print server.

2-28 Service Manual

4505

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

Double Click

Do ub Cl ick le

Do ub Cl ick le

Do ub Cl ick le

Primary Codes

Secondary Codes

Tertiary 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. G Light on Light off



Light blinking Light blinking slow

x

Diagnostic information 2-29

4505

Secondary error codes
Secondary codes
901 91x 92x 93x 94x 95x 96x 97x 98x 99x

Lights

Primary code


Continue






















Ready


Toner Low / Replace PC Kit






Load Paper










Paper Jam










Error











Software DC motor or transfer roll Fuser or toner sensor Printhead, drive motor, RIP to engine RIP to engine communication, engine electronics Controller card, specifically, NVRAM, ROM or 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 which is the primary indication or code. For brevity, this indication is not repeated in the following codes. 1. Controller software error/illegal trap (90x) Call the next level of support for a 900 error. For the other errors, which indicate a faulty programming process or faulty component on the controller card, replace the controller card.

Diagnostic information 2-31

4505 Controller software
Tertiary codes
900 901 902 903 904 905

Lights
Continue

G
Ready













G
Toner Low / Replace PC Kit

G
Load Paper





G
Paper Jam





G
Error Secondary code







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

906







RIP interface driver error

4505 Transfer roll CAUTION: When you see this symbol, there is a danger from hazardous voltage in the area of the product where you are working. Unplug the product before you begin, or use caution if the product must receive power in order to perform the task. Code 917 indicates a problem in the transfer roll circuit. Check the continuity from the cable connection on the HVPS (high voltage power supply) to the right side of the transfer roll.
Tertiary code

Lights
Continue

G
Ready

G
Toner Low / Replace PC Kit

G
Load Paper

G
Paper Jam


Error Secondary code

Diagnostic information 2-33

917









4505 Fuser, fan, or toner sensor error Codes 920 through 929 indicate a problem in the fuser (see "Fuser service check" on page 2-53 for more information), a stalled fan motor or a faulty toner sensor or toner cartridge.
Tertiary codes
920 921 922 923 924 925 926 927 928

Lights
Continue

G
Ready



















G
Toner Low / Replace PC Kit



G
Load Paper










Paper Jam









G
Error









Secondary code Fuser below temperature when printing Fuser below standby temperature at idle

Fan stalled Toner sensor or toner cartridge Incorrect fuser lamp installed Open circuit in thermistor path Fuser too hot during printing or idle Fuser failed to reach standby temperature

2-34 Service Manual

929







4505 Printhead, transport motor or RIP/engine communication error Codes 930 through 935 indicate a problem with the printhead. Check cables to the printhead. Replace the printhead as necessary. Codes 936 and 937 indicate a problem in the drive system.

Diagnostic information 2-35

4505 Code 939 indicates a communication failure between the RIP and engine processors.
Tertiary codes
930 931 932 933 934 935 936 937

Code
Continue

G
Ready

















G
Toner Low / Replace PC Kit

G
Load Paper










Paper Jam










Error Secondary code Wrong printhead Printhead - no first hsync. (Verify interlock switch is plugged in at J13.)









RIP/engine communication error Transport motor lost lock Transport motor initial lock failure

Printhead - lost hsync Mirror motor locked Mirror motor lost lock Mirror motor not at opening speed. (Verify +24 V dc on pin #5 of J11.)

2-36 Service Manual

939







4505 RIP to engine communication failure (controller card). This indicates fuser control in the LVPS has failed or the wrong LVPS has been installed.
Tertiary codes

Code
Continue

G
Ready

G
Toner Low / Replace PC Kit


Load Paper

G
Paper Jam

G
Error Secondary code

Diagnostic information 2-37

940



4505 NVRAM failure Error codes 950­954 indicate a problem in the NVRAM (nonvolatile random access memory). Replace the operator panel assembly. Codes 955­959 indicate a failed controller card assembly. Replace the controller card.

2-38 Service Manual

4505

Tertiary codes
950 951 952 954 955 956 957 958

Code
Continue

G
Ready

















G
Toner Low / Replace PC Kit




Load Paper









G
Paper Jam








Error







959







Secondary code NVRAM data does not match secure NVRAM RIP firmware cannot communicate with secure NVRAM NVRAM chip failure NVRAM CRC failure

SRAM failure NAND failure ASIC failure Processor failure Code ROM or NAND failed cyclic redundancy check (CRC)

Diagnostic information 2-39

4505 Note: NVRAM is on the operator panel printed circuit board (PCB) while secure NVRAM is on the controller PCB. Check margin alignments after replacing the operator panel assembly. See "Printhead service check" on page 2-61 for more information. If margin errors are unacceptable, corrections can only be made through software. Contact the next level of support or Lexmark at 1-800-539-6275.

2-40 Service Manual

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
960 961 962

Code
Continue

G
Ready







G
Toner Low / Replace PC Kit


Load Paper


Paper Jam



G
Error Secondary code



RAM in slot 1 is bad RAM soldered on the board is bad

Diagnostic information 2-41

963







4505 Network error Indicates an error in the network circuitry. Replace the controller card assembly.
Tertiary codes
970 971 972 973 974 975 976 978

Code
Continue

G
Ready

















G
Toner Low / Replace PC Kit




Load Paper








Paper Jam








Error







Secondary code

Unrecognizable network port

Unrecoverable software error in network port Bad checksum while programming port Flash parts failed while programming port

2-42 Service Manual

979







4505 Paper port communication failure Indicates an error communicating with Tray 2, if installed. Remove Tray 2 and recheck. If the error does not recur, replace Tray 2. If the error recurs, replace the controller card assembly
Tertiary codes
980 981 982 983

Code
Continue

G
Ready










Toner Low / Replace PC Kit

G
Load Paper

G
Paper Jam





G
Error





Secondary code Engine experiencing unreliable communications to specified device Engine protocol violation detected by the specified device

Invalid command parameter received by specified device Invalid command received by specified device Communications error detected by specified device

Diagnostic information 2-43

984





4505

Symptom tables
POST symptom table
Symptom The main motor, cooling fan, and fuser do not come on. POST completes except one or more lights do not come on. None of the lights come on. Main motor does not come on. Fan does not come on. Fuser lamp does not come on. Fuser lamp never turns off. The paper feed picks and tries to feed paper. Action See "Cover interlock switch service check" on page 2-51. See "Operator panel service check" on page 2-59. See "Operator panel service check" on page 2-59. See "Main motor service check" on page 2-58. See "Cooling fan service check" on page 2-48. See "Cold fuser service check" on page 2-47. See "Hot fuser service check" on page 2-56. See "Paper feed service checks" on page 2-61.

2-44 Service Manual

4505

Printer symptom table
Symptom Dead machine (no power) Fan noisy or not working Fuser parts melted Fuser lamp doesn't light Toner not fused to the paper Paper jams Main motor noisy or not moving Paper skew Printer not communicating with host Front access cover will not close Operator panel button not responding Operator panel lights are off or very dim Blank page Black page Heavy background Light print Action See "Dead machine service check" on page 2-52. See "Cooling fan service check" on page 2-48. See "Hot fuser service check" on page 2-56. See "Cold fuser service check" on page 2-47. See"Cold fuser service check" on page 2-47. See "Paper feed service checks" on page 2-61. See "Main motor service check" on page 2-58. See "Paper feed service checks" on page 2-61. See "Parallel port service check" on page 2-65. See "Cover interlock switch service check" on page 2-51. See "Operator panel service check" on page 2-59 or "Controller card service check" on page 2-49. See "Controller card service check" on page 2-49. See "Blank page" on page 2-67. See "Black page" on page 2-68. See "Heavy background" on page 2-69. See "Light print" on page 2-71.

Diagnostic information 2-45

4505
Symptom White or black lines or bands Toner on back of page Paper never picks Paper feeds continuously Paper wrinkled or bent Action See "White or black lines or bands" on page 2-72. See "Toner on back of page" on page 2-72. See "Paper never picks" on page 2-63. See "Paper picks during POST and/or continuously" on page 2-62. 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. Check for excessive toner buildup on the surface of the thermistor. Clean as necessary. With the printer unplugged, disconnect the thermistor cable from J15 on the controller card. Measure the resistance of the thermistor. The resistance measures from approximately 1K ohms immediately after printing or POR to approximately 240K ohms when thermistor reaches room temperature. (It may take 30 minutes to cool.) Replace the fuser assembly as necessary.

Fuser AC cables LVPS/HVPS Fuser

Diagnostic information 2-47

4505

Cooling fan service check
FRU Cooling fan Action 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 Controller card assembly Action Verify +24 V dc input from the LVPS/HVPS. · Turn the printer off. · Disconnect the LVPS/HVPS cable from the controller card at J7. See "Controller board" on page 5-3 for more information. · Turn the printer on. Verify +24 V dc from the cable connector of J9, pin 8. Verify that pin 7 on both the cable and the card connectors is ground. · If voltage is correct, check the continuity in the cable. If the cable is good, see the "Controller board" on page 5-3 for more information. · If grounds are not correct on the cable, first check it for continuity and then the LVPS/HVPS. · If the grounds are not correct on the controller card, replace the controller card. (Check with one probe on the connector pin and the other on the card's ground plane found at each screw head.)

Diagnostic information 2-49

4505 Controller card service check (continued)
FRU Controller card assembly Action Note: With all cables connected, the printer should complete POST within approximately 12­15 seconds in the following sequence: 1. All operator panel lights on solid momentarily. 2. Lights then flash on and off sequentially. After lights quit flashing, the light turns on solid. 3. The cooling fan comes on. 4. The fuser lamp comes on. 5. The drive motor runs. 6. The printhead motor runs. 7. The printer cycles down into standby mode/ready. If immediately following power­on the operator panel lights are active but the printer does not go through steps 1 and 2 above, replace the controller card assembly. Note: Settings for U.S. versus non­U.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 Cover interlock switch Action Disconnect the cover interlock cable from the controller card at J13. Verify continuity between cable pin 1 and pin 2 with the door closed but not open. Verify continuity between cable pin 1 and pin 3 with the door open but not closed. · If either fail continuity, replace the cover interlock switch. · If both pass continuity, turn the printer on and verify +5 V dc on pin 2 at J6 on the controller card. · Verify pins 1 and 3 are ground. · If voltage or 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 voltage should be within the following limits:

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

printer 200 V ac ­ 240 V ac for the 220 V printer
Action Unplug the printer and check the fuses on the LVPS/HVPS board for continuity. · If open, replace the LVPS/HVPS board. ­ If fuse opens again, see "LVPS/ HVPS service check" on page 2-57 for more information · If not open, unplug the cables at CN102 and CN201 (fuser and controller card respectively). Plug LVPS/HVPS board to source and turn switch on. Verify 24 V dc on pin 8 at connector CN201. Verify line voltage (110 or 220 V ac) across pins 1 and 2 of CN102