Lexmark 4500-00 Series Service Manual Download

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Diagnostic aids

3-3

4500–E320/E322

Printer modes summary table

Mode

Method of entry

Method of exit

Normal
printing

NVRAM power–on default
flag set to Normal

AND

Turn on printer with cover
closed.

Print engine cleaning
cycle page from special
function menu.

Operator panel reset from
hex trace.

Print quality test page
from special function
menu.

Reset defaults from
special function menu.

Turn off printer and follow
instructions for method of
entry.

Summary of Contents for 4500-00 Series

Page 1: ...rk E220 Lexmark E32x Lexmark and Lexmark with diamond design are trademarks of Lexmark International Inc registered in the United States and or other countries Table of Contents Index Safety and Notic...

Page 2: ...d to Lexmark International Inc Department D22A 032 2 740 West New Circle Road Lexington Kentucky 40550 U S A or e mail at ServiceInfoAndTraining Lexmark com Lexmark may use or distribute any of the in...

Page 3: ...rator panel 2 2 Status information 2 3 Attendance information 2 4 Service information 2 7 Service error codes 2 11 Operator panel light summary table 2 25 Error code table 2 26 Power On Self Test POST...

Page 4: ...81 Parallel port service check 2 85 Print quality service checks 2 86 Transfer roll service check 2 99 Resetting user defaults E320 E322 2 100 Restoring factory defaults E320 E322 2 101 Restoring fact...

Page 5: ...moval 4 7 Cooling fan removal 4 8 D roll removal 4 9 Engine board removal E320 E322 only 4 9 Fuser assembly removal 4 10 High voltage power supply HVPS removal 4 10 Low voltage power supply LVPS remov...

Page 6: ...1 Covers E320 E322 7 2 Assembly 2 Frame 7 8 Assembly 3 Fuser 7 10 Assembly 4 Main drive 7 12 Assembly 5 Paper feed 7 14 Assembly 6 Printhead 7 16 Assembly 7 Electronics 7 18 Assembly 8 Options 7 22 As...

Page 7: ...notices The following laser notice labels may be affixed to this printer as shown Laser advisory label Class 1 laser statement label APPAREIL LASER DE CLASSE 1 CLASS 1 LASER PRODUCT LASER KLASSE 1 LUO...

Page 8: ...service condition Laser Der Drucker erf llt gem amtlicher Best tigung der USA die Anforderungen der Bestimmung DHHS Department of Health and Human Services 21 CFR Teil J f r Laserprodukte der Klasse I...

Page 9: ...par l utilisateur ou de r vision l exposition des rayonnements laser sup rieurs des rayonnements de Classe I Avvertenze sui prodotti laser Questa stampante certificata negli Stati Uniti per essere con...

Page 10: ...l 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 con...

Page 11: ...worpen dat bij normaal gebruik bij onderhoud of reparatie conform de voorschriften nooit blootstelling mogelijk is aan laserstraling boven een niveau zoals voorgeschreven is voor klasse 1 Lasermeddele...

Page 12: ...suojalukitus ohitettaessa olet alttiina n kym tt m lle lasers teilylle l katso s teeseen VARNING Osynlig laserstr lning n r denna del r ppnad och sp rren r urkopplad Betrakta ej str len Laser notis D...

Page 13: ...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 l ser de classe I 1 i s...

Page 14: ...xiv Service Manual 4500 Japanese laser notice Chinese laser notice...

Page 15: ...Laser notices xv 4500 Korean laser notice...

Page 16: ...xvi Service Manual 4500...

Page 17: ...ons 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 re...

Page 18: ...pi elevato Il personale di assistenza autorizzato deve quindi adottare le precauzioni necessarie Sicherheitshinweise Die Sicherheit dieses Produkts basiert auf Tests und Zulassungen des urspr ngliche...

Page 19: ...i n de la m quina El personal cualificado debe ser consciente de este peligro y tomar las precauciones necesarias Informa es de Seguran a A seguran a deste produto baseia se em testes e aprova es do m...

Page 20: ...tions de seguretat si s utilitzen peces de recanvi no autoritzades La informaci pel manteniment d aquest producte est orientada exclusivament a professionals i no est destinada a ning que no ho sigui...

Page 21: ...Safety information xxi 4500...

Page 22: ...ion provides instructions for making printer adjustments and removing and installing FRUs 5 Connector Locations uses illustrations to identify the connector locations and test points on the printer 6...

Page 23: ...e desktop printers designed to fit into space critical environments and yet not sacrifice speed or ease of use The E220 E32x attaches to an IBM Personal Computer or other computers compatible with the...

Page 24: ...th 4MB of standard memory Lexmark E322 printer with 8MB of standard memory Lexmark E322n printer with standard Ethernet and 16MB of standard memory Rear paper support Tray 1 Manual feed Front paper su...

Page 25: ...21 printer with 8MB of standard memory Lexmark E323 printer with 16MB of standard memory Lexmark E323n printer with 16MB of standard memory and standard Ethernet Rear paper support Tray 1 Manual feed...

Page 26: ...cess memory NVRAM located on the operator panel printed circuit board PCB higher speed pages per minute ppm The E220 is similar to the E321 but has a slower speed Other differences are listed in the f...

Page 27: ...top or front of the printer Printer dimensions and clearance The following table contains the dimensions for each printer model This does not include packaging but does include the print cartridge th...

Page 28: ...s memory RAM is soldered on the controller card on both the E320 E322n and E220 E321 E323n Option E220 E320 E321 E322 E322n E323 E323n Tray 2 Avail able Avail able Avail able Avail able Avail able Ava...

Page 29: ...n of Radiation LED Light Emitting Diode LFCR Line Feed Carriage Return LVPS Low Voltage Power Supply NAND Not AND NVRAM Nonvolatile Random Access Memory OPC Optical Photoconductor PC Photoconductor PC...

Page 30: ...1 8 Service Manual 4500...

Page 31: ...printer Use the service error code user error message symptom table service checks and diagnostic aids in this chapter to determine the corrective action necessary to repair a malfunctioning printer...

Page 32: ...and one button The information provided by the six lights is classified into three groups Status Attendance Service Depending on the light sequence briefly approximately one second push the operator p...

Page 33: ...rinter is in a Ready state Ready indicates the printer is ready to receive and process data from the host system Brief button press executes a print test Long button press executes a printer reset Ope...

Page 34: ...the paper path The user indicates the jam is cleared by closing the cover or by performing a brief button press Paper jam A paper jam is detected Brief button press assumes the jam has been cleared A...

Page 35: ...fied to note that the connection exists Then each time the power is cycled on the printer if the setting states a connection exists the printer attempts to communicate with the adapter If the adapter...

Page 36: ...overy process for this error is 1 If this error occurs at power on and an ENA is attached to the printer verify the ENA is properly connected 2 When the printer is in the Ready state press the operato...

Page 37: ...re not recoverable However it may be possible to turn the printer off and back on to temporarily recover from the error condition if it is intermittent When a service error occurs the printer stops pr...

Page 38: ...When a service error occurs the printer stops printing and all operator panel lights blink in a continuous pattern indicating a service error until the printer is turned off Press and release the oper...

Page 39: ...g a fuser failure Once the error code is displayed and if the operator panel button is pushed again the operator panel displays the service error indication all six indicator lights blinking Continual...

Page 40: ...subcode is displayed if the operator panel button is pushed again all six indicator lights blink Continual pressing of the operator panel button causes the lights to repeat in the following order 1 S...

Page 41: ...l will display the service error indication all six indicator lights blinking Continual pressing of the operator panel button causes the lights to repeat in the following order 1 Service error indicat...

Page 42: ...is indicating a fuser failure over temperature subcode See Hot fuser service check on page 2 76 for more information Fuser failure under temperature error code The operator panel is indicating a fuser...

Page 43: ...is indicating a fuser failure under temperature subcode See Hot fuser service check on page 2 76 for more information Fuser failure under temperature error code while printing The operator panel is in...

Page 44: ...2 14 Service Manual 4500 E320 E322 Fuser failure thermistor open error code The operator panel is indicating a fuser failure thermistor open subcode Replace the fuser assembly...

Page 45: ...the operator panel displays the service error indication all six indicator lights blinking Continual pressing of the operator panel button causes the lights to repeat in the following order 1 Service...

Page 46: ...ervice error indication all six indicator lights blinking Continual pressing of the operator panel button causes the lights to repeat in the following order 1 Service error indication 2 Optional memor...

Page 47: ...perator panel button is pushed again the operator panel displays the service error indication all six indicator lights blinking Continual pressing of the operator panel button causes the lights to rep...

Page 48: ...displayed if the operator panel button is pushed again the operator panel will display the service error indication all six indicator lights blinking Continual pressing of the operator panel button c...

Page 49: ...ed Once the error code is displayed if the operator panel button is pushed again the operator panel displays the service error indication all six indicator lights blinking Continual pressing of the op...

Page 50: ...rred Once the error code is displayed if the operator panel button is pushed again the operator panel displays the service error indication all six indicator lights blinking Continual pressing of the...

Page 51: ...Once the error code is displayed if the operator panel button is pushed again the operator panel displays the service error indication all six indicator lights blinking Continual pressing of the oper...

Page 52: ...r panel button is pushed again the operator panel displays the service error indication all six indicator lights blinking Continual pressing of the operator panel button causes the lights to repeat in...

Page 53: ...operator panel button is pushed again the operator panel displays the service error indication all six indicator lights blinking Continual pressing of the operator panel button causes the lights to re...

Page 54: ...e error indication all six indicator lights blinking Continual pressing of the operator panel button causes the lights to repeat in the following order 1 Service error indication 2 Engine communicatio...

Page 55: ...ion 2 25 4500 E320 E322 Operator panel light summary table Operator panel light Description Operator panel light is on Operator panel light is off Operator panel light is blinking Operator panel light...

Page 56: ...Error Press Button Condition Ready Demo ready Offline remote Busy Waiting Restoring factory defaults Saving settings Resetting printer Flushing buffer Hex Trace Paper jam Load manual paper envelope Lo...

Page 57: ...hts when toner is low Ready and Toner Low Demo ready and toner low Offline remote and toner low Busy and toner low Waiting and toner low Restoring factory defaults Saving settings Resetting printer an...

Page 58: ...paper Tray 1 for side 2 of manual duplex and toner low Load paper Tray 2 and toner low Top cover open and toner low Toner cartridge error Printer error and toner low Flash memory full and toner low Di...

Page 59: ...tion Resolution reduction warning Font error Resource save off deficient memory Insufficient defrag memory Host interface error parallel ENA connection lost standard parallel port disabled standard US...

Page 60: ...splays the secondary service error code The following table contains the secondary service error codes Primary service error codes Serviceerror see page 2 8 Secondary service error codes Software erro...

Page 61: ...ilure see page 2 22 Font checksum see page 2 23 Engine communica tion failure see page 2 24 Fuser service error subcodes Fuser failure over temperature see page 2 12 Fuser failure under temperature se...

Page 62: ...pletes except one or more lights do not come on See the Main motor service check on page 2 77 None of the lights come on See the Operator panel service check on page 2 79 Main motor does not come on S...

Page 63: ...See the Main motor service check on page 2 77 Paper skew See the Paper feed service checks on page 2 81 Printer not communicating with host See the Parallel port service check on page 2 85 Top cover...

Page 64: ...e Toner on back of page on page 2 91 Paper jams See the Paper feed service checks on page 2 81 Paper never picks See the Paper never picks on page 2 83 Paper feeds continuously See the Paper picks dur...

Page 65: ...ghts on the operator panel indicate the status of the printer anytime it is powered on When the printer experiences a problem requiring operator intervention it indicates the source by blinking one or...

Page 66: ...ter toolkit to modify settings The operator panel may be used for Determining printer status See Status information light patterns on page 2 38 for more information Reviewing printer settings See Powe...

Page 67: ...atterns The following symbols are used in the status attendance and service information tables Operator panel light Description Operator panel light is on Operator panel light is off Operator panel li...

Page 68: ...rning Demo ready with toner low warning Hex Trace ready with toner low warning Busy with toner low warning Waiting with toner low warning Flushing Canceling job resetting printer activating changes Al...

Page 69: ...Invalid engine code invalid network code Note A double press of Continue causes a secondary light pattern which indicates further information on the type of invalid code status exists See Invalid cod...

Page 70: ...r Low Load Remove Paper Paper Jam Error Press Continue Status Invalid engine code Invalid network code Ready Data Toner Low Load Remove Paper Paper Jam Error Press Continue Attendance Condition Paper...

Page 71: ...Toner Low Load Remove Paper Paper Jam Error Press Continue Attendance Condition Complex page Insufficient collation area Defective flash Network interface error Resource save off deficient memory Pers...

Page 72: ...ata Toner Low Load Remove Paper Paper Jam Error Press Continue Service Condition Service error Note A double press of Continue causes a secondary light pattern which indicates further information on t...

Page 73: ...secondary codes The following pages show these codes Ready Data Toner Low Load Remove Paper Paper Jam Error Press Continue Service Condition Software error 90x Transfer roll error 91x Fuser toner sen...

Page 74: ...s Continue again to see the tertiary codes double press Continue the third time to return to the primary code All secondary codes have a flashing Ready Data light but not the Toner Low light All terti...

Page 75: ...des are generally non recoverable except in an intermittent condition when you can power on reset POR the printer to temporarily recover from the error condition Controller software error illegal trap...

Page 76: ...6 indicate an unrecoverable engine software error Replace the controller card Ready Data Press Continue Toner Low Load Remove Paper Paper Jam Error Ready Data Press Continue Toner Low Load Remove Pape...

Page 77: ...stic information 2 47 4500 E220 E321 E323 Transfer roll error Indicates a problem in the transfer roll area Check the cable from the HVPS CN1 to the controller card J3 Also check voltage at pin 4 of J...

Page 78: ...ser service check on page 2 74 for more information Incorrect fuser lamp installed 925 Open circuit in thermistor path 924 Fuser too hot during printing or idle 923 Fuser failed to reach standby tempe...

Page 79: ...r print cartridge Either the printer s toner sensor is faulty or the print cartridge is defective Ready Data Press Continue Toner Low Load Remove Paper Paper Jam Error Ready Data Press Continue Toner...

Page 80: ...per Jam Error Ready Data Press Continue Toner Low Load Remove Paper Paper Jam Error Primary Code Secondary Code Tertiary Codes Ready Data Press Continue Toner Low Load Remove Paper Paper Jam Error Mir...

Page 81: ...es a problem in the drive assembly RIP to engine communication failure controller card Indicates that the RIP processor cannot communicate with the engine processor Transport motor lost lock 937 Trans...

Page 82: ...which is used for fuser control It may indicate the wrong LVPS has been installed Ready Data Press Continue Toner Low Load Remove Paper Paper Jam Error Ready Data Press Continue Toner Low Load Remove...

Page 83: ...Paper Paper Jam Error Ready Data Press Continue Toner Low Load Remove Paper Paper Jam Error Primary Code Secondary Code Tertiary Codes Ready Data Press Continue Toner Low Load Remove Paper Paper Jam...

Page 84: ...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 Ready Data Press Continue Toner Low Load...

Page 85: ...21 E323 Controller card error ROM NAND Indicates a failed controller card assembly Replace the controller card SRAM failure 959 NAND failure 958 ASIC failure 957 Processor failure 956 Code ROM or NAND...

Page 86: ...ror indicates RAM failure Remove DIMM s and re POR the printer If the error persists replace the card If the error subsides check each DIMM independently Replace faulty DIMM 963 RAM in slot 2 is bad 9...

Page 87: ...Paper Paper Jam Error Ready Data Press Continue Toner Low Load Remove Paper Paper Jam Error Primary Code Secondary Code Tertiary Codes Ready Data Press Continue Toner Low Load Remove Paper Paper Jam E...

Page 88: ...t recur replace Tray 2 If the error recurs replace the controller card assembly Invalid command parameter received by specified device 984 Invalid command received by specified device 983 Communicati...

Page 89: ...rint quality test pages In configuration mode press and release Cancel until the top two lights come on Press and hold Continue until lights flash See the note in item 3 page 3 40 for more information...

Page 90: ...e 2 70 POST completes except one or more lights do not come on See the Operator panel service check on page 2 79 None of the lights come on See the Operator panel service check on page 2 79 Main motor...

Page 91: ...n motor noisy or not moving See Main motor service check on page 2 77 Paper skew See the Note regarding alignment on page 4 2 or Paper feed service checks on page 2 81 Printer not communicating with h...

Page 92: ...r bands See White or black lines or bands on page 2 91 Toner on back of page See Toner on back of page on page 2 91 Paper never picks See Paper never picks on page 2 83 Paper feeds continuously See Pa...

Page 93: ...s which involve measuring voltages of the LVPS engine boards must be performed with the printer positioned on its back side This provides the servicer access to the circuit boards underneath the print...

Page 94: ...n connector J7 on the engine board E320 E322 or J14 on controller card E220 E321 E323 Check for excessive toner buildup on the surface of the thermistor Clean as necessary With the printer unplugged d...

Page 95: ...index sequentially to the opposite end of the connector See RIP controller E220 E321 E323 only on page 5 8 for more information FRU Action Cooling fan Make sure the cooling fan motor cable plug is pr...

Page 96: ...uld apply 24 V dc to pin 1 See RIP controller E220 E321 E323 only on page 5 8 for more information If voltage is present replace the cooling fan first If the fan still doesn t function replace the con...

Page 97: ...3 and 4 Verify 5 V dc on cable pin 1 Verify that pins 2 5 and 6 on both the cable and the card connectors are grounded If voltages are correct check the continuity in the cable If the cable is good s...

Page 98: ...comes on 4 The fuser lamp comes on 5 The drive motor runs 6 The printhead motor runs 7 The printer cycles down into standby mode ready If immediately following power on the operator panel lights are a...

Page 99: ...Action Cover interlock switch Disconnect the cover interlock cable plug from the engine board Push the cover interlock switch to the closed position and check for continuity See Connector locations o...

Page 100: ...pin 1 and pin 2 with the door closed Verify continuity between cable pin 1 and pin 3 with the door open If either fail continuity replace the cover interlock switch If both pass continuity turn the p...

Page 101: ...propriate fuse If fuse opens again see Low voltage power supply LVPS service check on page 2 76 for more information If not open see power switch below Power switch Restore power and turn on the print...

Page 102: ...jumper cable from the engine board See Connector locations on page 5 1 for more information 4 Turn printer on If voltage is correct ensure J12 power supply unit PSU is properly seated in the J12 PSU c...

Page 103: ...ces the Ready light turns on solid 4 The cooling fan comes on 5 The fuser lamp comes on 6 The drive motor runs 7 The printhead motor runs 8 The printer cycles down into standby mode ready If the opera...

Page 104: ...g with bare hands as skin contains acids that can weaken the glass The line voltage to the printer must be within the following limits 100 V ac 127 V ac for the low voltage model printer 200 V ac 240...

Page 105: ...LVPS service check on page 2 76 for more information Make sure the fuser thermistor is correctly connected to the engine board If the problem persists disconnect the thermistor cable at J7 engine boar...

Page 106: ...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 FRU Action Low voltage po...

Page 107: ...e Engine board E320 E322 only on page 5 2 and page 5 7 for more information If these voltages are correct check the main motor cable for continuity If continuity exists on each wire replace the main m...

Page 108: ...the button or Continue button E220 E321 E323 Similarly check the continuity between pins 1 and 6 while pressing Cancel E220 E321 E323 If continuity is not present replace the operator panel Note Chec...

Page 109: ...is plugged in securely Run POST and check each light for proper operation Warning Do not replace the operator panel and controller card at the same time Each card contains the printer settings When e...

Page 110: ...ight does not turn on or an individual light stays on solid during POST replace the operator panel Verify that the button s function correctly Check continuity between pins 1 and 2 at the operator pan...

Page 111: ...or Make sure the input paper feed sensor is working properly A stuck or incorrectly installed sensor causes this error FRU Action Paper feed clutch assembly Check the pick roller clutch for wear The s...

Page 112: ...d E220 E321 E323 Make sure the input paper feed sensor is working properly Check for a broken or stuck flag on the input paper feed sensor Make sure the cable is seated on the engine board at J2 E320...

Page 113: ...ine board in E320 E322 or J12 controller card in E220 E321 E323 See Engine board E320 E322 only on page 5 2 or page 5 6 for more information If the solenoid is properly plugged in unplug unit and chec...

Page 114: ...for the media being printed Excessive heat can cause paper treeing problems poor stacking or curl FRU Action Registration roll assembly Lower registration roll Registration roll bushings The registrat...

Page 115: ...ling the parallel port pull up resistors See Parallel protocol on page 3 25 Try printing a test page after enabling resistors If the printer still does not print disable the resistors E220 E321 E323 p...

Page 116: ...Engine board E320 E322 Controller card E220 E321 E323 Blank pages can be caused by a defective printhead assembly HVPS LVPS engine board E320 E322 or controller card E220 E321 E323 Printhead errors ty...

Page 117: ...roll Replace the contacts or charge roll assembly as necessary Engine board LVPS board Controller card HVPS cable HVPS Make sure the cable from the HVPS to the engine or controller card is correctly...

Page 118: ...led and the high voltage contacts are clean If the cartridge is installed correctly try a new cartridge HVPS contacts HVPS board Engine board Controller card Check the contacts for correct installatio...

Page 119: ...re recommended paper is being used FRU Action Toner cartridge not a FRU The charge roll may have an unbalanced pressure against the photoconductor PC drum Open the cover about two inches and observe t...

Page 120: ...cartridge is installed correctly and is not low on toner If the problem continues install a new toner cartridge Transfer roll HVPS contact transfer roll HVPS board Check the transfer roll for signs o...

Page 121: ...inds or damage Replace the drive gear assembly as necessary FRU Action Print cartridge not a FRU Inspect the overall paper path for signs of spilled toner Gently clean the contaminated areas with a so...

Page 122: ...e 3 13 E320 E322 only for more information 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...

Page 123: ...rature Replace if necessary Try a different kind of paper Paper designed for copiers gives the best quality If you are printing on special media such as card stock or labels be sure you select the cor...

Page 124: ...or repetitive spots appear on the page Select a different media type or form type setting from your printer driver Try a different type of paper Paper designed for copiers gives the best quality Repl...

Page 125: ...Toner Low light is on and printing stops If you are using a 3K or 6K print cartridge and the Toner Low alarm is set to on the printer stops printing until you replace the print cartridge Download the...

Page 126: ...aper 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 Remove the paper from Tray 1 and f...

Page 127: ...the stack height indicator Make sure the paper is under both corner bucklers see loading paper in the User s Reference Remove the paper from the optional Tray 2 and fan the paper Check the rubber on...

Page 128: ...3 emulation the printer is flushing data Ready Data and Error lights are blinking Ensure the correct PostScript driver is being used The Lexmark E220 E320 and E321 do not support PostScript emulation...

Page 129: ...the right side of the transfer roll shaft If continuity is not indicated remove the left bearing and check continuity between the solder joint and spring loaded pin If continuity fails replace the HVP...

Page 130: ...setting user defaults E320 E322 When formatting problems occur or unexpected characters print try resetting the printer default settings to your user defaults Press and hold the operator panel button...

Page 131: ...ights blink 3 Press the operator panel button with a long button press hold until all the lights come on to reset the printer to the original factory defaults Once the settings are returned to the fac...

Page 132: ...ights come on to select the Hex Trace setting 4 Press the button with another long button press to initiate Hex Trace Data sent to the printer is printed out in hexadecimal and character representatio...

Page 133: ...nd the bottom two lights blink 3 Press the operator panel button with a long button press hold until all the lights come on to initiate print quality test pages Three pages print to help evaluate prin...

Page 134: ...and Toner Low lights come on and the bottom lights are off 3 Press and hold Continue until all lights flash to initiate print quality test pages Three pages print to help evaluate print quality The f...

Page 135: ...print quality test pages and advanced troubleshooting mode To enter the special function menu 1 Turn off the printer 2 Open the top cover 3 Turn the printer back on 4 When the Error light comes on in...

Page 136: ...top cover open and Continue pressed Close cover once the Error light is displayed Print the print quality test pages Top cover open with Continue pressed Cartridge lockout function enabled Power on wi...

Page 137: ...off in reverse sequence starting with Press Button and ending with Ready Each light remains on for approximately one second but no more than approximately two seconds This cycling repeats as needed d...

Page 138: ...e following operations may only be performed if the printer is in the correct operation mode The six modes are Normal printing Demo printing Diagnostics tests Special function menu Configuration Hex T...

Page 139: ...n default flag set to Normal AND Turn on printer with cover closed OR Print engine cleaning cycle page from special function menu OR Operator panel reset from hex trace OR Print quality test page from...

Page 140: ...trace OR Print quality test page from special function menu OR Reset defaults from special function menu Turn off printer and follow instructions for method of entry Diagnostics tests Turn on printer...

Page 141: ...engine clean cycle hex trace print quality test pages reset defaults or toggle demo mode function Configuration Enter the special function menu mode and then select the enter configuration mode option...

Page 142: ...3 6 Service Manual 4500 E320 E322 Normal printing mode 1 Turn the printer on 2 Verify the operator panel Ready light is on The printer is ready for normal operation...

Page 143: ...nter is turned on The printer posts the Busy indication on the operator panel Busy is posted until the demo print job completes or until some asynchronous event occurs for example reset or interventio...

Page 144: ...set button The menus page contains the following information Listing of all printer settings contained in the operator panel menus and their default values Printer information such as serial number pa...

Page 145: ...mory test Optional memory test When the printer enters Normal or Demo modes the total amount of installed memory detected during the POST sequence is compared with an NVRAM value representing the prin...

Page 146: ...When the cover open error is indicated on the operator panel Error light on release the button 6 Close the cover The printer automatically runs the diagnostics test If the test passes the Toner Low li...

Page 147: ...on mode Enter hex trace Print diagnostics print quality test page Set demo mode active inactive Entering special function menu 1 Turn the printer off 2 Open the printer cover 3 Turn the printer on 4 W...

Page 148: ...s executed the lights change the state to indicate the function is executed Double button press moves to next selection in the menu for example from engine clean cycle to reset defaults Ready Data Ton...

Page 149: ...elps eliminate small specs of toner present in the background when printing See the special function menu page 3 11 and this action Perform a long button press until all lights are on solid The printe...

Page 150: ...settings Enable port NPA mode Protocol Mode 1 Mode 2 Strobe adjust USB settings Enable port NPA mode PPDS activated Auto line feed carriage return LFCR carriage return line feed CRLF Auto line feed a...

Page 151: ...Double button press Moves through the configuration mode menu items Brief button press Moves through the displayed menu item value list Long button press Selects and saves the value displayed for the...

Page 152: ...The printer is in configuration mode when the Ready Data light comes on and the Toner Low Load Paper Paper Jam Error lights are off Press Button indicates the Par Enabled setting To exit configuratio...

Page 153: ...ef button presses cause the printer to cycle through the various values within the value list for the menu item displayed For Parallel Enabled a brief button press causes the off on auto Press Button...

Page 154: ...int quality test page registration adjustment Normal and special function menu Factory defaults Normal and special function menu Hex Trace Special function menu Execute engine cleaning cycle Special f...

Page 155: ...are on Print font samples The print font samples operation is not accessible through the operator panel Two PJL commands exist which let the user obtain samples of the stored fonts Print directory Pr...

Page 156: ...ics test page is centered on the page Adjust the top margin until the registration lines located at the bottom of the diamonds at the bottom of the page fall on the bottom edge of the page These setti...

Page 157: ...nts a hexadecimal and a character representation of a print job The printer does not recognize any print controls or commands in this mode A hex trace printout can be used to help isolate the cause of...

Page 158: ...tes print registration marks which aid the user during the print registration adjustment process In addition the first diagnostic test page also includes the current value of some user default setting...

Page 159: ...rallel port is enabled 2 Perform a brief button press to select the parallel port setting 3 Perform a long button press All lights blink once indicating the setting is saved 4 Exit the configuration m...

Page 160: ...all data received by the printer must be in NPA packets Any non packet data is rejected as bad packets When the light is off the printer is not performing any NPA processing When the light is blinking...

Page 161: ...ore information 2 Perform a double button press two times This moves to the parallel protocol item on the configuration menu The parallel protocol Load Paper light comes on solid 3 The current paralle...

Page 162: ...rm a double button press six times This moves to the parallel mode 2 item on the configuration menu The parallel mode 2 Data light is blinking 3 The current parallel mode 2 setting is indicated by the...

Page 163: ...parallel strobe item on the configuration menu The parallel strobe Load Paper light is blinking 3 The current parallel strobe setting is indicated by the off on auto Press Button light When the light...

Page 164: ...m a double button press three times This moves to the PPDS item on the configuration menu The PPDS Paper Jam light comes on solid 3 The current PPDS setting is indicated by the off on auto Press Butto...

Page 165: ...each port are turned off Printer language is changed to PPDS emulation If PPDS is inactive the following user default printer settings are changed PCL and PostScript SmartSwitch settings for each port...

Page 166: ...rmation 2 Perform a double button press four times This moves to the CRLF LFCR item on the configuration menu The CRLF LFCR Error light comes on solid 3 The current CRLF LFCR setting is indicated by t...

Page 167: ...de only allows the user to set one or the other to on or both to off If configuration mode is entered and both settings are set to on the initial value displayed shows both values off Off on auto Sett...

Page 168: ...nking the USB port is enabled Perform a brief button press to select a different USB port setting 4 Perform a long button press All lights blink once indicating the setting is saved 5 Exit the configu...

Page 169: ...the light is off the USB port does not search for NPA data within the received data When the light is blinking the USB port searches for optional NPA data within the received data When the light is on...

Page 170: ...interface cable The following cables are supported Part number Port Cable description 1329605 Standard parallel Lexmark 3 meter 10 ft IEEE 1284 compliant A connector host to B connector printer cable...

Page 171: ...inue until all lights cycle to save the value for a menu item Press and hold Cancel until all lights cycle to go to the home state Configuration menu group The configuration menu group contains a set...

Page 172: ...ing around the menu Printer settings configuration on page 3 38 and Printer diagnostics on page 3 39 are similar to the instructions printed by following step 4 on page 2 106 These menu items are desi...

Page 173: ...el returns to home state Settings are retained in NVRAM Exceptions are Hex Trace and demo mode activate Select Hex Trace On or demo mode activate The printer automatically POR s and returns with Ready...

Page 174: ...3 38 Service Manual 4500 E220 E321 E323 Printer settings configuration...

Page 175: ...Diagnostic aids 3 39 4500 E220 E321 E323 Printer diagnostics...

Page 176: ...argins accordingly When edge to edge is set on the printer graphic and printing engine shift all four margins to the physical edges of the paper 3 Print the print quality pages These are the same page...

Page 177: ...settings for mark history history mode Optra Forms mode and meditech mode can be set A service error history report network can be printed Dump NVRAM prints a hex dump of the NVRAM partition and the r...

Page 178: ...3 42 Service Manual 4500 E220 E321 E323...

Page 179: ...tatic electricity in your body to the printer Hold the ESD sensitive part by its edge connector shroud cover do not touch its pins If you are removing a pluggable module use the correct tool Do not pl...

Page 180: ...the printer on 3 Hold Cancel until the lights have cycled on and off 4 Close the door when the Error light comes on Wait for the four top lights to stay on 5 Press and release Cancel once and wait fo...

Page 181: ...ive assembly PN 12G4500 and PN 56P2441 need to be lubricated when a new assembly is installed Place a drop size or less of lubricant on each gear as shown below and rotate the gears to evenly distribu...

Page 182: ...cover 2 Remove the two plastic clips from the front cover support arm hinges Note Support and ease the charge roll assembly into a resting position when disengaging the front cover support arm hinges...

Page 183: ...uto sheet feed ASF assembly removal 1 Open the front cover See Front cover on page 4 4 for more information 2 Remove the top cover See Top cover on page 4 4 for more information 3 Remove the left side...

Page 184: ...cover See Top cover on page 4 4 for more information 3 Remove the left side cover See Left side cover on page 4 5 for more information 4 Remove two cooling fan screws 5 Remove the toner cartridge 6 Re...

Page 185: ...moval Warning For E220 E321 E323 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 setting...

Page 186: ...side cover on page 4 5 for more information 4 Remove two cooling fan screws 5 Remove the toner cartridge 6 For the E220 E321 E323 remove the right side cover and the controller board cover 7 Tilt the...

Page 187: ...ional Tray 2 connector from bracket 8 Remove the four main drive gear assembly screws 9 Remove the main drive gear assembly with drive motor from printer 10 Depress paper feed solenoid locking tab and...

Page 188: ...l on page 4 6 for more information 7 Remove the two fuser mounting screws 8 Disconnect the fuser wires 9 Release the tabs on each end of fuser assembly and lift out High voltage power supply HVPS remo...

Page 189: ...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...

Page 190: ...cage removal on page 4 7 for more information 6 Disconnect the drive motor cable 7 Remove optional Tray 2 connector from bracket 8 Remove the four main drive gear assembly screws 9 Remove the main dr...

Page 191: ...thead plate ground strap screw above the HVPS 5 Remove the controller cage screw from the printhead mounting plate 6 Disconnect the printhead cables first at the controller card for E220 E321 E323 onl...

Page 192: ...4 14 Service Manual 4500...

Page 193: ...Note The LVPS part number for E320 E322 and E220 E321 E323 is different but the input output values are the same Connector Pin no Signal CN1 1 AC H 2 AC N CN2 1 Heater on 2 AC N CN3 1 Ground 2 5 V dc...

Page 194: ...per PWM 2 Ground 3 Charge 4 24 V dc 5 Transfer PWM 6 Transfer enable 7 Not used 8 Transfer servo Connector Pin no Signal J1 HVPS 1 Developer PWM 2 Ground 3 Charge 4 24 V dc 5 Transfer PWM 6 Transfer e...

Page 195: ...J5 Main Motor 1 24 V dc 2 Ground 3 Motor enable 4 Ground 5 Motor signal J6 Toner Sensor 1 Ground 2 Toner signal 3 Light drive J7 Thermistor 1 Thermistor data 2 Ground J8 Not used 1 2 J9 Cover Open Sw...

Page 196: ...ller reset 3 Ready 4 Ground 5 Start 6 Engine notify 7 Ground 8 Controller present 9 24 V dc 10 SCL 11 Sample and hold 12 Ground 13 Printhead enable 14 SDA 15 Ground 16 5 V dc 17 LSU power 18 Ground 19...

Page 197: ...4500 J12 PSU 1 5 V dc 2 Ground 3 Interlock switch 4 Interlock switch 5 Ground 6 Ground 7 Fuser control 8 Hot roll power J13 Option Tray 1 Transmit 2 Receive 3 Tray detect 4 5 V dc 5 Ground 6 24 V dc...

Page 198: ...J2 Light Op Panel 1 Ground 2 FPIRQ 3 Light CLK 4 Light data 5 5 V dc 6 Ground J3 Video 1 Video 2 Ground J7 Controller to Engine 1 Engine POR 2 Ground 3 Notify 4 Controller present 5 SCL 6 Ground 7 DS...

Page 199: ...nector locations 5 7 4500 Controller E220 E321 E323 only J4 OPTION CARD J3 J2 J1 J8 J11 J12 J14 J15 J18 J19 J22 J10 J5 J6 J7 J16 J21 J17 J20 J4 J3 J2 J1 8 J5 J6 J7 J9 J21 J13 Network PCB Non network P...

Page 200: ...or Pin no Signal J1 LVPS 1 5 V dc I 2 5 6 Ground I 3 4 24 V dc I 7 ZEROX_C 8 HR_PSU J2 Fan 1 24 V dc 2 Return J3 HVPS 1 DEV_C 2 Ground 3 CHARGE_C 4 24 V dc 5 TX_C 6 TXENABLE_C 8 SERVO_OUT_C J4 Toner 1...

Page 201: ...OCK_C 3 MM_START_C 4 Ground 5 24 V dc J8 Main motor 1 6 Ground 2 XPRT_FB 3 XPRT_SPEED_R 4 XPRT_EN_C 5 XPRT_LOCK_C 7 24 V dc J9 Network network printer only J10 Erase J11 Paper Sensor 1 4 Ground 2 PAPE...

Page 202: ...6 24 V dc J16 Parallel Port non network printer only J17 DIMM J18 LED operator panel 1 Ground 2 5 V dc Continue button 1 I 2 0 V dc Continue pressed 3 LED CLK 4 LED DATA 5 5 V dc 6 5 V dc Cancel butto...

Page 203: ...320 E322 only Connector Pin no Signal CN4 to Engine Card 1 RX 2 TX 3 COM1 4 5 V dc 5 COM1 6 24 V dc CN5 to Motor 1 STP_A 2 STP_Na 3 STP_B 4 STP_nB CN6 to Solenoid 1 SOl 2 FB_SOL CN7 to PIC_JIG Flash D...

Page 204: ...5 12 Service Manual 4500 E220 E321 E323 wiring diagram...

Page 205: ...Preventive maintenance 6 1 4500 6 Preventive maintenance The E220 E32x does not require preventive maintenance...

Page 206: ...6 2 Service Manual 4500...

Page 207: ...e shown by one index number Parts peculiar to one or the other of the assemblies are listed separately and identified by description NA not available means not available as a FRU NS not shown in the A...

Page 208: ...7 2 Service Manual 4500 Assembly 1 Covers E320 E322...

Page 209: ...3 1 Cover right side 5 12G4457 1 Assembly operator panel 6 56P1099 1 Parts pack bushings clip spring 7 56P2373 1 Hinge right 8 12G4535 1 Spring front cover right 9 12G4543 1 Cover front E320 9 12G4542...

Page 210: ...7 4 Service Manual 4500 Assembly 1 cont Covers E220 E321 E323...

Page 211: ...nel 6 56P0683 1 Assembly operator panel white 6 56P1839 1 Assembly operator panel E220 6 56P1838 1 Assembly operator panel E220 white 7 56P1099 1 Parts pack bushings clip spring 8 56P2373 1 Hinge righ...

Page 212: ...7 6 Service Manual 4500 Assembly 1 cont Covers E220 E321 E323...

Page 213: ...3 Asm index Part number Units Description 15 56P1094 1 Assembly paper guide with exit tray black 15 56P1091 1 Assembly paper guide with exit tray white 16 56P1076 1 Cover left side 16 12G4451 1 Cover...

Page 214: ...7 8 Service Manual 4500 Assembly 2 Frame 11 7 5 9 2 10 6 8 14 1 3 4 13 12...

Page 215: ...racket right 5 56P0685 1 Assembly charge roll 6 12G4464 1 Spring charge roll right 7 99A1017 1 Roll charge 8 12G4463 1 Spring charge roll left 9 12G4533 1 Bracket left 10 12G4460 1 Fan cooling E320 E3...

Page 216: ...7 10 Service Manual 4500 Assembly 3 Fuser 7 12 10 1 2 3 4 6 8 9 5 11 11 8 7 5 6 6 5...

Page 217: ...sembly 220 V E320 E322 only 3 12G4493 1 Roller exit redrive 4 56P1053 1 Fuser assembly 110 V E220 E321 E323 only 4 56P1054 1 Fuser assembly 220 V E220 E321 E323 only 5 56P1099 3 Parts pack bushings cl...

Page 218: ...7 12 Service Manual 4500 Assembly 4 Main drive...

Page 219: ...4500 and 56P0684 differ only in the cable clamps The cable clamps can be removed and interchanged as needed Assembly 4 Main drive Asm index Part number Units Description 4 1 12G4500 1 Gear assembly dr...

Page 220: ...7 14 Service Manual 4500 Assembly 5 Paper feed 3 11 7 13 5 16 9 15 2 10 6 4 12 8 14 1 8 11 17...

Page 221: ...3 1 Clutch assembly paper feed E220 E321 E323 only 5 12G4538 1 Roller lower registration 6 12G4540 1 Gear registration roller 7 12G4477 1 Sensor cartridge 8 56P1099 1 Parts pack bushings clip spring 9...

Page 222: ...7 16 Service Manual 4500 Assembly 6 Printhead 8 5 2 1 3 6 4 7...

Page 223: ...1 1 Cable LSU J5 2 56P1068 1 Cable mirror motor J7 3 56P1087 1 Assembly printhead E220 E321 E323 only 4 56P1062 1 Cable cover open switch J6 5 56P1080 1 Interlock cover E220 E321 E323 only 6 12G4498 1...

Page 224: ...7 18 Service Manual 4500 Assembly 7 Electronics 8 5 2 6 4 1 3 7...

Page 225: ...ord Paraguay Austria Belgium France Netherlands Czech Slovak Countries Greece Hungary Finland Norway Sweden Germany Lebanon Syria Egypt Jordan Iran Bosnia Bulgaria Croatia Slovenia Macedonia Yugoslavi...

Page 226: ...7 20 Service Manual 4500 Assembly 7 cont 8 5 2 6 4 1 3 7...

Page 227: ...network 5 56P1071 1 Card controller E220 E321 5 56P1073 1 Card controller E323 5 56P1074 1 Card controller E323 network 6 12G4505 1 Cover cage E320 E322 only 6 56P1056 1 Cover cage E220 E321 E323 onl...

Page 228: ...7 22 Service Manual 4500 Assembly 8 Options 3 5 1 4 6 2...

Page 229: ...Base asm Tray 2 complete 6 12G4532 1 D roll feed Tray 2 Models E220 E321 E323 white 2 12G4515 1 Kit assembly feed roller 4 12G4513 1 Drawer Tray 2 5 56P1066 1 Base asm Tray 2 complete 6 12G4532 1 D r...

Page 230: ...7 24 Service Manual 4500 Assembly 8 cont Options 3 5 1 4 6 2...

Page 231: ...8MB Flash DIMM E323 only NS 99A1686 1 Optra Forms 16MB Flash DIMM E323 only NS 12G9833 1 MarkNet X2011e Ethernet 10 100Base TX NS 12G9832 1 MarkNet X2012e Ethernet 10 100Base TX 10Base2 1 port NS 12G9...

Page 232: ...G4524 1 Cable fuser lamp NS 12G4525 1 Cable ground wire NS 12G4526 1 Cable option NS 12G4527 1 Cable cover open switch J9 NS 12G4528 1 Cable AC receptacle NS 12G4545 1 Cable PSU J12 E220 E321 E323 onl...

Page 233: ...ous Asm index Part number Units Description NS 12G4529 1 Ring CS NS 12G4530 1 Clamp mini NS 12G4531 1 Parts pack screws NS 7371901 1 Kit field relocation NS 56P1099 1 Parts pack bushing clip spring NS...

Page 234: ...7 28 Service Manual 4500...

Page 235: ...obe 3 27 PPDS active inactive 3 29 print directory 3 19 print quality test pages 3 22 printer buffer 3 19 registration adj E320 E322 3 20 summary table 3 18 USB NPA mode 3 33 USB port 3 32 connector l...

Page 236: ...20 E322 3 20 reset 3 21 font samples E320 E322 3 19 H handling ESD sensitive parts 4 1 Hex Trace 3 5 Hex Trace mode using E220 E321 E323 2 102 Hex Trace mode E320 E322 3 21 how to use parts catalog 7...

Page 237: ...2 59 power on self test POST 2 32 2 60 PPDS E320 E322 3 29 preventive maintenance 6 1 print directory E320 E322 3 19 print quality problems solving 2 92 print quality test pages using 2 103 2 104 pri...

Page 238: ...90 toner on back of page 2 91 white or black lines 2 91 transfer roll 2 99 service error codes 2 11 2 45 controller card error 2 55 controller software error 2 45 controller software illegal trap 2 45...

Page 239: ...ine clean cycle 3 13 light summary table 3 12 operator panel 3 13 using 2 105 status information lights 2 38 symptom tables 2 32 2 60 POST 2 32 2 60 printer 2 33 2 61 T test pages print quality E320 E...

Page 240: ...I 12 Service Manual 4500...

Page 241: ...2G4459 Duct cooling white 7 5 12G4460 Fan cooling E320 E322 only 7 9 12G4461 Switch asm power white 110 V 7 9 12G4463 Spring charge roll left 7 9 12G4464 Spring charge roll right 7 9 12G4470 Roll tran...

Page 242: ...21 12G4503 Card controller E322 network 7 21 12G4504 Cage controller E320 E322 only 7 19 12G4505 Cover cage E320 E322 only 7 21 12G4506 Card engine E320 E322 only 7 21 12G4507 Card LVPS 110 V E320 E3...

Page 243: ...ront E322 7 3 12G4543 Cover front E320 7 3 12G4545 Cable PSU J12 7 26 12G9830 MarkNet X2030t Token Ring 3 ports 7 25 12G9831 MarkNet X2031e Ethernet 10 100Base TX 3 ports 7 25 12G9832 MarkNet X2012e E...

Page 244: ...E323 only 7 21 56P1057 Cable HVPS J3 7 26 56P1058 Cable input exit sensor J11 7 26 56P1059 Cable smart IC J13 7 26 56P1060 Cable motor J8 7 26 56P1061 Cable LSU J5 7 17 56P1061 Cable LSU J5 7 26 56P10...

Page 245: ...with exit tray black 7 7 56P1095 Cover front E321 white 7 5 56P1096 Cover front E323 white 7 5 56P1097 Card LVPS 110 V E320 E322 only 7 21 56P1098 Card LVPS 220 V E320 E322 only 7 21 56P1099 Parts pa...

Page 246: ...M E323 only 7 25 99A1685 Optra Forms 8MB Flash DIMM E323 only 7 25 99A1686 Optra Forms 16MB Flash DIMM E323 only 7 25 99A1752 4MB SDRAM SIMM E322 only 7 23 99A1757 2MB Flash DIMM E323 only 7 23 99A175...

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