LEXMARK E120, E120n Service Manual

• Table of contents

• Start diagnostics

Lexmark™ E120, E120n

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• 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.

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Edition: March 24, 2006

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 i

mplied 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 ServiceInfoAndTraining@Lexmark.com. Lexmark may use or distribute any o

f the information you supply in any way it believes appropriate without incurring any obligation to you.

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

All other trademarks are the property of their respective owners.

UNITED STATES GOVERNMENT RIGHTS

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

P/N 12G9629

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Table of contents. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iii

Notices and safety information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . vi

Laser notice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . vi

Safety information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . x

Preface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xiii

Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xiii

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

Maintenance approach . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1

Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

Overview of the printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1

E120 operator panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1

E120n operator panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

Front view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2

Rear view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3

Types of print media . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3

Choosing appropriate print media . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3

Paper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

Preprinted forms and letterhead . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-4

Transparencies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-4

Envelopes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

Labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

Card stock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5

Storing print media . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-5

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

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

Acronyms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6

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

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

Power-On Self Test (POST) sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-2

Overview of the operator panel—E120 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

Light patterns and error messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

Primary, secondary, and tertiary light patterns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-4

Power–On Self Test (POST) sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8

Overview of the operator panel—E120n . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9

Common primary and secondary light patterns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-9

Common primary light patterns—E120n . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-9

Additional information—primary codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-11

Additional information—secondary light patterns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-14

Service codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-17

Service primary code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-18

Service secondary error codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-18

Service tertiary error codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-18

Controller software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-19

Transfer roll . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19

Fuser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20

Printhead, transport motor, or RIP/engine communication error . . . . . . . . . . . . . . . . . . . . . . . .2-20

LVPS/HVPS failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21

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NVRAM failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21

RAM memory error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22

Network error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22

Symptom tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22

POST symptom table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22

Printer symptom table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-23

Service checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-24

Controller card service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-24

Operator Panel Service Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-25

Dead machine service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-25

Fuser service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-26

Cold fuser service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-27

Hot fuser service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-27

LVPS/HVPS service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-28

Main motor service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-28

Paper feed service checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-29

Paper jam error indication during POST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-29

Paper picks during POST and/or continuously . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-29

Paper picks but stops halfway through the printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-29

Paper never picks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-30

Paper occasionally mispicks or picks multiple sheets at once . . . . . . . . . . . . . . . . . . . . . . . . . 2-30

Paper “trees,” wrinkles, stacks poorly, or curls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-31

Print quality service checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-31

Using print quality test pages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-31

Blank page . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-32

Black page . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-33

Heavy background . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-33

Partial blank image/white spots (no periodic pattern) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-34

Variation in image density horizontally across page . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-34

Poor fusing of image . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-34

Light print . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-35

White or black lines or bands . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-35

Toner on back of page . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-36

Solving print quality problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-36

Printhead service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-40

Transfer roll service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-41

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

Service menus—E120 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

Printing menus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

Moving around the menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

Diagnostics mode printout sample . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

Diagnostics mode descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

Development . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

Service menus—E120n . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

Printing menus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

Diagnostics mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

Configuration menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

Moving around the menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

Diagnostics mode printout sample . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

Diagnostics mode descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5

Development . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5

Network . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6

Configuration menu printout sample . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7

Configuration menu descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8

Utilities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8

Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9

USB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9

Network . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10

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

Handling ESD-sensitive parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

Adjustment procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-2

Printhead assembly adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-2

Removal procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-4

Extender cover removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-4

Tray cover removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-4

Main tray removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5

Left cover removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5

Right cover removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7

Front door assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-8

Top cover assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-9

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

Transfer roll assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-12

Rear door assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-13

Transfer card and input sensor assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-14

Paper pick assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-15

Controller card removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-17

Operator panel removal (all models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18

LVPS/HVPS removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-19

Fuser removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-20

Locations and connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1

Front view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1

Rear view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1

Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2

Controller card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-2

LVPS/HVPS card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-4

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

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

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

Assembly 1: Covers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2

Assembly 2: Electronics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4

Assembly 3: Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6

Assembly 4: Miscellaneous . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8

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

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

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Notices and safety information

The following laser notice labels may be affixed to this printer as shown:

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 Klasse I übersteigen würde, Menschen keinesfalls erreicht.

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.

Laserinformatie

De printer voldoet aan de eisen die gesteld worden aan een laserprodukt van klasse I. Voor de Verenigde Staten zijn deze eisen vastgelegd in DHHS 21 CFR Subchapter J, voor andere landen in IEC 60825-1.

Laserprodukten van klasse I worden niet als ongevaarlijk aangemerkt. De printer is voorzien van een laser van klasse IIIb (3b), dat wil zeggen een gallium arsenide-laser van 5 milliwatt met een golflengte van 770-795 nanometer. Het lasergedeelte en de printer zijn zo ontworpen 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.

Lasermeddelelse

Printeren er godkendt som et Klasse I-laserprodukt, i overenstemmelse med kravene i IEC 60825-1.

Klasse I-laserprodukter betragtes ikke som farlige. Printeren indeholder internt en Klasse IIIB (3b)-laser, der nominelt er en 5 milliwatt galliumarsenid laser, som arbejder på bølgelængdeområdet 770-795 nanometer. Lasersystemet og printeren er udformet således, at mennesker aldrig udsættes for en laserstråling over Klasse I-niveau ved normal drift, brugervedligeholdelse eller obligatoriske servicebetingelser.

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Huomautus laserlaitteesta

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

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

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

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

Laser-notis

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

Laserprodukter i Klass I anses ej hälsovådliga. Skrivaren har en inbyggd laser av Klass IIIb (3b) som består av en laserenhet av gallium-arsenid på 5 milliwatt som arbetar i våglängdsområdet 770-795 nanometer. Lasersystemet och skrivaren är 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.

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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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.

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.

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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.

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.

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Preface

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

1. General information contains a general description of the printer and the maintenance approach used to

repair it. Special tools and test equipment are, 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).

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

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.

Appendix A contains service tips and information.

Appendix B contains representative print samples.

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.

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1. General information

The Lexmark™ E120 and E120n printers are monochrome laser printers designed for single users or small workgroups.

Maintenance approach

The diagnostic information in this manual leads to the correct field replaceable unit (FRU) or part. Use the error code charts, symptom index, and service checks to determine the symptom and repair the failure. See

“Diagnostic information” on page 2-1 for more information. See “Repair information” on page 4-1 for the

steps to replace FRUs. After completing the repair, perform tests as needed to verify the repair. See “Parts

catalog” on page 7-1 to help identify part numbers if parts need to be replaced

Models

There are two models:

• Lexmark E120—ENA support, host-based printing in a Windows environment, an 8,000 page per month

maximum duty cycle (one time only), and a two button, two light operator panel.

• Lexmark E120n—Built-in 10/100 BaseTX Ethernet, host-based printing in Windows (PCL) or Macintosh

(PostScript emulation) environment, a 10,000 page per month maximum duty cycle (one time only), and a two button, six light operator panel.

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

Item Lexmark E120 (4506-100) Lexmark E120n (4506-110)

Base memory 8MB 16MB

Maximum memory 8MB 16MB

Paper inputs Primary tray (tray 1), Priority feeder (manual feeder)

Emulations PCL PostScript emulation (Mac only), PCL, XL

Compatibility Windows Windows, Macintosh

Connectivity USB 2.0 USB 2.0, Ethernet

Photoconductor kit yield* 25,000 pages

* Photoconductor yield based on approximately 5% coverage of pages.

Overview of the printer

There are two available operator panels.

E120 operator panel

This model has two lights and two buttons. See “Diagnostics—E120” on page 2-2 for more information.

E120n operator panel

This model has six lights, two buttons, and an internal network adapter. See page “Diagnostics—E120n” on

page 2-8.

General information 1-1

4506-1xx

Front view

Top door

Rear view

50-sheet output bin

Operator panel

Paper support

Front door release button

Front door

Priority feeder with adjustable guides

Tray 1 cover/priority feeder paper path

Tray 1 with adjustable guides

Slide and attached backstop

Power cord port

USB port

Ethernet port (E120n only)

Rear door release

Cable lock access point

Rear door

Power button

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Specifications

Types of print media

Receive optimal use from the printer by properly loading trays. Never mix media types within a tray.

Source Sizes Types Weight Capacity

Primary Tray

(tray 1)

A4, A5, JIS-B5, letter, legal, executive, folio, statement, universal

3 x 5 inch, other Card stock 135–163 g/m

7¾, 9, 10, DL, C5, B5, other

Priority feeder

(manual feeder)

A4, A5, JIS-B5, letter, legal, executive, folio, statement, universal

A6 (long grain only) Plain paper, bond

3 x 5 inch, other Card stock 135–163 g/m

7¾, 9, 10, DL, C5, B5, other

Capacity for 20 lb print media, unless otherwise noted.

Universal size ranges:

• Tray 1: 76–216 x 190–356 mm (3.0–8.5 x 7.5–14.0 in.) (includes 3 x 5 in. cards)

• Priority feeder: 76–216 x 190–356 mm (3.0–8.5 x 7.5–14.0 in.) (includes 3 x 5 in. cards)

Choosing appropriate print media

Plain paper, bond paper,

transparency, label

Envelope 105 g/m

Plain paper, bond paper,

†

transparency, label,

paper

Envelopes 105 g/m

60–105 g/m

(16–28 lb)

(36–43 lb) bond

(28 lb) max 5 envelopes

60–163 g/m

(16–43 lb)

60–163 g/m

(16–43 lb)

(36–43 lb) bond

(28 lb) max

(sheets)

• 150 sheets

• 5 transparencies

• 5 labels

5 cards

• 15 sheets

• 5 transparencies

• 5 labels

30 sheets

5 cards

3 envelopes

To reduce printing problems and to receive the best print quality, try a sample of the media you are considering before buying large quantities.

Refer to the Card Stock & Label Guide available on the Lexmark Web site at www.lexmark.com for more information about which print media provides optimum results.

Paper

For the best print quality, use 20 lb (75 g/m2) xerographic, grain long paper. The printer can automatically

•

feed paper weights from 16 to 28 lb bond (60 to105 g/m Paper lighter than 16 lb (60 g/m

) might not be stiff enough to feed properly, causing jams.

) grain long and (64 to 105 g/m2) grain short.

• The laser printing process heats paper to high temperatures of 206°C (403°F). Use only paper able to

withstand these temperatures without discoloring, bleeding, or releasing hazardous emissions. Check with the manufacturer or vendor to determine whether the chosen paper is acceptable for laser printers.

General information 1-3

4506-1xx

Preprinted forms and letterhead

Use only forms and letterhead printed using an offset lithographic or engraved printing process.

•

• Choose forms and letterhead types that absorb ink, but do not bleed.

• Avoid rough or heavily textured surfaces.

Use media printed with heat-resistant inks designed for use in xerographic copiers. The ink must withstand

temperatures of 200°C (392°F) without melting or releasing hazardous emissions. Use inks that are not

affected by the resin in toner. Inks that are oxidation-set or oil-based should meet these requirements;

latex inks might not. If in doubt, contact the supplier.

Transparencies

Use transparencies designed specifically for laser printers. Transparencies must be able to withstand

•

temperatures of 185°C (365°F) without melting, discoloring, offsetting, or releasing hazardous emissions.

We recommend Lexmark laser printer transparencies, part number 70X7240 for letter size transparencies;

part number 12A5010 for A4 size transparencies.

• To prevent print quality problems, avoid getting fingerprints on transparencies.

Envelopes

Use envelopes made from 24 lb (90 g/m2) bond paper, or up to a maximum weight of 28 lb (105 g/m2).

•

• Use envelopes that can withstand temperatures of 185°C (365°F) without: – Sealing – Excessive curling – Wrinkling – Releasing hazardous emissions

• Do not use envelopes that: – Have excessive curl – Are stuck together – Are damaged in any way – Contain windows, holes, perforations, cutouts, or embossments – Have metal clasps, string ties, or metal folding bars – Have postage stamps attached – Have exposed adhesive when the flap is in the sealed position – Are self-sealing

If uncertain about the envelopes being considered for use, check with the supplier.

• A combination of high humidity (over 60%) and high printing temperatures may seal envelopes.

Labels

Use labels that can withstand temperatures of 185°C (365°F) without sealing, excessive curling, wrinkling,

•

or releasing hazardous emissions. Label adhesives, face sheet (printable stock), and topcoats must also be able to withstand 25 pounds per square inch (psi) (172 kilopascals) of pressure.

• Do not use labels with exposed adhesive.

• Do not print a large number of labels continuously.

• Do not use vinyl labels.

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Card stock

Use card stock that can withstand temperatures of 225°C (437°C).

•

• Use card stock up to a maximum weight of 43 lb (163 g/m

76 x 127 mm (3 x 5 inch).

) bond and down to a minimum size of

• Do not preprint, perforate, or crease card stock. This can significantly affect print quality and cause media

handling or jamming problems.

• Avoid using card stock that may release hazardous emissions when heated.

• Do not use preprinted card stock manufactured with chemicals that may contaminate the printer.

Preprinting introduces semi-liquid and volatile components into the printer.

Storing print media

Use the following guidelines to avoid print media feeding problems and uneven print quality.

• Store all print media in an environment where temperature is approximately 21°C (70°F) and relative

humidity is 40%.

• Store cartons of paper on a pallet or shelf rather than directly on the floor surface.

• If storing individual packages of paper out of the original carton, make sure they rest on a flat surface so

edges do not buckle, curl, or become damaged.

• Do not place anything on top of paper packages.

• Store transparencies and envelopes in their original boxes.

Tips on preventing jams

Most paper jams can be avoided by correctly loading paper and specialty media.

The following hints can help to avoid paper jams:

• Do not load wrinkled, creased, or damp paper.

• Never mix media types within a tray.

• Flex, fan, and straighten paper before loading it.

• Do not exceed the maximum stack height.

• Adjust all edge guides after loading media.

• Make sure the guides in the tray are positioned snugly against the paper or specialty media.

• Do not remove paper stacks while a job is printing. Wait for a Load Paper or Ready light sequence or

message before loading the tray.

• Before loading transparencies, fan the stack to prevent sheets from sticking together.

• Do not use envelopes that: – Have excessive curl – Are stuck together – Are damaged in any way – Contain windows, holes, perforations, cutouts, or embossing – Have 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 the current printing environment.

General information 1-5

4506-1xx

Tools

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

• Magnetic tip Phillips screwdrivers, large and small

• Volt -ohmmeter

Acronyms

ASIC Application Specific Integrated Circuit CRC Cyclic Redundancy Check DEV Developer Roll (of toner cartridge/photoconductor system) DIMM Dual In-Line Memory Module EEPROM Erasable Electrically Programmable Read-Only Memory ENA External Network Adapter FRU Field Replaceable Unit HVPS High Voltage Power Supply LED Light Emitting Diode LVPS Low Voltage Power Supply (110 V or 220 Vac) NVRAM Nonvolatile Random Access Memory PC Photoconductor PCL Printer Control Language PCU PC/Cleaner Unit POR Power-On Reset POST Power-On Self Test PPDS Personal Printer Data Stream RIP Raster Image Processor TAR Toner Add Roll TU Toner USB Universal Serial Bus V ac Volts alternating current V dc Volts direct current

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2. Diagnostic information

Start

CAUTION: Unplug power from the printer before connecting or disconnecting any other cable,

assembly, or electronic card. This is a precaution for personal safety and to prevent damage to the printer.

This chapter contains the codes and diagnostic tools to aid in providing corrective action for a malfunctioning printer. To determine the corrective action to repair a printer, look for the following information:

• A description of a problem. See “Symptom tables” on page 2-22.

• Information from the operator panel of the printer – Lexmark E120—This model has an operator panel containing two lights and two buttons. For

diagnostic information specific to these modes, see “Diagnostics—E120” on page 2-2.

– Lexmark E120n—This model has an operator panel with six lights and two buttons. For diagnostic

information specific to these models, see “Diagnostics—E120n” on page 2-8.

Diagnostic information 2-1

4506-1xx

Diagnostics—E120 2

Power-On Self Test (POST) sequence

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 turn on momentarily.

2. Lights then flash on and off sequentially.

3. After the lights quit flashing, the Ready/Data light flashes until the fuser comes up to temperature (5–20

additional seconds, depending on the initial temperature of the fuser) and then stays on.

4. The motor drive and fan come on.

5. If there is a problem in the printer such as a paper jam, the panel lights indicate the problem. See “” on

page 2-3 for more information.

6. The printer cycles down into standby mode, and the Ready/Data light comes on solid.

Overview of the operator panel—E120

The printer operator panel has two buttons and two lights. Lights indicate the status of the printer. Buttons are used to continue or cancel the current print job.

When the printer is turned on, both lights cycle as a self test is performed. Also, when the printer is reset, or when a printer setting is changed in the menus, both lights cycle.

To learn more about the panel lights or to determine the status of the printer when lights are on, see“Light

patterns and error messages” on page 2-3.

Continue

Cancel

Error

Ready / Data

• Press and release Continue to resume printing.

• Press and release Continue twice quickly to display the secondary light sequence.

• Press and release Continue twice quickly to display the tertiary light sequences if present.

• Press and release Continue from the Ready state to print the menu settings page.

• Press and release Cancel to cancel current job.

• Press and hold Cancel until all lights come on to reset.

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Light patterns and error messages

User attendance messages, paper jam errors, and service errors display an initial light pattern. This may be all the information you need. However, if you double-click on the panel, a second pattern may appear with more detailed information. If you double-click tertiary pattern, the initial pattern reappears. Not all initial level light patterns have secondary patterns; when you double-click , the pattern does not change.

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. Additional tertiary codes used for service (see “Service

codes” on page 2-6) indicate specific errors. See “” on page 2-3.

Double-click

again, a tertiary light pattern may appear. If there is not a

Note: If you send data to the printer and all lights flash immediately, and double-clicking does not change the display, there may be a code problem. Call the next level of support.

Diagnostic information 2-3

4506-1xx

Primary, secondary, and tertiary light patterns

The table below uses the following symbols to indicate solid, or blinking light patterns. When a number accompanies the blinking symbol, it refers to the number of times the light tuns off and on.

z Light continuously on

Light off

✷ Light blinks continuously

3✷ Light blinks three times, pauses and repeats pattern

x Light blinking slowly

Primary Secondary Tertiary

Ready/ Data

z Ready/Power Saver

x Hex Trace Ready or Demo Mode ready

✷ Busy, printing job, printing font list, printing menu settings, printing the print

zz Flushing buffer, resolution reduced while cancelling job, resetting printer

✷ Waiting or Not Ready (printer offline)

z Close door

✷✷ Service error. Double-click to display additional secondary and tertiary

1✷ 1✷ Close door (front door, rear

1✷ 3✷ 13 Invalid engine code or

3✷ 1✷ 31 Defective toner cartridge

3✷ 2✷ 32 Unsupported toner

3✷ 3✷ 33 Change cartridge or

Description Action

quality test page.

Resolution reduced (no pattern displays)

light patterns.

1. Make sure the top cover door, front door

door, or top cover door)

and rear doors are closed.

2. Make sure the front and rear door posts which close the switches are not damaged. Replace the door if the part is damaged.

3. Check the switches of the front and rear doors. With the door closed, the outermost pins (1 and 5) of J14 or J11 should indicate continuity when checked with a meter. If a switch has failed, replace the printer.

If the printer has had a code update just prior the code is not programmed. Code must

to this message, reload the code. Otherwise,

replace the controller card. be successfully downloaded to continue.

1. Verify that the toner cartridge and PC kit

or missing cartridge

are correctly installed.

2. Wait 10–20 seconds for the printer to verify the units.

3. Replace the toner cartridge or PC kit if necessary.

Replace the toner cartridge with one that is

cartridge

supported.

Install a new toner cartridge.

invalid refill

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Primary Secondary Tertiary

Ready/ Data

Description Action

3✷ 5✷ 35 Resource Save off;

insufficient memory

1. Briefly press to temporarily disable Resource Save.

2. Set Link Buffer to Auto.

4✷ 2✷ 42 Cartridge region

mismatch

While the message is displayed, the following steps may be taken:

1. Go to the Diagnostics menu (see

“Diagnostic aids” on page 3-1) and print

the print quality test pages. The first page shows the regions under “Cartridge Information.”

2. Change the cartridge to one corresponding to the region where the printer was purchased.

3. Call the next level of support.

1✷ 2✷ 12 Load media, load the

✷

manual feeder, or load the tray to complete side two of the manual duplex.

✷

1✷ 4✷ 14 Not Ready • Briefly press to return to the Ready

1. Load paper in the main tray.

2. Check the driver for incorrect paper selections.

3. Load paper for the manual duplex.

state.

• Briefly press to return to the Ready state.

• Hold longer to reset the printer.

✷

3✷ 4✷ 34 Short paper • Verify the actual paper size matches the

selected size in the driver or application.

• Briefly press to cancel the job.

• Briefly press to clear the message and continue printing.

• Hold longer to reset the printer.

✷

3✷ 7✷ 37 Insufficient collation

area, memory too full

• Set Collation to Off in driver.

• Briefly press to cancel the job.

• Briefly press to clear memory and continue printing the remainder of the job. Some data will be lost.

• Hold longer to reset the printer.

✷

3✷ 8✷ 38 Memory full • Delete fonts, macros, and other data in

RAM.

• Simplify the print job.

• Briefly press to cancel the job.

• Briefly press to clear the message and continue printing. Some data may be lost.

• Hold longer to reset the printer.

✷

3✷ 9✷ 39 Complex page • Try simplifying the job.

• Briefly press to cancel job.

• Briefly press to clear message and continue printing.

• Hold longer to reset the printer.

✷

5✷ 4✷ 54 ENA connection lost

during POR

• Check the connections to the ENA and POR the printer.

• Briefly press to clear the message.

✷

8✷ 4✷ 84 Photoconductor near full • Customer should make plans to replace

the PC kit.

• Briefly press to clear the message and continue printing.

Diagnostic information 2-5

4506-1xx

Primary Secondary Tertiary

Ready/ Data

8✷ 8✷ 88 Toner low 1. Replace the toner cartridge.

✷

Ready/ Data

Description Action

2. Briefly press to clear the message and continue printing.

✷

10✷ zz1✷ 201 Paper jam between

input sensor and exit sensor

1. Open the rear and top doors, remove the PC kit if necessary and clear the paper jam.

2. Check the paper path for the cause of the jam and repair as necessary.

✷

10✷ zz2✷ 202 Paper jam at the exit

sensor

1. Open the rear and top doors and remove the paper jam.

2. Check the paper path for the cause of the jam and repair as necessary.

✷

10✷ zz10✷ 200 Paper jam at the input

sensor

1. Open the front and rear covers, remove the toner cartridge and PC kit if necessary. Remove the paper jam.

2. Check the paper path for the cause of the jam and repair as necessary.

Service codes

✷✷

10✷ 10✷ 900 Reprogram or replace the controller card. See

“Controller card removal” on page 4-17.

✷✷

10✷ 1✷ 901 Service—Engine flash

error

Flash memory if faulty. Replace the controller card. See “Controller card removal” on

page 4-17.

✷✷ ✷✷ ✷✷ ✷✷ ✷✷ ✷✷

10✷ 2✷ 902 Engine service errors Replace the controller card. See “Controller 10✷ 3✷ 903 Engine service errors

card removal” on page 4-17.

10✷ 4✷ 904 Engine service errors 10✷ 5✷ 905 Engine service errors 10✷ 6✷ 906 Engine service errors

1✷ 7✷ 917 Transfer roll Check the circuitry. See “Transfer roll

service check” on page 2-41.

✷✷

2✷ 10✷ 920 Fuser is below

temperature.

2✷ 1✷ 921 Fuser is below standby

temperature.

2✷ 2✷ 922 Fuser failed to reach

• Check all connectors to the fuser assembly.

• Replace the fuser. See “Fuser removal”

on page 4-20.

standby temperature.

✷✷

2✷ 3✷ 923 Fuser is too hot during

printing or at idle.

✷✷

2✷ 4✷ 924 The thermistor has an

open circuit.

✷✷

2✷ 5✷ 925 Incorrect fuser lamp

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Primary Secondary Tertiary

Ready/ Data

Description Action

✷✷

✷✷ ✷✷ ✷✷ ✷✷ ✷✷

✷✷

✷✷ ✷✷

✷✷

✷✷ ✷✷ ✷✷ ✷✷ ✷✷

3✷ 10✷ 930 Wrong printhead

installed

3✷ 1✷ 931 No first HYSNC

• Check all connections to the printhead.

• Replace the printhead. See “Printhead

removal” on page 4-12.

3✷ 2✷ 932 Lost HYSNC 3✷ 3✷ 933 Mirror motor locked 3✷ 4✷ 934 Mirror motor lost lock. 3✷ 5✷ 935 Mirror motor unable to

reach operating speed

3✷ 6✷ 936 Transport motor initial

lock failed

3✷ 7✷ 937 Transport motor lost

• Check the connection to the main motor.

• Verify continuity in the cable.

• Call the next level of support.

lock

3✷ 9✷ 939 RIP to engine

communications error

Replace the controller card. See “Controller

card removal” on page 4-17.

4✷ 10✷ 940 Zero crossing failure • Check the connections on the LVPS card.

• Replace the LVPS. See “LVPS/HVPS

removal” on page 4-19.

5✷ 10✷ 950 Controller card

failure—Data mismatch between secure EEPROM and NVRAM

5✷ 1✷ 951 Controller card

failure—Secure EEPROM failure

If either the operator panel or controller card were replaced proceeding the error message, then either an incorrect card was installed or the printer was improperly powered on.

Note: The controller card and operator panel cannot be replaced at the same time without a POR in between. Printer settings on each FRU are obtained from the other. The settings are lost if both are installed and powered on at the same time.

5✷ 2✷ 952 NVRAM CRC failure • Check all the connections on the controller 5✷ 4✷ 954 NVRAM chip failure

card.

• Replace the controller card. See

“Controller card removal” on page 4-17.

5✷ 5✷ 955 Code ROM/NAND

failure

Replace the controller card. See “Controller

card removal” on page 4-17.

5✷ 6✷ 956 Controller card failure 5✷ 7✷ 957 Controller card failure 5✷ 9✷ 959 Controller card failure 5✷ 8✷ 958 NAND failure 6✷ 10✷ 960 RAM memory errors Replace the controller card. See “Controller

card removal” on page 4-17.

Diagnostic information 2-7

4506-1xx

Primary Secondary Tertiary

Ready/ Data

Description Action

✷✷

8✷ 10✷ 980 Engine is experiencing

unreliable communications with the specified device.

8✷ 1✷ 981 Engine protocol

violation is detected by the device.

8✷ 2✷ 982 Communication error is

detected by the specified device.

8✷ 3✷ 983 Invalid command is

received by the specified device.

8✷ 4✷ 984 Invalid command

parameter is received by the specified device.

9✷ 10✷ 990 Device equipment

check

9✷ 1✷ 991 Device system card

failure

Replace the controller card. See “Controller

card removal” on page 4-17.

Replace the controller card. See “Controller

card removal” on page 4-17.

Replace the controller card. See “Controller

card removal” on page 4-17.

Diagnostics—E120n 2

Power–On Self Test (POST) sequence

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 turn on momentarily.

2. Lights then flash on and off sequentially.

3. After the lights quit flashing, the light flashes until the fuser comes up to temperature (5–20 additional

seconds, depending on the initial temperature of the fuser) and then stays on.

4. The motor drive and fan come on.

5. If there is a problem in the printer such as a paper jam, the panel lights indicate the problem. See

“Common primary light patterns—E120n” on page 2-9 for more information.

6. The printer cycles down into standby mode, and lights solid.

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Overview of the operator panel—E120n

The printer operator panel has two buttons and six lights (the Continue button is both a light and button). Lights indicate the status of the printer. Buttons are used to continue or cancel the current print job.

When the printer is turned on, all lights cycle as a self test is performed. Also, when the printer is reset, or when a printer setting is changed in the menus, all lights cycle.

Cancel

Toner low / Replace PC kit

Paper jam

Continue

Ready / Data

Load / Remove paper

Error

• Press and release Continue to resume printing.

• Press and release Continue from the Ready state to print the menu pages.

• Press and release Continue twice quickly to display the secondary light sequence.

• Press and release Continue twice quickly to display the tertiary light sequence.

• Press and release Cancel to cancel the current job.

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

Common primary and secondary light patterns

Common primary light patterns—E120n

The table below uses the following symbols to indicate solid or blinking light patterns.

z Light on

Light off

✷ Light blinking

x Light blinking slowly

Diagnostic information 2-9

4506-1xx

In the table below, white rows are primary codes, and secondary codes are in gray.

The secondary light pattern is related to the primary light pattern immediately preceding it.

Description/action

z Ready/Power Saver. See “Ready/Power Saver” on page 2-11.

✷ Busy (processing or printing). See “Busy” on page 2-11.

x Hex Trace Ready. See “Hex Trace Ready” on page 2-11.

zz Waiting. See “Waiting” on page 2-12

✷✷Flushing/Resolution reduced. See “Flushing / Resolution

z Not Ready (printer offline). See “Not ready” on page 2-12.

zzLoad media. See “Load media” on page 2-12. z ✷ Load manual feeder. See “Load manual feeder” on page 2-12. ✷ z Print side two of a duplex job. See “Print side two of duplex job”

z Toner low. See “Toner low” on page 2-13.

z ✷ Replace the photoconductor. See “Replace the photoconductor

zzPaper jam. Press and release twice briefly to display secondary

z z z 200 Paper jam input sensor. See “200 Paper jam at the input

z z z 201 Paper jam between input and exit sensors. See “201 Paper

z z z 202 Paper jam exit sensor. See “202 Paper jams as a printed job

zzCartridge errors. Press and release twice briefly to display

z ✷ z 42 Cartridge region mismatch. Install the correct cartridge. z ✷ z 33 Change cartridge/invalid refill. Install a new cartridge.

z z z 31 Defective cartridge/missing cartridge

z z z 32 Unsupported toner cartridge

zzInvalid engine code/Invalid network code

z z z Invalid engine code z ✷ z Invalid network code

zzz Programming engine code/Programming system code

zzzzzzCancel job/Reset printer

zzPrinter error. Press and release twice briefly to display

z z z Standard network software error in the manual feeder z z z Complex page. See “Complex page” on page 2-15. z ✷ z Insufficient printer memory

z z z Insufficient collation area

reduced” on page 2-12.

z Close door. See “Close door / Insert cartridge” on page 2-12.

on page 2-12.

kit” on page 2-13.

error codes.

sensor” on page 2-14.

jams between the input sensor and exit sensor” on page 2-14.

exits the printer.” on page 2-15.

secondary error codes.

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4506-1xx

z ✷ z PPDS font error

z z z Defective flash z ✷ z Insufficient defrag memory

z z z Network interface errors z ✷ z ENA connection lost

z z z z Memory full

z z z z Short paper

✷✷✷✷✷✷Service error see “Service codes” on page 2-17

Additio nal info rm at ion —pr ima ry codes

The following tables explain the primary light patterns (or codes), the secondary error codes, what these codes mean, and how to clear them. User attendance and status information is included. For service information, see “Service

codes” on page 2-17.

Primary codes—additional information

Description/ Light pattern

Ready/Power Saver • Printer is ready to receive and

Busy • Printer is busy receiving and

✷

Meaning Action

process data.

• Printer is in Power Saver mode.

processing data or printing.

• Printer is formatting the flash memory.

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

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

• 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 the User’s Reference for more information.

• Busy:

– Wait for the message to clear. – Press and release to cancel the print

job.

– Press and hold to reset the printer.

• 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 the printer.

• Receiving/processing data from a host interface:

– Wait for the message to clear. – Press and release to stop processing. – Press and hold to reset printer.

Hex Trace Ready Printer is in the Ready mode and

Hex Trace is active.

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

• Or, press and hold to reset the printer.

Diagnostic information 2-11

+ 85 hidden pages