LEXMARK E120, E120n Service Manual

Download

• Table of contents

• Start diagnostics

Lexmark™ E120, E120n

4506-1xx

• 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.

4506-1xx

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

4506-1xx

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

iii Service Manual

4506-1xx

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

Table of contents iv

4506-1xx

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

v Service Manual

4506-1xx

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.

Notices and safety information vi

4506-1xx

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.

vii Service Manual

4506-1xx

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.

Notices and safety information viii

4506-1xx

ix Service Manual

4506-1xx

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.

Safety information x

4506-1xx

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.

xi Service Manual

4506-1xx

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.

Safety information xii

4506-1xx

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.

xiii Service Manual

4506-1xx

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

1-2 Service Manual

4506-1xx

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.

1-4 Service Manual

4506-1xx

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

1-6 Service Manual

4506-1xx

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.

2-2 Service Manual

4506-1xx

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

2-4 Service Manual

4506-1xx

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

2-6 Service Manual

4506-1xx

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.

2-8 Service Manual

4506-1xx

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.

2-10 Service Manual

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

4506-1xx

Primary codes—additional information (continued)

Description/ Light pattern

Waiting Printer is waiting until a print

Flushing / Resolution reduced • Printer is flushing corrupted

✷✷

Not ready Printer is not ready to receive or

Close door / Insert cartridge The printer door is open. • Close the door.

Meaning Action

timeout occurs, or until it receives additional data.

print data.

• Printer is processing data or printing pages, but the resolution of a page in the current print job is reduced from 600 dots per inch (dpi) to 300 dpi to prevent a memory full error.

process data, or the printer ports are offline.

• Press and release to print the contents of the print buffer.

• Press and release to cancel the print job.

• Press and hold to reset the printer.

• Wait until is on to print other jobs.

• Press and release to cancel print job.

• Press and hold to reset printer.

• Press to return to the Ready or Busy state.

• Press and release to cancel the print job.

• Press and hold to reset the printer.

• Check the switches and cables under the left cover.

Load media The printer is out of media, or the

media did not feed properly, thereby not making it to the input sensor in the allotted time.

Load manual feeder Printer prompts to load a single

sheet of media in the manual feeder.

z ✷

Print side two of duplex job Print the other side of a duplex

print job.

✷ z

• Load media into tray 1 and press to resume printing.

• Check that the media is loaded correctly in tray 1. (Do not overfill.)

•Press to cancel the print job.

• Load media in the manual feeder with the side to be printed facing up.

•Press to resume printing.

• Press and hold to reset the printer.

• Reinsert the print job in tray 1 using the instructions in the driver pop-up menu to orient the pages correctly (printed side up, loading edge to front of the printer).

•Press to resume printing.

• Press and hold to reset the printer.

2-12 Service Manual

4506-1xx

Primary codes—additional information (continued)

Description/ Light pattern

Toner low The toner in the toner cartridge is

Replace the photoconductor kit The photoconductor kit drum is

z ✷

toner cartridge error / toner cartridge is not installed

Meaning Action

getting low.

full and needs to be replaced.

The toner cartridge is not installed, or the printer detects a toner cartridge error.

The error is caused by a defective cartridge, an unsupported cartridge, an invalid refill, or a cartridge meant to be used in another geographic region.

• Send a print job.

•Press to print the menu settings page for

a list of current settings.

• Remove the toner cartridge, and shake it to extend the life of the cartridge.

• Replace the toner cartridge.

• Press and hold to reset the printer.

Note: The light may not come on if the starter toner cartridge is installed in a base model.

• Press to resume printing.

• Replace the photoconductor kit.

• Reset the counter.

• If the toner cartridge is not installed, install it.

• If the toner cartridge is installed, remove it and install a new toner cartridge.

Invalid engine code / Invalid network code

Programming engine code / Programming system code

✷

Cancel job / Reset printer • The current print job is

zz z zzz

The code in an internal print server has not been programmed, or the programmed code is not valid.

New code is being loaded into the engine or firmware code flash.

canceled.

• The printer is resetting to the user default settings.

– Any active print jobs are

canceled.

– A user default setting

remains in effect until changed or until the printer is restored to factory default settings.

• Download valid network code to the internal print server.

• Press twice quickly to see the secondary error code.

Wait for the message to clear. When the printer has finished loading the code, it performs a soft reset.

Wait for the message to clear.

Diagnostic information 2-13

4506-1xx

Primary codes—additional information (continued)

Description/ Light pattern

Service error The printer has a service error,

✷✷ ✷ ✷✷✷

Printer error The printer has one of the

Meaning Action

and printing has stopped.

following errors:

• Memory is full, insufficient to save what is in the buffer, or insufficient to defragment flash memory.

• A page is too complex to print or is shorter than the set page margins.

• Resolution of a formatted page is reduced to 300 dpi.

• A font error occurred.

• Communication with the host computer is lost.

Additional information—secondary light patterns

Turn the printer off and back on. If the lights are still blinking, contact the next

level of support. Press and release twice quickly to view the

secondary message. See “Service primary

code” on page 2-18.

• Press twice quickly to see the secondary

error code. See “Additional information—

secondary light patterns” on page 2-14 for

more information.

•Press to clear the secondary message.

• When the and lights are both on, a secondary error has occurred.

• When the and lights are both on, a paper jam secondary error has occurred.

• When the lights are both on, a toner cartridge error has occurred.

Press and release twice to display the secondary error code light pattern.

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

Secondary light patterns—additional information

Description/ Light pattern

200 Paper jam at the input sensor

zz z

201 Paper jams between the input sensor and exit sensor

zzz

Meaning Action

Media has stopped over the input sensor.

Paper has cleared the input sensor but not made it to the exit sensor.

Open the front and rear covers and remove the toner cartridge to access the area. Check for obstructions and remove them.

Open the front and rear doors and check the paper path for obstacles. The fuser should be inspected.

2-14 Service Manual

4506-1xx

Secondary light patterns—additional information (continued)

Description/ Light pattern

202 Paper jams as a printed job exits the printer.

zzz

Complex page The page may not print correctly

zz z

31 toner cartridge missing or defective

Meaning Action

A paper jam has occurred as the paper is exiting the printer.

because the print information on the page is too complex (that is, too large for the printer memory).

The toner cartridge is either missing or defective.

Open the rear and top doors and clear the paper jam.

• Press to clear the message and continue

processing the print job (some of the print data may be lost).

• To avoid this error in the future: – Reduce the complexity of the page by

reducing the amount of text or graphics on the page and deleting unnecessary downloaded fonts or macros.

–Set Page Protect to on in the Local Printer

Setup Utility.

• Install additional printer memory.

• Install the correct toner cartridge and PC kit.

• Check the toner cartridge and PC kit contacts at the upper left side.

zzz

32 Unsupported toner cartridge The toner cartridge is

unsupported.

zz z

33 Invalid refill The toner cartridge has an invalid

refill.

z ✷ z

42 Region mismatch The toner cartridge was

manufactured for a different geographic region than the printer.

z ✷ z

Replace the cartridge.

Replace the cartridge with a cartridge from the same region as the printer.

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.

If the printer has been moved from a different geographic location, call the next level of support.

Diagnostic information 2-15

4506-1xx

Secondary light patterns—additional information (continued)

Description/ Light pattern

37 Insufficient collation area The printer memory does not have

zz z

Network interface errors The printer cannot establish

zzz

54 Network or ENA connection lost

z ✷ z

Meaning Action

the free space necessary to collate the print job. This may happen due to one of these errors:

• Memory is full.

• A page is too complex to print.

• A page is shorter than the set page margins.

• Memory is insufficient to save what is in the buffer.

communication with the network.

The printer has lost the connection to an external print server (also called an external network adapter or ENA).

This light pattern is displayed if your printer is connected to the network, but it cannot detect the print server when you turn on the printer.

• Press to clear the message and continue

printing the job (the job may not print correctly).

• Press and release to cancel the print job.

• Press and hold to reset the printer.

• To avoid this error in the future: – Simplify the print job. Reduce the

complexity of the page by reducing the amount of text or graphics on the page and deleting unnecessary downloaded fonts or macros.

– Install additional printer memory.

Press to clear the message and continue printing (the job may not print correctly).

• Make sure the cable connecting the ENA and

the printer is securely attached.

• Turn the printer off and then on to reset the

printer.

• Press and hold to reset the printer.

Memory full The printer is processing data, but

zz z z

Short paper The paper length is too short to

zz z z

Invalid engine code The code in an internal print server

zzz

the memory used to store pages is full.

print the formatted data. This occurs when the printer does not know the media size loaded in the tray, or there is a problem feeding the media.

has not been programmed, or the programmed code is not valid.

• Press to clear the message and continue

printing the job (the job may not print correctly).

• Press and release to cancel the print job.

• Press and hold to reset the printer.

• To avoid this error in the future:

Simplify the print job. Reduce the complexity of the page by reducing the amount of text or graphics on the page and deleting unnecessary downloaded fonts or macros.

• Make sure the print media you loaded is large

enough.

• Open the front cover, clear the paper path,

and close the cover to resume printing.

• Press to clear the message and continue

printing the job.

• Press to cancel the print job.

Download valid engine code to the internal print server.

2-16 Service Manual

4506-1xx

Secondary light patterns—additional information (continued)

Description/ Light pattern

Invalid network code The code in an internal print server

z ✷ z

Meaning Action

has not been programmed, or the programmed code is not valid.

Service codes

All service errors are indicated by all lights flashing as the primary notification or code. The secondary light pattern indicates an area or function which has the error. Tertiary codes (shown on the following pages) indicate specific device errors. When all lights flash, double-click to see the secondary code. Double-click again to see the tertiary code. If you double-click again, you return to the primary light pattern.

In the following example:

• The primary light pattern indicates a service error (all flashing). Double-click for more information.

• The secondary light pattern indicates a fuser or toner sensor error. Double-click for more information.

• The tertiary light pattern indicates that the fuser is below temperature when printing. If you double-click

again, the original primary light pattern will appear.

Download valid network code to the internal print server.

Primary pattern

Note: If you send data to the printer and all lights flash simultaneously, and double-clicking does not produce a secondary code, you may have a code problem. Call the next level of support.

Secondary pattern

Tertiary pattern

Diagnostic information 2-17

4506-1xx

Service primary code

When this code appears, double-click to reveal the secondary codes.

z Light on

Light off

✷ Light blinking

x Light blinking slowly

Description/action

✷✷✷✷✷✷This service primary code indicates that a secondary code is

available.

Service secondary error codes

Secondary light pattern

Service secondary light patterns

Description/action

✷ 90x Software ✷ ✷ 91x DC motor or transfer roll ✷ ✷ 92x Fuser or toner sensor ✷ ✷ ✷ 93x Printhead, drive motor, RIP to engine ✷ ✷ 94x RIP to engine communications, engine electronics ✷ ✷ ✷ 95x Controller card (NVRAM, ROM, or NAND) ✷ ✷ ✷ 96x RAM memory ✷ ✷ ✷ ✷ 97x Network ✷ ✷ 98x Paper port communications ✷ ✷ ✷ Programming error ✷ ✷ ✷ ✷ ✷ Unsupported firmware/controller card

Service tertiary error codes

Service error codes are generally non-recoverable except in an intermittent condition when you can POR (power-on reset) the printer to temporarily recover from the error.

Note: All service errors are initially communicated by all lights flashing which is the primary indication or code. For brevity, this indication is not repeated in the following codes.

2-18 Service Manual

4506-1xx

Controller software

Controller software errors are in the 90x group/illegal trap (90x).

Service tertiary light patterns—controller software (90x)

Description/action

✷ When this secondary code is received, one of the following tertiary

✷ 900 RIP error Replace the controller card or ✷✷901 Engine error ✷✷902 ✷✷✷903 ✷✷ 904 ✷✷✷905 ✷✷✷906

light patterns is available.

reload the engine code. See

“Controller card removal” on page 4-17.

Transfer roll

CAUTION: When you see this symbol, there is a danger from hazardous voltage in the area of

the product where you are working. Unplug the product before you begin, or use caution if the product must receive power in order to perform the task.

Code 917 indicates a problem in the transfer roll circuitry.

Service tertiary light patterns—transfer roll (91x)

Description/action

✷ ✷ When this secondary code is received, one of the following tertiary

✷ ✷✷✷917 Transfer roll circuitry Check the continuity from the cable

light patterns is available.

connection on the HVPS (high voltage power supply) to the right side of the transfer roll.

Diagnostic information 2-19

4506-1xx

Fuser

Codes 920 through 925 indicate a problem in the fuser (see “Fuser service check” on page 2-26 for more information) or toner cartridge.

Service tertiary light patterns—fuser (92x)

Description/action

✷ ✷ When this secondary code is received, one of the following tertiary

✷ 920 Fuser below temperature when

✷✷921 Fuser below standby temperature

✷✷922 Fuser failed to reach standby

✷✷✷923 Fuser too hot during printing or idle ✷✷ 924 Open circuit in thermistor path ✷✷✷925 Incorrect fuser lamp installed. Check the AC voltage.

light patterns is available.

Replace the fuser.

printing

(see “Fuser service check” on

page 2-26 for more information)

temperature

Change the fuser to match the voltage.

Printhead, transport motor, or RIP/engine communication error

Codes 930 through 935 indicate a problem with the printhead. Check cables to the printhead. Replace the printhead as necessary.

Codes 936 and 937 indicate a problem in the drive system.

Code 939 indicates a communication failure between the RIP and engine processors.

Service tertiary light patterns—printhead, transport motor, or RIP/engine communication error (93x)

✷ ✷ ✷ When this secondary code is received, one of the following tertiary

✷ 930 Wrong printhead Check connectors. Replace the ✷✷931 No first HYSNC ✷✷932 Printhead lost

✷✷✷933 Mirror motor locked

✷✷ 934 Mirror motor lost

✷✷✷935 Mirror motor not at

2-20 Service Manual

Description/action

light patterns is available.

printhead.

HYSNC

but no HYSNC

lock

operating speed.

4506-1xx

Service tertiary light patterns—printhead, transport motor, or RIP/engine communication error (93x)

✷✷✷936 Transport motor

initial lock failure

✷ ✷✷✷937 Transport motor lost

lock

✷✷ ✷939 RIP/engine

communication error

Replace the printer or call the next level of support.

LVPS/HVPS failure

Service tertiary light patterns—printhead, transport motor, or RIP/engine communication error (94x)

Description/action

✷ ✷ Zero signal for fuser control has failed on LVPS.

✷ 940 Replace the LVPS/HVPS. See “LVPS/HVPS removal”

on page 4-19.

NVRAM failure

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

“Controller card removal” on page 4-17.

Note: NVRAM is on the operator panel printed circuit board while secure NVRAM is on the controller card.

Check margin alignments after replacing the operator panel assembly. If margin errors are unacceptable, corrections can only be made through software. Contact the next level of support.

Service tertiary light patterns—NVRAM failure (95x)

Description/action

✷ ✷ ✷ When this secondary code is received, one of the following tertiary

✷ 950 Secure EEPROM

✷✷951 Secure EEPROM

✷✷952 NVRAM CRC failure ✷✷ 954 NVRAM chip failure ✷✷✷955 Code ROM or

✷✷✷956 Processor failure ✷ ✷✷✷957 ASIC failure ✷✷ 958 NAND failure ✷✷ ✷959 SRAM failure

light patterns is available.

data does not match NVRAM.

failure

NAND failed CRC

Check the connectors for the operator panel.

Replace the operator panel, if necessary.

Check the connectors for the controller card.

Replace controller card, if necessary.

Diagnostic information 2-21

4506-1xx

RAM memory error

This error indicates RAM failure.

Service tertiary light patterns—RAM memory error (96x)

Description/action

✷ ✷ ✷ When this secondary code is received,

✷ 960 RAM soldered on the board is bad • POR the printer.

the following tertiary light pattern is available.

• Replace the controller card.

Network error

Indicates an error in the network circuitry.

Service tertiary light patterns—Network error (97x)

Description/action

✷ ✷ ✷ ✷ When this secondary code is received, one of the following tertiary

✷✷✷975 Unrecognizable network port Replace the controller ✷✷✷976 Unrecoverable software error in

✷✷ 978 Bad checksum while programming

✷✷ ✷979 Flash parts failed while

light patterns is available.

network port.

port

programming port

card. See “Controller card

removal” on page 4-17.

Symptom tables

POST symptom table

Symptom Action

The main motor, cooling fan, and fuser do not come on.

POST completes, except one or more lights do not come on.

None of the lights come on. See “Controller card service check” on page 2-24.

Main motor does not come on. See “Main motor service check” on page 2-28.

Fan does not come on. See “Fan noisy or not working.” on page 2-23.

The paper feed picks and tries to feed paper.

2-22 Service Manual

See “Main motor service check” on page 2-28.

See “Operator Panel Service Check” on page 2-25.

See “Paper feed service checks” on page 2-29.

4506-1xx

Printer symptom table

Symptom Action

Dead machine (no power). See “Dead machine service check” on page 2-25.

Fan noisy or not working. Unplug the fan at CN404 on the LVPS/HVPS. Turn the printer on and

Fuser parts melted. See “Hot fuser service check” on page 2-27.

Fuser lamp does not light. See “Fuser service check” on page 2-26.

Fuser lamp never turns off. See “Hot fuser service check” on page 2-27.

Toner is not fused to the paper. See “Fuser service check” on page 2-26.

Paper jams. See “Paper feed service checks” on page 2-29.

Main motor is noisy or not moving. See “Main motor service check” on page 2-28.

Paper skews. See “Paper feed service checks” on page 2-29.

Operator panel button is not responding. See “Controller card service check” on page 2-24.

Operator panel lights are off or very dim. See “Controller card service check” on page 2-24.

Blank page See “Blank page” on page 2-32.

Black page See “Black page” on page 2-33.

Heavy background See “Heavy background” on page 2-33.

Light print See “Light print” on page 2-35.

verify +24 V dc on pin 1. If the voltage is not correct, replace the LVPS/ HVPS. If it is correct, the most likely failure is the fan. Contact the next level of support.

White or black lines or bands See “White or black lines or bands” on page 2-35.

Toner on back of page See “Toner on back of page” on page 2-36.

Paper never picks. See “Paper never picks” on page 2-30.

Paper feeds continuously. See “Paper picks during POST and/or continuously” on page 2-29.

Paper is wrinkled or bent. See “Paper “trees,” wrinkles, stacks poorly, or curls” on page 2-31.

Diagnostic information 2-23

4506-1xx

Service checks

Service checks which involve measuring voltages on the LVPS/HVPS (low voltage power supply/ high voltage power supply board) should be performed with the printer positioned on its back side.

Note: When you make voltage readings, always use frame ground unless another ground is specified. See the wiring diagram in the back of the book for more information.

Controller card service check

FRU Action

Controller card assembly

Warning: Do not replace the operator panel and controller card at the same time. Each card contains the printer settings. When either of these cards is new, it obtains some of the settings from the other card. Settings are lost when both are new and replaced at the same time.

POST (Power-On Self Test) Note: The printer should complete POST in approximately 30 seconds.

If the printer fails to display lights or activate the drive motor, fuser or fan, check the following in order:

1. Power to the LVPS/HVPS

2. Power from the LVPS/HVPS to the controller card

3. Cables are plugged in correctly, especially for the operator panel. The printer will not power-up without a functioning operator panel.

4. The controller card assembly.

5. The operator panel. See “Operator Panel Service Check” on page 2-25.

2-24 Service Manual

4506-1xx

FRU Action

Controller card assembly

Check input voltages to the controller card from the LVPS/HVPS. Warning: Check the following at CN402 on the LVPS/HVPS with the flat cable

unplugged and the printer on. Do not check voltages on a flat cable due to potential damage to electrical components.

• 24 V dc at pins 18, 16, 15, 14, 13, and 12

If any of these voltages are incorrect, replace the LVPS/HVPS. See “LVPS/

HVPS removal” on page 4-19.

• With the cable unplugged on both ends, check the continuity of the cable. If the cable is damaged, replace it.

Check the output voltage of the controller card with all cables disconnected on the controller card except the thermistor at J2 and the LVPS/HVPS at J6. The measurements should be as follows: (all dc)

Connectors Pins (voltage measured in V dc)

1234567816 J1 (Exit sensor) +5 V GND +5 V GND J2 (Thermistor) GND J3 (Cartridge) +5 V J4 (Main mtr) +5 V +5 V +5 V +5 V GND +5 V J5 (USB) J6 (LVPS/

HVPS) J9 (Transfer) +5 V +5 V GND +24 V J10 (Solenoid) +24 V J11 (Rear cvr) GND GND GND J12 (Mirror mtr) GND +24 V J13 (LSU) GND GND +5 V J14 (Front cvr) +5 V GND GND GND J15 (Op panel)+5 V+5 V+5 VGND +5 V+5 V+5 V

+5 V

Controller card assembly (continued)

Turn off the printer and connect the front and rear door switches to the controller card. Close the doors, turn the printer on, and check the following:

Connectors Pins

12345678 J11 (Rear cover) +5 V dc GND GND GND J13 (LSU) GND +5 V dc GND +5 V dc +5 V dc

Diagnostic information 2-25

4506-1xx

Operator Panel Service Check

Operator panel (2 LED and 6 LED)

Dead machine service check

CAUTION: Check the AC line voltage. The voltage should be within the following limits:

• 100 V ac (volts alternating current) – 127 V ac for the 110 V printer

• 200 V ac – 240 V ac for the 220 V printer

For information about the LVPS/HVPS, see “LVPS portion of the LVPS/HVPS” on page 2-28.

Check the switches (buttons) with the printer off and operator panel cables disconnected.

• Check continuity between the ground and pin 6 (pins numbered from top) of J40 (operator panel card) while pressing . Check continuity between ground and pin 7 while pressing .

• If either fail continuity, replace the operator panel. See “Operator panel

removal (all models)” on page 4-18.

• Connect the operator panel cable and turn the printer on. Verify +5 V dc on pin 1 of J40. If this fails, verify +5 V dc on pin 1 of J15 on the controller card. Replace the cable if the voltage is verified on the controller card but not on the operator panel.

• Disconnect the cable at both ends to perform a continuity check.

2-26 Service Manual

4506-1xx

Fuser service check

When toner is partially fused to the paper, it is usually caused by a low fuser temperature.

Warning: Avoid handling the lamp as much as possible, as it is easily broken. Be careful not to touch the

glass housing with bare hands because skin acids can weaken the glass.

Note: The lamp is not a service part.

The line voltage to the printer must be within the following limits:

• 100 V ac–127 V ac for the 110 V model printer

• 200 V ac–240 V ac for the 220 V model printer

Turn the printer off, and wait a few minutes for the fuser lamp to cool. Turn the printer on, and observe the lamp turning on during POST. In the Ready state (not Power Saver), the lamp will cycle on and off at approximately 15 second cycles.

You can see the light from the lamp by opening the right side cover and observing the rear opening through which the fuser power cables pass.

FRU Action

Fuser power cable LVPS/HVPS Fuser

Fuser (continued)

Unplug the printer, and disconnect the fuser lamp cable plug from the LVPS/ HVPS board connector at CN403 (100/110 V ac) or CN401 (220 V ac).

Check for continuity across the fuser lamp by checking across the cable connector pins.

• If there is continuity, turn the printer on with only the fuser power disconnected at CN403/CN401.

Measure the voltage at connector CN102 on the LVPS/HVPS. It should match the line voltage. If line voltage is not present, see “Main motor

service check” on page 2-28 for more information.

Make sure the fuser thermistor is correctly connected to the controller board. If the problem persists, disconnect the thermistor cable at J2, and check for approximately +5 V dc on pin 1. Pin 2 should be grounded. If voltage is incorrect on pin 1, see “Controller card service check” on page 2-24 for more information.

• If there is no continuity, replace the fuser. See “Fuser removal” on

page 4-20.

Disconnect the thermistor cable from J2 on the controller card. Measure the resistance across the ends of the thermistor cable. Replace the fuser assembly if the resistance is lower than 7K ohm.

Note: Resistance measures approximately 450K ohms when cool and 1K ohms when hot.

Diagnostic information 2-27

4506-1xx

Cold fuser service check

Make sure the correct voltage lamp is installed. The voltage rating is stamped on one of the lamp contacts.

FRU Action

If the fuser lamp comes on and a fuser failure light error code displays, be sure the thermistor is contacting the hot roll, and the thermistor cable is firmly seated in connector J2 on the controller card.

Check for excessive toner buildup on the surface of the thermistor. Clean as necessary.

LVPS/HVPS Fuser

With the printer unplugged, disconnect the thermistor cable from J2 on the controller card.

Measure the resistance of the thermistor. The resistance measures from approximately 7K ohms immediately after printing or POR to approximately 450K ohms when the thermistor reaches room temperature. (It may take 30 minutes to cool.)

Replace the fuser assembly as necessary.

Hot fuser service check

Note: Ensure the correct lamp is installed.

FRU Action

LVPS/HVPS Fuser

Replace the fuser assembly as necessary.

2-28 Service Manual

4506-1xx

LVPS/HVPS service check

LVPS/HVPS LVPS portion of the LVPS/HVPS

Use the voltage meter to verify the appropriate voltage at the printer end of the power cable. Disconnect the power cable from the printer and the fuser cable (CN403) and check the following:

• Continuity across the power switch when it is on. Leave the power switch turned on.

• Continuity from the lower blade of the 110/220 V ac receptacle (designated “L” on the controller card) to the following:

- Each end of the two fuses

- Pin 1 of the fuser connector (CN403)

If any of these fail, replace the LVPS/HVPS. See “LVPS/HVPS removal” on

page 4-19.

Disconnect the cable from the controller card (CN402) and the fan (CN404). Reconnect the fuser, turn the power switch off and reconnect the power cord into the printer. Turn the printer on and verify the following:

• +24 V dc at pins 12, 13, 14, 15, 16, and 18 on CN402 (pins 12, 13, 14, 15, and 16 are interconnected)

• +24 V dc at pin 1 on CN404

Turn the printer off and verify grounds on pins 2, 4, 6, 8, and 17 of CN402. If any of these voltages or grounds fail, replace the LVPS/HVPS. See “LVPS/HVPS

removal” on page 4-19.

HVPS portion of the LVPS/HVPS

Remove the LVPS/HVPS to inspect the HVPS contacts. Clean the contacts, both springs and pads, if necessary.

Note: The voltage for the transfer roll is created on the transfer card and input sensor assembly. See “Transfer roll service check” on page 2-41.

Main motor service check

FRU Action

Main motor (not a FRU)

Controller card Warning: Do not

replace the operator panel and controller card at the same time. Each card contains the printer settings. When either of these cards is new, it obtains some of the settings from the other card. Settings are lost when both are new and replaced at the same time.

Turn off the printer, and unplug the main motor cable at J4. Turn on the printer, and check for +5 V dc on pins 1, 2, 3, 4, and 6. Pin 5 should be grounded:

J4 pins Voltages

Pins 1, 2, 3, 4, and 6 Approx. +5 V dc

Pin 5 Ground

• If these voltages are correct, call the next level of support.

• If these voltages are not correct, see “LVPS/HVPS card” on page 5-4, or replace the controller card. See “Controller card removal” on page 4-17.

Note: The main motor is not a service part.

Diagnostic information 2-29

4506-1xx

Paper feed service checks

Paper jam error indication during POST

FRU Action

Fuser (exit sensor) Paper pick assembly

(input sensor)

Paper pick assembly (Input sensor)

Fuser (exit sensor)

If the exit sensor flag is not resting within the paper exit sensor during POST, the printer displays a paper jam message. Make sure the flag is operating freely and is correctly installed. Make sure the wire spring in the top cover is properly positioned relative to the sensor. See the photo on page 4-11.

Make sure the paper sensors are working properly. A stuck or incorrectly installed sensor causes this error.

Paper picks during POST and/or continuously

FRU Action

Paper pick assembly Check the clutch area. Verify the solenoid spring which holds the lever in place is

attached properly. Replace the assembly as necessary.

Paper picks but stops halfway through the printer

FRU Action

Transfer card and input sensor assembly

Paper pick assembly Fuser Miscellaneous cable

assembly

• The printer indicates where the jam occurs.

- A 200 paper jam (see “200 Paper jam at the input sensor” on

page 2-14) indicates the paper did not activate the input sensor. Access

this jam through the front and rear doors.

- A 201 jam (see “201 Paper jams between the input sensor and exit

sensor” on page 2-14) indicates the paper activated the input sensor,

but did not make it to the exit sensor. Access this jam through the rear and top doors.

- A 202 jam (see “202 Paper jams as a printed job exits the printer.” on

page 2-15) indicates the paper has not cleared the exit sensor. Access

this jam through the rear and top cover doors.

• Check the paper path for any obstruction that could cause a jam.

• Inspect the input sensor and exit sensor mechanisms.

Note: The input sensor is soldered on the transfer card and input sensor assembly. The flag for this sensor is part of the paper picking assembly. The cable connecting the card to the controller card is available in the miscellaneous cable assembly.

The exit sensor and flag are part of the fuser assembly and are not service items alone. The cable for the exit sensor is part of the miscellaneous cable assembly.

2-30 Service Manual

4506-1xx

Paper never picks

FRU Action

Paper pick assembly Open the left cover, and verify the solenoid and clutch are functioning when an

attempt is made to feed the paper.

• If the shaft of the assembly rotates and paper does not move, remove the picking assembly and inspect the pick roll and pad. Replace the assembly if necessary.

• If the shaft does not rotate, observe the solenoid when a paper pick is requested. If the solenoid does not function, do the following:

With the printer off, disconnect the solenoid at J10 on the controller card. Turn the printer on and verify +24 V dc on pin 1 of the card connector.

- If the voltage fails, check the controller card. See “Controller card

service check” on page 2-24.

- If the voltage is correct, replace the paper pick assembly. See “Paper

pick assembly removal” on page 4-15.

- If the solenoid is functioning, remove the assembly and check for

blockage. Replace the assembly if necessary. See “Paper pick

assembly removal” on page 4-15.

Paper occasionally mispicks or picks multiple sheets at once

FRU Action

Tray Check the tray for paper catch points.

Do not mix paper types in the tray.

Paper pick assembly Remove the left side cover and observe the solenoid when a paper pick is

requested. If the solenoid does not function, do the following: With the printer off, disconnect the solenoid at J10 on the controller card. Turn

the printer on and verify +24 V dc on pin 1 of the card connector.

• If the voltage fails, check the controller card. See “Controller card service

check” on page 2-24.

• If the voltage is correct, replace the paper pick assembly. See “Paper pick

assembly removal” on page 4-15.

• Occasional mispicks (pick without a request) is typically caused by a faulty clutch assembly. Replace the paper pick assembly. See “Paper pick

assembly removal” on page 4-15.

• Multiple-sheet feeds following a request is a failure of the paper separation pad. Remove the assembly to inspect the pads and paper path. Replace the assembly if necessary.

Diagnostic information 2-31

4506-1xx

Paper “trees,” wrinkles, stacks poorly, or curls

FRU Action

Fuser This problem is most likely due to a worn backup roll. It causes the printer to run

Print quality servic e chec k s

Note: Ensure the covers are in place. An opening may allow light to expose the photoconductor, resulting in a ‘dirty’ print. Extreme environmental conditions, temperatures, and humidity will affect the print quality.

Using print quality test pages

To help isolate print quality problems, like streaking, print test pages using the print quality test pages.

hotter than required for the media being printed. Excessive heat can cause paper treeing problems, poor stacking, or curl. Replace the fuser. See “Fuser

removal” on page 4-20.

Print the menu sheet (press and release with the printer in ready mode). Look at the paper settings. Some, such as card stock or rough texture may

require a higher fuser temperature, which leads to more of these problems (except stacking) in plain paper.

• Change settings using the printer driver.

• Use the local printer setup utility (included on the CD) to change the NVRAM settings.

Try a different ream of paper. Moist paper has a higher tendency to crease (treeing) and curl.

A contaminated thermistor can cause the fuser temperature to be elevated. The fuser has to be removed to determine contamination. A worn or damaged hot roll can also cause the media to experience a higher temperature than appropriate for the selected media. Try settings for lower temperature media (light weight, smooth finish) before replacing the fuser.

Model E120

To print the print quality test pages:

1. Enter Diagnostics mode: a. Turn off the printer. b. Open the front access cover. c. Turn on the printer while pressing and holding . d. When the light stays on, close the cover. e. Wait (approximately 10 seconds) until the printer drive activates.

2. Press and release .

The Ready/Data light will be on solid.

3. Press and hold until all the lights flash to initiate printing the quality test pages. The error log (history)

will also print. The first four pages print to help you evaluate print quality. The first page has various fonts, the second page is gray, the third page is black, and the last page is blank. The following pages list errors and other

printer information.

Use the test pages to isolate problems such as light or toner streaks. The following pages identify solutions for most print quality problems.

To exit print quality test pages, turn the printer off.

2-32 Service Manual

4506-1xx

Model E120n

To print the print quality test pages:

1. Enter the Configuration menu. a. Turn off the printer. b. Open the front access cover. c. Turn on the printer while pressing and holding . d. When the light stays on, close the cover. e. Wait (approximately 10 seconds) until the printer drive activates.

2. Slowly press and release three times until the and lights come on.

3. Press and hold until all the lights flash to initiate printing the quality test pages.

Three pages print to help you evaluate print quality. The first page has various fonts, the second page is gray, and the third page is black. Once the paper exits into the output bin, the printer returns to the home state (four top lights on).

Use the test pages to isolate problems such as light or toner streaks. See “POST symptom table” on

page 2-22 for solutions to these problems.

To exit the Configuration menu, turn the printer off.

Blank page

FRU Action

Toner cartridge (not a FRU)

Printhead LVPS/HVPS Controller card

Remove the toner cartridge, and gently shake it to evenly distribute the toner. Check the cartridge for damage or contamination. Straighten or clean it as

necessary. Try a different toner cartridge.

Blank pages can be caused by a defective printhead assembly, LVPS/HVPS, or controller card.

Note: Printhead errors typically result in printer service errors. A blocked or absent laser beam will result in a blank page. Check for blockage of the beam or dust on the lens.

If these steps fail, replace the LVPS/HVPS, controller, or printhead in that order.

Diagnostic information 2-33

4506-1xx

Black page

Note: Incorrect laser exposure or incorrect charging of the photoconductor causes an all black page. Always

verify the same results from a different toner cartridge assembly and developer before proceeding.

FRU Action

PC kit (not a FRU) Toner electrodes (not

a FRU)

LVPS/HVPS board Controller card

Check the three electrical contacts at the right rear of the toner cartridge assembly for contamination or damage. Correct them as necessary.

Check continuity between the spring behind the LVPS/HVPS (DEV, TAR, and doctor blade) contact tips for the toner cartridge assembly. If continuity fails, call the next level of service.

Check the contact for the PC kit. No charge on the charge roll will result in a black page. Try a different PC kit.

With the printer off, disconnect the cable from CN402 on the LVPS/HVPS card. Turn the printer on, and verify +24 V dc on pins 18, 16, 15, 14, 13, and 12 on the

connector. With the printer off, verify the ground on pins 2, 4. 6, 8, and 17.

• If the voltage is incorrect, replace the LVPS/HVPS board. See “LVPS/HVPS

removal” on page 4-19.

• If voltage is correct and the toner electrodes are good, check continuity on the cable. Replace the cable if necessary.

As much as possible, check the cable while in plugged position but not plugged. Flat cables open when bent but close when straightened.

• If voltages are correct and the cable is good, check the controller card. See

“Controller card service check” on page 2-24.

Heavy background

Poor development or poorly charged toner particles cause excessive background. This is more noticeable as the toner cartridge nears end-of-life.

FRU Action

Toner cartridge (not a FRU) PC Kit (not a FRU)

LVPS/HVPS Controller card

Check the toner darkness setting in the driver. Try a lower setting. Make sure the toner cartridge and PC Kit are correctly installed and the high

voltage contacts are clean. If the toner cartridge and PC Kit are installed correctly, try a new PC Kit first and

then try a new toner cartridge. Check the darkness setting.

Check the contacts for correct installation and contamination where contact is made between the toner cartridge assembly and the LVPS/HVPS board. Clean the contacts as necessary.

If this does not correct the problem, replace the following FRUs one at a time in the order shown:

• LVPS/HVPS board

• Controller card

2-34 Service Manual

4506-1xx

Partial blank image/white spots (no periodic pattern)

FRU Action

Toner cartridge (not a FRU)

Paper (not a FRU) Make sure recommended paper is being used.

Remove the toner cartridge assembly, and gently shake the assembly to evenly distribute the toner.

Check to make sure the dust cover is in place and in use. If the dust cover is not in place, spotting can result.

Check to make sure the laser light path is not blocked. If the toner cartridge is low, try a new one.

Variation in image density horizontally across page

FRU Action

PC Kit (not a FRU) The charge roll may have an unbalanced pressure against the PC

Tr a n s fe r ro ll Warning: Do not touch the black portion of the transfer roll.

(photoconductor) drum. Try a new PC Kit.

Check the springs in the left and right transfer roll bearings. The bearing assemblies should support the transfer roll, applying even pressure to the PC drum.

Replace the transfer roll assembly if the springs or bearing show signs of damage or fatigue.

Inspect the transfer roll for signs of wear, damage, or contamination. Replace the transfer roll as necessary.

Rear door Check pivots.

Check for spring damage. Check for interferences. Check the latching operation.

Poor fusing of image

FRU Action

Fuser The fuser may not be operating at the proper temperature to fuse the toner to the

Paper (not a FRU) Make sure recommended paper is being used.

paper. See“Hot fuser service check” on page 2-27 for more information.

Diagnostic information 2-35

4506-1xx

Light print

FRU Action

Toner cartridge (not a FRU)

Tr a n s fe r ro ll LVPS/HVPS board

Print a menu page (press and release when the printer is in the ready state) and check for the correct media type setting.

Check darkness in the printer driver. Make sure the toner cartridge and PC kit are installed correctly and that the toner

cartridge is not low on toner. If the problem continues, install a new toner cartridge. Recheck the condition of the PC Kit before replacing it (if necessary).

Check the transfer roll for signs of toner buildup and contamination. Inspect the HVPS contact (transfer roll) for contamination. Verify the high voltage cable is plugged into the LVPS/HVPS. If all components appear free of contamination, replace the following FRUs one

at a time in the order shown:

• Transfer roll

• LVPS/HVPS board

White or black lines or bands

FRU Action

Toner cartridge (not a FRU)

Banding appears as light or dark horizontal lines on a uniformly gray page or on a page with a large area of graphics. Banding is primarily due to a variation in the speed of the paper as it feeds through the printer, especially in the developer and transfer process. It can also be a result of overly moist or dry environments.

Check to make sure the laser light is not blocked while the printer is turned off. Inspect the toner cartridge, paper feed components, the drive coupler, and drive

gears for debris, binds, or damage. (The coupler retracts when the front door is opened.) Close the door and inspect the previously mentioned areas from the rear of the printer. Try a new ream of paper.

PC Kit (not a FRU) Check the charge roll for a discoloration pattern that matches the row pattern on

2-36 Service Manual

the pages. If the pattern is present, try a different PCU.

4506-1xx

Toner on back of page

FRU Action

PC Kit (not a FRU) Print a menu page (press and release when the printer is in the ready state)

Fuser The fuser hot roll can cause toner deposits on the back of the paper if toner is

Transfer roll Check to make sure that the paper size being used is large enough for the image

and check settings for the correct media type. Inspect the overall paper path for signs of spilled toner. Gently clean the contaminated areas with a soft cloth.

building up on the hot roll. This buildup may transfer to the backup roll, later transferring to the back of the paper.

Inspect the hot roll and backup roller for signs of contamination. Replace the fuser as necessary.

settings in the driver. Printing the images off of the paper will transfer the toner to the transfer roll, and then to the back of the page. Correct the paper size or the settings and run test pages to clear up the roll.

A transfer roll contaminated with toner can cause toner to transfer to the back of printed pages.

Inspect the transfer roll for contamination, and replace it as necessary.

Solving print quality problems

To solve many print quality problems, replace supply or maintenance items that have reached the end of their intended life. Use the following table for solutions. For defects repeating down the page at a fixed distance, see the chart at the back of the book to determine the cause.

Symptom Cause Solution

White lines • The toner cartridge or the fuser

ABCDE

may be defective.

• The laser beam’s path may be blocked in a certain area of the lens.

ABCDE ABCDE

Streaked horizontal lines

If the lines are parallel to lines that are supposed to be there, see

“Ghost images” on page 2-38.

The toner cartridge or the fuser may be defective, empty, or worn.

• Replace the toner cartridge or the fuser, as needed.

• Check the lens opening (above the toner cartridge) for debris. Remove particles.

Replace the toner cartridge or the fuser, as needed.

Diagnostic information 2-37

4506-1xx

Symptom Cause Solution

Streaked vertical lines • The toner is smeared before

Print irregularities • The paper has absorbed

ABCDE ABCDE

fusing to the paper.

• The toner cartridge is defective.

• The PCU cleaner is full.

moisture due to high humidity.

• The paper may not meet printer specifications.

• The fuser is worn or defective.

ABCDE

Light print • The Toner Darkness setting is

too light.

• The paper may not meet printer specifications.

• The toner cartridge is low.

• The toner cartridge is defective.

• If paper is stiff, try feeding from the priority feeder.

• Replace the toner cartridge.

• Replace the PCU kit.

• Load paper from a fresh package.

• Avoid textured paper with rough finishes.

• Check to make sure that the dust cover is in place and in use. (Absence of the dust cover will cause spotting.)

• Make sure the printer driver paper type setting matches the type of paper being used.

• Replace the fuser.

• Select a different Toner Darkness setting from the printer driver before sending the job to print.

• Try paper from a new package.

• Avoid textured paper with rough finishes.

• Make sure paper loaded in the tray is not damp.

• Replace the toner cartridge.

Dark print • The Toner Darkness setting is

Poor transparency print quality

(Print has inappropriate light or dark spots, toner is smeared, or horizontal or vertical light bands appear.)

Toner specks • The toner cartridge is defective.

too dark (check driver)

• The toner cartridge is defective.

• The transparencies may not meet printer specifications.

• The Form Type setting in the printer driver is set to a media other than transparency.

• The fuser is worn or defective.

• Toner is in the paper path.

• The long-life photoconductor kit is exhausted.

• Select a different Toner Darkness setting from the printer driver before sending the job to print.

• Replace the toner cartridge.

• Use only transparencies recommended by the printer manufacturer (use care not to touch transparency surfaces with your fingers).

• Make sure the Form Type setting is set to transparency.

• Replace the toner cartridge.

• Replace the fuser.

• Remove toner.

• Replace the long-life photoconductor kit.

2-38 Service Manual

4506-1xx

Symptom Cause Solution

Toner rubs off paper easily when sheets are handled

Gray background • The Toner Darkness setting is

ABCDE

• The Paper Texture setting is wrong for the type of paper or specialty media being used.

• The Paper Weight setting is wrong for the type of paper or specialty media being used.

• The fuser is worn or defective.

too dark or too light.

• The toner cartridge is defective.

• The long-life photoconductor kit is exhausted.

ABCDE ABCDE

Uneven print density The toner cartridge is running low on

ABCDE

toner.

The toner cartridge is defective.

ABCDE ABCDE

• Change the Paper Texture from Normal to Smooth or Rough.

This setting can be changed using the Local Printer Setup Utility (Windows), or through Printer Settings (Macintosh). See the Software and Documentation CD for additional information.

• Change the Paper Weight from Plain to Card Stock (or another appropriate weight).

• Replace the fuser.

• Select a different Toner Darkness setting from the printer driver before sending the job to print.

• First, remove and reset the toner cartridge. If the problem persists, replace the toner cartridge.

• Replace the long-life photoconductor kit.

Remove the toner cartridge and shake it gently left to right to redistribute the remaining toner.Reprint the pages.

Remove and reset the toner cartridge. If the problem persists, replace the toner cartridge.

Check the springs on the front door which push on the cartridge when the front door is closed.

Ghost images The Form Type setting in the printer

driver is incorrectly set.

Make sure the Form Type setting is correct for the paper or specialty media used.

Diagnostic information 2-39

4506-1xx

Symptom Cause Solution

Specifically located ghost images

Grouped streaks along the left or right (not shown) side of the printed page

The long-life photoconductor kit is exhausted.

Note: From the top of the image to the top of the ghost is 71mm.

The long-life photoconductor kit is exhausted.

Note: Streaks repeat at 71mm intervals.

Replace the long-life photoconductor kit.

Streaks appear on the page.

Uneven printing

ABCDE

The long-life photoconductor kit is exhausted.

The toner cartridge is not properly installed.

Note: Unevenness reoccurs at 71mm intervals.

ABCDE

(Print voids occur on the right hand side of the page.)

Incorrect margins The Form Size setting in the printer

driver is different from the paper size loaded in the tray. For example, A4 size paper is loaded into the tray, but the Form Size setting is not set to A4.

Replace the long-life photoconductor kit.

• Remove and then reinsert the toner cartridge.

• Check the springs on the front door which push against the cartridge when the door is closed.

Change the Form Size setting to the appropriate size.

2-40 Service Manual

4506-1xx

Symptom Cause Solution

Skewed print (Print is inappropriately

slanted.)

Blank pages The toner cartridge is defective or

Solid black pages • The toner cartridge is defective.

• The tray guide is not in the correct position.

• The priority feeder guides are not in the correct position for the paper size loaded in the feeder.

• Contaminated pick roll and/or separator pad

empty. Contacts are blocked Laser light is blocked or not present

• The printer requires service.

• The long-life photoconductor kit is defective.

• Reposition the guide to fit lightly against the paper stack.

• Reposition the priority feeder guides to fit lightly against the print media.

• Check the transfer roll springs for free operation.

• Check the rear door latching.

• Remove debris from the pick roll and/or separator pad.

• Remove and clean the paper pick assembly. See “Paper pick

assembly removal” on page 4-15

for more information.

• First, remove and reset the toner cartridge. If problem persists, replace the toner cartridge.

• Check and clear contacts.

See “Blank page” on page 2-32 for more information.

• First, remove and reset the toner cartridge. If problem persists, replace the toner cartridge.

• Check the PC contacts

• Replace the long-life photoconductor kit.

See “Black page” on page 2-33 for more information.

Paper (except card stock) curls badly as it exits the bin.

Printhead service check

FRU Action

Printhead

The Paper Texture setting is wrong for the type of paper or specialty media being used.

1. Unplug the printer.

2. Disconnect the printhead cables from J12 and J13 on the controller card. Turn the printer on.

3. On the controller card, verify +24 V dc on pin 5 at J12 and +5 V dc on pin 5 at J13. Be sure the front and rear doors are closed when checking.

4. Verify grounds on pin 4 at J12 and on pin 6 at J13.

- If voltages or grounds are incorrect, check the controller card. See

“Controller card service check” on page 2-24 for more information.

- If voltages are correct, replace the printhead (comes with cables). See

“Printhead removal” on page 4-12.

- A faulty printhead will typically be indicated in a service error.

Change the Paper Texture from Rough to Normal or Smooth.

This setting can be changed using the Local Printer Setup Utility (Windows) or through Printer Settings (Macintosh). See the Software and Documen tat ion CD for additional information.

Diagnostic information 2-41

4506-1xx

Transfer roll service check

FRU Action

Check the transfer roll area for debris, and clean the area as necessary. Verify continuity between the spring below the left side (facing the rear of the

printer) bearing and the conical compression spring on the left side of the door. Verify continuity in the spring and the cable connection on the LVPS/HVPS.

Tr a n s fe r ro ll

Inspect the roll for signs of wear or damage and replace it if necessary.

Tr a n s fe r ro ll Rear door assembly

See “Paper “trees,” wrinkles, stacks poorly, or curls” on page 2-31 for symptoms of transfer roll problems.

Warning: The transfer roll should not be touched except on gear and metal shaft.

The conical shaped spring on the left side of the rear door (facing the rear of the printer) contacts the transfer card and input sensor assembly when the door is closed.

• Make sure the contacts are clean.

• Inspect the spring (cone-shaped on one end and cylinder-shaped on the other end) Clean and remove any debris from the spring and contact with the bearing of the transfer roll.

Note: The spring does not directly contact the transfer roll shaft. Therefore a

continuity check cannot be made between the shaft and spring. Check continuity between the left side of the anti-static brush base and the semicircular wire form on the right side of the door. Clean the contact as necessary including the one made between the wire form and frame as the door is closed. This is only a grounding circuit, not part of the high voltage circuit.

Push the ends of the transfer roll against the springs. The bearings should move up and down smoothly. Rotate the roll using the gear. It should rotate uniformly and freely. Inspect the transfer roll for contamination. Replace it as necessary.

Inspect the rear door assembly for any damage and replace it as necessary.

2-42 Service Manual

4506-1xx

3. Diagnostic aids

This chapter explains the tests and procedures to identify printer failures and to verify that repairs have corrected the problem.

There are different test menus that can be accessed during POR to identify problems with the printer.

Service menus—E120

Printi ng men u s

To enter Diagnostics mode, turn off the printer, open the front access cover, press and hold while turning on the printer. Close the cover when the light displays.

Print menus by pressing and holding until the lights flash. See “Diagnostics mode printout sample” on

page 3-2.

Moving around the menu

The menu items are designated by the non-indented items listed along the left edge of the page (bottom as printed from the printer). These items are also un-shaded.

• Press and release to move sequentially from one menu item to another.

• Press and hold to jump to home state (top four lights on).

• Press and release to move through the menu settings.

This action rotates only through the possible settings of the selected menu item.

Diagnostic aids 3-1

4506-1xx

Diagnostics mode printout sample

3-2 Service Manual

4506-1xx

Diagnos tics mode desc rip tio ns

Development

Menu item Use setting to Value

Print quality pages Print the print quality test pages and history

Defaults Change default media sizes and designations from

Service menus—E120n

Printi ng men u s

Diagnostics mode

To enter Diagnostics mode, turn off the printer, open the front access cover, and press and hold while turning on the printer. Close the cover when the light displays.

information by pressing and holding until the lights flash.

Help isolate print quality problems, such as streaking. Four or more pages print:

• A text page with printer information, cartridge information, current margin settings, and a graphic

• Two pages with graphics

• A blank page

• An error log (history)

Note: The cartridge lockout function is disabled.

U.S. to non-U.S. to metric.

U.S. (default) Non-U.S.

Print menus by pressing and holding until the lights flash. See “Diagnostics mode printout sample” on

page 3-4.

Configuration menu

To enter Configuration menu, turn off the printer, open the front access cover, turn on the printer while pressing and holding , and close the cover once the light displays.

Print menus by pressing and holding until the lights flash. See “Configuration menu printout sample” on

page 3-7

Moving around the menu

The menu items are designated by the non-indented items listed along the left edge of the page (bottom as printed from the printer). These items are also un-shaded.

• Press and release to move sequentially from one menu item to another.

• Press and hold to jump to the home state (top four lights on).

• Press and release to move through the menu settings (indicated by the and lights).

This action rotates only through the possible settings of the selected menu item.

Diagnostic aids 3-3

4506-1xx

Diagnostics mode printout sample

3-4 Service Manual

4506-1xx

Diagnostics mode descriptions

To enter Diagnostics mode, do the following:

1. Turn the printer off.

2. Open the front access cover.

3. Press and hold while turning the printer on.

4. Close the cover when the light displays.

Print menus by pressing and holding until the lights flash.

Development

Menu item Use this setting to Value

Print quality pages Print test pages by pressing and holding until

Defaults Change sizes and designations to metric. U.S. (default)

Edge to Edge Allow a shift of all four margins (top, bottom, right,

Continuous print— simplex Tray 1

Print History Print a history of errors.

Configuration ID Allow the printer ID to match the label ID after the

the lights flash. Help isolate print quality problems, such as

streaking. The three pages print:

• A text page with printer information, cartridge information, current margin settings, and a graphic

• The two pages with graphics.

Note: The cartridge lockout function is disabled.

and left) to the physical edge of the page (printable area of supported paper).

Continuously print pages containing cross lines, printer information, and margin settings.

Press and hold until the lights flash to begin. Place the desired number of pages in the tray to

limit the printing.

Press and hold until the lights flash to print.

controller card is replaced.

Non-U.S. Off (default)

0x400D01 (default) 0x400D89

Diagnostic aids 3-5

4506-1xx

Network

Menu item Use this setting to Value

History Print a history of errors. (same as Print History)

Press and hold until the lights flash to print.

Mark History Append a tag to the history report to indicate the

most recent crashes.

History Mode Post the 976 error code to the user each time it

occurs. The default (modified) internally resets the posting but records it in the history. A substantial number of consecutive errors result in posting 976.

Dump NVRAM Print a hex dump of the network NVRAM partition.

Press and hold until the lights flash to initiate this action.

Reinit NVRAM Reset the network NVRAM to factory defaults.

Press and hold until the lights flash to initiate this action.

Meditech Mode Prevent the network card from accepting more

than one 9100 mode connection at a time.

Mark Do not mark (default) Modified (default) Every time

Ye s No (default)

3-6 Service Manual

4506-1xx

Configuration menu printout sample

Diagnostic aids 3-7

4506-1xx

Configuration menu descriptions

To enter the Configuration menu, turn off the printer, open the front access cover, turn on the printer while pressing and holding , and close the cover once the light displays.

Print menus by pressing and holding until the lights flash.

Utilities

Use the Utilities menu to troubleshoot printer problems.

Menu Item Use this setting to Values

Reset Factory Defaults Return the printer settings to factory default

Hex Trace Help isolate printing problems when unexpected

Print Quality Test Pages Help isolate print quality problems, such as

Reset Photoconductor Counter

values. Sometimes resetting the printer to the original

settings solves formatting problems. All menu items are reset to the factory default

values except:

• All settings in the Parallel, Network, LocalTalk, and USB menus.

• All downloaded resources (fonts, macros, and symbol sets) in printer memory (RAM) are deleted.

Resources in flash memory are unaffected.

characters print or characters are missing. Hex Trace helps determine if there is a problem

with the language interpreter or the cable by providing information about what the printer is receiving.

To exit Hex Trace, turn off the printer.

streaking. Four pages print to help evaluate print quality:

• A text page with printer information, cartridge information, current margin settings, and a graphic.

• Two pages with graphics.

• A blank page.

Return the photoconductor counter to zero. The replace photoconductor message should be

cleared only when the photoconductor kit has been replaced.

Off (default) On

3-8 Service Manual

4506-1xx

Setup

Use the Setup menu to configure how the printer formats the end of a line depending on the computer system being used.

Menu item Use this setting to Values

Demo Mode Put the printer into demo mode where internal

sheets print with each press of . To deactivate, turn the printer off, and re-enter the

configuration group. Set to Deactivate.

Auto CR After LF Specify whether the printer automatically performs

a carriage return after a line feed control command.

Auto LF after CR Specify whether the printer automatically performs

a line feed after a carriage return control command.

Energy Conserve On

Deactivate (default) Activate

Off (default) On

Off (default)

USB

Use the USB menu to change printer settings on jobs sent through a USB port.

Menu item Use setting to Values

NPA Mode Send print jobs to the printer and query printer

status information simultaneously.

MAC Binary PS Configure the printer to process Macintosh binary

PostScript print jobs.

Off On Auto (default) Off—The printer filters

PostScript print jobs using Standard protocol.

On—The printer processes raw binary PostScript print jobs from computers using the Macintosh operating system. This setting often causes Windows print jobs to fail.

Auto (default)—The printer processes print jobs from computers using either Windows or Macintosh operating systems.

Diagnostic aids 3-9

4506-1xx

Network

Use the network menu to change printer settings on jobs sent through a network port (either standard network or network opt <x>).

Menu item Use setting to Values

NPA Mode Send print jobs to the printer and query printer

status information simultaneously.

MAC Binary PS Configure the printer to process Macintosh binary

PostScript print jobs.

Set Card Speed Automatically detect the connection speed of your

network. This setting can be disabled to set the speed

manually.

Off Auto (default)

Off—The printer filters PostScript print jobs using Standard protocol.

On—The printer processes raw binary PostScript print jobs from computers using the Macintosh operating system. This setting often causes Windows print jobs to fail.

Auto (default)—The printer processes print jobs from computers using either Windows or Macintosh operating systems.

Auto (default)—The printer detects the current network speed.

10Mbps, half duplex—Forces the printer to try to connect to the network only at 10Mbps, half duplex.

10Mbps, full duplex—Forces the printer to try to connect to the network only at 10Mbps, full duplex.

100Mbps, half duplex— Forces the printer to try to connect to the network only at 100Mbps, half duplex.

100Mbps, full duple—Forces the printer to try to connect to the network only at 100Mbps, full duplex.

3-10 Service Manual

4506-1xx

4. Repair information

Warning: Read the following before handling electronic parts.

Handling ESD-sensitive parts

Many electronic products use parts that are known to be sensitive to electrostatic discharge (ESD). To prevent damage to ESD-sensitive parts, use the following instructions in addition to all the usual precautions, such as turning off power before removing logic boards:

• Keep the ESD-sensitive part in its original shipping container (a special “ESD bag”) until you are ready to

install the part into the printer.

• Make the least-possible movements with your body to prevent an increase of static electricity from clothing

fibers, carpets, and furniture.

• Put the ESD wrist strap on your wrist. Connect the wrist band to the system ground point. This discharges

any static 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 place the ESD-sensitive part on the printer cover or on a metal table; if you need to put down the

ESD-sensitive part for any reason, first put it into its special bag.

• Printer covers and metal tables can be electrical grounds. They increase the risk of damage because they

make a discharge path from your body through the ESD-sensitive part. (Large metal objects can be discharge paths without being grounded.)

• Prevent ESD-sensitive parts from being accidentally touched by other personnel. Install covers when you

leave the printer unattended and do not put unprotected ESD-sensitive parts on a table.

• If possible, keep all ESD-sensitive parts in a grounded metal cabinet (case).

• Be extra careful in working with ESD-sensitive parts when cold-weather heating is used because low

humidity increases static electricity.

Repair information 4-1

4506-1xx

Adjustment procedures

Printhead assembly adjustment

A printhead needs to be correctly positioned after it has been removed. Align it to the frame or use the same position as the removed printhead.

Skew is caused by a sheet being fed through the printer while misaligned. The entire image is rotated relative to the sheet edges. However, a misaligned printhead causes the horizontal lines to appear skewed while the vertical lines remain parallel to the vertical edges.

Skew Printhead

There are no adjustments for skew. Check the pick roll (paper pick assembly) for wear, the paper path for obstructions, the fuser for proper setting, and the tray paper guides for fit to the media.

To align the printhead:

misalignment

1. For the E120n model—Enter the Diagnostics Menu. See “Service menus—E120n” on page 3-3, and

print the Cont Prt Simplex Tray 1 (Quick Test).

Note: In order to limit the number of printouts, place only one sheet at a time in the main tray.

For the E120 model—The E120 can be adjusted in the same manner as the E120n. However, this model

does not print the same sheet. You may have to find or create a page with lines going horizontally across the page. Otherwise, follow the same procedure to adjust the printhead.

2. Fold the printed test page on the left side so that a few millimeters of grid lines wrap around the outside of

the fold.

3. Fold a second vertical fold near the center so that the left side top edge aligns with the right side top edge.

4-2 Service Manual

4506-1xx

4. If the top margin of the grid lines of the right flap is greater than the top margin of the grid lines on the left

flap, adjust the printhead clockwise relative to the printer and recheck. See the left side of the figure below. Adjust the printhead counterclockwise if the left side grid lines extend below the right side. See the right side of the figure below.

5. After obtaining a properly adjusted image on the paper, tighten all three screws.

Repair information 4-3

4506-1xx

Removal procedures

CAUTION: Remove the power cord from the printer or electrical outlet before you connect or

disconnect any cable, electronic board, or assembly for personal safety and to prevent damage to the printer. Disconnect any connections between the printer and PCs/peripherals.

Note: Some removal procedures may require removing cable ties. If so, you must replace the cable ties during reassembly to avoid pinching wires, obstructing the paper path, or restricting mechanical movement.

Note: Before beginning any removal, remove the toner cartridge and PC kit. Warning: Cover the PC kit to block light to the PC drum. It can be damaged by excessive light.

Extender co ve r rem o v a l

1. Rotate the extender cover (A) toward the front of the printer.

2. Pinch the pivot on the extender cover and remove it.

Tray cover removal

Lift and pull out the tray cover.

4-4 Service Manual

4506-1xx

Main tray remo v al

1. Remove the tray cover. See “Tray cover removal” on page 4-4.

2. Align the front of the printer with the front edge of the table.

3. Put pressure with your thumb in the center of the tray and pull out.

Left cover removal

1. Open the rear door and remove the screw (A).

Repair information 4-5

4506-1xx

2. Remove the screw (B).

3. Pull the cover away from the printer and lift to remove it.

4-6 Service Manual

4506-1xx

Right cover removal

1. Open the rear door and remove the lower right screw (A).

2. Open the front door and remove the screw (B).

Repair information 4-7

4506-1xx

3. Pull the front of the cover to unlatch (B), pull the bottom out, and lift the cover to removeit.

Front door assembly removal

1. Remove the left cover. See “Left cover removal” on page 4-5.

2. Remove the right cover. See “Right cover removal” on page 4-7.

3. Grasp the right pivot and remove it from the pivot shaft (A).

4. Gently slide the front door toward the left side while lifting to the right side.

5. Once the left pivot is separated, lift the front door away from the printer.

4-8 Service Manual

4506-1xx

Top cover assembly removal

1. Remove the front door assembly. See “Front door assembly removal” on page 4-8.

2. Remove the two screws (A) from the front of the printer.

3. Remove the two screws (B) from the back of the printer.

Repair information 4-9

4506-1xx

4. Lift the front of the cover and unhook the rear.

4-10 Service Manual

4506-1xx

Reinstallation note: Close the top door before reinstalling the top cover. When the top cover is in place, open

the top door and press vertically on the front leg of the flag. It should rotate downward and return by the force of the cantilever spring in the cover.

Repair information 4-11

4506-1xx

Printhead removal

1. Remove the top cover. See “Top cover assembly removal” on page 4-9.

2. Remove the three screws (A).

3. Disconnect the printhead cables at J12 and J13 on the controller card.

4. Remove the printhead.

Note: After reinstalling the printhead, check the alignment. If necessary, perform the “Printhead assembly

adjustment” on page 4-2 before the final reinstallation of the top cover.

Transfer roll assembly

1. Turn the back of the printer to face you.

2. Open the back door.

3. Lift the right side of the transfer roll until the shaft unsnaps from the bearing (A).

4. Pull the roll to the right and slide the left end of the shaft from the bearing.

4-12 Service Manual

4506-1xx

Rear door assembly

Note: Be careful not to touch the transfer roll during this removal.

1. Open the rear door.

2. Remove the two screws (A).

3. Remove the transfer card cover (B).

AA B

4. Press the right side door stop (C) to the left and rotate the cover slightly to free the stop.

5. Detach the right hinge from its pivot (D) with a short, quick motion.

Repair information 4-13

4506-1xx

6. Press the left side door stop (E) to free it from the printer.

7. Pull out the left side of the rear door.

Transfer card and input sensor assembly removal

1. Remove the left cover. See “Left cover removal” on page 4-5.

2. Remove the rear door assembly. See “Rear door assembly” on page 4-13.

3. Remove the three screws (A).

4-14 Service Manual

4506-1xx

4. Disconnect the cable (B) from the controller card at J9.

5. Remove the card and cable assembly carefully by sliding the cable through the retainer (C).

Paper pick assembly removal

1. Remove the transfer card and input sensor assembly. See “Transfer card and input sensor assembly

removal” on page 4-14.

2. Remove the four screws (A).

Repair information 4-15

4506-1xx

3. Press the locking tab (B) on the gear hub while sliding the gear from the shaft.

4. Remove the gears and spring (C) from the shaft.

5. Disconnect the cable (D) from the controller card at J10.

6. Remove the paper pick assembly.

4-16 Service Manual

4506-1xx

Contr ol ler card remov al

Warning: Do not replace the operator panel and controller card at the same time. Each card contains the

printer settings. When either of these cards is new, it obtains some of the settings from the other card. Settings are lost when both are new and replaced at the same time.

1. Remove the left cover. See “Left cover removal” on page 4-5.

2. Disconnect all of the cables.

3. Remove the four screws (A).

4. Push the latch in the plastic standoff (B) using a screwdriver or spring hook while gently pulling the bottom

of the card away from the printer.

AB A

5. Remove the card.

6. When re-installing, be sure the printhead cable is routed through the upper right side of the controller card

cutout.

Repair information 4-17

4506-1xx

Operator panel removal (all models)

Warning: Do not replace the operator panel and controller card at the same time. Each card contains the

printer settings. When either of these cards is new, it obtains some of the settings from the other card. Settings are lost when both are new and replaced at the same time.

1. Remove the left cover. See “Left cover removal” on page 4-5.

2. Disconnect the cable from the controller card at J16.

3. Remove the two screws (A).

4. Remove the card assembly.

Warning: Do not change the operator panel at the same time as you change a controller card. Special settings

will be lost.

4-18 Service Manual

4506-1xx

LVPS /HVPS removal

1. Remove the right cover. See “Right cover removal” on page 4-7.

2. Disconnect the three cables (A) connected to the LVPS/HVPS card.

3. Remove the four common screws (B) and the unique screw (C).

4. Squeeze the latch (D) to free the card.

Repair information 4-19

4506-1xx

Fuser removal

1. Remove the top cover assembly. See “Top cover assembly removal” on page 4-9.

2. Remove the two screws (A).

3. Disconnect the cables from the LVPS/HVPS (CN403) and the controller card (J1 and J2).

4. Remove the fuser along with the sensor and cables.

4-20 Service Manual

4506-1xx

5. Locations and connections

Locations

Front view

Top door

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

Rear view

USB port

Ethernet port (E120n only)

Rear door release

Cable lock access point

Rear door

Power button

Power cord port

Locations and connections 5-1

4506-1xx

Connectors

Control ler car d

5-2 Service Manual

4506-1xx

Controller card connector pin values (only J2, thermistor, and J6 LVPS/HVPS connected)

Connector Pin # Value

J1 Exit sensor 1+5 V dc

2Ground

3+5 V dc

4Ground

J2 Thermistor 2Ground

J3 toner cartridge 1+5 V dc

J4 Main motor 2+5 V dc

3+5 V dc

4+5 V dc

5Ground

6+5 V dc

J5 USB

J6 LVPS/HVPS 16 +5 V dc

J9 Transfer 1+5 V dc

5+5 V dc

6Ground

7 +24 V dc

J10 Solenoid 1 +24 V dc

J11 Rear cover 2Ground

3Ground

4Ground

J12 Mirror motor 4Ground

5 +24 V dc

J13 LSU 1Ground

6Ground

8+5 V dc

J14 Front cover 1+5 V dc

2Ground

3Ground

4Ground

J15 Operator panel 1 +5 V dc

2+5 V dc

3+5 V dc

4Ground

6+5 V dc

7+5 V dc

8+5 V dc

Locations and connections 5-3

4506-1xx

LVPS/HVPS card

5-4 Service Manual

4506-1xx

LVPS/HVPS pin values (turn the switch on and unplug the cables except for the AC input)

Connector Pin # Value

CN402 12 +24 V dc

13 +24 V dc

14 +24 V dc

15 +24 V dc

16 +24 V dc

(F403Fused)

2 Ground

4 Ground

6 Ground

8 Ground

17 Ground

CN403 1 110/220 V ac

CN404 1 +24 V dc

+24 V dc

Locations and connections 5-5

4506-1xx

5-6 Service Manual

4506-1xx

6. Preventive maintenance

The E120 and E120n do not require preventive maintenance.

Preventive maintenance 6-1

4506-1xx

6-2 Service Manual

4506-1xx

7. Parts catalog

How to use this parts catalog

The following legend is used in the parts catalog:

Asmindex

Part number

Units/mach

Units/ FRU

Description

• Asm-index: Identifies the assembly and the item in the diagram. For example, 3-1 indicates Assembly 3

and item number 1 in the table.

• Part number: Identifies the unique number that identifies this FRU.

• Units/mach: Refers to the number of units actually used in the base printer.

• Units/FRU: Refers to the number of units packaged together and identified by the part number.

• NS: (Not shown) in the Asm-Index column indicates that the part is procurable but is not pictured in the

illustration.

• PP: (Parts Packet) in the parts description column indicates the part is contained in a parts packet.

• Model information used in the parts catalog:

Abbreviation used

E120 4506-100 Lexmark E120 Non-network

E120n 4506-110 Lexmark E120n Network

Machine type and model

Description

Network capability

Par ts catalog 7-1

LEXMARK E120, E120n Service Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Table of contents

Notices and safety information

Laser notice

Laser

Avis relatif à l’utilisation de laser

Avvertenze sui prodotti laser

Avisos sobre el láser

Declaração sobre Laser

Laserinformatie

Lasermeddelelse

Huomautus laserlaitteesta

Laser-notis

Laser-melding

Avís sobre el Làser

Consignes de sécurité

Norme di sicurezza

Sicherheitshinweise

Pautas de Seguridad

Informações de Segurança

Informació de Seguretat

Preface

1. General information

Maintenance approach

Models

Overview of the printer

E120 operator panel

E120n operator panel

Front view

Rear view

Specifications

Types of print media

Choosing appropriate print media

Storing print media

Tips on preventing jams

Tools

Acronyms

2. Diagnostic information

Start

Power-On Self Test (POST) sequence

Light patterns and error messages

Primary, secondary, and tertiary light patterns

Common primary and secondary light patterns

Service codes

Symptom tables

POST symptom table

Printer symptom table

Service checks

Controller card service check

Operator Panel Service Check

Dead machine service check

Fuser service check

LVPS/HVPS service check

Main motor service check

Paper feed service checks

Print quality servic e chec k s

Printhead service check

Transfer roll service check

3. Diagnostic aids

Printi ng men u s

Moving around the menu

Diagnostics mode printout sample

Diagnos tics mode desc rip tio ns

Printi ng men u s

Moving around the menu

Diagnostics mode printout sample

Diagnostics mode descriptions

Configuration menu printout sample

Configuration menu descriptions

4. Repair information

Handling ESD-sensitive parts

Adjustment procedures

Printhead assembly adjustment

Removal procedures

Extender co ve r rem o v a l

Tray cover removal

Main tray remo v al