Xerox PE 120 i, PE 120 Service Manual

Service

Manual

WorkCentre® PE120/120i

Service Manual

Warning

The following servicing instructions are for use by qualified service personnel only. To avoid personal
injury, do not perform any servicing other than that contained in the operating instructions, unless you
are qualified to do so.

First Printing: September 2004

071-0874-00

Copyright © 2004 Xerox Corporation. All Rights Reserved. Unpublished rights reserved under the copyright laws of the United States. Contents of
this publication may not be reproduced in any form without permission of Xerox Corporation.

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Contents

1 Precautions

1.1 Safety Warnings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1

1.2 Safety Cautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2

1.2.1 Toxic Material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2

1.2.2 Electric Shock and Fire Safety Precautions. . . . . . . . . . . . . . . . . . . . . . . . . .1-2

1.2.3 Handling Precautions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3

1.2.4 Assembly and Disassembly Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3

1.2.5 Bodily Injury Warnings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-4

1.3 ESD Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-5

2 Reference Information

2.1 Tools for Troubleshooting the system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1

2.2 Common Acronyms and Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-2

2.3 Selecting a Location for the system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-4

3 Specifications

3.1 General Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1

3.2 Electrical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-2

3.3 Environmental Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-2

3.4 Routine Maintenance Items and Consumables . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-2

3.5 Media Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-3

3.6 Print Engine Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-4

3.7 Scan Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-5

3.8 Copy Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-6

3.8.1 Telephone Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-7

3.9 Fax Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-8

4 Product Summary

4.1 Printer Components - Front View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-1

4.1.2 Rear View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-2

4.1.3 Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-3

4.2 System Layout. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-5

4.2.1 Scanner Paper Path . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-5

4.2.2 Print Engine Paper Path . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-5

4.2.3 Print Engine Paper Path Rollers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-6

4.3 System Summary. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-6

4.3.1 Paper Feed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-8

4.2.4 Transfer Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-8

4.2.5 Drive Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-8

4.2.6 Fuser Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-8

4.2.7 Laser Scanner Unit (LSU). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-9

4.2.8 Toner Cartridge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-10

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4.3 Main Controller Board (PBA). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-11

4.3.1 ASIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-12

4.3.2 Memory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-13

4.3.3 Flash Memory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-13

4.3.4 SDRAM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-13

4.3.5 Battery Backup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-13

4.3.6 Sensor Input Circuit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-13

4.4 Switching Mode Power Supply (SMPS) and High Voltage Power Supply (HVPS)4-15

4.4.1 High Voltage Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-15

4.4.2 Switching Mode Power Supply. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-17

4.4.3 Fuser AC Power Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-18

4.5 Engine F/W . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-18

4.5.1 Feeding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-18

4.5.2 Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-19

4.5.3 Transfer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-19

4.5.4 Fusing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-19

4.6 OPE (Control Panel) PBA. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-20

4.7 USB Host. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-20

4.8 Fax Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-20

4.8.1 Modem. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-20

4.8.2 LIU PBA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-21

4.8.3 Tel-Line Connection Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-21

4.8.4 Transformer Circuit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-22

4.8.5 On Hook State . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-22

4.8.6 Off Hook State. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-22

4.8.7 Signal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-23

5 Disassembly

5.1 Precautions for Disassembly/Reassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1

5.1.1 Precautions When Removing Circuit Boards . . . . . . . . . . . . . . . . . . . . . . . .5-1

5.2 Rear Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-2

5.3 Side Covers Right and Left . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-3

5.4 Front Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-4

5.5 Scanner Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-4

5.6 ADF Motor Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-8

5.7 OPE (Control Panel) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-9

5.8 Middle Cover and Exit Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-10

5.9 Controller Shield Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-11

5.10 Engine Shield and Exit Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-12

5.11 SMPS and LIU. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-13

5.12 Fuser Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-14

Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14

Heat Roller and Halogen Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14

Guide and Fuser Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14

Thermistor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15

5.13 Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-15

5.14 Laser Scanner Unit (LSU). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-16

5.15 CRUM Board. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-16

5.16 Drive Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-17

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5.17 Cover Mid Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-17

5.18 Transfer Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-18

5.19 Feed Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-18

5.20 Pick Up Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-20

MP or Main Cassette Pick Rollers . . . . . . . . . . . . . . . . . . . . . . . . . 5-21

6 Alignment and Adjustments

6.1 Paper Path . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-1

6.1.2 Copy and Scan Paper Path. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-2

6.1.3 Printer Paper Path . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-2

6.2 Clearing Paper Jams. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-3

6.2.1 Clearing ADF Jams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-4

6.2.1.1 ADF Misfeed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4

6.2.1.2 ADF Exit Misfeed or ADF Roller Misfeed . . . . . . . . . . . . . 6-4

6.2.2 Jam 0 - Paper in the Feed Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-5

6.2.3 Jam 1 - Paper in the Fuser Area or Around the Toner Cartridge. . . . . . . . . .6-5

6.2.4 Jam 2 - Paper in the Exit Area. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-6

6.2.5 MP Tray Jam - Paper in the Bypass Tray . . . . . . . . . . . . . . . . . . . . . . . . . . .6-6

6.3 Control Panel Menu. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-7

6.4 Tech Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-8

6.4.1 Entering Tech Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-8

6.4.2 Tech Mode Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-8

6.4.3 Data Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-8

6.4.4 Machine Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-10

6.4.5 Report . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-10

6.5 Engine Test Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-11

6.5.1 Entering Engine Test Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-11

6.5.3 Detailed Description Engine Test Mode . . . . . . . . . . . . . . . . . . . . . . . . . . .6-12

6.6 Identify Sale Date . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-13

6.8 Periodic Defective Image or Abnormal Printing. . . . . . . . . . . . . . . . . . . . . . . . . . .6-14

6.9 Error Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-15

7 Troubleshooting

7.1 Paper Feed Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-1

7.1.1 Wrong Print Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-1

7.1.2 Jam 0 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-1

7.1.3 Jam 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-2

7.1.4 Jam 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-2

7.2.5 Multiple Pick . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-3

7.2.6 Paper Rolled in the Fuser. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-3

7.2.7 Paper Rolled in the OPC Drum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-3

7.2.8 Defective ADF. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-4

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7.2 System Malfuction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-5

7.2.1 LCD Display is Defective . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-5

7.2.2 Defective Control Panel Keypad. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-5

7.2.3 Fuser Gear Melted Due to Overheating, Causing a Paper Jam . . . . . . . . . . .7-5

7.2.4 Paper Empty Error. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-6

7.2.5 Paper Empty Error Without Indication . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-6

7.2.6 Cover Open . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-6

7.2.7 No Error Message when the Cover is Open . . . . . . . . . . . . . . . . . . . . . . . . .7-6

7.2.8 Defective Motor Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-7

7.2.9 No Power. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-7

7.2.10 Printed Vertical Lines Become Curved. . . . . . . . . . . . . . . . . . . . . . . . . . . .7-7

7.3 Print Quality Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-8

7.3.1 Wrong Print Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-8

7.3.2 Vertical White Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-8

7.3.3 Horizontal Black Band . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-9

7.3.4 Black/White Spot. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-9

7.3.5 Light Image . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-10

7.3.6 Dark Image or Completely Black Print. . . . . . . . . . . . . . . . . . . . . . . . . . . .7-10

7.3.7 Uneven Density . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-11

7.3.8 Background Contamination. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-11

7.3.9 Ghosting 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-12

7.3.10 Ghosting 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-12

7.3.11 Ghosting 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-13

7.3.12 Ghosting 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-13

7.3.13 Stains on the Front of the Page . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-13

7.3.14 Stains on the Back of the Page . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-14

7.1.15 Blank Page is Printed 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-14

7.3.16 Blank Page is Printed 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-14

7.4 Fax and Phone Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-15

7.4.1 No Dial Tone . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-15

7.4.2 Defective MF Dial. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-15

7.4.3 Defective FAX FORWARD/RECEIVE . . . . . . . . . . . . . . . . . . . . . . . . . . .7-16

7.4.4 Defective FAX FORWARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-16

7.4.5 Defective FAX RECEIVE 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-16

7.4.6 Defective FAX RECEIVE 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-16

7.4.7 Defective FAX RECEIVE 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-17

7.4.8 Defective FAX RECEIVE 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-17

7.4.9 Defective Automatic Receiving. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-17

7.5 Copy Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-18

7.5.1 White Copies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-18

7.5.2 Black Copies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-18

7.5.3 Abnormal Noise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-18

7.5.4 Defective Image Quality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-18

7.6 Scanning Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-19

7.6.1 PC Scanning Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-19

7.6.2 Poor Quality Output of PC Scanned Images . . . . . . . . . . . . . . . . . . . . . . . .7-19

7.7 Toner Cartridge Servicing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-20

7.7.1 Precautions for Toner Cartridges. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-20

7.7.2 Toner Cartridge Life . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-20

7.7.3 Redistributing Toner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-20

Table of Contents

iv

7.9 Software Problems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-21

7.9.1 The Printer is Not Responding to the Print Command . . . . . . . . . . . . . . . .7-21

7.8.2 The Printer is Not Responding to a Print Command or

Strange Fonts are Printing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-21

7.8.3 SPOOL Error. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-22

7.9 Networking Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-22

8 Parts List

8.1 Main Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-2

8.2 Main Drive Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-5

8.3 ADF Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-6

8.4 Control Panel OPE Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-10

8.5 Scanner Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-12

8.6 Middle Cover Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-14

8.7 Frame Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-15

8.8 Fuser Unit Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-18

8.9 MP Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-20

8.10 Tray 1 (Cassette) Unit Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-22

8.11 Tray 2 (SCF - Optional Cassette) Unit Assembly. . . . . . . . . . . . . . . . . . . . . . . . .8-24

Xerox Options and Accessories. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-26

9Block Diagram

10 Connection Diagram

Service Manual 1-v

1-vi WorkCentre PE 120/120i

Precautions

Precautions

1

In order to prevent accidents and to prevent damage to the system, please read the precautions listed below
carefully before servicing the system.

1.1 Safety Warnings

1. Only to be serviced by appropriately qualified service engineers.

High voltages and lasers inside this product are dangerous. This system should only be serviced by a suitably
trained and qualified service engineer.

2. Use only Xerox replacement parts.

There are no user serviceable parts inside the system. Do not make any unauthorized changes or additions to
the system, these could cause the system to malfunction and create electric shock or fire hazards.

3. Laser Safety Statement: The system is certified in the U.S. to conform to the requirements of DHHS 21 CFR,

chapter 1 Subchapter J for Class 1 laser products, and elsewhere, it is certified as a Class 1 laser product
conforming to the requirements of IEC 825. Class 1 laser products are not considered to be hazardous. The
laser system and system are designed so there is never access to laser radiation above a Class 1 level during
normal operation, user maintenance, or prescribed service condition.

Warning

Never operate o r serv ice th e syst em with the p rotect ive cov er rem o ved from Laser assembly. The reflected
beam, although invisible, can damage your eyes. When using this product, these basic safety precautions
should always be followed to reduce the risk of fire, electrical shock, and bodily injury.

CAUTION - INVISIBLE LASER RADIATION

WHEN THIS COVER OPEN.

VORSICHT - UNSICHTBARE LASERSTRAHLUNG,

ATTENTION - RAYONNEMENT LASER INVISIBLE EN CAS

ATTENZIONE - RADIAZIONE LASER INVISIBILE IN CASO DI

PRECAUCION - RADIACION LASER IVISIBLE CUANDO SE ABRE.

ADVARSEL. - USYNLIG LASERSTRÅLNING VED ÅBNING, NÅR

ADVARSEL. - USYNLIG LASERSTRÅLNING NÅR DEKSEL

D’OUVERTURE. EXPOSITION DANGEREUSE
AU FAISCEAU.

APERTURA. EVITARE L’ESPOSIZIONE AL
FASCIO.

EVITAR EXPONERSE AL RAYO.

SIKKERHEDSBRYDERE ER UDE AF FUNKTION.
UNDGÅ UDSAETTELSE FOR STRÅLNING.

ÅPNES. STIRR IKKE INN I STRÅLEN.
UNNGÅ EKSPONERING FOR STRÅLEN.

VARNING - OSYNLIG LASERSTRÅLNING NÄR DENNA DEL

ÄR ÖPPNAD OCH SPÄRREN ÄR URKOPPLAD.
BETRAKTA EJ STRÅLEN. STRÅLEN ÄR FARLIG.

VAR O! - AVAT TAESSA JA SUOJALUKITUS OHITETTAESSA

OLET ALTTIINA NÄKYMÄTTÖMÄLLE LASER­SÄTEILYLLE ÄLÄ KATSO SÄTEESEEN.

DO NOT OPEN THIS COVER.

WENN ABDECKUNG GEÖFFNET.
NICHT DEM STRAHL AUSSETZEN.

Service Manual 1-1

Precautions

1.2 Safety Cautions

1.2.1 Toxic Material

This product contains toxic materials that can cause illness if ingested.

1. Please keep toner cartridges away from children. The toner powder contained in the toner cartridge can be

harmful and if swallowed you should contact a doctor immediately.

1.2.2 Electric Shock and Fire Safety Precautions

Failure to use the following instructions can cause electric shock or potentially cause a fire:

1. Use only the correct voltage, failure to do so could damage the system and potentially cause a fire or electric

shock.

2. Use only the power cable supplied with the system. Use of an incorrectly specified cable could cause the cable

to overheat and potentially cause a fire hazard.

3. Do not overload the po wer socket, this can lead to overheating of the cables inside the wall and could lead to a

fire hazard.

4. Do not allow water or other liquids to spill into the system, this can cause electric shock. Do not allow paper

clips, pins, or other foreign objects to fall into the system as these could cause a short circuit leading to electric
shock or fire hazard.

5. Never touch the plugs on either end of the power cable with wet hands, this can cause electric shock. When

servicing the system, remove the power plug from the wall socket.

6. Use caution when inserting or removing the power connector. The po wer connector must be inserted

completely otherwise poor contact could cause overheating possibly leading to a fire. When remo ving the
power connector, grip it firmly and pull.

7. Do not allow the power cable to become twisted, bent sharply around corners or become damaged. Do not

place objects on top of the power cable. If the power cable is damaged, it can overheat and cause a fire or
exposed cables can cause electrical shock. Replace a damaged power cable immediately , do not reuse or repair
the damaged cable. Some chemicals can eat through the coating on the power cable, weakening the cover, or
exposing cables causing fire and shock risks.

8. Ensure that the power sockets and plugs are not cracked or broken in any way. Any defects should be repaired

or replaced immediately. Take care not to cut or damage the power cable or plugs when moving the system.

9. Use caution during thunder or lightening storms. Xerox recommends that this system be disconnected from the

power source when these weather conditions are present. Do not touch the system or the po wer cord if it is still
connected to the wall socket in these weather conditions.

10. Avoid damp or dusty areas, install the system in a clean well ventilated location. Do not position the system

near a humidifier. Damp and dust build up inside the system can lead to overheating and cause a fire.

11. Do not position the system in direct sunlight. This will cause the temperature inside the system to rise leading

to the system failing to work properly and in extreme conditions could lead to a fire.

12. Do not insert any metal objects into the system through the ventilator fan or other parts of the casing, it could

come into contact with a high voltage conductor inside the system and cause an electric shock.

1-2 WorkCentre PE 120/120i

Precautions

1.2.3 Handling Precautions

The following instructions are for personal safety, to avoid injury, and to avoid damaging the system:

1. Ensure the system is installed on a level surface, capable of supporting its weight. Failure to do so could cause

the system to tip or fall.

2. The system contains many rollers, gears, and fans. Take great care to ensure that you do not catch your fingers,

hair, or clothing in any of these rotating devices.

3. Do not place any small metal objects, containers of water, chem icals, or other liquids close to the system which

if spilled could get into the system and cause damage, electric shock, or a fire hazard.

4. Do not install the system in areas with high dust or moisture levels, beside an open window, or close to a

humidifier or heater.

5. Do not place candles or burning cigarettes on the system. These can cause a fire.

1.2.4 Assembly and Disassembly Precautions

Always use Xerox parts. Take care to note the exact location of parts and cable routing before disassembling any
part of the system. Ensure all parts and cables are replaced correctly.

Please use the following procedures before disassembling or replacing any parts:

1. Check the contents of the system memory and make a note of any user settings. These will be erased if the

mainboard or network card is replaced.

2. Ensure that power is disconnected from the wall socket before servicing or replacing any electrical parts.

3. Disconnect system interface cables and power cables before servicing or replacing any parts.

4. Only use approved spare parts. Ensure that part number, product name, any voltage, current, or temperature

rating are correct.

5. When removing or re-fitting any parts do not use excessive force, especially when fitting screws into plastic.

6. Take care not to drop any small parts into the system.

Handling of the OPC Drum

The OPC Drum can be irreparably damaged if the following instructions are not used:

■ Exposure to light. Take care not to expose the OPC Drum either to direct sunlight or to fluorescent or

incandescent room lighting. Exposure for as little as 5 minutes can damage the surface photoconductive
properties and will result in print quality degradation. Take extra care when servicing the system. Remove
the OPC Drum and store it in a black bag or other lightproof container.

■ Take care when working with the covers open, as light is admitted to the OPC area and can damage the

OPC Drum.

■ Take care not to scratch the green surface of OPC Drum Unit.

■ If the green surface of the Drum Cartridge is scratched or touched, the print quality will be compromised.

Service Manual 1-3

Precautions

1.2.5 Bodily Injury Warnings

1. Use caution around internal components.

The fuser unit works at a high temperature. Use ca ution when working on the system. Wait for the fuser to cool
down before disassembly.

2. Use caution when working around rotating parts or moving gears.

When operating the system, do not put your hands into any moving parts (Paper feeding entrance, motor, fan,
etc.). Remove jewelry and loose clothing before servicing the system.

3. This system weighs

side of the system. Back injury could result if you do not lift the system properly.

4. Ensure the system is installed properly.

5. Ensure the system is installed on a flat, level surface, capable of supporting its weight. Failure to do so could

cause the system to tip or fall possibly causing personal injury or damaging the system.

6. Do not install the system on a sloping or unstable surface. After installation, double check that the system is

stable.

15.6 kg. Use safe lifting and handling techniques. Use the lifting handles located on each

1-4 WorkCentre PE 120/120i

Precautions

1.3 ESD Precautions

Some semiconductor components, and the respective sub-assemblies that contain them, are vulnerable to damage
by Electro-Static Discharge (ESD). These components include Integrated Circuits (ICs), Large-Scale Integrated
circuits (LSIs), field-effect transistors, and other semiconductor chip components. The following techniques will
reduce the occurrence of component damage caused by static electricity.

Be sure the power is off to the chassis or circuit board, and observe all other safety precautions.

■ Immediately before handling any semiconductor components assemblies, drain the electrostatic charge from

your body. This can be accomplished by touching an earth ground source or by wearing a wrist strap device
connected to an earth ground source. Wearing a wrist strap will also prevent accumulation of additional bodily
static charges. Be sure to remove the wrist strap before applying power to the unit under test to avoid potential
shock.

■ After removing a static sensitive assembly from its anti-static bag, place it on a grounded condu ctiv e surf ace. If

the anti-static bag is conductive, you may ground the bag and use it as a conductive surface.

■ Do not use freon-propelled chemicals. These can generate electrical charges sufficient to damage some

devices.

■ Do not remove a replacement component or electrical sub-assembly from its protective package until you are

ready to install it.

■ Immediately before removing the protective material from the leads of a replacement device, touch the

protective material to the chassis or circuit assembly into which the device will be installed.

■ Minimize body motions when handling unpackaged replace ment devices. Motion, such as your clothes

brushing together, or lifting a foot from a carpeted floor, can generate enough static electricity to damage an
electro-statically sensitive device

■ Handle IC’s and EPROM’s carefully to avoid bending pins.

■ Pay attention to the direction of parts when mounting or inserting them on Printed Circuit Boards (PCB’s).

Service Manual 1-5

Precautions

1-6 WorkCentre PE 120/120i

Reference Information

Reference Information

2

This section contains a tools list, list of abbreviations used in this manual, and a clearance required specification
when installing the WorkCentre PE120/120i.

2.1 Tools for Troubleshooting the system

The following tools are recommended for safe and easy troubleshooting as described in this service manual:

■ Digital Voltage Meter (DVM)

■ Screwdrivers

■ Tweezers

■ Cotton swabs

■ Cleaning equipment: dry, lint-free cloth and/or mild detergent

■ Type II Toner Vacuum

■ Soft bristle brush

Service Manual 2-1

Reference Information

2.2 Common Acronyms and Abbreviations

The following table covers the acronyms and abbreviations that may be used in this manual.

Definition Definition

AC Alternating Current EP Electro Photographic

ADC Analog-to-Digital Converter EPP Enhanced Parallel Port

AP Access Point F/W Firmware

ASIC Application Specific Integrated Circuit FCF/FCT Tray 1 or First Cassette Feeder

Ass’y Assembly FIFO First In First Out or Front In Front Out

BIOS Basic Input Output Sytem FISO Front In Side Out

BLDC Motor Brushless Dc Motor FPOT First Print Out Time

CMOS Complementary Metal Oxide

Semiconductor

CN or CON Connector HBP Host Based Printing

CPU Central Processing Unit HDD Hard Disk Drive

CRUM Customer Replaceable Unit Memory HTML Hyper Text Markup Language

dB Decibel HV High Voltage

dBA A Weighted Decibel HVPS High Voltage Power Supply

dBm Decibel Milliwatt I/F Interface

DC Direct Current I/O Input/Output

DCU Diagnostic Control Unit IC Integrated Circuit

DIMM Dual In-line Memory Module ICC International Color Consortium

DPI Dots Per Inch IDE Intelligent/integrated Drive Electronics

DRAM Dynamic Random Access Memory IEEE Institute of Electrical and Electronics

DVM Digital Voltmeter IIT Image Input Terminal (Scanner)

GDI Graphic Device Interface

GIF Graphic Interchange Format

GND Ground

Engineers, Inc.

ECM Error Correction Mode IOT Image Output Terminal (Print Engine)

ECP Enhanced Capability Port IPA Isopropyl Alcohol

ECU Engine Control Unit IPC Inter Process Communication

EEPROM Electronically Erasable

Programmable Read Only Memory

EMI Electro Magnetic Interference ITB Image Transfer Belt (Transfer Belt)

IPM Images Per Minute

2-2 WorkCenter PE 120/120i

Reference Information

Definition Definition

LAN Local Area Network PPM Pages Per Minute

lb. Pound(s) PS PostScript

LBP Laser Beam system PTL Pre-Transfer (Erase) Lamp

LCD Liquid Crystal Display PWM Pulse Width Moduration

LED Light Emitting Diode Q’ty Quantity

LSU Laser Scanner Unit RAM Random Access Memory

LVPS Low Voltage Power Supply

MB Megabyte RET Resolution Enhancement Technology

MDMC Multiple Document Multiple Copies ROM Read Only Memory

MHz Megahertz SDMC Single Document Multiple Copies

MPBF Mean Prints Between Failure SCF/SCT Tray 2 Or Second Cassette Feeder

MPF/MPT Multi-Purpose Tray SMPS Switching Mode Power Supply

MPU Main Processing Unit SPGPm Samsung system Graphic Processor

NIC Network Interface Card SPL Samsung Printing Language

NPC Network system Card Spool Simultaneous Peripheral Operation Online

NVRAM Non-volitale Random Access Memory SURF Surface Rapid Fusing

OPC Organic Photo Conductor SW Switch

OPE Operator Control Panel Sync Synchronous

PABX/PSTN Public Telephone Network T1 ITB or Transfer Belt Imaging

PBA Print Board Assembly T2 Transfer Roller Imaging

PCI Peripheral Component Interconnect TAD Telephone Answering Device

PCL system Command Language TRC Toner Reproductive Curve

PDF Portable Document Format URL Uniform Resource Locator

PDL Page Description Language USB Universal Serial Bus

Ping Packet Internet or Inter-network

Grouper

PnP Plug-n-Play

PPD PostScript Printer Description

WHQL Windows Hardware Quality Lab

Service Manual 2-3

Reference Information

2.3 Selecting a Location for the system

■ Leave enough room to open the ADF, system trays, covers, and allow for proper ventilation

■ Provide the proper environment

■ A sturdy, level surface

■ Away from the direct airflow of air conditioners, heaters, or ventilators

■ Free from extreme fluctuations in temperature, sunlight, or humidity

■ Clean, dry, and free from excessive dust

2-4 WorkCenter PE 120/120i

Specifications

Specifications

3

The specifiations in this manual are correct at the time of printing. Product specifications are subject to change
without notice.

3.1 General Specifications

Item Specification

Major Functions Fax, Copy, Print, Scan, ADF, Direct Print, Scan-to-USB Memory, Scan to PC

Width 450 mm (17.7 in.)

Depth 423 mm (16.7 in.)

Height 456 mm (18 in.)

Weight w/ Toner Cartridge 15.6 kg

User Interface Control Panel (OPE) with LCD display

I/O Interface Parallel, USB 2.0

MPU SPGPm / 166 Mhz

Warm-up time from cold: < 42 seconds

from standby:

Operating System Windows: 98 / ME / NT 4.0 / 2000 / XP

MAC: Supports printing only, english only, user must download drivers from the world
wide web.

WHQL Windows 2000 and XP only

Driver Printer: GDI, PCL6, PCL5e (std), PostScript Level 3 (PE120i only)

Network Printing ­PE120i only

Memory* *Upgrading to more than the standard 32 MB of memory will only improve print

Protocol: SPX/IPX, TCP/IP, Ethertalk, SNMP, HTTP 1.1, DLC/LLC

functions. The memory allocation for other system components is as follows:

■ 12 MB PostScript

■ 4 MB Fax

■ 2 MB System

■ 2 MB Scan

Standard 32 MB standard

Optional 16, 32, 64, and 128 SDRAM DIMM, 100 pin

Service Manual 3-1

Specifications

3.2 Electrical Specifications

Item Specification

Input Voltage 110 ~ 127 VAC 220 ~ 240 VAC

Input Range 90 ~ 135 VAC 180 ~ 270 VAC

Input Frequency: 50/60 Hz 50/60 Hz

Frequency tolerance +

Power Consumption Ready: 70 Watts

Power Saver Mode User settings available ON/OFF

Noise Printing 54 dBA

3 Hz +3 Hz

Average: 370 Watts
Maximum: 700 Watts
Sleep Mode: 30 Watts

Copy 55 dBA

Standby 33 dBA

3.3 Environmental Specifications

Item Operating Storage Optimum

Temperature

Humidity 10 - 80% RH 20 - 95% RH 30 - 70% RH

Altitude 2,500 meters (8,200 feet) maximum

10 ~ 32

o

C (50 ~ 90o F) 0 ~ 40 o C (32 ~ 104o F) 20 - 25o C

3.4 Routine Maintenance Items and Consumables

Items Life Item Life

System Life 150,000 pages Standard Toner Cartridge 3,500

Pick Roller 150,000 pages High Capacity Toner 5,000

Friction Pad (Tray) 150,000 pages No Toner level sensing.

Friction Pad (ADF) 20,000 pages

Transfer Roller 60,000 pages

Fuser 80,000 pages

3-2 WorkCentre PE 120/120i

Toner pixel counter

Maximum Monthly Volume

Print: 15,000 pages
Scan : 1,000 pages
ADF : 1,000 pages

Specifications

3.5 Media Specifications

For more information on sizes, weights and approved media support for this system see the user manual..

Item Specification

Input Capacity Tray 1

Optional Tray 2

MP/Bypass Tray 50 sheets

ADF 50 sheets

Output Capacity Face Down 150 sheets 20 lb. bond

Face Up 1 sheet

Media Sizes Tray 1

Optional Tray 2

MP/Bypass Tray Envelope 6 3/4, 7 3/4, #9, #10, DL, C5, B5

Minimum 76 x 127 mm ( 3 x 5 in.)

Maximum 216 x 356 mm ( 8.5 x 14 in.)

ADF Size Width: 142 x 216 mm (5.6 x 8.5 in.) Length: 148 x 356 mm (5.8 x 14 in.)

Media Weight Tray 1

Optional Tray 2

MP/Bypass Tray

ADF 12.5 ~ 28 lb

Paper Path Standard output Bottom to middle front (FIFO)

250 sheets

A4, Letter, Legal, Folio, Executive, B5

16 ~ 24 lb (60 ~ 90 g/m2)

16 ~ 43 lb (60 ~ 163 g/m2)

Straight through (Bypass) Face up, single sheet

Print Skew Top Tray 1: 1.5/177.8 mm

Tray 2: 2.0/177.8 mm

Side Tray 1: 2/243.5 mm

Tray 2: 2.5/243.5 mm

Copy Skew Top Tray 1: 2.5/190 mm

Tray 2: 3.0/190 mm

Side Tray 1: 3.5/277 mm

Tray 2: 4.0/1277 mm

Service Manual 3-3

Specifications

3.6 Print Engine Specifications

Item Specification

Print Speed Up to 22 ppm/Ltr, 20 ppm/A4 (600 dpi)

Print emulation GDI, PCL6, PCL5e (std), PostScript Level 3 (PE120i only)

Auto Emulation Sensing Yes

Font Type

Number 45 Scalable, 1 bitmap

Power Save Yes ON/OFF

Resolution Normal 600 x 600 dpi

RET Yes (1200 x 1200 dpi)

Toner Save Yes Dedicated control panel button

Dedicated Print Memory 16 MB Upgradeable

FPOT From Standby/Ready approx. 10 seconds from laser “ON”

From Cold status less than 50 seconds

Printable Area Letter 208 x 273 mm

Halftone (Gray scale) 128 levels

3-4 WorkCentre PE 120/120i

3.7 Scan Specifications

Item Specification

Scan Method Color, single CCD

Scan Speed ADF USB 1.1, 300 dpi, Letter, 128 MB RAM, all speeds are approximate

Line art 75 seconds

Grayscale 75 seconds

Color 150 seconds

Scan Speed on Platen Lineart 75 seconds

Grayscale 75 seconds

Color (75 / 300 dpi) 150 seconds

Resolution Optical 600 x 1200 dpi

Enhanced 4800 x 4800 dpi

Halftone 256 level

Specifications

Scan Size Max media width 216 mm (8.5 in.)

Effective scan width 208 mm (8.2 in.)

Scan-to Image, OCR, FAX, Direct Scan-to-USB memory, Application

Scan depth Color 24 bit

Mono 1 bit for lineart, 8 bit for grayscale

Service Manual 3-5

Specifications

3.8 Copy Specifications

Item Specification

Copy quality selection or image
type selection modes

FCOT Standby/Ready approx. 10 seconds from platen

Copy Speed SDMC all modes 22 cpm/Ltr, 20 cpm/A4

Origin Alignment Platen Rear left

Resolution Scan 600 x 300 dpi, 600 x 600 dpi

Zoom range Platen 25% to 400%

Text 600 x 300 dpi

Text/Photo 600 x 300 dpi

Photo 600 x 600 dpi

approx. 15 seconds from ADF

Cold status 50 seconds

MDMC text mode
(600 x 300 dpi)

MDMC photo mode
(600 x 600 dpi)

ADF Center

Print 600 x 600 dpi

ADF 25% to 100%

14 cpm

8 cpm

Multi-copy 1 - 99 sheets

Preset Yes

Collation Copy Yes 600 x 300 dpi

Darkness Control 3 levels

Auto return to default mode Yes 15, 30, 60, 180 seconds, or OFF

Changeable default modes Contrast, Image, Reduce/Enlarge, Number of copies

Special Copy N-up Yes, ADF only

Collation Copy Yes, ADF only

AutoFit Copy Yes, Platen only

2-sided Copy Yes, Platen only

Clone Yes, Platen only

Poster Yes, Platen only

3-6 WorkCentre PE 120/120i

3.8.1 Telephone Specification

Specifications

Item

Handset No

On-hook dial Yes

Search Yes (phonebook)

1-touch Dial 40 each: 20 dedicated buttons plus shift

Speed Dial 200 locations (00 - 99), including 1-touch dials

TAD I / F Ye s

Tone/pulse Selectable in technical mode

Pause Yes

Auto Redial Yes

Last Number Redial Yes

Distinctive Ring* Yes *If available by local telephone service

Caller ID No

External Phone Interface Yes

Report and List Print Out Tx/Rx Journal Yes

Specification

provider

Confirmation Yes

Help List No

Auto Dial List Yes

Sound Control Ring Volume Low, Medium, High, OFF

Key Sound ON or OFF

Alarm Sound ON or OFF

Speaker ON or OFF

Service Manual 3-7

Specifications

3.9 Fax Specification

Item

Compatibility ITU-T G3

Communication System PSTN/PABX

Modem Speed 33.6 Kbps

TX Speed 3 seconds

Compression MH/MR/MMR/JBIG/JPEG

Color Fax Yes; Send only

ECM Yes

Resolution Standard 203 x 96 dpi

Fine 203 x 196 dpi

Super Fine 300 x 300 dpi

Scan Speed Standard 2.5 sec/Ltr

ADF Fine/S. Fine 5 sec/Ltr

Rx Fax Duplex Print Out No

Multiple Page Scan Speed Standard 14 ppm/ Ltr

Receive Mode Fax, TEL, Answer/Fax, DRPD

Specification

Memory Capacity 4 MB

Optional Memory Upgrade No

Max locations to store 1
group dial

Fax Forward Yes (ON/OFF)

Broadcasting up to 209 locations

Cover Page Yes

Delayed Fax Yes

Memory RX Yes

Functions Voice Request No

TTI and RTI Yes

Polling No

Recall No

Auto Reduction Yes

Junk Fax Barrier Yes

Secure Receive Yes

199 locations

Memory Back-up Yes 43 hours maximum

3-8 WorkCentre PE 120/120i

Product Summary

4

This section describes the functions and operating principals of the systems main components.

4.1 Printer Components - Front View

Product Summary

USB Flash
Drive Port

Automatic

Document Feeder

Document Guides

Document Cover

Document
Input Tray

Document
Output Tray

Document Glass/
Platen

Control Panel

Front Output Tray
(Face Down)

Front Door

Paper Output
Extension

Paper Tray
(Tray 1)

MP/Bypass
Tray

Toner

Cartridge

Paper Level Indicators

The figure above shows the WorkCentre PE120i.

Optional Paper
Tray (Tray 2)

Service Manual 4-1

Product Summary

4.1.2 Rear View

Rear Door

Control
Board Cover

Rear Output Slot

(Face Up)

Power Switch

AC Power Cord

Connector

Line Jack

EXT Jack

Network Port

(

WorkCentre

PE120i

Parallel
Connector

USB
Connector

Tray 2 Cable Connector

The figure above shows the WorkCentre PE120i.

Only

)

4-2 WorkCentre PE 120/120i

Product Summary

4.1.3 Control Panel

1 Allows you to store frequently-dialed fax numbers and dial them with the touch of a few

buttons.

2

Scan

3

Copy

Allows you to shift the one-touch buttons to the numbers 21 through 40.

Allows you to access a list of your PC software programs that an image can be scanned
to. You must create the scan list using the Xerox software (ControlCentre) provided with
this machine.

Also allows you to scan and save documents in a USB flash drive, and manage it when it
is inserted into the USB port of your machine. See Chapter 10, Installing a USB Flash
Drive.

Adjusts the density of the documents for the current copy job.

Selects the document type for the current copy job.

Selects the number of copies.

Allows you to use special copy features, such as Clone, Collation, Auto Fit, 2 Sides on 1
page, 2-/4-Up (multiple pages on a sheet), and Poster Copying.

Makes a copy smaller or larger than the original.

4 Displays the current status and prompts during an operation.

Turns on when the toner cartridge is empty.

Service Manual 4-3

Product Summary

4.1.3 Control Panel (Continued)

5 Uses to scroll through the available options for the selected menu item.

Confirms the selection on the display.

Enters Menu mode and scrolls through the menus available.

Sends you back to the upper menu level.

Stops an operation at any time.
In Standby mode, clears/cancels the copy options, such as the darkness, the document

type setting, the copy size, and the number of copies.

Starts a job.

6 Dials a number or enters alphanumeric characters.

7

Fax

8 Allows you to directly print files stored on a USB flash drive when it is inserted into the

9

Save

Adjusts the resolution of the documents for the current fax job.

Allows you to send a fax to multiple destinations.

Allows you to store frequently-dialed fax numbers as one or two-digit speed dial or group
dial numbers for automatic dialing and edit the stored numbers. Also allows you to print a
Phonebook list.

In Standby mode, redials the last number or in Edit mode, inserts a pause into a fax
number.

Engages the telephone line.

USB port in the front of your machine.

Allows you to save on toner by using less toner to print a document.

Allows you to save on call costs by sending a fax at a preset toll-saving time. Using this
feature, you can take advantage of lower long distance rates at night, for example.

4-4 WorkCentre PE 120/120i

Product Summary

White-Sheet

4.2 System Layout

The system is made up of the an Automatic Document Feeder (ADF), scanner, platen, and control panel and the
print engine, which performs the systems print, power, controller and interface functions.

4.2.1 Scanner Paper Path

Scanner Part

3

2

4.2.2 Print Engine Paper Path

Engine Part

7

CCD-Module

5

Fuser

6

White-Sheet

White-Sheet

7

1

4

8

1

Doc. Paper (50 Sheets)

Pickup Roller

2

ADF Roller

3

Sensor - Doc.

4

Sensor - Regi

5

Sensor - Scan

6

Feed Roller

7

Exit Roller

8

3

L S U

CR

PR

OPC

TR FR

5

Toner Cartridge

DR

SR

PTL

6

2

4

R

/

K

C

I

P

1

1

Paper Input (Cassette)
Paper Input (Manual Feeder)

2

Paper Out (Face Down)

3

Paper Empty Sensor (Manual)

4

5

Paper Empty Sensor (Cassette)
Paper Feeding Sensor

6

Paper Exit Sensor

7

Service Manual 4-5

Product Summary

4.2.3 Print Engine Paper Path Rollers

L S U

Fuser

PR

1

OPC Drum

Charge Roller

2

Supply Roller

3

Developing Roller

4

4.3 System Summary

The system consists of the following main functional components:

1) The Firmware

Engine firmware controls the print, copy, scan and fax processes.

CR

DR

OPC

SR

PTL

TR FR

5

Transfer Roller

Heat Roller

6

Pressure Roller

7

Toner Cartridge

MP Sensor

R

/

K

C

I

P

2) The Image Input Terminal (IIT)

1. Automatic Document Feeder (ADF), Scanner, and Control Panel

The scanner uses a photosensitive sensor. It consists of a CCD module, Connection board, ADF board, AFE
(Analog Front End), Image Processor (Located in CPU), platen glass and ADF mechanism.

The scanner carriage contains two Xenon lamps, a CCD, mirrors and lenses. The output of the CCD is
connected to the main controller board by a ribbon cable that follows the path of the carriage.

When a document is scanned using the document glass (platen), the carriage moves across the scanner,
illuminating the original and projecting the image onto the CCD.

When a document is scanned using the automatic document feeder (ADF), the scan carriage moves to a fixed
position under the constant velocity transport (CVT) glass and the image is captured as the document moves
through the ADF.

The WorkCentre PE120 scanner can be used to scan color or black and white images, including line art,
photographs, and printed text.

CCD Module Specification

■ Resolution: 600dpi

■ Maximum scan wide: 8.5”

■ Color filter: Red, Green, Blue

■ Output channel: 3 channels (R, G, B)

4-6 WorkCentre PE 120/120i

Product Summary

■ Effective pixel: 5,400 pixel *3

■ Voltage: 24 V and 5 V

■ Pre-heating time: Maximum 30 seconds (70% of light output reached)

■ The life span of a lamp: 30,000 hours (25

o

C)

Image Processor Specification

■ Operating frequency: 66MHz

■ Image sensor interface: 200/300/600 dpi CIS or CCD

■ Line time: Copy, FAX, Binary (Lineart, Halftone) PC Scan: 1.5ms/Line Color PC Scan (Grey, 256 Color,

True Color): 4.5ms/Line

■ A/D conversion: 10 bit conversion

Note

For more information about scan settings, review the Scanning sections of the WorkCentre PE120 User
Guide and the Multifunction Basics Prerequisite Training.

3) The Print Engine

1. Engine Frame

2. Paper Feed

The paper feed system consists of a 250-sheet main paper tray , a bypass tray (MP), pickup rollers, friction pads, and feed
rollers. The rollers and sensors in the paper feed path control paper registration and guide the paper through the image
transfer, image development, image fusing and exit assemblies. The paper path has an anti-static connection to ground to
eliminate problems due to static charge on the paper.

3. Main drive mechanism

The main drive is a bi-polar, two phase motor. It drives the drum, paper pick, and paper feed rollers using a gear train
mechanism.

4. Image development unit

Using a Laser Scanner Unit (LSU), this portion of the mechanism creates the image on the OPC drum (part of the
integrated toner cartridge).

5. Image transfer unit

This unit uses the high voltages supplied by the HVPS to move the image from the OPC drum onto the paper.

6. Image fusing unit

This unit permanently fixes the toner image onto the paper. This is ach ieved using a temperature controlled heating unit
(the fuser).

7. Electronic boards include:

a. The Main control board, consisting of:

■ Main processor asic (166 MHz SPGPm)

■ Memory (Flash ROM containing the control program and DRAM for working memory)

■ Engine interface parts (motor control, fuser control, HVPS control, and sensors)

■ PC Interface (USB , Parallel, Network)

■ Bus, DMA and I/O handling

b. PC Interface

Service Manual 4-7

Product Summary

4.3.1 Paper Feed

The paper feed system consists of an automatic document feeder, a 250-sheet main paper tray, bypass tray (MP),
pickup rollers, friction pads and feed rollers. The rollers and sensors in the paper feed path control paper
registration and guide the paper through the image transfer, image development, image fusing and exit assemblies.
The paper path has an anti-static connection to ground to eliminate problems due to static charge on the paper.

1. Paper Separation Method

Individual sheets are separated into each tray using the ‘friction pad’ method. When paper feeds into the
system it passes over a spring loaded friction pad that separates the sheets of paper.

2. Paper Tray (cassette)

The paper trays use a ‘center loading’ method. There are no paper size sensors, instead a software process is
used to detect the size of the first sheet of paper as it is fed through the printer. Both the rear and side paper
guides are adjustable for various paper sizes.

There is a ‘Paper Empty’ sensor which detects the presence of paper (Capacity: 250 sheets).
There is an indicator flag on the front of the tray which indicates the amount of paper remaining.

3. Pick-Up Roller

The pick-up roller is used to pick and feed paper into the printer. It also is used to remove any static charge on
the paper.

4. Bypass Tray (MP)

The multi-purpose tray is used to hold non-standard or custom paper sizes and special media (envelopes,
transparencies, etc.). There is a bypass tray paper empty sensor. The Bypass Tray uses a friction pad method to
ensure paper separation and can hold a maximum of 50 sheets of paper or envelopes.

5. Lower Tray Assembly (Tray 2)

The optional tray unit is universal with the main tray and also has a capacity of 250 sheets.

4.2.4 Transfer Assembly

The transfer roller transfers toner from the OPC drum to the paper. Toner is transferred from the OPC drum onto
the paper using a PTL (Pre-Transfer Lamp) and a transfer roller. The PTL shines light onto the OPC, reducing the
electrical charge on the OPC surface improving the efficiency of the transfer.

4.2.5 Drive Assembly

The drive assembly receives power from the main controller board. The main motor powers the paper feed, toner
cartridge, fuser unit and all pick-up, feed, and exit rollers.

4.2.6 Fuser Assembly

The fuser assembly uses a heat lamp process. This consists of a heat lamp, heat roller, pressure roller, thermistor,
and thermostat. By use of heat and pressure, toner is melted to adhere to the paper surface in order to complete the
printing process.

4.2.6.1 Thermistor and Thermostat

The thermistor is used to detect the temperature of the heating unit and feeds this information into the main
processor.

4-8 WorkCentre PE 120/120i

Product Summary

If the heat lamp becomes too hot, the thermostat cuts off the power to the lamp in order to prevent o verheating and
any potential fire hazard is removed.

4.2.6.2 Heat Roller

The heat roller transfers the heat from the heat lamp to the paper. The surface of the heat roller is coated with
Teflon so that toner does not stick to the surface.

4.2.6.3 Pressure Roller

A pressure roller, mounted under the heat roller, is made of a silicon resin and the surface is also coated with
Teflon. When paper passes between the heat roller and the pressure roller the toner powder is melted and
permanently fixed to the surface of the paper.

4.2.6.4 Safety Features

To prevent overheating:

■ 1st protection device: Hardware cuts off when overheated.

■ 2nd protection device: Software cuts off when overheated.

■ 3rd protection device: Thermostat cuts off main power to the lamp.

Safety device

■ Fuser power is cut off when the front cover is opened.

■ Laser power is cut off when the front cover is opened.

■ The temperature of the fuser cover's surface is maintained at less than 80º C to protect the user. A caution

label is attached where the customer can see it easily when the rear cover is opened.

4.2.7 Laser Scanner Unit (LSU)

This is the core of the laser printer . It converts the video data receiv ed from the computer into an electrostatic latent
image on the surface of the OPC drum. This is achieved by controlling the laser beam and exposing the surface of
the OPC drum to the laser light. A rotating polygon mirror reflects the laser light onto the OPC. Each face of the
mirror produces one scan line. As the OPC drum turns, the laser scans, to create the full page image.

The HSYNC signal is created when the laser beam from the laser unit reaches the end of the polygon mirror and
this signal is sent to the controller. The controller detects the HSYNC signal to adjust the vertical line of the image
on paper. In other words after the HS YNC signal is detected the image data is sent to the laser unit to adjust the left
margin on the paper.

Service Manual 4-9

Product Summary

4.2.8 Toner Cartridge

The toner cartridge is an integral unit containing the OPC unit and toner unit. The OPC unit consists of the OPC
drum and charge roller. The toner cartridge unit consists of the toner, supply roller, developing roller, and blade
(doctor blade).

-430V

-950V

-580V

Developing Method Non magnetic 1 element contacting method

Tone r Non magnetic 1 element shatter type toner

Toner Life 3,500 sheets / 5,000 sheets (ISO19752 standard)

Toner remaining sensor No

OPC Cleaning Film OPC using an electro-static cleaning process

Management of waste toner Collected using an electro-static process and retained within the toner

cartridge. No waste toner to dispose of.

OPC Drum protecting shutter No

Toner CRUM Reader Identifies whether toner is Xerox branded toner or whether a Non-Xerox toner

cartridge is installed in the printer

4-10 WorkCentre PE 120/120i

Product Summary

4.3 Main Controller Board (PBA)

The engine board and controller board have been integrated into a single board consisting of the CPU and printer
control functions. The CPU functions as the bus controller, I/O handler, motor driver and PC interface. The main
board sends the current image video data to the laser unit and manages the electrophotographic printing process.
Circuits on the main board driv e the main motor (paper feed, cartridge, fuser), clutch, pre-transfer lamp, heat-lamp
and fan. The signals from the paper feed jam sensor an d paper empty sensor are inputted to the main board from the
power supply board. Network Card shown in illustration, not available on the PE 120.

Service Manual 4-11

Product Summary

4.3.1 ASIC

■ Completely integrated system for embedded applications

■ 32 bit RISC architecture, efficient and powerful ARM9 core

■ LSU interface module for interfacing PVC or HPVC with LSU

■ 2 channel general purpose DMA controller for high speed I/O

■ Dual memory bus architecture

■ Operation frequency: AHB Bus: 60 Mhz, Internal system bus: 120 Mhz

■ Operation voltage: 3.3 V

■ Power on reset time: below 5.6 ms

4-12 WorkCentre PE 120/120i

Product Summary

4.3.2 Memory

The board has Flash ROM and DRAM memory units. There is 1 SODIMM socket to enable extra DRAM.

4.3.3 Flash Memory

Record system program and download system program by PC interface.
Fax for Journal list, and memory for One Touch Dial, Speed Dial List.

■ Capacity: 4 MB

■ Access Time: 70 nsec

4.3.4 SDRAM

SDRAM is used as swath buffer during printing, scan buffer during scanning, ECM buffer in fax receiving, and
system working memory area

■ Capacity: 32 MB

■ Max frequency: 133 Mhz

■ Store fax receive memory data by using a battery

4.3.5 Battery Backup

Backup power is provided by a 3.6 V rechargeable lithium battery. It provides power to the SDRAM to retain any
faxes in momory when the main power is lost. Typically, backup power will last up to 43 hours. The battery
requires 48 hours to charge.

4.3.6 Sensor Input Circuit

4.3.6.1 Paper Empty Sensing

The Paper Empty sensor (Photo Interrupter) on the SMPS/HVPS PBA (CON2-2) is monitored by the CPU on
signal. When the cassette is empty, the system displays a message on the LCD.

4.3.6.2 MP/Bypass Tray Sensing

Presence of paper in the bypass tray is detected by the MP sensor (photo interrupter) on the SMPS/HVPS PBA
(CON2-14). The CPU monitors this sensor to recognize paper in tray, and paper feed if there is paper present.

4.3.6.3 Paper Feed Sensor

When paper passes the actuator on the feed sensor (CON2-1), it is detected by the photo interrupter. The CPU
monitors the signal and starts the process of creating the image after a specified delay time. If the feed sensor is not
detected within one second after paper is fed, a paper jam0 occurs and is reported on the LCD. When a toner
cartridge is inserted it also operates the paper feed sensor. A message is displayed on the LCD if no cartridge is
detected.

Service Manual 4-13

Product Summary

4.3.6.4 Toner Remaining Sensing

The printer does not have a toner remaining sensor.

4.3.5.5 Paper Exit Sensing

This detects paper exiting from the system using an exit sensor on the engine board (CON2-24) and actuator on the
frame. The CPU detects the on/off time of the exit sensor during normal operation or a jam2 is reported on the
LCD.

4.3.6.6 Cover Open Sensing

The cover open actuator is located on the front cover and the sensor is on the main frame. When the front cover is
open the +24 V and +5 V supplies to the DC fan, solenoid, main motor, polygon motor in the laser unit, HVPS and
laser diode are cut off. The CPU monitors the cover open signal and reports an open state on the LCD.

4.3.6.7 DC Fan/Solenoid Driving Circuit

A fan is driven by a transistor and controlled by a signal from the CPU (FAN (SMPS CON2-23). When the signal
is high, the fan is activated by turning on the transistor, and is off when the system is in sleep mode. There are two
solenoids driven by the paper pick and MP signals. The drive time is 300ms. The diode protects the driving
transistor from the back EMP pulse which is generated when the solenoid is de-energized.

4.3.6.8 Motor Driving Circuit

The main motor drives the paper feed, developing unit, fuser, and exit assembly. The circuit is driven by software
which controls the acceleration, constant speed, and deceleration profiles. The Motor is driven using an A3977
driver IC.

4.3.6.9 Transfer

The charging voltage, developing voltage, and the transfer voltage are controlled by pulse width modulation
(PWM). Each output voltage is changeable according to the PWM duty cycle. The transfer voltage used when the
paper passes the transfer roller is decided by environment recognition. The resistance value of the transfer roller
changes due to the environment of the room or within the printer. This change in resistance in turn changes the
value of the voltage due to loading. This voltage is fed back into the printer through the A/D converter. Based on
the value fed back the PWM cycle is changed to maintain the required transfer voltage.

4.3.6.10 Fusing

The temperature of the heat roller's surface is detected according to the resistance value of the thermistor. The
thermistor resistance is measured using the A/D converter and thus the CPU can determine the temperature of the
heat roller. The AC power is controlled b y comparing the targ et temperature to the v alue from the thermistor. If the
value from the thermistor is out of the controlled range while controlling the fusing process, an error is reported.

4-14 WorkCentre PE 120/120i

Product Summary

4.4 Switching Mode Power Supply (SMPS) and High Voltage Power Supply (HVPS)

The SMPS and HVPS are on one integrated board.
The SMPS supplies the DC power to the printer. It takes either 110 V or 220 V and outputs the +5 V and +24 V

supplies to the main board.
The HVPS creates the high voltage for the THV/MHV/S upply/ Dev and supplies it to the toner cartridge. The CPU

is used to modify some of these voltage settings to provide the ideal voltages to create the image.
The HVPS uses the 24 V and outputs the high voltage for THV/MHV/BIAS and the outputted high voltage is then

supplied to the toner, OPC cartridge, and transfer roller.

4.4.1 High Voltage Power Supply

1) Transfer High Voltage (THV+)

High voltage is used to transfer toner from the OPC Drum to the paper.

■ Output Voltage: +1300 V DC +50 V

■ Error Indicators: If the high voltage is not present, low density printing occurs due to toner on the OPC

Drum not being transferred to the paper. It is possible that waste toner o ver -flo w can occur if this condition
persists. Ghost images may appear which repeat at 76 mm intervals.

2) Charge Voltage (MHV)

The charge voltage charges the surface of the OPC Drum to -900V ~ -1000V.

■ Output voltage: -1550 V DC ± 50 V

■ Error Indicators: If MHV is not present the OPC drum surface has no charge and toner is attracted to the

entire OPC surface. A black page is printed out when this happens.

Service Manual 4-15

Product Summary

3) Cleaning Voltage (THV-)

The cleaning voltage removes toner contamination from the rear side of the paper by sending (-) polarity to the
transfer roller, forcing toner to transfer back to the OPC drum.

■ Output Voltage: -1200V, +300V/-150V

■ Error Indicators: Smudges and toner contamination on the reverse side of the printed page.

4) Developing Voltage (DEV)

The developing voltage develops toner on the section of the OPC drum surface exposed by the LSU. When
printing, the exposed v oltage on the OPC is -180V, unexpo sed is -900~-1000V, and the exposing voltage on t he
DEV is -430V. Therefore toner with (-) polarity is developed onto an exposed section of the OPC.

■ Output Voltage: -430V DC ± 20V

■ Error Indicators:

a. If DEV is GND, print density gets extremely low.
b. When DEV is floating due to a po or connection between the frame and cartridge contacts, print density

is too high.

5) Supply

The supply voltage supplies toner to the developing roller.

■ Output voltage: -580V DC ± 50V (Use ZENER, DEV Gear)

■ Error Indicators:

a. When SUP is GND print density gets extremely low.
b. If SUP is floating due to a poor connection between the frame and cartridge contacts, density is

extremely low printing blank or very light prints.

6) OPC Ground ZENER Voltage

The OPC ground voltage prevents image contamination under low temperature and low humidity
environmental conditions. When the system prints without an output voltage, -130V DC ± 15V is maintained
on the OPC ground. (-103V, ZENER diode is connected to the OPC ground).

■ Error Indicators:

a. When the ZENER diode is at -0 V image problems in the proper environment generally do not occur,

but in low temperatures and lo w humidity environments, it is possible that contamination can occur on
the entire printed image

b. When the ZENER diode is disconnected, a blank page is printed out. (It is the same when a ZENER

diode is disconnected from OPC ground.)

4-16 WorkCentre PE 120/120i

Product Summary

4.4.2 Switching Mode Power Supply

The SMPS is the power source for the entire printer system. The SMPS supplies DC power for driving the printer,
and the AC heater control which supplies power to fuser. The SMPS has two output channels: 3.3 V and +24 V.

1) AC Input

Input Rated Voltage: AC 220 V ~ 240 V, AC 120 V ~ AC 220 V (EXP version)
Input Voltage Range: AC 198 V ~ 264 V, AC 90 V ~ 135 V, AC 198 V ~ 264 V (EXP version)
Rated Frequency: 50/60 Hz
Frequency Range: 47 ~ 63 Hz
Input Current: Under 4.0A RMS/2.0A RMS (When the fuser lamp is off and input / output voltages are in

range)

2) Rated Output Power

No Item CH2 CH3 Remark

1.

2.

3.

4.

5.

6.

7.

8.

9.

Channel name +5 V +24.0 V
CONNECTOR PIN CON 23

5 V PIN: 3, 4
GND PIN: 5, 6, 7

Rated output +5 V ± 5%

(4.75 ~ 5.25 V)

Max output current 0.14A 2.0 A
Peak loading current 0.14A 2.5 A 1ms
Ripple noise voltage 100mVp-p Under 500mVp-p
Maximum output 0.35 W 48 W
Peak output 0.7 W 60 W 1ms
Protection for loading

shortage and overflowing
current

CON 3
24 V PIN: 11, 12, 13
GND: 9, 10, 18
+24 V ± 10%

(21.6 ~ 26.4 V)

-

3) Power Consumption

No Item CH2 +5 V CH3 +24.0 V Remark

1.

2.

3.

Standby 0.07 A 0.4 A AVG: 55 Wh
Printing 0.14 A 2.0 A AVG: 280 Wh
Sleep Mode 0.01 A 0.4 A AVG: 20 Wh

4) EMI Requirement:

CISPR, FCC, CE, MIC, C-Tick

5) Safety Requirement:

IEC950, C-UL, TUV, Semko, iK, CB, CCC, EPA

Service Manual 4-17

Product Summary

4.4.3 Fuser AC Power Control

The Fuser (HEAT LAMP) is heated using AC power. The AC power is controlled by a triac (THY1), a
semiconductor switch. 'On/Off control' is achieved when the gate of the Triac is turned ON/OFF by a photo triac
(PC1), this is an insulting part. The AC control is a passive circuit. It turns the heat lamp ON/OFF by taking a
signal from the engine control section. When the 'HEATER ON' signal is activated by the engine, the LED of PC1
(Photo Triac) flashes. The flashing light causes the Triac (PC1) to switch and voltage is supplied to the gate of
Triac THY1. As a result, AC current flows to the heat lamp, and heat is produced.

When the signal is OFF , PC1 is OFF, and the voltage is cut off at the gate of triac THY1, this triac is off, and in turn
the heat lamp is turned off.

1) Triac (THY1) feature:

■ 12A, 600V SWITCHING

2) Phototriac Coupler (PC3)

■ Turn On If Current : 15mA ~ 50mA(Design: 16mA)

■ High Repetive Peak Off State Voltage : Min 600V

4.5 Engine F/W

4.5.1 Feeding

While feeding from the universal trays, the drive for the pickup roller is controlled by the pick-up solenoid. The
printer feeds the paper from the bypass tray according to the information provided by the MP sensor , and by dri ving
the main motor, inserts the paper in front of the feed sensor.

Jam Description

This is an indcation that the leading edge of the paper did not pass the feed sensor.

■ After paper pick, paper does not enter the printer due to a misfeed.

■ After paper pick, the paper enters the printer but it does not reach the feed sensor in the

specified amount of time.

■ If paper has been picked, and the feed sensor is not ON, the printer will re-pick. If after re-

picking the feed sensor is still not reported as ON, this error will occur.

Jam 0

Jam 1

■ Even though the paper reaches the feed sensor, the feed sensor is not ON.

This is an indication that the leading edge of the paper has already passed the feed sensor.

■ After the leading edge of the paper passes the feed sensor, the trailing edge of the paper

does not pass the feed sensor within the specified time. (The feed sensor cannot be OFF
during this time.)

■ After the leading edge of the paper passes the feed sensor, the paper does not reach the exit

sensor within the specified time. (The exit sensor cannot be ON during this time.)

The paper is between the feed sensor and the exit sensor.

Jam 2

■ After the trailing edge of the paper passes the feed sensor, the trailing edge of the paper does

not pass the exit sensor within the specified time.

4-18 WorkCentre PE 120/120i

Product Summary

4.5.2 Drive

The main motor drives the paper feed, developing unit, and the fuser. It is driven by software which controls the
acceleration, constant speed and deceleration profiles. The motor is managed with an A3977 driver IC and
controlled by step and enable signals from the CPU.

4.5.3 Transfer

The charging voltage, developing voltage and the transfer voltage are controlled by PWM (Pulse Width
Modulation). Each output voltage is changeable according to the PWM duty cycle. The transfer voltage used when
the paper passes the transfer roller is decided by en vironment recognition. The resistance v alue of the transfer roller
changes due to the surrounding environment in the room or within the set, this change in resistance in turn changes
the value of the voltage due to loading. This voltage is fed back into the set through the A/D converter. Based on
this fed back value the PWM cycle is changed to maintain the required transfer voltage.

4.5.4 Fusing

The temperature of the heat roller's surface is detected according to the resistance value of the thermistor. The
thermistor resistance is measured using the A/D converter and thus the CPU can determine the temperature of the
heat roller. The AC power is controlled by comparing the target temperature to the value from the thermistor . If the
value from the thermistor is out of the controlling range while controlling the fusi ng process, the error stated in the
table occurs.

Error Description
Open Heat Error:

When warming up: it has been lower than 68 °C over 25 sec

Lower Heat Error:

Standby: It has been lower than 100°C over 25 sec
Printing: 2 consecutive pages: it has been lower than 145°C over 5 sec, 3 consecutive page: it has been 40°C

lower than the fixed fusing temperature over 4 seconds.

Over Heat Error:

It has been higher than 220°C over 3 seconds.

4.5.5 LSU

The LSU consists of the LD (Laser Diode) and the polygon motor control. When the printing signal occurs, the LD
is turned on and the polygon motor is enabled. When the light sensor detects the beam, Hsync occurs. When the
polygon motor speed becomes a normal, LReady occurs. If these two conditions are satisfied, the status bit of the
LSU controller register becomes 1 and the LSU is judged to be ready. If the two conditions are not satisfied, the
error shown in the table below occurs.

Error Description
Polygon Motor Error:

The polygon motor’s speed isn’t normal.

Hsync Error:

The polygon motor’s speed is normal, but the Hsync signal is not created.

Service Manual 4-19

Product Summary

4.6 OPE (Control Panel) PBA

The control panel board consists of various functin keys and an LCD to display system status, operator messages,
menu items, and errors. Communication between the OPE and the CPU on the main board is serial.

4.7 USB Host

The USB host board provides power to the USB connector to enable USB memory drive, used in conjunction with
the USB direct printing and Scan to USB fumctions.

4.8 Fax Section

4.8.1 Modem

■ Group3 Facsimile Modem (Entire FM336/314 Family)

■ External Handset Support (not implemented on SCX4720F)

■ Requires Discrete Line Interface Unit (LIU )

■ V.34 Half-Duplex Mode

■ V.90 PCM/V.34 Duplex Data Modes

V24

Interface

Host

Processor

/RTS XTLI

/CTS

TXD

TDCUK

XTCLK

/RLSD

RXD

/RDCLK

/DTR

/DSR**

/RI*

FM336

/RD

/WR

/CS

/D[x:0]

RS[4:0]

IRQ

/RESET

TXRQ*

RXRQ**

Modem

EYESYNC

XTLO

CLKIN

RIN

TXA1

TXA2

DH

RINGD

/TALK

EYEXY

EY RCLK

SPKR

+SV

+3.3V
AGND
DGND

Crystal

OR

Oscillator

telephone
line

Line

Interface

TIP

RING

Optional

Eye Pattern

Generator

Speaker
Amplifier

Power Supply

4-20 WorkCentre PE 120/120i

Product Summary

4.8.2 LIU PBA

The LIU board is the Line Interface Unit. It consists of a Tel_line Interface circuit and Telephone circuit. The
Tel_Line circuit consists of a matching transfer to conform to the impedance of the receiving telephone line and a
circuit to isolate the fax machine from the PSTN, and a surge absorber to protect against lighting strike surges on
the incoming line.

The T elephone circuit consists of a ring detection circuit, speech circuit, external hook detection circuit, and recall
circuit.

4

1

1. TRANS MATCHING T1

2. TRANS MATCHING T2

3. RELAY RE1

4. VARISTOR VAR1/VAR2

5

3

6

2

5. JACK MODULAR(TEL) MJ1

6. JACK MODULAR(EXT) MJ2

4.8.3 Tel-Line Connection Circuit

■ The Tel-Line Connection Circuit connects the fax machine to the PSTN using Tip and Ring terminals.

■ Use Modular Plug : RJ-11C

■ Arr1, Arr2 and Arr3 are protection components to prevent damage due to overvoltage surges, e.g.

lightening.

Service Manual 4-21

Product Summary

4.8.4 Transformer Circuit

■ The Transformer circuit is a line impedance matching circuit which matches the internal impedance of the

fax machine to the external -48Volt DC impedance of the PSTN system.

■ The Transformer circuit insolates the fax machine electrically from the PSTN.

4.8.5 On Hook State

■ DC10V ~ DC100V, DC Resistance: 5M. and over

■ DC150V ~ DC200V, DC Resistanc : 30K. and over

Ring Sensitivity

■ Ring detection voltage: 40Vrms ~ 150Vrms

■ Ring detection frequency: 15.3Hz ~ 68Hz

■ Ring detection current: 20mA ~ 100mA

Pseudo Ring Sound

■ Ring frequency: 750Hz + 1020Hz

■ Ring Interrupt period: Mark/Space controlled by CPU/Modem

4.8.6 Off Hook State

DC Resistance

■ DP Dial Mode (DC 30mA) : 50 ~ 220 .

■ DTMF Dial Mode (DC 20mA) : 50 ~ 300 .

■ DTMF Dialing (DC 20mA) : 50 ~ 540 .

■ Matching (Input AC Impedance): 600 .±30% for 300Hz ~ 3.4KHz

■ Minimum Line Current detecting Off Hook:

■ 20mA (Handset Hook Off)

■ 15mA (External Handset Hook Off)

■ Minimum Line Current for DP Dial transmission: 20mA ~ 120mA, Product Margin : 20mA and over

4-22 WorkCentre PE 120/120i

4.8.7 Signal

■ Input Signal Level Range : - 0dBm ~ - 48dBm

■ DP (Dial Pulse) Dial

■ Make / Brake Ratio : 40 : 60

■ Pulse Speed : 10 ± 0.8 pps, Minimum Pause : above 60 msec

■ DTMF Signal

■ Coding Format

L H 1209 Hz 1446 Hz 1477 Hz

697 Hz 1 2 3
770 Hz 4 5 6
852 Hz 7 8 9
941 Hz * 0 #

■ Transmission Level

L H Level Typical

High -6 +

Low -8 +

Twist +

2 dBm -6.7 dBm
2 dBm -6.7 dBm

2 dBm 2.0 dBm

Product Summary

Service Manual 4-23

Product Summary

4-24 WorkCentre PE 120/120i

Disassembly

5

5.1 Precautions for Disassembly/Reassembly

Disassembly

■ Use only approved Xerox spare parts. Ensure that

the part number, product name, any voltage,
current or temperature ratings are correct. Failure
to do so could result in damage to the printer,
circuit overload, fire or electric sh ock.

■ Do not make any unauthorized changes or

additions to the printer, this could cause the printer
to malfunction and create electrical shock or fire
hazards.

■ When disassembling the printer, note where each

screw goes. Using the wrong screw could lead to
printer failure, short circuits, or electrical shock.

■ Do not disassemble the laser unit. Once it is

disassembled dust is admitted to the mirror
chamber and will seriously degrade print quality.
There are no serviceable parts inside.

■ Regularly check the condition of the power cord,

plug and socket. Bad contacts could lead to
overheating and f ire. Damaged cables could lead to
electric shock or component malfunctions.

Caution

Many of the parts are
held in place with
plastic latches. The
latches break easily;
Remove them
carefully. To remove
such parts, gently pull
the hook end of the
latch away from the
part where it is latched.

Caution

To prevent damaging the toner cartridge and
degrading print quality, protect the toner cartridge
from light when removing it from the printer.

5.1.1 Precautions When Removing Circuit Boards

Static electricity can damage a board, follow the ESD
precautions in Section 1 of this manual when handling
or storing a board.

Precautions when moving and storing boards:

■ Place boards in an approved anti-static

discharge bag.

■ Do not store a board where it is exposed to

direct sunlight.

Precautions when replacing boards:

■ Disconnect power connectors first, before

disconnecting other cables.

■ Do not touch any soldered connections,

connector terminals, or other electronic parts
when handling insulated parts.

Precautions when checking boards:

■ Before touching a board, touch a grounded

area on the printer chassis to discharge any
static electrical charge on the body or wear an
anti-static wrist strap.

■ Do not touch the board with your bare hands or

metal objects, this can create a short circuit or
cause an electrical shock. T ake extra care when
handling boards containing sensors, motors or
lamps as they may get hot.

■ Take care when fitting, or removing, screws.

Check for hidden screws. Always ensure that
the correct screw is used. When toothed
washers are removed, ensure they are refitted
in their original positions

Service Manual 5-1

Disassembly

5.2 Rear Cover

(PL 8.1.23)

1. Remove 4 screws securing the rear cover.

2. Remove the rear cover from the frame and scanner

assembly.

3. Unclip the face up cover from the rear cover, as

shown, then lift the face up cover out.

Face Up Cover

Rear Cover

5-2 WorkCentre PE 120/120i

5.3 Side Covers Right and Left

(PL 8.1.14, 21)

1. First remove:

a. Rear cover, see page 5-2.
b. Paper tray.

Disassembly

Side Cover (RH)

Cassette

2. Open the front cover.

3. For the right side cover, remove 2 screws from the

front and 1 screw on the back.

4. Release the 3 clips underneath the cover and ease

the rear screw bracket ov er its locating pin. Pull the
cover to the right and remove it from the frame.

5. For the left side cover repeat steps 3 ~ 5, except

disconnect the loudspeaker wiring harness if
equiped

.

Side Cover (LH)

Service Manual 5-3

Disassembly

5.4 Front Cover

(PL 8.1.22)

1. Open the front cover and remove the toner

cartridge.

2. Unclip the front cover from the frame and remove.

Front Cover

5.5 Scanner Assembly

(PL 8.5)

1. First remove:

a. Rear cover, see page 5-2.
b. Side covers, see page 5-3.
c. To replace the OPE (Control Panel) Assembly,

do steps 6 and 7 only.

d. To remove the Scan Upper, remove the ADF

then do steps 8 and 9 only.

e. To remove the CCD Module, remove the ADF

then do steps 10 through 11.

f. To remove the Drive Motor, remove the ADF

then do steps 8, 9, 12 and 14.

g. To remove the Open Sensor, remo ve the ADF

then do steps 8, 9, 15 and 16.

2. Remove 2 screws securing the scanner assembly.

5-4 WorkCentre PE 120/120i

Disassembly

3. Disconnect 5 connectors and the ground wire

screw from the PBA (main board).

4. Pull up on the scanner assembly to remove it

partially from the print engine.

5. Free the scanner cable harness from the clips

underneath to remove the scanner from the frame

.

6. Lift the front part of the OPE front cover to release

the tabs securing it to the scanner.

COVER-OPE FRONT

Service Manual 5-5

Disassembly

7. Release the 3 clips on the front of the control panel,

unroute the wiring harness through the frame, and
remove the control panel (OPE).

Clips

8. Remove 4 screws securing the scan upper.

10. Remove the CCD cable as shown.

CCD Cable

11. Pull up on the CCD shaft to remove it from the

scanner.

Scanner Module

CCD Shaft

9. Unclip the scan upper from the scan assembly by

releasing 2 clips on each side, then pull the scan
upper straight up to remove.

Scan Upper

5-6 WorkCentre PE 120/120i

12. Squeeze the spring to release the tension on the belt

and lift the belt from the pulley. The belt should
still be attached to the scan module.

Spring

Belt

Disassembly

13. Remove the reduction gear and idle gear .

Gear-Reduction

Gear-Timing

Caution

When reassembling the scanner module: Place the
belt tension spring as close to the right side of the
scanner as possible.
When refitting the scan upper cover take care to
ensure that the cover open switch is not trapped.

15. Unplug the connector from the open sensor

assembly.

16. Unlatch the open sensor and remove.

Open Sensor

14. Remove 3 screws from the motor bracket and

remove the motor.

Motor Bracket

17. Remove the CCD lock.

Unlock

CCD Lock

Lock

Service Manual 5-7

Disassembly

5.6 ADF Motor Assembly

(PL 8.3.3)

1. First remove:

a. Rear cover, see page 5-2.
b. Left side cover, see page 5-3.

Note

It is not necessary to disassembly the ADF to
replace the separator pad, simply open the cover
and remove the pick up assembly.

1. Unclip the harness from the platen cover and

remove 2 screws securing the ADF assembly.

2. Lift up on the ADF assembly and thread the

harness out of the frame, then remove the ADF.

ADF Ass’y

3. Remove the open cover.

Open Cover

Caution

When working on the ADF motor, do not
contaminate any of the rubber surfaces with grease
or oil.

4. Release the bushing and rotate the pick up

assembly until it reaches the slot as shown below.
then lift the pick up assembly out.

Pick up Ass’y

Bushing

5-8 WorkCentre PE 120/120i

Disassembly

5. Remove 2 screws securing the upper cover, and

remove the cover.

Upper Cover

6. Unplug 1 connector and remove 5 screws securing

the ADF motor assembly. Remove the motor.

Note

Before removing the motor assembly, note the
position of the ferrite and harness routing.

ADF Motor Ass’y

ADF Lower Ass’y

5.7 OPE (Control Panel)

(PL 8.4)

1. First remove:

a. Rear cover, see page 5-2.
b. Side covers, see page 5-3.
c. Steps 6 and 7 on page 5-4.

2. Remove 10 scre ws securing the control panel co ver

to the control panel board.

Replacement Notes:

Caution

When refitting the ADF motor assembly, ensure
the harness and ferrite are properly located and
clear of the motor fan and white bar clip.

OPE Cover

OPE PBA

Service Manual 5-9

Disassembly

5.8 Middle Cover and Exit Roller

(PL 8.6) and (PL 8.7.63)

1. First remove:

a. Rear cover, see page 5-2.
b. Left and right side covers, see page 5-3.
c. Scanner assembly, see page 5-4.

2. Remove 4 screws securing the middle cover.

4. Remove the exit gear and bearing to remove the

exit roller.

3. Remove 2 screws securing the controller shield to

the middle cover , see 5.9 step 2. Unclip the middle
cover from the frame, be sure and release the shield
assembly locator pegs, then lift the cover off.

Middle Cover

5-10 WorkCentre PE 120/120i

5.9 Controller Shield Assembly

(PL 8.1.7)

1. First remove:

a. Rear cover, see page 5-2.
b. Right side cover, see page 5-3.\

2. Remove all the connectors and 5 screws. Remove

the shield.

Controller Shield Ass’y

Disassembly

Main Board

Bracket

3. Remove the network card if equiped (2 screws).

4. Remove 3 screws to remove the bracket from the

main board.

Service Manual 5-11

Disassembly

5.10 Engine Shield and Exit Board

(PL 8.1.10)

1. First remove:

a. Rear cover, see page 5-2.
b. Left and right side covers, see page 5-3.

2. Unplug the exit, AC, LIU, and fan connectors.

Exit Connector

Main Connector

AC Connector

3. Remove 11 screws securing the engine shield and

tilt to one side.

4. Unplug all the HVPS and SMPS harnesses.

Fan Connector

Engine Shield Assy

5. Remove 2 screws to remove the exit board.

Exit Board

5-12 WorkCentre PE 120/120i

5.11 SMPS and LIU

Disassembly

(PL 8.1.6 and PL 8. 1.13)

1. First remove:

a. Rear cover, see page 5-2.
b. Left and right side covers, see page 5-3.
c. Engine shield assembly, see page 5-12.

2. Remove 2 screws securing the inlet bracket.

Inlet Bracket

4. Remove 3 screws securing the SMPS and lift out

the SMPS.

SMPS

3. Remove 1 screw from the engine shield ground

wire.

5. Remove 3 screws securing the LIU and lift out the

LIU>

Service Manual 5-13

Disassembly

5.12 Fuser Assembly

(PL 8.8)

1. First remove:

a. Rear cover, see page 5-2.

2. Unplug 2 connectors, one to the main board and

one to the SMPS.

3. Remove 4 screws securing the fuser assembly.

Fuser Ass’y

Heat Roller and Halogen Lamp

1. Remove 2 screws securing the halogen lamp then

separate the lamp from the heat roller.

Heat Roller

Halogen Lamp

Thermostat

1. Remove 2 bolts securing the thermostat, take care

not to lose the nuts. Remove the thermostat.

Bolts

Thermostat

Nuts

Guide and Fuser Cover

1. Remove 4 screws to remove the fuser cover.

2. Remove 2 screws from the input guide.

Claw

Fuser Cover

5-14 WorkCentre PE 120/120i

guide Input

Disassembly

Thermistor

1. Unroute the thermistor wiring harness.

Thermistor

5.13 Fan

2. Remove 1 screw securing the thermistor.

Thermistor

(PL 8.1.27)

1. First remove:

a. Rear cover, see page 5-2.
b. Right side cover, see page 5-3.

2. Unplug the connector from the SMPS to the

exhaust fan.

3. Remove 1 screw and take out the fan.

DC Fan

1.

Service Manual 5-15

Disassembly

5.14 Laser Scanner Unit (LSU)

(PL 8.1.4)

1. First remove:

a. Rear cover, see page 5-2.
b. Left and right side covers, see page 5-3.
c. Scanner assembly, see page 5-4.
d. Front cover, see page 5-4.
e. Middle cover, see page 5-10.

2. Remove 4 screws securing the LSU to remove it

from the frame.

3. Unplug the 2 connectors.

5.15 CRUM Board

(PL 8.7)

1. First remove:

a. Laser unit, see page 5-16.

2. Remove 4 screws to separate the CRUM board

from the main frame. Do not lose the springs.

5-16 WorkCentre PE 120/120i

CRUM Board

5.16 Drive Assembly

Disassembly

(PL 8.2)

1. First remove:

a. Rear cover, see page 5-2.
b. Side cover, see page 5-3.
c. Controller shield, see page 5-11.

2. Remove 5 screws securing the drive assembly.

Drive Ass’y

3. Take out the drive assembly then unplug the

connector from the motor board.

Drive Ass’y

Caution

The 6 screw holes have numbers stamped into the
base plate, when reinstalling the drive assembly the
screws must be tightened in the order they are
numbered. Screw 6 is fitted with the controller
shield.

5.17 Cover Mid Front

(PL 8.1.19)

1. First remove:

a. Rear cover, see page 5-2.
b. Side cover, see page 5-3.
c. Middle cover, see page 5-10.

2. Remove 4 screws securing the cover mid front and

release 2 clips from the center as shown.

clips

Cover Mid Front

Service Manual 5-17

Disassembly

5.18 Transfer Assembly

(PL 8.1.7)

1. First remove:

a. Rear cover, see page 5-2.
b. Left and right side covers, see page 5-3.
c. Scanner assembly, see page 5-4.
d. Front cover, see page 5-4.
e. Middle cover, see page 5-10.
f. Laser unit, see page 5-16.

2. Remove the transfer roller by pressing the latch

with a small screwdriver.

3. Unlatch the bushing and remove. Lift the transfer

roller out as shown.

Transfer Roller

Bushing

Note

Experienced technicans may be able to remove the
transfer roller by performing step 2 only.

Hook

5.19 Feed Assembly

(PL 8.1.15)

1. First remove:

a. Rear cover, see page 5-2.
b. Left and right side covers, see page 5-3.
c. Front cover, see page 5-4
d. Scanner assembly, see page 5-4.
e. Middle cover, see page 5-10.
f. Controller shield, see page 5-11.
g. Drive assembly, see page 5-17.

2. Remove 4 screws securing the guide paper front.

Guide Paper Front

5-18 WorkCentre PE 120/120i

Disassembly

3. Remove the screws on the left and right sides of the

paper guide to remove the guides and the spring as
shown.

Screw

Spring

Guide Paper

4. Remove the 3 screws securing the feed bracket and

remove the bracket.

5. Remove the feed gear 2.

Feed Gear2

6. Remove the feed gear 1.

Feed Bracket

Feed Gear1 Ass’y

7. Remove feed roller and feed roller 1 as shown.

Feed Roller

Feed Roller1

Service Manual 5-19

Disassembly

5.20 Pick Up Assembly

(PL 8.7)

1. First remove:

a. Rear cover, see page 5-2.
b. Left and right side covers, see page 5-3.
c. Front cover, see page 5-4
d. Scanner assembly, see page 5-4.
e. Middle cover, see page 5-10.
f. Controller shield, see page 5-11.
g. Engin e shield, see page 5-12
h. Drive assembly, see page 5-17.
i. Feed assembly, see page 5-18

2. Remove the pick up gear assembly.

Pick up Gear Ass’y

4. Remove the 2 screws securing th e manual soleno id

and pick up solenoid.

Pick Up Solenoid

Manual Solenoid

3. Take out the pick up assembly as shown.

Bush

1

2

Replacement

1. To replace the pick up roller, slide the stopper

securing the sponge roller to the right and then turn
the sponge roller to remove from the shaft.

Stopper

Sponge Roller

Note

It is not necessary to disassemble the system to
replace the MP or Main cassette pick rollers.

Shaft

5-20 WorkCentre PE 120/120i

Disassembly

MP or Main Cassette Pick Rollers

1. Remove the main paper tray, toner cartridge, and

front cover, see page 5-4.

Main Cassette

1. Release the white catch and slide the locking piece

as far to the side as possible.

2. Slide the white collar as far to the side as possible.

3. Slide the pick up roller until it is free from the

white collar on the opposite end.

4. Rotate the pickup roller around the drive shaft until

it can be removed.

2. Slide the white collar as far to the side as possible.

3. Slide the pick up roller until it is free from the

white collar on the opposite end.

4. Rotate the pickup roller around the drive shaft until

it can be removed.

MP Pick Roller

1. Release the white catch and slide the locking piece

as far to the side as possible.

Service Manual 5-21

Disassembly

5-22 WorkCentre PE 120/120i

Alignment and

Sensor-Doc

Sensor-Regi

White-Sheet

Sensor-Scan

Alignment and Adjustments

6

Adjustments

This chapter describes some of the main service procedures including: Using EDC mode, clearing paper jams
and test patterns. Much of this chapter is also included in the user's guide.

6.1 Paper Path

Scanner Part

ADF-Roller

Pickup-Roller

ADF-Idle Roller

Feed-Roller

Sensor-Regi

Sensor-Regi

CCD-Module

Sensor-Scan

Sensor-Scan

White-Sheet

White-Sheet

Sensor-Doc

Sensor-Doc

Doc-Paper(30Sheets)

Exit-Roller

Engine Part

Toner Cartridge

DR

SR

PTL

TR FR

6

3

2

8

R

/

K

C

I

P

4

Fuser

PR

7

1

L S U

CR

OPC

5

1. After receiving a print command, the printer feeds paper from the main cassette or the bypass tray.

2. The paper being fed passes the paper feed sensor. (Jam 0 occurs if the sensor is not actuated within a specified

amount of time).

3. Having passed the paper feed sensor the paper moves to the paper exit sensor via the print process. (Jam 1

occurs if the sensor is not actuated within a specified amount of time)

4. The paper then passes through the paper exit sensor and out of the system. (Jam 2 occurs if the trailing edge of

the paper does not pass the exit sensor within the specif ied time between the papers leading edge acti v ating the
exit sensor).

Service Manual 6-1

Alignment and Adjustments

White-Sheet

6.1.2 Copy and Scan Paper Path

Scanner Part

6.1.3 Printer Paper Path

Engine Part

7

CCD-Module

5

3

6

White-Sheet

White-Sheet

2

1

1

Doc. Paper (50 Sheets)

Pickup Roller

2

4

ADF Roller

3

Sensor - Doc.

4

8

Sensor - Regi

5

Sensor - Scan

6

Feed Roller

7

Exit Roller

8

3

Fuser

PR

7

1

1

Paper Input (Cassette)
Paper Input (Manual Feeder)

2

Paper Out (Face Down)

3

Paper Empty Sensor (Manual)

4

L S U

CR

OPC

TR FR

5

5

Paper Empty Sensor (Cassette)
Paper Feeding Sensor

6

Paper Exit Sensor

7

Toner Cartridge

DR

SR

PTL

6

4

R

/

K

C

I

P

2

6-2 WorkCentre PE 120/120i

6.2 Clearing Paper Jams

Sensor-Doc

Sensor-Regi

White-Sheet

Sensor-Scan

Alignment and Adjustments

L S U

Empty Sensor

CR

DR

OPC

SR

PTL

TR FR

Toner Cartridge

MP Sensor

Feed

Sensor

R

/

K

C

I

P

ADF-Idle Roller

Sensor-Regi

Sensor-Regi

Feed-Roller

ADF-Roller

Sensor-Scan

Sensor-Scan

White-Sheet

White-Sheet

Pickup-Roller

Sensor-Doc

Sensor-Doc

Doc-Paper(30Sheets)

Exit-Roller

Fuser

EXIT
Sensor

PR

Document Jam (in the ADF area) Paper Jam 0 ( in the paper feed area)

Fuser

EXIT
Sensor

L S U

Toner Cartridge

CR

DR

OPC

PR

Empty Sensor

SR

PTL

Feed

Sensor

TR FR

P

MP Sensor

R

/

K

C

I

Fuser

EXIT
Sensor

PR

L S U

Empty Sensor

CR

DR

OPC

PTL

TR FR

Toner Cartridge

SR

Feed

Sensor

R

/

K

C

I

P

MP Sensor

Paper Jam 1 (around the fuser or toner cartridge) Paper Jam 2 ( in the fuser or exit path)

The leading causes of paper jams are:

■ The tray is loaded improperly or overfilled.

■ The tray has been pulled out during a print job.

■ The front cover has been opened during a print

job.

■ Paper that does not meet specif ications has been

used.

■ Paper that is outside of the supported size range

Fuser

EXIT
Sensor

L S U

Toner Cartridge

CR

DR

OPC

PR

Empty Sensor

SR

PTL

Feed

Sensor

TR FR

P

MP Sensor

R

/

K

C

I

has been used.

MP Tray Jam (in the bypass tray area)

If a paper jam occurs, an error message appears on the LCD display. Remove any visible jammed paper in the
system. If there is no paper visible, look inside the printer. If the paper tears while removing a jam, ensure that ALL
fragments of paper are removed from within the system.

Caution

Do not use tweezers or other sharp metal tools when removing a paper jam. You can damage the toner
cartridge, fuser rollers, or damage wiring leading to the potential for electric shock.

Service Manual 6-3

Alignment and Adjustments

6.2.1 Clearing ADF Jams

“Document Jam” appears on the display if a jam has occured while feeding paper through the ADF.

6.2.1.1 ADF Misfeed

1. Open the top cover and gently pull the document gently to the right and out the ADF

2. Close the ADF top cover and reload the document(s).

Note

To prevent ADF document jams, use the platen for thick, thin or mixed document media.

6.2.1.2 ADF Exit Misfeed or ADF Roller Misfeed

1. Lift the document cover.

2. Turn the release knob to remove misfeeds from the feed or exit area.

3. Close the document cover and reload the documents.

6-4 WorkCentre PE 120/120i

Alignment and Adjustments

6.2.2 Jam 0 - Paper in the Feed Area

1. Open and close the front cover, this causes the jammed paper to automatically exit the system.

2. If the paper does not exit the system, open the paper tray and remove pulling the media straight out.

3. Open and close the front cover to resume printing.

Note

If there is too much resistance, the paper does not
move when pulling on it or if the paper is not
visible, go to Jam 1, fuser or toner cartridge jam.

6.2.3 Jam 1 - Paper in the Fuser Area or Around the Toner Cartridge

Caution

The fuser area is HOT. Be careful when removing paper.

1. Open the front cover and remove the toner cartridge.

2. Remove the jammed paper by pulling it straight out.

3. Replace the toner cartridge and close the front cover to continue printing.

Front

Back

Service Manual 6-5

Alignment and Adjustments

6.2.4 Jam 2 - Paper in the Exit Area

1. Open and close the front cover, this causes the jammed paper to automatically exit the system.

2. Remove the jammed paper by pulling it straight out.

3. If there is any resistance, open the rear cover and and remove the jammed paper from the back of the system.

Front

Back

6.2.5 MP Tray Jam - Paper in the Bypass Tray

This jam occurs when using the MPT or bypass tray. The system does not detect paper in the tray due to the
absence of media or improper loading.

6-6 WorkCentre PE 120/120i

6.3 Control Panel Menu

Alignment and Adjustments

1.Paper Setting

Copy Tray
Fax Tray
Paper Tray
Paper Size

5.Fax Feature

Delay Fax
Priority Fax
Add Page
Cancel Job

2.Machine Setup

Machine ID
Date&Time
Clock Mode
Language
Power Save
Scan Power Save
Import Settings
Export Settings
USB Mode

6.Advanced Fax

Send Forward
RCV Forward
Toll Save
Junk Fax Setup
Secure Receive
Prefix Dial
Stamp RCV Name
ECM Mode

3.Copy Setup

Change Default
Timeout

7.Reports

4.Fax Setup

Receive Mode
Ring to Answer
Lighten/Darken
Redial Term
Redials
MSG Confirm.
Auto Report
Auto Reduction
Discard Size
RCV Start Code
DRPD Mode

Phone Book
Sent Report
RCV Report
System Data
Scheduled Jobs
MSG Confirm
Junk Fax List

8.Network Setup

Reset Network
Config Network
Set to Default
Print Net CFG

9.Sound/Volume

Speaker
Ringer
Key Sound
Alarm sound

Service Manual 6-7

0.Maintenance

Clean Drum
Auto Cleaning
Notify toner
Clear Settings

Alignment and Adjustments

6.4 Tech Mode

In Tech (service) Mode the technician can check the system and perform various tests to help with diagnosing
problems. While in Tech Mode the system still performs all normal operations.

6.4.1 Entering Tech Mode

1. Press the following buttons in order: Menu, #, 1, 9, 3, 4

2. The LCD displays ‘TECH’ and the system is now in Tech Mode.

6.4.2 Tech Mode Menu

6.4.3 Data Setup

SEND LEVEL:

This sets the fax send level for the transmission signal. Typically, the transmission (send) lev el should be under

-12 dBm.

Note

The send fax level is set for optimal performance at the factory. Do not change this setting unless it is
needed for troubleshooting.

DIAL MODE:

This function chooses the dialing method for Tone or Pulse. The default is Tone.

MODEM SPEED

This sets the modem speed.
When the fax establishes communication with a remote set, the value of the maximum modem speed is

checked for both transmitter and receiver. The lowest value is used. It is best set to the default setting of

33.6Kbps.

6-8 WorkCentre PE 120/120i

Alignment and Adjustments

ERROR RATE

When the error rate is about to exceed the set value, the Baud rate automatically adjusts to 2400 bps, this
ensures that the error rate remains below the set value. You can select a rate between 5% and 10%.

CLEAR ALL MEMORY

All the values are returned to default, and all the information which was set by the user will be erased.

1. Select Clear All Memory in TECH MODE.

2. Push the ENTER button.

3. Select your country group. (There are four country groups. Refer to the table below.)

4. Push the ENTER button again, the system will now clear all memory.

Caution

If the main board is replaced, a memory clear needs to be performed for the system to operate properly.

Country Group USA/Canada UK Russia South Africa

Country

USA/Canada UK Russia South Africa

Mexico Germany India

Brazil France Oman

Italy Poland

Spain Bangladesh

Austria Kuwait

Netherlands Moroco

Belgium Algeria

Portugal Pakistan

Sweden UAE

Norway Bahrain

Denmark Srilanka

Finland Saudi Arabia

Switzerland Chile

Greece Peru

Ireland Argentina

Turkey Hungary

Romania

Bulgaria

Czech

Service Manual 6-9

Alignment and Adjustments

6.4.4 Machine Te st

SWITCH TEST

This feature is used to test all the buttons/keys on the control panel. The results are displayed on the LCD each
time a button/key is pressed.

MODEM TEST

This is used to hear various transmission signals to the telephone line from the modem. It is also used to check
the modem, amplifier and speaker. If no transmission signal sound is heard, the modem piece on the main
board, amplifier, speaker or speaker harness is faulty.

DRAM TEST

This tests the systems DRAM. The results appear on the LCD. If all memory is working properly the LCD
reports <OK>.

ROM TEST

This tests the systems ROM. The result and the software version appear on the LCD:

■ FLASH VER: #.##V

■ ENGINE VER: #.##V

PATTERN TEST

This prints a test pattern to verify the system is function properly. This is a factory use only test.

SHADING TEST

This prints a test pattern to see if the scan quality, determined by characteristics in the CCD, are optimal. If
image quality is noticeably poor the CCD may need replacement. This is a factory use only test.

6.4.5 Report

PROTOCOL LIST

This list shows the sequence of the CCITT group 3 T:30 protocol during the most recent sending or receiving
operation. Use this list to check for send and receive errors.

SYSTEM DATA

This list provides the user system data settings and tech mode settings.

6-10 WorkCentre PE 120/120i

Alignment and Adjustments

6.5 Engine Test Mode

The engine test mode supplies functions to check the condition of each device in the print engine and displays the
result of the test on the LCD. It is divided into 5 functions (0 - 4).

6.5.1 Entering Engine Test Mode

1. Press the following buttons in order: Menu, #, 1, 9, 3, 1

2. The LCD briefly displays ‘ENGINE TEST’ and the system is now in Engine Test Mode.

3. Press 0, 1, 2, 3, or 4 to select the test number.

Test Number Sub Number Engine Test Results

1 Motor Test 1 : On, 2 : Off – next test selected

2 Pick Up Test 1 : On, 2 : Off – next test selected

0

3 Fan Test 1 : On, 2 : Off – next test selected

4 Manual Clt Test 1 : On, 2 : Off – next test selected

5 PTL Test 1 : On, 2 : Off – next test selected

1 LSU Motor Test 1 : On, 2 : Off – next test selected

1

2

3

4

2 LSU Hsync Test 1 : On, 2 : Off – next test selected

3 LD Test 1 : On, 2 : Off – next test selected

1 Feed Sensor Test 1. Check : read the sensor 2. Next : Next Sensor test

2 Exit Sensor Test 1. Check : read the sensor 2. Next : Next Sensor test

3 Cover Sensor Test 1. Check : read the sensor 2. Next : Next Sensor test

4 Empty Sensor Test 1. Check : read the sensor 2. Next : Next Sensor test

5 Manual Sensor Test 1. Check : read the sensor 2. Next : Next Sensor test

1 Therm ADC 180 1 : On, 2 : Off (maintain the fusing temp. 80ÞC)

2 Therm ADC 140 1 : On, 2 : Off (maintain the fusing temp. 135ÞC)

3 Therm ADC 120 1 : On, 2 : Off (maintain the fusing temp. 160ÞC)

4 Therm ADC 100 1 : On, 2 : Off (maintain the fusing temp. 191ÞC)

1 MHV Test 1 : On, 2 : Off (-1550V ± 50V)

2 Dev Bias Test 1 : On, 2 : Off (-430V ± 20V)

3 THV EN/NEG Test 1 : On, 2 : Off (-1200V +300V/-150V)

4 THV ON (1300V) 1 : On, 2 : Off (+1300V ± 20V)

5 THV ADC 1300V 1 : On, 2 : Off (ADC Value : 101 ± 5)

6 THV ADC 600V~3500V 1 : On, 2 : Off (Compare each ADC Value)

Service Manual 6-11

Alignment and Adjustments

6.5.3 Detailed Description Engine Test Mode

Function Name Description Display

01. Motor Test The main motor starts when executed and stops when
the stop key is pressed.

02. Pick Up Test Automatically stops, when the execution key is chosen. Tray 1, 2 Solenoid On/Off

03. Fan Test The fan starts at execution and stops when the stop key
is pressed.

04. Manual Clutch Test The tray 2,3 clutch is on for 1second at execution and
then automatically stops.

The main motor runs for 2 seconds from the time of the
clutch ON, in order to check the clutch state.

05. PTL Test PTL(Pre-Transfer Lamp) turns on at execution and stops
when the stop key is pressed.

11. LSU Motor The laser motor starts when executed and stops when
the stop key is pressed.

12. LSU Hsync Test The LSU motor starts and "Laser Ready" is displayed if
the motor spins at the correct speed, otherwise a "Laser
Error" will display.

13. LD Test "Diode On" is displayed, when the laser diode is on.
Otherwise "Diode Off" is displayed.

21. Feed Sen Test These functions allow the current state of the sensor to

22. Exit Sen Test

23. Cover Sen Test This allows the current state of the cover sensor to be

24. Empty Sen Test These functions allow the current state of the sensor to be"Sensor Off" or “ Sensor On ”

be displayed.

displayed. Actuate the sensor and confirm that the
message changes: "Cover Open" /" Cover Close”

Main Motor On/Off

Fan On/Off

Tray 2, 3 Clutch On/Off

PTL On/Off

Laser Motor On/Off

Laser Leady On/Off

Diode On/Off

"Sensor Off" or “ Sensor On ”

"Cover Open" or "Cover Close"

25. Manual Sen Test displayed.

31. Therm ADC 180 "Current value" is displayed on the upper line of the LCD,

32. Therm ADC 140

33. Therm ADC 120

34. Therm ADC 100

41. MHV Test These functions are provided to check whether the

42. Dev Bias Test Dev Bias On/Off

43. THV EN/NEG Test THV EN/NEG On/Off

44. THV ON(1300V) THV On/Off

45. THV ADC 1300V ADC value displayed.

46. THV ADC 600V~3500 ADC value displayed.

and "Target value" is displayed on the bottom line.
Target value is limited from "191°

control of the HVPS is functioning correctly.

C

" to "80°

C

Target temperature and
output temperature from
thermistor and ADC.

MHV On/Off

6-12 WorkCentre PE 120/120i

Alignment and Adjustments

6.6 Identify Sale Date

This function confirms the date that the consumer bought the product and used the product for the first time. When
the consumer first operates the system, it will start the scan and page counters. The time the system was first used is
also displayed.

Note

These settings are stored even after a memory delete (Clear All Memory).

To use this function:

1. Press MENU, #, 1, 9, 3, # in sequence. The Firmware version is displayed on the LCD.

2. Press 1 (on the number keypad) : The LCD display shows "Updated date"

3. Press 2 (on the number keypad) : The LCD display shows "Product first use date"

Service Manual 6-13

Alignment and Adjustments

6.8 Periodic Defective Image or Abnormal Printing

If a mark or other printing defect occurs at regular intervals down the printed page it may be caused by a damaged
or contaminated roller. Measure the repeating defect and refer to the table below to identify the problem
component.

L S U

Fuser

PR

1

OPC Drum

Charge Roller

2

Supply Roller

3

Developing Roller

4

No Roller Defective image Typical defect

1 OPC Drum 75.5 mm white spot on black image or black spot
2 Charge Roller 37.7 mm black spot
3 Supply Roller 44.9 mm light or dark horizontal density image band
4 Developing Roller 35.2 mm horizontal density band
5 Transfer Roller 47.1 mm Back side contamination/transfer fault
6 Heat Roller 77.8 mm black spot and fuser ghost
7 Pressure Roller 75.4 mm black spot on the backside

CR

DR

OPC

TR FR

Toner Cartridge

SR

PTL

R

/

K

C

I

P

5

Transfer Roller

Heat Roller

6

Pressure Roller

7

MP Sensor

PTL

6-14 WorkCentre PE 120/120i

Alignment and Adjustments

6.9 Error Messages

The front panel displays the printer's status or error messages. Refer to the list below for an explanation of these
messages and how to clear problems.

MP TRAY JAM [DOOR OPEN]

A paper jam has occurred in the bypass feeder or the media has been improperly fed.
Solution: Clear the paper jam. Load paper in the bypass feeder correctly.

Cancel ? 1. Yes 2. No

While storing the document in memory the memory has become full.
Solution: To cancel the fax job, press the ‘1’ button to accept “Yes.” If you want to send the pages that were

stored press the ‘2’ button to accept “No.” This will send ONLY the pages stored. The remaining pages should
be sent later when more memory becomes available.

[COMM. Error]

The multi-function printer has a communication problem.
Solution:Ask the sender to try again.

Low Heat Error / Open Heat Error

There is a problem in the fuser unit.
Solution: Check thermostat, thermister contact point & Heating Lamp.

[Over Heat]

The printer has overheated.
Solution: The system will automatically return to standby mode when it cools down to a normal operating

temperature. If this error persists, check the Fuser assembly and wiring.

Delayed Function Full

The delayed fax job list or memory space is full.
Solution: Cancel any unnecessary delayed fax jobs.

Document Jam

The loaded document has jammed in the Automatic Document Feeder (ADF).
Solution: Clear the document jam.

[Door Open]

The front or rear cover is not securely latched.
Solution: Close the cover until it locks into place.

Service Manual 6-15

Alignment and Adjustments

Enter Again

Unavailable item entered.
Solution: Enter the correct item again.

Function Impossible

A combination of printer functions that can not be used at the same time.
Solution: Reduce the number of selected functions or use only one function at a time.

Group Not Available

Selected a group location number where only a single location number can be used, such as when adding
locations for a broadcasting operation.

Solution: Use a speed dial number or dial the number manually using the numb er keypad.

[LSU Error]

A problem has occurred in the Laser Scanning Unit (LSU).
Solution: Use Engine Test mode to test LSU. Replace the LSU

Invalid Cartridge or No Cartridge

A non-Xerox brand toner cartridge is installed.
Solution: You must use a Xerox toner cartridge.

[Line Error]

The system cannot connect with the remote machine or has lost contact because of a problem with the phone
line.

Solution: Try again. If the problem persists, wait an hour or so for the line to clear and try again. Or, turn the
ECM on.

Memory Full

The memory is full.
Solution: Delete any unnecessary documents (delayed transmission, broadcast or polling jobs) or retransmit

after more memory becomes available. This can also be caused when a large complex document with many
pages is being sent, try splitting the job into more than one operation.

[No Answer]

The remote fax machine has not answered after several redial attempts.
Solution: Try again. Verify the number to make sure a fax can be received.

No. Not Assigned

The speed dial location used has no number assigned to it.
Solution: Dial the number manually using the number keypad or assign the number.

6-16 WorkCentre PE 120/120i

Alignment and Adjustments

No. Not Available

The user tried to delete the number for a delayed fax job.
Solution: Verify the number to be deleted and try again. Or Delete the number after the delayed fax job is

completed or deleted.

[No Paper] Add Paper

The paper in the paper tray has run out.
Solution: Load paper in the paper tray.

Operation Not Assigned

The user is performing an Add / Cancel operation, but there are no jobs waiting.
Solution: Check the display to see if there are any scheduled jobs. The display should indicate if any scheduled

jobs are in Standby mode, for example, Delay Fax.

[Paper Jam 0] Open/Close Door

Paper has jammed in the feeding area of the paper tray.
Solution: Clear the jam.

[Paper Jam 2] Check Inside

Paper has jammed in the paper exit area.
Solution: Clear the jam.

[Power Failure]

The power has been turned off and then on and the printer’s memory has not been saved.
Solution: The printer’s memory was not saved due to a power failure. The job will need to be started over.

Registered

The group dial location is already registered with another speed dial number.
Solution: Select another group dial location.

[Retry Redial?]

The multi-function printer is waiting for a specified time interval to redial a previously busy station.
Solution: You can press <Select>to immediately redial, or <Cancel>to cancel the redial operation.

[Toner Low]

The toner is almost empty.
Solution: Take out the toner cartridge and gently shake it. By doing this, you can temporarily reestablish

printing operations.Or Replace the toner cartridge with a new one for the best print quality.

Priority Fax Function Full

The priority fax job queue is full.
Solution: Cancel any unnecessary priority fax jobs.

Service Manual 6-17

Alignment and Adjustments

[Incompatible]

The remote machine did not have the requested feature, such as a sending a color fax. This message also occurs
if the remote machine does not have enough memory space to complete the operation you are attempting.

Solution: Reconfirm the remote machine’s features.

[Jam 1] or [No Cartridge]

Paper has jammed in the paper exit area. Or, the toner cartridge is not installed.
Solution: Clear the jam. Or, install the toner cartridge.

[Line Busy]

The receiving party did not answer or the line is already engaged.
Solution: Try again after a few minutes.

Load Document

The user attempted to set up a copy or fax operation with no document loaded into the ADF.
Solution: Load a document into the ADF and try again.

Scanner Locked

The scanner module is locked
Solution: Unlock the scanner and press Stop/Clear.

[Stop Pressed]

The Stop/Clear button has been pressed during a copy or fax operation.
Solution: Try again.

[Toner Empty] Replace Toner

The toner cartridge has run out. The machine stops printing.
Solution: Replace the toner cartridge with a new one.

[Retry Redial?]

The system is waiting for a specified time interval to redial a previously busy station.
Solution: You can press Enter to immediately redial, or Stop/Clear to cancel the redial operation.

6-18 WorkCentre PE 120/120i

Troubleshooting

7

7.1 Paper Feed Problems

7.1.1 Wrong Print Position

Printing begins at the wrong position on the paper.

Possible Cause Solution

Troubleshooting

1. Defective feed sensor. a. Replace the defective acutator/sensor.

7.1.2 Jam 0

Description:
Paper does not leave the tray.
Jam 0 occurs if the paper is fed into the printer.

L S U

Fuser

EXIT

PR

Sensor

Empty Sensor

Possible Cause Solution

1. Defective solenoid.

2. Defective tray or bypass knock up plate and springs.

3. Defective or damage paper separator pad.

4. Contaminated pick rollers.

CR

DR

OPC

SR

PTL

TR FR

Toner Cartridge

MP Sensor

Feed

Sensor

R

/

K

C

I

P

a. Use Tech Mode to test the solenoid.

Replace the solenoid if defective.

b. Check the cassette or bypass tray knock up

plate. Repair or replace as required.

c. Clean the separator pad, or replace as

required.

d. Replace the tray if defective.
e. Clean the pick rollers. Replace if defective.
f. Ensure all rollers are free from debris and

rotating freely.

g. Check the SMPS, main board and all

connections. Replace any defective parts.

Service Manual 7-1

Troubleshooting

7.1.3 Jam 1

Fuser

EXIT
Sensor

Description:
There is a paper jam in front of or inside the fuser.

L S U

Toner Cartridge

CR

DR

OPC

PR

Empty Sensor

SR

PTL

Feed

Sensor

TR FR

P

MP Sensor

R

/

K

C

I

There is a paper jam stuck in the discharge roller
and in the fuser, just after passing the feed actuator.

Possible Cause

1. Defective exit sensor/actuator.

2. Defective feed actuator.

7.1.4 Jam 2

Fuser

EXIT

PR

Sensor

Possible Cause Solution

L S U

Empty Sensor

CR

DR

OPC

SR

PTL

TR FR

Toner Cartridge

MP Sensor

Feed

Sensor

R

/

K

C

I

P

Solution

a. Replace the exit sensor, SMPS, or main

board.

b. Replace the feed actuator and spring if

defective.

Description:
There is a jam in front of or inside the fuser.
Paper is stuck in the discharge roller and in the

fuser just after passing through the feed actuator..

1. If the paper has exited the printer and a Jam2 occurs the

exit sensor is defective:

■ After paper passes the exit sensor, the flag should return

to its normal position. The flag may stick or return too
slowly due to contamination or foreign objects
obstructing its path.

2. If there is an accordian paper jam in the fuser:

■ The guide claw is damaged.

■ The spring on the guide is damaged.

■ The heat roller or pressure roller is contaminated with

toner.

7-2 WorkCentre PE 120/120i

a. Look for debris or contamination around the

exit sensor and actuator.

b. Check the exit sensor and actuator for

damage.

c. Replace if defective.
d. Replace the fuser.

7.2.5 Multiple Pick

Description: Multiple sheets of paper are picked from the tray at the same time.

Possible Cause Solution

Troubleshooting

1. The paper guides are set incorrectly.

2. The paper has a rough surface.

3. The friction pad is damaged or contaminated.

4. The solenoid is not functioning properly.

7.2.6 Paper Rolled in the Fuser

Description: There is an accordian jam in the fuser.

Possible Cause Solution

1. The pressure roller or heat roller is damaged or not

functioning properly.

2. The paper guides or springs are damaged.

a. Adjust the guides so they fit snuggly against

the paper in the tray.

b. Make sure the paper size selected in the

print driver is the same as the paper in the
tray.

c. Use the appropriate supported paper type

for this printer. Try a paper with a smoother
surface.

d. Clean the friction pad or replace if

damaged.

e. Replace the solenoid.

a. Replace the fuser.

7.2.7 Paper Rolled in the OPC Drum

Description: Paper is caught or rolled up in the OPC.

Possible Cause Solution

1. The paper is too thin.

2. The paper is curled.

a. Use the appropriate supported paper type

for this printer.

b. Load a fresh ream of paper.

NOTE: To remove paper rolled up in the OPC:

■ Remove the toner cartridge from the printer,

take care not to touch the green surface. use
the gerar on the side to rotate the OPC drum
and pull the paper from the toner cartridge.

■ Clean any fingerprints on the OPC gently with a

soft, lint free cloth, using caution not to scratch
the surface.

Service Manual 7-3

Troubleshooting

7.2.8 Defective ADF

Description: The ADF does not operate correctly

Possible Cause Solution

1. The ADF rubber or holder rubber are damaged or

contaminated.

2. The ADF document sensors (3 paper sensors) are not

working correctly.

a. Replace the contaminated or damaged part.
b. Replace the sensors or ADF.

7-4 WorkCentre PE 120/120i

7.2 System Malfuction

7.2.1 LCD Display is Defective

Description: Strange characters are displayed on the LCD window and the control panel buttons do not work.

Possible Cause Solution

Troubleshooting

1. Memory needs to be cleared.

2. The control panel or harness may be defective.

a. Use Clear All Memory from Tech Mode.
b. Try reseating the control panel harness.

Replace the harness or control panel if
defective.

c. Replace the main board.

7.2.2 Defective Control Panel Keypad

Description: The buttons on the control panel do not work, or respond incorrectly.

Possible Cause Solution

1. Memory needs to be cleared.

2. The control panel or harness may be defective.

a. Use Clear All Memory from Tech Mode.
b. Try reseating the control panel harness.

Replace the harness or control panel if
defective.

c. Replace the main board.

7.2.3 Fuser Gear Melted Due to Overheating, Causing a Paper Jam

Description: Constant jam where paper is entering the fuser unit or the fuser rollers are not turning.

Possible Cause Sequence of Repair Actions

1. The heat lamp, thermistor, thermostat, or fuser rollers are

damaged.

Service Manual 7-5

a. Verify the fuser is running at optimal

temperatures.

b. Run a cleaning page.
c. Replace the fuser unit.
d. Replace the SMPS.
e. Replace the main board.

Troubleshooting

7.2.4 Paper Empty Error

Description: Paper empty is displayed even when paper is loaded in the tray.

Possible Cause Sequence of Repair Actions

1. The paper empty sensor or actuator is damaged or faulty.

2. The SMPS or main board is faulty.

3. Faulty cable or connector.

a. Replace the defective actuator or sensor.
b. Replace the SMPS.
c. Replace the main board.

7.2.5 Paper Empty Error Without Indication

Description: The tray is empty but not being reported on display.

Possible Cause Sequence of Repair Actions

1. The paper empty sensor or actuator is damaged or faulty.

2. The SMPS or main board is faulty.

3. Faulty cable or connector.

a. Replace the defective actuator or sensor.
b. Check and replace the wiring to the control

panel if faulty.

c. Replace the SMPS.
d. Replace the main board.

7.2.6 Cover Open

Description: A cover open message is displayed, even though the cover is closed.

Possible Cause Sequence of Repair Actions

1. The interlock may be stuck or faulty.

2. The interlock tab on the front cover may be damaged.

3. The sensor switch on the main board may be defective.

a. Use Tech Mode to run the Cover Sensor

b. Replace the interlock switch if faulty.
c. Replace the front cover.
d. Replace the main board.

7.2.7 No Error Message when the Cover is Open

Description: The front cover is open, but nothing is reported on the display.

Possible Cause Sequence of Repair Actions

1. The interlock may be stuck or damaged.

2. The control panel LED may be faulty.

3. The sensor switch on the main board may be faulty.

a. Use Tech Mode to run the Cover Sensor

b. Replace the interlock if faulty.
c. Replace the front cover.
d. Replace the cabling or control panel.
e. Replace the main board.

Test to check the cover switch operation.

Test to check the cover switch operation.

7-6 WorkCentre PE 120/120i

7.2.8 Defective Motor Operation

Description: The main motor is faulty and paper does not feed into the printer, resulting in a Jam0.

Possible Cause Sequence of Repair Actions

Troubleshooting

1. The main motor harness or motor board may be faulty.

2. The main board may be faulty.

a. Check motor operation.
b. Replace the motor or harness if faulty.
c. Replace the main board.

7.2.9 No Power

Description: When the printer is powered ON the LEDs on the control panel do not come on.

Possible Cause Sequence of Repair Actions

1. The SMPS or power input are faulty.

2. Control panel doesn’t come on, but other normal start-up

sounds are heard.

3. After replacing the SMPS, the lamps do not come on and

no start up sounds are heard.

a. Replace the power supply cable.
b. Check the power fuse on the SMPS, replace

the SMPS if necessary.

c. Check the control panel wiring. Replace the

harness or control panel if faulty.

d. Replace the main board.

7.2.10 Printed Vertical Lines Become Curved

Description: When printing the vertical lines are not straight.

Possible Cause Sequence of Repair Actions

1. The +24 V supply to the laser unit is faulty. a. Use the DCU test 05 to test the laser motor.
b. If the voltage is stable, replace the laser

unit.

c. If the voltage is not 24 volts, replace the

SMPS.

d. Replace the main board.

Service Manual 7-7

Troubleshooting

7.3 Print Quality Problems

7.3.1 Wrong Print Position

Example Possible Cause Sequence of Repair Actions

Printing begins with the paper in the wrong position.

1. Defective feed sensor. a. Replace the defective actuator.

7.3.2 Vertical White Lines

Example Possible Cause Sequence of Repair Actions

There are white, vertical voids in the printed image.

a. Clean the laser window with a

recommended cleaner (IPA) and a clean
cotton swab.

b. If dirt is inside the laser unit, replace it.
c. Replace the toner cartridge.
d. Open the front cover and check/remove any

contamination inside the printer that
corresponds to the position of the voids.

e. If the problem is not solved, replace the

toner cartridge.

f. Replace the transfer roller.

Digital Printer
Digital Printer
Digital Printer
Digital Printer
Digital Printer

1. Contamination on the window or

internal lens of the laser mirror.

2. Foreign object inside the toner

cartridge.

3. Low toner.

4. If the fuser is defective, voids occur

periodically at the top of a black
image.

5. Contamination on the OPC drum.

6. Depression or deformation on the

surface of the transfer roller.

7.3.3 Horizontal Black Band

Example Possible Cause Sequence of Repair Actions

Dark or blurry horizontal stripes periodically appear on the printed image.

Digital Printer
Digital Printer
Digital Printer
Digital Printer
Digital Printer

1. Bad contacts on the toner cartridge

high voltage terminals.

2. The rollers in the toner cartridge

may be contaminated.

■ Charge roller = 37.7 mm

■ Supply roller = 44.9 mm

■ Develop roller = 35.3 mm

■ Transfer roller = 47.1 mm

a. Clean all HV contacts on the cartridge and

primter frame.

b. Ensure all toner or paper dust particles are

removed.

c. Clean the Gear that has a relatively small

tooth gap on the OPC drum.

d. If the problem persists replace the toner

cartridge.

7-8 WorkCentre PE 120/120i