E460dn Service Manual

Revision Date: July 1, 2013
Lexmark E460dn
Lexmark E460dw
4513-630
4513-63W
4513-6EW
Table of contents
Start diagnostics
Safety and notices
Trademarks
Index
Lexmark and Lexmark with diamond design are

trademarks of Lexmark International, Inc., registered
in the United States and/or other countries.
Downloaded from www.Manualslib.com manuals search engine

4513-630, -63W, -6EW
Edition: July 1, 2013
The following paragraph does not apply to any country where such provisions are inconsistent with local law:
LEXMARK INTERNATIONAL, INC. PROVIDES THIS PUBLICATION AS IS WITHOUT WARRANTY OF ANY KIND,
EITHER EXPRESS OR IMPLIED, INCLUDING, BUT NOT LIMITED TO, THE IMPLIED WARRANTIES OF
MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. Some states do not allow disclaimer of express or
implied warranties in certain transactions; therefore, this statement may not apply to you.
This publication could include technical inaccuracies or typographical errors. Changes are periodically made to the
information herein; these changes will be incorporated in later editions. Improvements or changes in the products or the
programs described may be made at any time.
Comments may be addressed to Lexmark International, Inc., Department D22X/002-1, 740 West New Circle Road,
Lexington, Kentucky 40550, U.S.A or e-mail at [email protected]. Lexmark may use or distribute any
of the information you supply in any way it believes appropriate without incurring any obligation to you.
References in this publication to products, programs, or services do not imply that the manufacturer intends to make these
available in all countries in which it operates. Any reference to a product, program, or service is not intended to state or
imply that only that product, program, or service may be used. Any functionally equivalent product, program, or service that
does not infringe any existing intellectual property right may be used instead. Evaluation and verification of operation in
conjunction with other products, programs, or services, except those expressly designated by the manufacturer, are the
users responsibility.
Lexmark, Lexmark with diamond design and MarkVision are trademarks of Lexmark International, Inc., registered in the
United States and/or other countries.
PCL is a registered trademark of the Hewlett-Packard Company.
All other trademarks are the property of their respective owners.
2008 Lexmark International, Inc.

All rights reserved.
UNITED STATES GOVERNMENT RIGHTS

This software and any accompanying documentation provided under this agreement are commercial computer software
and documentation developed exclusively at private expense.
P/N 12G9813

4513-630, -63W, -6EW
Table of contents
Table of contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iii

Notices and safety information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . vii
Laser notice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . vii
Lithium warning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xiii
Safety information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xiii
Preface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xvi
Change history . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . v-xvi
Conventions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xvi
General information .................................................................... 1-1

Maintenance approach . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Overview of the operator panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Memory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Print quality settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Connectivity and compatibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Media trays and supply capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Types of print media . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
Tips on preventing jams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
Paper path . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
Acronyms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
Diagnostics information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Symptom tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Service errors (9xx.xxs) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
User status and attendance messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Overview of the operator panel and menus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Diagram of the printer menus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Messages and error codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
User attendance messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Cartridge error messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
Paper jam error codes (200-series) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
Service error codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15
Symptom tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21
POST symptom table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21
Printer symptom table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22
Service checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-23
Controller board service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-23
Cooling fan service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-24
Cover interlock switch service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-24
Dead machine service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-25
Fuser service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-26
LVPS/HVPS service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-26
Main motor service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-27
Media feed clutch service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-27
Operator panel service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-28
Paper feed service checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-28
Paper jam error indication during POST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-28
Media picks but stops halfway through the printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-28
Media never picks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-29
Table of contents iii

4513-630, -63W, -6EW
Media occasionally mispicks or picks multiple sheets at once . . . . . . . . . . . . . . . . . . . . . . . . .2-29

Media skews . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-29
Media trees, wrinkles, stacks poorly, or curls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-30
Parallel or USB port service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-30
Print quality service checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-31
Blank page . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-31
Black page . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-32
Heavy background . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-32
Partial blank image/white spots (no repeating pattern) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-33
Variation in image density horizontally across page . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-33
Poor fusing of image . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-33
Light print . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-34
White or black lines or bands . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-34
Toner on back of page . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-34
Solving print quality problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-35
Printhead service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-38
Service software service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-39
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-41
Transfer roll service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-42
Tray 2 service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-42
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-42
Diagnostic aids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

Accessing service menus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Configuration menu (CONFIG MENU) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-2
Entering Configuration Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-2
Available menus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Maintenance Count Value (Maint Cnt Value) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Reset Maintenance Count Value (Reset Maint Cnt) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Reset Photoconductor Maintenance Counter (Reset PC Cnt) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Print Quality Pages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-3
Reports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Menu Settings Page . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Event Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Panel Menus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
PPDS Emulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Demo Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Factory Defaults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Action For Prompts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Energy Conserve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Font Sharpening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-5
Exit Configuration Menu (Exit Config Menu) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-5
Diagnostics menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
Entering Diagnostics menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
Registration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
Margins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
Quick Test page . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
Print Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
Input sources . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
Print Quality Pages (Prt Quality Pgs) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-8
Hardware Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
Panel Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
Button Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
DRAM Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
Duplex Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
Quick Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
Top Margin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
Left Margin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
Sensor Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-10
iv Service Manual

4513-630, -63W, -6EW
Duplex Feed 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11

Input Tray Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
Feed Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
Sensor Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
Output bin tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12
Feed Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12
Sensor Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12
Base Sensor Test (B. Sensor Test) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12
Printer Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13
Defaults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13
Printed Page Count (Page Count) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13
Permanent Page Count (Perm Page Count) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13
Serial Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14
Service Tag (only on some printers) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14
Engine Setting 1 through 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14
Model Name . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14
Configuration ID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14
Edge to Edge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14
Par S Strobe Adj (parallel strobe adjustment) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14
EP Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15
EP Defaults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15
Fuser Temperature (Fuser Temp) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15
Transfer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15
Print Contrast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15
Charge Roll . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15
Gap Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15
Automatic Darkness Adjustment (Auto Dark Adj) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16
Reports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16
Event log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16
Display Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16
Print Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17
Clear Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17
Exit Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17
Printhead assembly electronic adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18
Printhead assembly mechanical adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19
Repair information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

Handling ESD-sensitive parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Removal procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
ACM pick tire roller removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Bezel removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
Controller board removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
Cover open sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
Door mount removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
Duplex removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
Duplex/main motor gear drive interface removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13
Fan removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16
Front access door removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17
Fuser removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21
Left print cartridge guide removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-24
Left side cover removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-25
Lower front cover removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-27
LVPS/HVPS removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-29
Main motor gear drive removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-32
Manual feed clutch removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-34
Manual feed solenoid removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-36
Media ACM ASM feeder removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-39
Media feed clutch removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-42
Media manual input sensor removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-46
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Multipurpose feeder (MPF) removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-49

Multipurpose feeder (MPF) feed clutch removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-52
Nameplate removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-54
Operator panel removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-55
Paper input and duplex sensor assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-56
Printhead removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-57
Rear door and rear cover removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-58
Rear exit guide assembly with sensor and reversing solenoid removal . . . . . . . . . . . . . . . . . . . 4-60
Right side cover assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-62
Toner level sensor removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-64
Top cover assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-65
Transfer roll removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-67
Upper front guide assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-68
Wear strip (tray 1 and 250-sheet tray 2) removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-69
Wear strip (550-sheet tray 2) removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-70
Locations and connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Front view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Rear view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1
Lexmark E460dn controller board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Lexmark E460dw controller board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
Lexmark E460dn, E460dw controller board connector pin values . . . . . . . . . . . . . . . . . . . . . . . . 5-4
Preventive maintenance ............................................................... 6-1

Safety inspection guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Lubrication specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Maintenance kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Parts Catalog ........................................................................... 7-1

How to use this parts catalog . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
Assembly 1: Covers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
Assembly 2: Electronics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
Assembly 3: Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6
Assembly 4: Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8
Assembly 5: Power cords . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .I-1
Part number index. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .I-3
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Notices and safety information
The following laser notice labels may be affixed to this printer.
Laser notice
The printer is certified in the U.S. to conform to the requirements of DHHS 21 CFR Subchapter J for Class I (1)
laser products, and elsewhere is certified as a Class I laser product conforming to the requirements of IEC
60825-1.
Class I laser products are not considered to be hazardous. The printer contains internally a Class IIIb (3b) laser
that is nominally a 7 milliwatt gallium arsenide laser operating in the wavelength region of 655-675 nanometers.
The laser system and printer are designed so there is never any human access to laser radiation above a Class
I level during normal operation, user maintenance, or prescribed service condition.
Laser
Der Drucker erfllt gem amtlicher Besttigung der USA die Anforderungen der Bestimmung DHHS
(Department of Health and Human Services) 21 CFR Teil J fr Laserprodukte der Klasse I (1). In anderen
Lndern gilt der Drucker als Laserprodukt der Klasse I, der die Anforderungen der IEC (International
Electrotechnical Commission) 60825-1 gem amtlicher Besttigung erfllt.
Laserprodukte der Klasse I gelten als unschdlich. Im Inneren des Druckers befindet sich ein Laser der Klasse
IIIb (3b), bei dem es sich um einen Galliumarsenlaser mit 7 Milliwatt handelt, der Wellen der Lnge 655-675
Nanometer ausstrahlt. Das Lasersystem und der Drucker sind so konzipiert, da im Normalbetrieb, bei der
Wartung durch den Benutzer oder bei ordnungsgemer Wartung durch den Kundendienst Laserbestrahlung,
die Klasse I bersteigen wrde, Menschen keinesfalls erreicht.
Avis relatif lutilisation de laser

Pour les Etats-Unis : cette imprimante est certifie conforme aux provisions DHHS 21 CFR alina J concernant
les produits laser de Classe I (1). Pour les autres pays : cette imprimante rpond aux normes IEC 60825-1
relatives aux produits laser de Classe I.
Les produits laser de Classe I sont considrs comme des produits non dangereux. Cette imprimante est
quipe dun laser de Classe IIIb (3b) (arsniure de gallium dune puissance nominale de 7 milliwatts) mettant
sur des longueurs donde comprises entre 655 et 675 nanomtres. Limprimante et son systme laser sont
conus pour impossible, dans des conditions normales dutilisation, dentretien par lutilisateur ou de rvision,
lexposition des rayonnements laser suprieurs des rayonnements de Classe I .
Avvertenze sui prodotti laser

Questa stampante certificata negli Stati Uniti per essere conforme ai requisiti del DHHS 21 CFR Sottocapitolo
J per i prodotti laser di classe 1 ed certificata negli altri Paesi come prodotto laser di classe 1 conforme ai
requisiti della norma CEI 60825-1.
I prodotti laser di classe non sono considerati pericolosi. La stampante contiene al suo interno un laser di classe
IIIb (3b) allarseniuro di gallio della potenza di 7mW che opera sulla lunghezza donda compresa tra 655 e 675
nanometri. Il sistema laser e la stampante sono stati progettati in modo tale che le persone a contatto con la
stampante, durante il normale funzionamento, le operazioni di servizio o quelle di assistenza tecnica, non
ricevano radiazioni laser superiori al livello della classe 1.
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4513-630, -63W, -6EW
Avisos sobre el lser

Se certifica que, en los EE.UU., esta impresora cumple los requisitos para los productos lser de Clase I (1)
establecidos en el subcaptulo J de la norma CFR 21 del DHHS (Departamento de Sanidad y Servicios) y, en
los dems pases, rene todas las condiciones expuestas en la norma IEC 60825-1 para productos lser de
Clase I (1).
Los productos lser de Clase I no se consideran peligrosos. La impresora contiene en su interior un lser de
Clase IIIb (3b) de arseniuro de galio de funcionamiento nominal a 7 milivatios en una longitud de onda de 655 a
675 nanmetros. El sistema lser y la impresora estn diseados de forma que ninguna persona pueda verse
afectada por ningn tipo de radiacin lser superior al nivel de la Clase I durante su uso normal, el
mantenimiento realizado por el usuario o cualquier otra situacin de servicio tcnico.
Declarao sobre Laser

A impressora est certificada nos E.U.A. em conformidade com os requisitos da regulamentao DHHS 21 CFR
Subcaptulo J para a Classe I (1) de produtos laser. Em outros locais, est certificada como um produto laser da
Classe I, em conformidade com os requisitos da norma IEC 60825-1.
Os produtos laser da Classe I no so considerados perigosos. Internamente, a impressora contm um produto

laser da Classe IIIb (3b), designado laser de arseneto de potssio, de 7 milliwatts ,operando numa faixa de
comprimento de onda entre 655 e 675 nanmetros. O sistema e a impressora laser foram concebidos de forma
a nunca existir qualquer possiblidade de acesso humano a radiao laser superior a um nvel de Classe I
durante a operao normal, a manuteno feita pelo utilizador ou condies de assistncia prescritas.
Laserinformatie
De printer voldoet aan de eisen die gesteld worden aan een laserprodukt van klasse I. Voor de Verenigde
Staten zijn deze eisen vastgelegd in DHHS 21 CFR Subchapter J, voor andere landen in IEC 60825-1.
Laserprodukten van klasse I worden niet als ongevaarlijk aangemerkt. De printer is voorzien van een laser van
klasse IIIb (3b), dat wil zeggen een gallium arsenide-laser van 7 milliwatt met een golflengte van 655-675
nanometer. Het lasergedeelte en de printer zijn zo ontworpen dat bij normaal gebruik, bij onderhoud of reparatie
conform de voorschriften, nooit blootstelling mogelijk is aan laserstraling boven een niveau zoals
voorgeschreven is voor klasse 1.
Lasermeddelelse
Printeren er godkendt som et Klasse I-laserprodukt, i overenstemmelse med kravene i IEC 60825-1.
Klasse I-laserprodukter betragtes ikke som farlige. Printeren indeholder internt en Klasse IIIB (3b)-laser, der
nominelt er en 7 milliwatt galliumarsenid laser, som arbejder p blgelngdeomrdet 655-675 nanometer.
Lasersystemet og printeren er udformet sledes, at mennesker aldrig udsttes for en laserstrling over Klasse
I-niveau ved normal drift, brugervedligeholdelse eller obligatoriske servicebetingelser.
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Laserilmoitus
Tm tulostin on sertifioitu Yhdysvalloissa DHHS 21 CFR Subchapter J -standardin mukaiseksi luokan I (1) -
lasertuotteeksi ja muualla IEC 60825-1 -standardin mukaiseksi luokan I lasertuotteeksi.
Luokan I lasertuotteita ei pidet haitallisina. Tulostimen sisll on luokan IIIb (3b) laser, joka on nimellisteholtaan
7 mW:n galliumarsenidilaser ja toimii 655 - 675 nanometrin aallonpituuksilla. Laserjrjestelm ja tulostin ovat
rakenteeltaan sellaisia, ett kyttj ei joudu alttiiksi luokkaa 1 suuremmalle steilylle normaalin kytn,
yllpidon tai huollon aikana.
Huomautus laserlaitteesta
Tm kirjoitin on Yhdysvalloissa luokan I (1) laserlaitteiden DHHS 21 CFR Subchapter J -mrityksen mukainen
ja muualla luokan I laserlaitteiden IEC 60825-1 -mrityksen mukainen.
Luokan I laserlaitteiden ei katsota olevan vaarallisia kyttjlle. Kirjoittimessa on sisinen luokan IIIb (3b) 7
milliwatin galliumarsenidilaser, joka toimii aaltoalueella 655 - 675 nanometri. Laserjrjestelm ja kirjoitin on
suunniteltu siten, ett kyttj ei altistu luokan I mrityksi voimakkaammalle steilylle kirjoittimen normaalin
toiminnan, kyttjn tekemien huoltotoimien tai muiden huoltotoimien yhteydess.
VARO! Avattaessa ja suojalukitus ohitettaessa olet alttiina nkymttmlle lasersteilylle. l katso

steeseen.
VARNING! Osynlig laserstrlning nr denna del r ppnad och sprren r urkopplad. Betrakta ej strlen.
Laser-notis
Denna skrivare r i USA certifierad att motsvara kraven i DHHS 21 CFR, underparagraf J fr laserprodukter av
Klass I (1). I andra lnder uppfyller skrivaren kraven fr laserprodukter av Klass I enligt kraven i IEC 60825-1.
Laserprodukter i Klass I anses ej hlsovdliga. Skrivaren har en inbyggd laser av Klass IIIb (3b) som bestr av
en laserenhet av gallium-arsenid p 7 milliwatt som arbetar i vglngdsomrdet 655-675 nanometer.
Lasersystemet och skrivaren r utformade s att det aldrig finns risk fr att ngon person utstts fr
laserstrlning ver Klass I-niv vid normal anvndning, underhll som utfrs av anvndaren eller annan
freskriven servicetgrd.
Laser-melding
Skriveren er godkjent i USA etter kravene i DHHS 21 CFR, underkapittel J, for klasse I (1) laserprodukter, og er
i andre land godkjent som et Klasse I-laserprodukt i samsvar med kravene i IEC 60825-1.
Klasse I-laserprodukter er ikke betrakte som farlige. Skriveren inneholder internt en klasse IIIb (3b)-laser, som
bestr av en gallium-arsenlaserenhet som avgir strling i blgelengdeomrdet 655-675 nanometer.
Lasersystemet og skriveren er utformet slik at personer aldri utsettes for laserstrling ut over klasse I-niv under
vanlig bruk, vedlikehold som utfres av brukeren, eller foreskrevne serviceoperasjoner.
Notices and safety information ix

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Avs sobre el Lser

Segons ha estat certificat als Estats Units, aquesta impressora compleix els requisits de DHHS 21 CFR, apartat
J, pels productes lser de classe I (1), i segons ha estat certificat en altres llocs, s un producte lser de classe
I que compleix els requisits dIEC 60825-1.
Els productes lser de classe I no es consideren perillosos. Aquesta impressora cont un lser de classe IIIb
(3b) darsenir de gal.li, nominalment de 7 mil.liwats, i funciona a la regi de longitud dona de 655-675
nanmetres. El sistema lser i la impressora han sigut concebuts de manera que mai hi hagi exposici a la
radiaci lser per sobre dun nivell de classe I durant una operaci normal, durant les tasques de manteniment
dusuari ni durant els serveis que satisfacin les condicions prescrites.
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Notices and safety information xi

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xii Service Manual

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Lithium warning
CAUTION
This product contains a lithium battery. THERE IS A RISK OF EXPLOSION IF THE BATTERY
IS REPLACED BY AN INCORRECT TYPE. Discard used batteries according to the battery
manufacturers instructions and local regulations.
Safety information
The safety of this product is based on testing and approvals of the original design and specific
components. The manufacturer is not responsible for safety in the event of use of unauthorized
replacement parts.
The maintenance information for this product has been prepared for use by a professional service person
and is not intended to be used by others.
There may be an increased risk of electric shock and personal injury during disassembly and servicing of
this product. Professional service personnel should understand this and take necessary precautions.
CAUTION: When you see this symbol, there is a danger from hazardous voltage in the area of the
product where you are working. Unplug the product before you begin, or use caution if the product
must receive power in order to perform the task.
Consignes de scurit
La scurit de ce produit repose sur des tests et des
agrations portant sur sa conception d'origine et sur des composants particuliers. Le fabricant n'assume
aucune responsabilit concernant la scurit en cas d'utilisation de pices de rechange non agres.
Les consignes d'entretien et de rparation de ce produit s'adressent uniquement un personnel de
maintenance qualifi.
Le dmontage et l'entretien de ce produit pouvant prsenter certains risques lectriques, le personnel
d'entretien qualifi devra prendre toutes les prcautions ncessaires.
ATTENTION : Ce symbole indique la prsence d'une tension dangereuse dans la partie du
produit sur laquelle vous travaillez. Dbranchez le produit avant de commencer ou faites preuve
de vigilance si l'excution de la tche exige que le produit reste sous tension.
Norme di sicurezza
La sicurezza del prodotto si basa sui test e sull'approvazione del progetto originale e dei componenti
specifici. Il produttore non responsabile per la sicurezza in caso di sostituzione non autorizzata delle
parti.
Le informazioni riguardanti la manutenzione di questo prodotto sono indirizzate soltanto al personale di
assistenza autorizzato.
Durante lo smontaggio e la manutenzione di questo prodotto,
il rischio di subire scosse elettriche e danni alla persona pi elevato. Il personale di assistenza
autorizzato deve, quindi, adottare le precauzioni necessarie.
ATTENZIONE: Questo simbolo indica la presenza di tensione pericolosa nell'area del prodotto.
Scollegare il prodotto prima di iniziare o usare cautela se il prodotto deve essere alimentato per
eseguire l'intervento.
Lithium warning -xiii

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Sicherheitshinweise
Die Sicherheit dieses Produkts basiert auf Tests und Zulassungen des ursprnglichen Modells und
bestimmter Bauteile. Bei Verwendung nicht genehmigter Ersatzteile wird vom Hersteller keine
Verantwortung oder Haftung fr die Sicherheit bernommen.
Die Wartungsinformationen fr dieses Produkt sind ausschlielich fr die Verwendung durch einen
Wartungsfachmann bestimmt.
Whrend des Auseinandernehmens und der Wartung des Gerts besteht ein zustzliches Risiko eines
elektrischen Schlags und krperlicher Verletzung. Das zustndige Fachpersonal sollte entsprechende
Vorsichtsmanahmen treffen.
ACHTUNG: Dieses Symbol weist auf eine gefhrliche elektrische Spannung hin, die in diesem
Bereich des Produkts auftreten kann. Ziehen Sie vor den Arbeiten am Gert den Netzstecker des
Gerts, bzw. arbeiten Sie mit groer Vorsicht, wenn das Produkt fr die Ausfhrung der Arbeiten
an den Strom angeschlossen sein mu.
Pautas de Seguridad
La seguridad de este producto se basa en pruebas y aprobaciones del diseo original y componentes
especficos. El fabricante no es responsable de la seguridad en caso de uso de piezas de repuesto no
autorizadas.
La informacin sobre el mantenimiento de este producto est dirigida exclusivamente al personal
cualificado de mantenimiento.
Existe mayor riesgo de descarga elctrica y de daos personales durante el desmontaje y la reparacin de
la mquina. El personal cualificado debe ser consciente de este peligro y tomar las precauciones
necesarias.
PRECAUCIN: este smbolo indica que el voltaje de la parte del equipo con la que est
trabajando es peligroso. Antes de empezar, desenchufe el equipo o tenga cuidado si, para
trabajar con l, debe conectarlo.
Informaes de Segurana
A segurana deste produto baseia-se em testes e aprovaes do modelo original e de componentes
especficos. O fabricante no responsvel pela segunrana, no caso de uso de peas de substituio
no autorizadas.
As informaes de segurana relativas a este produto destinam-se a profissionais destes servios e no
devem ser utilizadas por outras pessoas.
Risco de choques elctricos e ferimentos graves durante a desmontagem e manuteno deste produto.
Os profissionais destes servios devem estar avisados deste facto e tomar os cuidados necessrios.
CUIDADO: Quando vir este smbolo, existe a possvel presena de uma potencial tenso
perigosa na zona do produto em que est a trabalhar. Antes de comear, desligue o produto da
tomada elctrica ou seja cuidadoso caso o produto tenha de estar ligado corrente elctrica para
realizar a tarefa necessria.
-xiv Service Manual

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Informaci de Seguretat
La seguretat d'aquest producte es basa en l'avaluaci i aprovaci del disseny original i els components
especfics.
El fabricant no es fa responsable de les qestions de
seguretat si s'utilitzen peces de recanvi no autoritzades.
La informaci pel manteniment daquest producte est orientada exclusivament a professionals i no est
destinada
a ning que no ho sigui.
El risc de xoc elctric i de danys personals pot augmentar durant el procs de desmuntatge i de servei
daquest producte. El personal professional ha destar-ne assabentat i prendre
les mesures convenients.
PRECAUCI: aquest smbol indica que el voltatge de la part de l'equip amb la qual esteu
treballant s perills. Abans de comenar, desendolleu l'equip o extremeu les precaucions si, per
treballar amb l'equip, l'heu de connectar.
Safety information -xv

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Preface
This manual contains maintenance procedures for service personnel. It is divided into the following chapters:
1. General information contains a general description of the printer and the maintenance approach used to
repair it. Special tools and test equipment, as well as general environmental and safety instructions, are
discussed.
2. Diagnostic information contains an error indicator table, symptom tables, and service checks used to
isolate failing field replaceable units (FRUs).
3. Diagnostic aids contains tests and checks used to locate or repeat symptoms of printer problems.
4. Repair information provides instructions for making printer adjustments and removing and installing
FRUs.
5. Connector locations uses illustrations to identify the connector locations and test points on the printer.
6. Preventive maintenance contains the lubrication specifications and recommendations to prevent
problems.
7. Parts catalog contains illustrations and part numbers for individual FRUs.
Change history
Revision date Updates

2013/07/01 Updated Media ACM ASM feeder removal on page 4-39.
2012/08/08 Changed all cross-references that call for the left side cover removal procedures.
2011/10/28 Added this warning: Warning: Do not strip the insulation off the red and black wires. The
connectors will not work if the insulation is removed, in step 8 of Media feed clutch
removal on page 4-42.
2011/9/14 Revised the media feed clutch assembly removal procedure in Media feed clutch
Conventions
Note: A note provides additional information.
Warning: A warning identifies something that might damage the product hardware or software.
There are several types of caution statements:
CAUTION
A caution identifies something that might cause a servicer harm.
CAUTION
This type of caution indicates there is a danger from hazardous voltage in the area of the
product where you are working. Unplug the product before you begin, or use caution if the
product must receive power in order to perform the task.
-xvi Service Manual

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CAUTION
This type of caution indicates a hot surface.
CAUTION
This type of caution indicates a tipping hazard.
Conventions -xvii

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-xviii Service Manual

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1. General information
The Lexmark E460dn and E460dw are monochrome laser printers designed for single users or small
workgroups. This book contains information on E460dn and E460dw. For more information on E260d
and E260dn, see the 4513-220, -230 service manual. For information on E360d and 360dn, see the
4513-420, -430 service manual. minute on letter-size media (29 ppm on A4, 25ppm on legal).
Maintenance approach
The diagnostic information in this manual leads to the correct field replaceable unit (FRU) or part. Use the error
code charts, symptom index, and service checks to determine the symptom and repair the failure. See
Diagnostics information on page 2-1 for more information. See Repair information on page 4-1 to help
identify parts. After completing the repair, perform tests as needed to verify the repair.
General information 1-1

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Overview of the operator panel

The control panel consists of these items:
A 4-line, liquid crystal display (APA) that can show both graphics and text
Eight buttons: Back , Menus , Stop , Select , and Navigation (up arrow , down
arrow , left arrow , and right arrow )
Keypad
Indicator light
Menu Back
1 2 3
4 5 6
Stop 7 8 9
0
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Specifications
Memory
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Lexmark E460dn
Lexmark E460dw
Standard memory 64MB 64MB
Maximum memory 576MB 576MB
Optional memory
128MB
256MB
512MB
Optional flash memory
64MB
256MB
Optional font cards (DBCS)
Option slots
Memory slots 1 1
Flash memory/option card 2 2
Both slots are active for either a 256MB Flash memory card, a font card, or a DLE. Multiple Flash, font, or DLE cards
are not supported.
Print quality settings
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Lexmark E460dn
Lexmark E460dw
Print resolution
1200 Image quality
2400 Image quality
600 X 600 dpi
1200 X 1200 dpi
1200 Image quality is defined as 600 dpi with 2 bit IET (Image Technology) default mode for all models.
2400 Image quality is defined as 600 dpi with 4 bit IET.
True 1200 dpi at 1/2 the rated speed

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Connectivity and compatibility
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Item 4513-6EW
Lexmark E460dn
Lexmark E460dw
Data stream emulations
Host based printing
PCL 5e and PCL 6
PostScript 3
PPDS migration tool
PDF v1.6
XPS
HTML (including DBCS)
Direct image
Compatibility Windows/Macintosh/Linux Windows/Macintosh/Linux
Standard local connections
Parallel x
USB*
Standard network connections
Ethernet (10/100 Base Tx)
Wireless ethernet 802.11b/g/n x
Optional local connections
Optional network connections:

external print server support
*All models are USB 2.0 Certified devices supporting Hi-Speed data transfer.
Includes the HD photo image format
Includes support for the following graphics formats: TIFF, TIF, JPG, GIF, PNG, BMP, PCX, AND DCX
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Media trays and supply capacity
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Lexmark E460dn
Lexmark E460dw
Available input trays
Integrated 250-sheet tray
50-sheet MP feeder
1-sheet manual feed slot x x
Optional input sources
250-sheet drawer
550-sheet drawer
Maximum input sheet capacity 850 850

(excluding envelopes) (excluding envelopes)
Manual/integrated print duplex Integrated Integrated
Envelope conditioning x x
Available output trays
Standard 150-sheet sensing bin
Toner and photoconductor
Toner cartridge 1,500 standard pages SWE 7,000 standard pages SWE
3,500 standard pages SWE
High toner cartridge 9,000 standard pages 9,000 standard pages

15,000 standard pages
Photoconductor kit Up to 30,000 Up to 30,000
Declared value in accordance with ISO/IEC 19752
Up to 30,000 pages, based on an average of 3 pages per job and approximately 5% coverage per page. Yields may
vary based on customer usage.

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Types of print media
Note: Ensure trays are properly loaded. Never mix media types within a tray.
Source Sizes Types Weight Input capacity* (sheets)
Input tray 1 A4, A5, A6,JIS-B5, Plain paper, 60-90 g/m 250 paper
letter, legal, executive, recycled, labels, 50 labels**
(250-sheet tray) oficio (Mexico), folio, bond, letterhead, (16-24 lb)
statement preprinted, colored
paper, light paper,
heavy paper,
rough/cotton,
custom type [x]
2nd Drawer option A4, A5, JIS-B5, letter, Plain paper, 60-90 g/m 250 paper
legal, executive, oficio recycled, labels, 550 paper
(250/550-sheet (Mexico), folio, bond, letterhead, (16-24 lb)
drawer) 50 labels**
statement preprinted, colored
paper, light paper,
heavy paper,
rough/cotton,
custom type [x]
Multipurpose A4, A5, A6,JIS-B5, Plain paper, 60-163 g/m 50 paper

feeder letter, legal, executive, transparency, 15 lables**
oficio (Mexico), folio, recycled, labels, (16-43 lb)
10 transparencies
statement bond, letterhead,
preprinted, colored
paper, light paper,
heavy paper,
rough/cotton,
custom type [x]
Card stock*** 120-163 g/m 20

(16-43 lb)
Index Bristol
75-163 g/m
(46-100 lb)
Tag
7 , 9, 10, DL, C5, B5, Envelopes 75 g/m (20 lb) 7

other Rough envelopes
Duplex A4, letter, legal, oficio Plain paper, 60-90 g/m

(Mexico), folio recycled, bond,
letterhead, (16-24 lb)
preprinted, colored
paper, light paper,
heavy paper,
custom type [x]
* Capacity for 20 lb print media, unless otherwise noted.

** Use for occasional printing only.
*** Grain short is recommended. Use rear exit for best results.
Japanese Industry Standard
If a source supports size sensing and is activated, then neither the oficio value nor the folio value appears in that
sources list of supported media sizes. These values only appear in a sources list of supported media sizes either when
the source is non-size sensing or when the sources size sensing hardware is deactivated and then the device is power
cycled.
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Tips on preventing jams

Paper path
I
J
F
G E
C B
H
D
K
A Paper path AB 125.3 mm

B Manual feed sensor BC 9.0 mm
C Upper end feed rolls CD 59.8 mm
D Input sensor DE 44.9 mm
E Transfer roll EF 112.7 mm
F Fuser FG 21.4 mm
G Fuser exit rolls GH 114.8 mm
H Fuser exit sensor HI 7.5 mm
I Exit rolls IJ 17.0 mm
J Exit sensor/narrow media sensor IK 211.7 mm
K Duplex unit KL 93.4 mm
L Duplex sensor LM 8.4 mm
M Auto compensator

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Most paper jams can be avoided by correctly loading paper and specialty media in the printer.
The following hints can help prevent paper jams:
Use only the recommended print media.

Do not overload the print media sources. Make sure the stack height does not exceed the maximum height
indicated by the stack line on the labels in the sources.
Do not load wrinkled, creased, damp, or curled print media.
Flex, fan, and straighten print media before loading it. If jams do occur with the print media,then try feeding
one sheet at a time through the manual feeder.
Do not mix print media sizes, weights, or types in the same print media source.
Push all trays in firmly after loading them.
Note: Make sure the media stack is below the maximum media fill indicators on the 250-sheet tray before
pushing the tray into the printer.
Make sure paper guides are positioned before loading the paper or specialty media.
Do not remove trays while a job is printing.
Before loading transparencies, fan the stack to prevent sheets from sticking together.
Do not use envelopes that:
Have excessive curl
Are stuck together
Are damaged in any way
Contain windows, holes, perforations, cutouts, or embossments
Have metal clasps, string ties, or metal folding bars
Have postage stamps attached
Have any exposed adhesive when the flap is in the sealed position
Use only recommended media. Refer to the Card Stock & Label Guide available on the Lexmark Web site
at www.lexmark.com for more information about which media provides optimum results for the current
printing environment.
Tools
The removal and adjustment procedures require the following tools and equipment:
Spring hook
Needle nose pliers
Volt-ohmmeter
#1 and #2 Phillips screwdriver
Slotted screwdriver
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Acronyms
ACM Autocompensator Mechanism (or paper feed)
ADC Analog-to-digital Converter
ASIC Application Specific Integrated Circuit
CBM Complete Bill Of Material
DEV Development Roll (of print cartridge/photoconductor
system)
DIMM Dual In-Line Memory Module
ENA External Network Adapter
FRU Field Replaceable Unit
HBP Host Based Printing
HVPS High Voltage Power Supply
LCD Liquid Crystal Diode
LED Light Emitting Diode
LSU Laser Scanning Unit
LVPS Low Voltage Power Supply
NVRAM Nonvolatile Random Access Memory
PC Photoconductor
PCL Printer Control Language
POR Power-On Reset
POST Power-On Self Test
PPDS Personal Printer Data Stream
PRC Peoples Republic of China
TAR Toner Add Roll
SDR Synchronous Dynamic RAM
SWE Shipped With Equipment
USB Universal Serial Bus
V ac Volts alternating current
V dc Volts direct current

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2. Diagnostics information
Start
CAUTION: Unplug power from the printer before connecting or disconnecting any cable,
assembly, or electronic card. This is a precaution for personal safety and to prevent damage to the
printer.
Use the service error code, user status message, user error message, symptom table, service checks, and
diagnostic aids in this chapter to determine the corrective action necessary to repair a malfunctioning printer.
They will lead you to solutions or service checks, including use of various tests.
Symptom tables
If your machine completes the PowerOn Self Test (POST) sequence on page 2-1 without an error and you
have a symptom, then go to Messages and error codes on page 2-5. Locate your symptom, and take the
appropriate action.
Service errors (9xx.xxs)
If a service error code appears while you are working on the machine, then go to Messages and error codes
on page 2-5, and take the indicated action for that error.
Service error codes are indicated by a three-digit error code followed by a period and additional numbers in the
format XXX.YY. In most cases, five digits are shown.
User status and attendance messages
User status messages provide the user with information on the current status of the printer. Ready displays
on the first line of the display unless invoked, and then Power Saver displays. If a user status message is
displayed, then go to Messages and error codes on page 2-5.
User attendance messages are indicated by a two- or three-digit error code that provides the user with
information that explains a problem with a print cartridge, paper jam, option, port, and so on. If a user error
message displays, then go to User attendance messages on page 2-5 and Paper jam error codes
(200-series) on page 2-9.
PowerOn Self Test (POST) sequence

The following is an example of the events that occur during the POR sequence when the printer is turned on.
1. Diamonds are displayed on the operator panel.

2. While code is being loaded into DRAM, dots scroll across the operator panel.
3. A screen is displayed with the memory and processor speed. A typical example of this message is:
*64MB
4. Performing Self Test is displayed.

5. Busy is displayed.
6. Close Door will be displayed if the cover is open.
7. Any cartridge errors, such as Defective Cartridge, are displayed.
8. Applicable maintenance messages are displayed.
9. Applicable toner low messages are displayed.
10. The printer displays Ready.
Diagnostics information 2-1

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Overview of the operator panel and menus

The operator panel on your printer is a 4-line, back-lit, grayscale display that can show both graphics and text.
The Back, Menu, and Stop buttons are located to the left of the display, the navigation buttons are located
below the display, and the numeric pad is located to the right of the display.
Menu Back LCD Select Keypad
button button display button
Menu Back
1 2 3
4 5 6
Stop 7 8 9
0
Indicator Stop Navigation

light button buttons
The use of the buttons and the layout of the display panel are described in the following table.
Operator panel
Button Function
Back Press and release to return to the previous screen.
Menus Press and release to open the menus. The menus are available only when
the printer is in the Ready state.
Pressing also returns the operator panel to the top level menu screen if
pressed while in a menu.
Stop Press once to return to the previous display screen while in the menus.
Press twice to exit the menus and return to the Ready state.
Press to stop printer activity.
Press to cancel a print job. Stopping will display momentarily.
Stopped will then display to offer a list of settings that may be selected.
Navigation Up arrow and Down arrow buttons
Press or to scroll through menus, menu items, or printer options.
Left arrow and Right arrow buttons

Press or to increase or decrease a value or to scroll through text that
rolls to another screen.
Select button
Press and release to open a menu, to display the available values or
settings, or to save the displayed value as the new user default setting.
Note: When a new setting is saved as the default setting, it remains in effect until
new settings are saved or until factory defaults are restored. Settings chosen
from a software program can also change or override the user default settings
selected from the operator panel.
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Operator panel (Continued)
Button Function
Keypad Use the keypad to enter numbers or symbols on the display.
Indicator light The indicator light indicates printer status.

If the light is off, then the printer power is off.
If the light is blinking green, then the printer is warming up, processing data,
or printing.
If the light is solid green, then the printer is on, but idle.
If the light is blinking red, then operator panel intervention is needed.
Display panel The display shows messages describing the current state of the printer and
indicating possible printer problems that must be resolved.
The top line of the display is the header line. It will display the current status and
the Supplies (Warnings) status. This is where printer status, supplies messages,
and show-me screens are viewed.

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Diagram of the printer menus
The diagram shows the menu index on the operator panel and the menus and items available under each menu.
Not all menus or selections will be available in all situations. These are accessed through the driver.
Paper Menu Finishing Menu Utilities Menu Job Menu

Paper Source Duplex Print Menus Reset Printer
Paper Size Duplex Bind Print Stats
Paper Type Copies Print Net Setup
Custom Types Blank Pages Print Fonts
Universal Setup Collation Print Directory
Substitute Size Separator Sheets Factory Defaults
Paper Texture Separator Source Format Flash
Paper Weight Multipage Print Defragment Flash
Paper Loading Multipage Order Hex Trace
Multipage View
Multipage Border
PostScript Menu PCL Emul Menu Setup Menu Quality Menu

Print PS Error Font Source Eco-Mode Print Resolution
Font Priority Font Name Quiet Mode Toner Darkness
Point Size Printer Language Small Font Enh.
Pitch Power Saver
Symbol Set Resource Save
Orientation Print Timeout
Lines per Page Wait Timeout
A4 Width Auto Continue
Tray Renumber Jam Recovery
Auto CR after LF Page Protect
Auto LF after CR Display Language
Toner Alarm
PPDS Menu Parallel Menu Network Menu USB Menu

Orientation Std Parallel Standard Network Standard USB
Lines per Page
Lines per Inch
Page Format
Character Set
Best Fit
Tray 1 Renumber
Auto CR after LF
Auto LF after CR
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4513-630, -63W, -6EW
Messages and error codes

User attendance messages
The printer control panel displays messages describing the current state of the printer and indicates possible
printer problems that must be resolved. This topic provides a list of all printer messages, explains what they
mean, and tells how to clear the messages.
The following table lists the messages in alphanumerical order. A message can also be located using the index.
User attendance messages
Message Action
Activating Demo Mode Wait for the message to clear.
Activating Menu Changes Wait for the message to clear.
Activating/Deactivating PPDS Wait for the message to clear.
Busy Wait for the message to clear, or cancel the print job.
Cancelling Job Wait for the message to clear.
Change Cartridge Invalid Refill The printer has detected an unsupported refilled cartridge. Remove the
indicated print cartridge, and install a new one.
Close door Close the specified door to clear the message.
Deactivating Demo Mode Wait for the message to clear.
Defragmenting Flash DO NOT POWER OFF Warning: Do not turn the printer off while this message is displayed.
Wait for the message to clear.
Disabling Menus Wait for the message to clear.

Note: The printer settings cannot be changed from the control panel while
the menus are disabled.
Enabling Menus Wait for the message to clear.
Flushing Buffer Wait for the message to clear.
Formatting Flash DO NOT POWER OFF Warning: Do not turn the printer off while this message is displayed.
Wait for the message to clear.
Invalid Engine Code Download valid engine code to the printer.
Invalid Standard Network Code The code in an internal print server is not valid. The printer cannot receive
and process jobs until valid code is programmed into the internal print
server. Download valid code to the internal print server.
Note: The network code can be downloaded while this message is
displayed.
Load manual feeder with <Custom Type> Load the specified media in the manual feed tray or multipurpose
feeder.
Load manual feeder with <Custom To ignore the manual feed request and print on media already
String> installed in one of the input sources, press .
If the printer finds a tray that has media with the correct media type
Load manual feeder with <size>
and size, then it feeds media from that tray. If the printer cannot find
Load manual feeder with <size> <type> a tray with the correct media type and size, then it prints on
whatever media is installed in the default input source.
Cancel the current job.

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User attendance messages (Continued)
Message Action
Load <src> with <Custom Type Name> Load the input source with the correct type and size media.
Load <src> with <Custom String>
Load <src> <size>
Load <src> <type> <size>
Maintenance Replace the maintenance items and, if necessary, reset the printer
maintenance counter.
Menus Disabled The printer menus are disabled. The printer settings cannot be changed
from the control panel.
Note: A job can still be canceled.
Contact a system support person.
Network A network interface is the active communication link.
Network Card Busy An internal print server (also called an internal network adapter or INA) is
being reset. Wait for the message to clear.
Not Ready The printer is not ready to receive or process data. Someone pressed
to take the printer offline. Press to make the printer ready to receive
jobs.
Parallel A parallel interface is the active communication link.
Performing Self Test The printer is running the series of start-up tests it performs after it is
turned on. Wait for the message to clear.
Power Saver Send a job to print.

Press to warm the printer to normal operating temperature and
display the Ready message.
Printing Directory List The printer is processing or printing a directory of all files stored in flash
memory. Wait for the message to clear.
Printing Font List The printer is processing or printing a list of all available fonts for the
specified printer language. Wait for the message to clear.
Printing Menu Settings The printer is processing or printing the menu settings page. Wait for the
message to clear.
Printing Device Statistics The printer is printing statistical information about the printer. Wait for the
message to clear.
Printing Quality Test Pages The printer is formatting and printing the Print Quality Test, which consists
of 4 pages. Page 1 contains a mixture of graphics and text, pages 2 and 3
contain only graphics, and page 4 is a blank page. If Duplex is turned on,
then the pages are duplexed; otherwise they are simplexed. Wait for the
message to clear.
Prog Engine Code The printer is programming new engine code. Wait for the message to
DO NOT POWER OFF clear and the printer to reset.
Warning: Do not turn the printer off while this message is displayed.
Program Flash The printer is storing resources, such as fonts or macros, in flash memory.
DO NOT POWER OFF Wait for the message to clear.
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User attendance messages (Continued)
Message Action
Prog System Code The printer is programming new system code. Wait for the message to
DO NOT POWER OFF clear and the printer to reset.
Ready Send a job to print.
Remove Paper Standard Bin The standard output bin is full.
Resetting Maint Cnt Valu The printer is resetting the counter that tracks wear on the fuser.
Resetting PC Cnt Value The printer is resetting the counter that tracks wear on the photoconductor.
Resetting the Printer Wait for the message to clear.
Res Reduced The printer is reducing the resolution of a page in the current job from 600
dots per inch (dpi) to 300 dpi to prevent a 38 Memory Full error. Res
Reduced remains on the display while the job prints.
Restoring Factory Defaults Wait for the message to clear.

Note: When factory default settings are restored:
All downloaded resources (fonts, macros, symbol sets) in the
printer memory are deleted.
All menu settings return to the factory default except:
The Display Language setting in the Setup Menu
All settings in the Parallel Menu, Network Menu, and
USB Menu
Std Bin Full The standard bin is full.
Toner Low Replace the toner cartridge.

Press to clear the message and continue printing.
Tray <x> Missing Insert the tray into the printer.
USB The printer is processing data through the specified USB port.
Waiting The printer has received a page of data to print, but is waiting for an End of
Job command, a Form Feed command, or additional data.
Press to print the contents of the buffer.

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Cartridge error messages
Error Description Action
30.XX Cartridge errors
30.01 No bucket transition out of the top bucket. If the cartridge Replace the cartridge.
has not been refilled, then it usually is a mechanical
problem with the cartridge. During development, it could
also have the wrong chip installed.
30.02 No bucket transition out of the middle buckets. If the

cartridge has not been refilled, then it usually is a
mechanical problem with the cartridge. During
development, it could also have the wrong chip installed.
30.03 No bucket transition out of the lowest bucket. If the

cartridge has not been refilled, then it usually is a
mechanical problem with the cartridge. During
development, it could also have the wrong chip installed.
30.04 Excessive bucket jump. If the cartridge has not been

refilled, then it usually is a mechanical problem with the
cartridge.
30.05 Cartridge has run past it's life such that the cartridge has to
been totally void of printable toner. During development, it
could also have the wrong chip installed.
31.XX Defective cartridge errors
31.01 Cartridge missing. Smartchip installed backwards or Replace the cartridge.

missing. Cable loose on controller board. Bad, dirty or
broken contacts. Bad chip. Wrong cartridge installed.
31.02 Authentication Failure. Failed to authenticate the device,

possible cartridge is from another family, or the chip is
defective.
31.03 ECC Failure. Clone or defective device.
31.04 Read Failure. Intermittent contact with the device, cable on Check the contact pins (on the
system card not seated well, gross electrical noise, right side, under the cartridge) for
defective device. damage. Replace if possible.
31.05 Write Failure. Intermittent contact with the device, cable on

system card not seated well, gross electrical noise,
defective device.
31.06 SRL. Clone device. Replace the cartridge.
31.07 Penalty. Too many POR/CC events have occurred.
31.08 Unsupported SC Firmware. Clone or defective device.
32.XX Unsupported cartridge errors
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32.01 MC CC Mismatch. Incorrect cartridge installed in printer or Replace the cartridge.

printer settings are incorrect (based on cartridge capacity).
32.02 Down-level device installed on cartridge.
32.03 Down-level device installed on cartridge.
32.04 Unknown toner type indicated by the device.
32.05 OEM Mismatch. Incorrect cartridge installed in printer, or

printer settings are incorrect (based on cartridge OEM
identification).
32.06 Printer already married to a SWE cartridge. Must purchase Replace the cartridge with a new
after-market cartridge. one from the correct geography.
32.07 SWE cartridge already married to a printer.
Paper jam error codes (200-series)
Note: The Event log (See Event log on page 3-16) will list any of these errors that have occurred.
Repeating jams or jam messages can be caused by any of the following:
Faulty/contaminated pick solenoids or worn cams of the solenoids.

Faulty/contaminated flags or springs.
Debris in the paper path.
Media not of the specified length.
Faulty media feed clutch. See Media feed clutch service check on page 2-27.
200.00 Paper jam around input sensor. Remove the PC kit and paper or debris at the input
sensor.
200.01 Classic input jam. The media is too long over the input First, remove the PC kit and paper or debric at the
sensor. Possible causes include multi-sheet feed, tray input sensor. Then, inspect the flag on the input
size sensing problem, and media slippage. sensor. It should rotate freely. Replace the sensor if
necessary. Finally, check the paper size settings in
200.02 The main input sensor never became uncovered from the printer and the driver.
the sheet ahead.
200.03 The video never started on the page at the input Check the printhead. See Printhead service
sensor within two inches after hitting the input sensor check on page 2-38.
200.04 The media at the input sensor before interrupt Carefully remove the tray and notice if the leading
occurrednot enough time elapsed since the printhead edge of the media is pointed upward and out of the
started to expect the printhead mirror motor lock. tray. If so, then inspect the tray wear strips and
Possible causes include bouncy sensor or replace if necessary.
exceptionally fast pick perhaps due to media pre-
staged in the source tray. Inspect the input sensor flag and replace it if it does
not rotate freely or is too loose.
200.06 Imaged page not expected page (bouncy passthru Remove the toner cartridge/PC kit. At the front,
sensor) remove the upper front guide, and inspect the flag on
the manual input sensor. If the flag is loose, then
replace it. See Media manual input sensor
200.08 Media reached the input sensor before the EP was Inspect the tray for prestaging. Verify the proper
ready media and inspect the tray wear strips. Replace the
wear strips if necessary.

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200.09 Transfer servo never started Inspect the LVPS/HVPS. See Controller board
service check on page 2-23.
200.12 Media detected at manual feeder sensor when not Carefully remove the tray and notice if the leading
expected. Possible causes include user insert of media edge of the media is pointed upward and out of the
when motor is running or pre-staged media in the tray. tray. If so, then inspect the tray wear strips and
replace if necessary.
Inspect the input sensor flag and replace it if it does

not rotate freely or is too loose.
200.13 The input sensor is covered when the media is not Remove the toner cartridge/PC kit and inspect the
expected (media in machine during warm-up) input sensor flag. Replace the flag if necessary.
200.14 Trailing edge cleared manual feed, but did not Remove the toner cartridge/PC kit. At the front,
successfully debounce the sensor. Potential causes remove the upper front guide, and inspect the flag on
are a small gap or a bouncy manual feed sensor. the manual input sensor. If the flag is loose, then
200.15 UNRECOVERABLE NO GAP JAM. Engine detected Remove the toner cartridge/PC kit. At the front,
no gap at the manual feeder sensor, attempted to remove the upper front guide, and inspect the flag on
open the gap by stopping the feed rolls, but no trailing the manual input sensor. If the flag is loose, then
edge was ever seen at the input sensor. replace it. See Media manual input sensor
Verify that the media is approved. Inspect the wear

strips in the input tray, and replace if necessary.
200.16 Transport motor error detected Inspect the main motor. See Main motor service
check on page 2-27.
200.17 Took too long to ramp up transport motor
200.18 Manual feeder sensor never became uncovered from Remove the toner cartridge/PC kit. At the front,
the sheet ahead. remove the upper front guide, and inspect the flag on
the manual input sensor. If the flag is loose, then
200.19 The media never reached the input sensor, but was Remove the toner cartridge/PC kit, and inspect for
detected at manual feeder sensor. debris in the paper path. Check the bottom of the PC
kit for any obstructions. Remove the upper front
guide, and inspect the pinch rollers.
200.20 The media is too long over the manual feeder sensor. Verify that the media is approved. Inspect the wear
Possible causes include multi-sheet feed, media size strips in the tray, and replace if they are worn.
(length) problem, pre-staged media in the tray.
200.22 FAILED SMALL GAP OR NO GAP JAM RECOVERY.

Engine detected small gap or no gap at the manual
feeder sensor, opened the gap by stopping the feed
rolls, but never saw the leading edge of the second
page at the input sensor.
200.23 Laser Servo never started due to potential conflict with Verify that the media is approved. Inspect the wear
the transfer servo. Possible causes: slow or missing strips in the tray, and replace if they are worn.
transport motor positional feedback, or the media is
transferred too quickly to the input sensor. Check the main motor. See Main motor service
check on page 2-27.
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200.24 The measured gap at the input sensor is too small to Verify that the media is approved. Inspect the wear
meet the video delivery requirements. (There is not strips in the tray, and replace if they are worn.
enough time since prior image finished to start new
image)
200.26 The trailing edge never cleared the input sensor when
feeding out the media that was detected during warm-
up.
200.27 Printhead Driver: Mirror motor fell out of lock condition Check the printhead. See Printhead service
after the media at the input sensormore time elapsed check on page 2-38.
since the printhead than the expected stable lock time,
but less than the printhead jitter-stable specification.
Mirror motor fell out of lock condition after media at the

input sensormore time elapsed since the printhead
than expected stable lock time, but less than the
printhead jitter-stable specification.
200.28 First writing line of a page at the developer nip, but Verify that the media is approved. Inspect the wear
laser servo cleanup is not complete. Likely pre staged strips in the tray, and replace if they are worn.
media or a fast paper feed.
200.29 Printhead drive control out of range due to an external Check the cable routing for the printhead. See
event beyond what the control is designed to handle. Printhead service check on page 2-38.
Probable causes: ESD or noise on hsync signal.
200.30 Narrow media sensor covered during warm-up. Check that the narrow media flag rotates freely and
securely. If it is dislodged or broken, then repalce the
rear exit guide. See Rear exit guide assembly
with sensor and reversing solenoid removal on
page 4-60.
200.32 Media more than 14 inches too long over the manual Verify that the media is approved. Inspect the wear
feeder sensor. Possible causes include multi-sheet strips in the tray, and replace if they are worn.
feed or pre-staged media in the tray.
200.33 Page from tray 1 did not reach the input sensor after Verify that the pick tires are clean, not worn, or filled
multiple attempts. Page did make it out of the tray at with paper dust. Replace the pick tires if necessary.
least as far as the manual feeder sensor. Possible See ACM pick tire roller removal on page 4-3.
cause is that the page stalled at the alignment gate.
The alignment roller may be binding. Call the next
200.34 Timed out waiting for page from tray 1 to reach the level of support.
input sensor after multiple pick attempts, but the page
was later detected at the input sensor while waiting for
any page(s) ahead to clear the paper path. Possible
cause is that the page is delayed at the alignment
gate.
200.35 Failed to create hsync during auto alignment Check the printhead. See Printhead service
check on page 2-38.
200.36 Lost hsyncs during auto alignment
200.37 Timeout on data collection during auto alignment
200.38 Interpage servo gap is smaller than expected for

printhead offset target evaluation
200.42 Rogue sheet is at the manual feed sensor while Retry alignment.
flushing the paper path prior to declaring MPF source
empty.
200.43 The media is at the input sensor before interruption Remove the media, realign the stock, and re-insert.
occurs. Possible causes include bouncy sensor or an Do not let the top sheets to go beyond the wear
exceptionally small gap, perhaps due to the media strips.
being pre-staged in the source tray.

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201.00 Paper jam between input and exit sensor Remove the toner cartridge/PC kit and check for
obstructions between the input sensor and the fuser.
if the media continues to stop at the entrance or in
the fuser, then replace the fuser. See Fuser
201.01 Transport motor identification failed to identify either Check the main motor. See Main motor service
motor after two tries. check on page 2-27.
201.02 Exit sensor never made by leading edge of page. Also Remove the PC kit and paper or debris at the input
known as internal jam. sensor.
201.03 Video never started on the page at the input sensor Check the printhead. See Printhead service
within two inches after hitting the input sensor check on page 2-38.
201.05 Restart attempted after an internal jam without the Check the paper path and remove any media in the
cover open/close event. It is likely that the jam was path.
never cleared.
201.25 Exit sensor never made by leading edge of media Remove the toner cartridge/PC kit and check for
when feeding out the media that was detected during obstructions between the input sensor and the fuser.
warm-up. if the media continues to stop at the entrance or in
the fuser, then replace the fuser. See Fuser
201.26 Page at fuser nip before fuser started ramping toward removal on page 4-21.
desired temperature. Indicates code may be receiving
more interrupts than intended
201.27 Page at fuser nip before fuser reached acceptable

operating temperature. Page arrived at fuser earlier
than expected, so it was probably staged prematurely.
202.00 Paper jam around exit sensor. Open the rear cover and look for obstructions in the
path way. If there are none, then inspect for damage
at the fuser, rear door, exit guide, and top cover.
Often, the leading edge of the media will indicate the
vacinity of damage. If damage is found, then replace
the damaged part.
Note: Print a page with the rear door open to isolate
the fuser from the other parts.
202.01 Exit sensor never broke on the trailing edge of the Open the rear door, and inspect the flag on the exit
sheet at the exit sensor. sensor. The flag is located behind the fuser exit
rollers, about mid printer. If the flag does not rotate
202.02 Exit sensor never broke from sheet ahead of page freely or has no spring action, then replace the fuser.
heading toward the exit sensor. See Fuser removal on page 4-21.
202.06 Exit sensor bounced
202.13 Exit sensor covered, media not expected (media not in

machine during warm-up)
202.25 Exit sensor never broke from the sheet ahead of the
page heading toward the exit sensor when feeding out
the media detected during warm-up.
202.26 Trailing edge never cleared exit sensor when feeding Open the rear door, and inspect the flag on the exit
out media that was detected during warm-up. sensor. The flag is located behind the fuser exit
rollers, about mid printer. If the flag does not rotate
freely or has no spring action, then replace the fuser.
See Fuser removal on page 4-21.
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202.32 Long media or shingled multi feed stopped before Check the paper setting and correct if needed. While
sending to duplex. feeding along the media, and immediately after it
enters the output bin, open the reat door and
obscure the trailing edge and the sensor flag. If there
is slippage in the exit guide, then replace the exit
guide. See Rear exit guide assembly with sensor
and reversing solenoid removal on page 4-60.
231.00 Duplex jam while reversing into the device Open the rear cover and look for obstructions
between the rear cover ribs, the fuser exit rollers,
231.01 Duplex sensor never made by leading edge reversing and below. The media entering the duplex passes
into the duplex. outside the exit roller while the media exiting the
fuser passes above and inside the exit rollers.
231.02 Bouncy duplex sensor never made. Remove the tray, open the duplex door, and remove
the obstructions. If there are no obstructions and the
232.00 Duplex jam while staging in the device problem persists, then disconnect all of the cables,
tilt the printer onto its back (be sure to protect the
232.01 Duplex sensor never broke by the sheet ahead after antenna on a wireless unit), and inspect the flag of
reversing into the duplex. the duplex sensor. If the flag does not rotate freely,
then replace the paper input and duplex sensor. See
Paper input and duplex sensor assembly
232.02 Page in duplex ahead of current reversing page never removal on page 4-56.
staged.
Check the belt and drive of the duplex unit. Replace
233.00 Duplex jam while picking from the device it if necessary.
233.01 Page in duplex never picked.
233.02 Feed error picking from the duplex.
233.03 Paper never reached the input sensor, but was

detected at the manual feed sensor.
234.01 Duplex sensor covered during warm-up.
235.01 Invalid duplex media Check the media. Duplex supports A4, letter, legal,
oficio, and folio media sizes.
241.00 Paper jam near tray 1. Remove the tray and inspect the media path for
obstructions. Check the pick rollers. Replace the pick
241.10 Second pick attempt failed from Tray 1 rollers if they are worn or clogged with dust. See
ACM pick tire roller removal on page 4-3. Also
check the wear strips, and replace if necessary.
241.12 Second pick from manual feeder, tray 1, or feeder Remove the tray and inspect the media path for
failed when the media was in the source while other obstructions. Check the pick rollers. Replace the pick
sheets were committed to the paper path. rollers if they are worn or clogged with dust. See
ACM pick tire roller removal on page 4-3. Also
241.16 Failed to feed from tray 1. Pages in the paper path check the wear strips and the manual feeder, and
have been flushed to the output bin. replace if necessary.
241.17 MISIDENTIFIED SMALL GAP JAM. Engine detected

small gap at the manual feeder sensor, attempted to
open the gap by stopping the feed rolls, trailing edge
was seen at the input sensor, manual feeder sensor is
no longer covered.
241.19 Second pick attempted failed from Tray 1, no pages

printed since calling a 241.10 or a prior 241.19.
242.00 Paper jam near tray 2. Remove Tray 2 and inspect for obstruction in the
paper path. Check the pick tires for wear or paper
dust. Replace if necessary. Check the wear strips
and replace if necessary.
242.01 Took too long to ramp up dc feed motor Check the connection with Tray 2. (Lift the printer
and re-set it on Tray 2.) If the error persists, then
242.08 Received lots of dc feed interrupts before losing them replace Tray 2.

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242.10 Second pick attempt failed from Tray 2 Remove Tray 2 and inspect for obstruction in the
paper path. Check the pick tires for wear or paper
242.12 Second pick from manual feeder, tray 1, or feeder Check the wear strips and replace them if worn.
failed when media was in the source, other sheets
were committed to the paper path.
242.16 Failed to feed from tray 2. Pages in the paper path Remove Tray 2 and inspect for obstruction in the
have been flushed to the output bin. paper path. Check the pick tires for wear or paper
251.00 Paper jam near the manual feeder. Inspect the pick roller on the MPF or the rollers on
the manual feed. If the MPF pick roller is damaged or
251.10 Second pick attempt failed from manual feeder. worn, then replace the MPF. For a printer with a
manual feed only (no MPF), clean the roller.
251.11 Failed to feed from manual feeder. Pages in the paper
path have been flushed to the output bin.
251.12 Second pick from manual feeder, tray 1, or feeder

failed when media was in the source while the other
sheets were committed to the paper path.
251.19 Media never reached the input sensor from the manual
feeder.
251.20 The media in the MPF has been pushed in too far. Remove the media, realign the stock, and re-insert.
Do not let the top sheets to go beyond the wear
251.21 The media in the MPF has been pushed in too far. strips.
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4513-630, -63W, -6EW
Service error codes
Service error codes are generally non-recoverable except in an intermittent condition when the printer can be
put into POR to temporarily recover from the error condition.
Engine software service errors
900.xx Code detected unusual event of timing See Service software service check on
page 2-39
902.xx Engine software error Replace the controller board. See Controller
board service check on page 2-23
DC pick motor errors
914.00 DC pick motor error
914.01 Lost encoder feedback
Transfer service errors
917.xx Transfer service error Replace the transfer roll. See Transfer roll
Fuser service errors
920.00 Under temperature during steady state control. Replace the fuser. See Fuser service check
on page 2-26.
920.01 Fuser took too long to heat up after transitioning to new
enhanced mode.
920.02 Fuser fell too far below desired temperature while

printing.
920.03 Fuser too cool while checking for slope change.
920.04 Fuser too cool when heating to desired temperature

after slope change.
920.05 Fuser under temperature while printing
920.08 Fuser temperature did not increase after IR recovery.
920.20 Belt fuser under temperature during steady state control.

This can occur in printing or standby modes.
921.00 Under temperature during standby control.
921.01 Fuser temperature did not reach standby temperature

after two attempts
922.00 Fuser failed to ramp to target temperature
922.01 Fuser did not reach standby temperature in time

(standby control)
922.02 Hot roll took too long to reach the beginning lamp
detection temperature.
922.03 Hot roll reached final lamp detection temperature, but

took longer than largest time in lookup table.

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922.04 Hot roll timed out in trying to reach the final lamp Replace the fuser. See Fuser service check
detection temperature. on page 2-26.
922.05 Did not roll over to a steady state control in time after the
hot roll lamp detection.
922.06 Hot roll did not reach the operating temperature in time
(new enhanced control).
922.07 Media reached fuser nip, and fuser is under temperature
922.08 Fuser warm-up failure (motor start condition)
922.09 Fuser warm-up failure (compression set)
922.20 Belt fuser failed to reach the preheat temperature for the
motor to start during warm-up.
922.21 Belt fuser was under temperature when the media

reached the fuser nip.
923.00 Fuser is over temperature.
923.01 Fuser is over temperature. This applies to the fuser and

belt fusers.
924.00 Open thermistor check.
924.01 Open thermistor check failure. This applies to the fuser

and belt fusers.
924.02 Open thermistor check failure. The ADC failed to

converge. Possible noisy thermistor signal. This applies
to the fuser and belt fusers.
925.xx Wrong fuser installed. The fuser type stored in the

cartridge ID does not match the actual fuser installed in
the printer.
Fan service errors
927.00 Service fan error Replace the fan. See Cooling fan service
check on page 2-24.
927.03 Main fan took too long to ramp up
927.04 Main fan is under speed or stalled during speed

adjustment state
927.05 Main fan overspeed during speed adjustment state.
927.06 Main fan capture data is invalid, and speed control is at

maximum in fan control idle state
927.07 Main fan capture data is invalid, and speed control is at

maximum in fan control adjustment state.
Toner service errors
929.00 Toner sensor error Remove the toner cartridge, and shake it Try a
different toner cartridge, if possible. If the error
929.01 No home window persists, then replace the toner level sensor. See
Toner level sensor removal on page 4-64.
929.02 No sensor transition (closed)
929.03 No sensor transition (open)
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Printhead service errors
930.00 Wrong printhead installed Replace the printhead. See Printhead service
check on page 2-38.
931.00 No first hsync
931.01 No first hsync
932.00 Lost hsyncs
932.01 Lost hsyncs
933.01 Printhead boost signal failure
934.00 Mirror motor lost lock.
934.01 Mirror motor lost lock.
935.00 No initial mirror motor lock
935.01 Timed out waiting for mirror motor lock
935.10 Printhead sweep error, swept through Hz range without

finding the resonant frequency
935.12 Printhead sweep error, coarse sweep state
935.15 Printhead open-loop error, check prelim amp state
935.16 Printhead open-loop error, enable amp Kp state
935.17 Printhead closed-loop error, amp Kp failed to converge
935.18 Printhead closed-loop error, enable amp Ki state
935.19 Printhead closed-loop error, amp Ki failed to converge
935.20 Printhead closed-loop error, enable offset controller

state
935.21 Printhead closed-loop error, load scan regs state
935.22 Printhead closed-loop error, fwd and rev capture times

differ by too much
935.23 Printhead closed-loop error, check sweep accuracy

state
935.25 Printhead closed-loop error, off-resonant PI effort state
935.26 Timed out on POR sweep
935.27 Exceeded maximum open loop drive level when

configuring for sweep re-try.
935.28 Exceeded maximum open loop drive level when setting

operating Hz.
Transport motor service errors

4513-630, -63W, -6EW
936.01 No lock detected at normal motor start Replace the main motor gear drive. See Main
motor service check on page 2-27
936.02 No lock detected at motor start for motor ID
936.03 No halls detected at motor start
936.04 Failed to stop within timeout Replace the main motor gear drive. See Main
motor service check on page 2-27
936.05 Stall detected during speed control
937.00 Main transport motor lost lock
937.01 Main transport motor lost lock, detected by engine

control
937.02 Overspeed detected during position control
937.03 Overspeed detected during speed control
Power supply service errors
940.00 LVPS service error Replace the LVPS/HVPS. See LVPS/HVPS

940.01 Line frequency outside allowed range of 45Hz-64Hz
940.02 Line frequency below 43Hz
940.03 No zero cross detected on belt fuser model
Controller board and operator panel service errors
948.xx Failed engine board Replace the controller board. See Controller
board service check on page 2-23.
949.xx
950.xx Mismatch between EEPROM and mirror memory Install a new controller bored or operator panel.
See Controller board service check on
Note: A new controller board or operator panel has been page 2-23 or Operator panel service check
installed, and has not been properly prepared for this on page 2-28.
use. Install a new note. Do not install both the controller
board and the operator panel at the same time without a
POR in between.
951.xx Error with secure NVRAM on the controller board Replace the controller board. See Controller
952.xx A recoverable MVRAM Cyclic Redundancy Check error Performing POR will clear this error.
occurred.
953.xx NVRAM chip failure with mirror Replace the operator panel. See Operator
panel service check on page 2-28.
954.xx NVRAM chip failure with system part. Replace the controller board. See Controller
955.xx The code ROM or NAND flash failed the Cyclic
Redundancy Check or the NAND experienced an
uncorrectible multi-bit failure.
956.00 RIP card failure: processor failure
956.01 Processor overtemp
957.xx RIP card failure: ASIC failure
958.xx Printer has performed more than 100 shift and reflash
operations as a result of ECC bit corrections
2-18 Service Manual

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Firmware or controller board errors
959.01 Controller verification failure of pensive boot code Call the next level of support to update the
firmware, or replace the controller board. See
959.02 Failure to authenticate Signature Verification Code Controller board service check on
page 2-23.
959.03 Signature Verification Code failed to authenticate a code Update firmware and call the next level of
partition. support, or replace the controller board. See
Controller board service check on
959.04 Jump to unverified address page 2-23.
959.05 Unknown boot failure Update firmware and call the next level of
support, or replace the controller board. See
Controller board service check on
page 2-23
959.20 Pensive hardware failure Replace the controller board. See Controller
959.21 Pensive did not respond to command request.
959.22 Challenge secret failure
959.23 Pensive self test failed during initialization. Replace the controller board. See Controller
959.24 EEPROM retention error
959.25 Insufficient device space during HW prog
959.26 Incremental counter reset exceeds maximum value
959.27 Increment count failed due to max value limit
959.28 Invalid SP memory configuration
Memory and emulation errors
960.xx RAM memory error: RAM soldered on the controller Replace the controller board. See Controller
board is bad board service check on page 2-23.
961.xx RAM memory error: memory card in slot is bad. Replace the memory card.
964.xx Download Emulation Cyclic Redundancy Check Error: Disable the Download Emulation. Program the
checksum failure detected in the emulation header or download emulation into the firmware card again.
emulation file. If this does not resolve the problem, then replace
the firmware card and download the emulation
again.
Network errors
975.xx Unrecognizable network Call the next level of support.
976.xx Unrecoverable software error in network port
978.xx Bad checksum while programming network port
979.xx Flash parts failed while programing network port
Other errors

4513-630, -63W, -6EW
980.xx Engine experiencing unreliable communication with the Call the next level of support.
specified device
981.xx Engine protocol violation detected by the specified

device
982.xx Communications error detected by the specified device
983.xx Invalid command received by the specified device
984.xx Invalid command parameter received by the specidied Call the next level of support.
device
990.xx An equipment check condition has occurred in the

specified device, but the device is unable to identify the
exact component failure.
991.xx The specified device has detected an equipment check

in its system card.
2-20 Service Manual

4513-630, -63W, -6EW
Symptom tables
POST symptom table
Symptom Action
The main motor, cooling fan, and fuser do not come See Cover interlock switch service check on page 2-24.
on.
POST completes, but the LCD does not come on. See Operator panel service check on page 2-28.
Main motor does not come on. See Main motor service check on page 2-27.
Fan does not come on. See Cooling fan service check on page 2-24.
Fuser does not cycle. See Fuser service check on page 2-26.
Fuser does not turn on and off. See Fuser service check on page 2-26.
The paper feed picks and tries to feed media. See Paper feed service checks on page 2-28.
Note: Investigate any displayed codes before proceeding with these symptoms. For example, a missing toner cartridge will
prevent POST from completing.

4513-630, -63W, -6EW
Printer symptom table
Symptom Action
Fan noisy or fan not working. See Cooling fan service check on page 2-24.
Fuser parts melted. See LVPS/HVPS service check on page 2-26.
Toner not fused to the media. See Fuser service check on page 2-26 or Solving print
quality problems on page 2-35.
Paper jams. See Paper feed service checks on page 2-28.
Main motor noisy or not moving. See Main motor service check on page 2-27.
Media skew. See Paper feed service checks on page 2-28.
Printer not communicating with host. See Parallel or USB port service check on page 2-30.
Front access door will not close. See Cover interlock switch service check on page 2-24.
Operator panel button not responding. See Operator panel service check on page 2-28.
Operator panel lights are off or very dim. See Operator panel service check on page 2-28.
Blank page. See Blank page on page 2-31.
Black page. See Black page on page 2-32.
Heavy background. See Heavy background on page 2-32.
Light print. See Light print on page 2-34.
White or black lines or bands. See White or black lines or bands on page 2-34.
Toner on back of page. See Toner on back of page on page 2-34.
Media never picks. See Media never picks on page 2-29.
Media feeds continuously. See Media occasionally mispicks or picks multiple sheets
at once on page 2-29.
Media wrinkled or bent. See Media trees, wrinkles, stacks poorly, or curls on
page 2-30.
Dead machine (no power). See Dead machine service check on page 2-25.
Print quality problems See Solving print quality problems on page 2-35.
Light print
Blurred characters
Toner on both sides of media
Toner not fused
Streaks
Blank pages
2-22 Service Manual

4513-630, -63W, -6EW
Service checks
Service checks which involve measuring voltages on the LVPS/HVPS (low voltage power supply/
high voltage power supply board) should be performed with the printer positioned on its back side.
Note: When making voltage readings, always use frame ground unless another ground is
specified. See the wiring diagram in the back of the book for more information.
Controller board service check

Controller board service check
FRU Action
Controller board POST (Power-On Self Test)

assembly
Note: The printer should complete POST in approximately 30 seconds.
Warning: Do not
replace the operator If the printer fails to display lights or activate the drive motor, fuser, or fan, then check the
panel and controller following order:
board at the same 1. Power to the LVPS/HVPS
time. Each card 2. Power from the LVPS/HVPS to the controller board
contains the printer
settings. When either 3. Cables are plugged in correctly, especially for the operator panel. The printer will not
of these cards is new, power-up without a functioning operator panel.
it obtains some of the 4. The controller board assembly. The LED adjacent to J12 will be illuminated if the card is
settings from the other powered and good.
card. Settings are lost 5. The operator panel. See Operator panel service check on page 2-28.
when both are new
and replaced at the Verify +24 V dc input from the LVPS/HVPS.
same time.
1. Turn the printer off.
2. Disconnect the LVPS/HVPS cable from the controller board at J502.
3. Turn the printer on.
4. Verify +24 V dc on positions 6, 17, and 19 of the cable connector (LVPS/HVPS).
5. If voltage is correct, then check the continuity in the other conductors of the cable. If the
cable is good, then turn the printer off, and check the connectors to the controller board.
6. Verify that pins 10, 12, 14, 16, and 18 on both the cable and the card connector are
grounded.
7. If grounds are not correct on the cable, but the cable passes continuity otherwise, then
check the LVPS/HVPS.
8. If the grounds are not correct on the controller board, then replace the controller board.
(Check with one probe on the connector pin and the other on the cards ground plane
found at each screw head.)
Controller board voltage outputs

Turn the printer off, and plug the LVPS/HVPS cable into J502 of the controller board. See
the wiring diagram at the end of the manual which identifies the output voltages and
grounds for a good controller board.
Turn the printer off before plugging or unplugging any connectors.

4513-630, -63W, -6EW
Controller board service check (Continued)
FRU Action
LVPS/HVPS Verify main power to controller board

With the printer off, unplug the LPS/HVPS cable at J502 on the controller board. Verify
grounds on pins 10, 12, 14, 16 and 18 for both the cable and the controller board. If any of
these grounds are incorrect, then check the cable for continuity. If the cable fails continuity,
then call the next level of support.
Turn the printer on with the cable still unplugged, and verify the following on the cable
(controller board will not be powered):
Pins Voltage
6, 17, 19 +24 V dc
1, 3-5, 11, 13, +5 V dc
15
If any of the voltages are incorrect, then replace the LVPS/HVPS. See Dead machine
Cooling fan service check
FRU Action
Cooling fan Make sure the fan cable plug is properly seated at J9 (controller board).
Turn the printer on. Within a few seconds, the controller board assembly should apply
+24 V dc to pin 2.
If voltage is not present, then check or replace the controller board. See Controller
board removal on page 4-6.
If voltage is present then check pin 1 for 24 V dc as well. If it is close to 24 V dc while the
fan is still idle, then replace the fan. See Fan removal on page 4-16.
Cover interlock switch service check
Note: Make sure a print cartridge assembly is installed and the cover closes all the way, engaging the cover
open switch lever.
FRU Action
Cover interlock switch Disconnect the cover interlock cable from the controller board at J7.
With the printer turned off:
1. Verify continuity between cable pin 1 and pin 2 with the door closed and discontinuity
with the door open.
2. Verify continuity between cable pin 1 and pin 3 with the door open and discontinuity with
the door closed.
3. Verify discontinuity between cable pins 2 and 3 whether the door is open or closed.
If any fail, then replace the cover interlock switch.
If both pass continuity, then turn the printer on, and measure +5 V dc on pin 2 at J7 on
the controller board.
Verify pin 3 at J7 is ground.
If voltage or ground is not present, then see Controller board service check on
page 2-23 for more information.
2-24 Service Manual

4513-630, -63W, -6EW
Dead machine service check
CAUTION: Check the AC line voltage. The voltage should be within the following limits:
100 V ac (volts alternating current) 127 V ac for the 110 V printer

200 V ac 240 V ac for the 220 V printer
FRU Action
Unplug the printer. Remove the LVPS/HVPS, and check the fuses for continuity.
If open, then replace the LVPS/HVPS.
If not open, then check the switch continuity across its conductors with the switch on.
Turn the switch off. Plug the AC line into the LVPS/HVPS and switch unit on.
Note: Voltages may be exposed at several places on the board. Do these verifications, and
LVPS/HVPS then unplug the card:
Pins Voltage
CN201-6, 17, +24 V dc
19
CN201-10, 12, Ground
14, 16, 18
CN201-1,3, 5, +5 V dc
11,13, 15
If voltages are not correct, then replace the LVPS/HVPS.

If voltages are correct, then check the controller board. See Controller board service
check on page 2-23.

4513-630, -63W, -6EW
Fuser service check
When toner is partially fused to the media, it is usually caused by low fuser temperature.
The line voltage to the printer must be within the following limits:
100 V ac-127 V ac for the 110 V model printer

200 V ac-240 V ac for the 220 V model printer
This printer uses a belt fuser and therefore does not have a lamp.
Fuser service check
FRU Action
Unplug the printer, and disconnect the fuser cable plug from the LVPS/HVPS board
connector at CN102.
Check for continuity across the fuser by checking across the connector pins.
If there is continuity, then check the LVPS/HVPS. See LVPS/HVPS service check
on page 2-26.
Fuser power cable If there is no continuity, then disconnect the fuser power cable at both ends, and check
LVPS/HVPS each conductor for continuity. Replace cable if necessary.
Fuser
If the cable tests good, then replace the fuser.
Reconnect the cables, turn the printer on, and at &12, check for approximately +5 V dc on
pin 1 and ground on pin 2. If line voltage is incorrect on pin 1, then see Controller board
service check on page 2-23 for more information.
Disconnect the thermistor cable from J12 on the controller board.

Measure the resistance across the ends of the thermistor cable.
Replace the fuser assembly if the resistance is lower than 1K ohm or shorted.
Note: Resistance measures approximately 400K ohms when cool and 1K ohms hot.
Fuser
LVPS/HVPS service check
FRU Action
LVPS portion of board

Fuses that open typically indicate a faulty LVPS/HVPS.
Disconnect the power cable, and open the LVPS/HVPS enough to test the switch. The
switch will show continuity across the conductors with a meter when the switch is on. If the
switch is good, then see Dead machine service check on page 2-25 for more
LVPS/HVPS diagnostics.
HVPS portion of board
Problems with the HVPS are exhibited in the print quality. See Print quality service
checks on page 2-31 for more information.
2-26 Service Manual

4513-630, -63W, -6EW
Main motor service check
FRU Action
Turn off the printer, and unplug the main motor cable at J17. Turn on the printer, and check
for the following voltages at J17:
J17 pins Voltages

Main motor gear drive Pins 1-4, 6 Approx. 5 V dc
Main motor cable
LVPS/HVPS Pins 7-9 18 V dc24 V dc
Controller board
Warning: Do not Verify ground at pin 5 for both the card and cable.
replace the operator
panel and controller If these voltages are correct, then check the main motor cable for continuity.
board at the same - Remove the left side cover to access the connector on the motor.
time. Each card - If continuity exists on each wire, then replace the main motor gear drive which
contains the printer includes the motor.
settings. When either - If continuity does not exist on one or more of the wires, then call the next level of
of these cards is new, support.
it obtains the settings If these voltages are not correct, then see Lexmark E460dn, E460dw controller
from the other card. board connector pin values on page 5-4, or replace the controller board. See
Settings are lost when Controller board removal on page 4-6.
both are new and
replaced at the same
time.
Media feed clutch service check
Step Action and questions Yes No
1 Clear the paper path of all sheets of Go to step 3. Go to step 2.

paper. Turn on the printer. Open the front
door of the printer.
Is the paper overlapping with no space

between the trailing edge of the first
sheet and leading edge of the second?
2 Check the paper path sensors for any dirt, Problem resolved Go to step 3.
dust or paper that might be obstructing
the sensors.
Does this solve the problem?
3 Replace the media feed clutch. See Problem resolved Contact your next level of
Media feed clutch removal on support.
page 4-42.
Does this solve the problem?

4513-630, -63W, -6EW
Operator panel service check
Inspect the operator panel cable for damage. Make sure the cable is plugged in securely. Run POST, and check
each light for proper operation. See PowerOn Self Test (POST) sequence on page 2-1.
LCD Operator panel service check
FRU Action
Operator panel (LCD) Lights

Controller board
If the LCD does not come on, then open the controller board cage and locate the operator
Warning: Do not panel connector at J3. Make sure the cable is properly connected to the controller board
replace the operator and the controller board has input voltage to it.
panel and controller
board at the same With the printer on, verify the following without disconnecting the cable:
time. Each card Pins 1, 3, 5, and 6: 3.3 v
contains the printer Pin 2: 5 v
settings. When either
of these cards is new, Pins 4 and 7: GND
it obtains the settings If these are approximately correct and the operator panel is not functioning, then replace
from the other card. the operator panel.
Settings are lost when
both are new and If any are incorrect, then see Controller board service check on page 2-23.
replaced at the same
time. Buttons
If the buttons do not respond, then replace the operator panel. There is no test or repair for
the faulty switches on the operator panel.
Paper feed service checks
Paper jam error indication during POST
FRU Action
Fuser (exit sensor) If the exit sensor flag, which is visible at the back of the fuser, is in any position other than
vertical, then the printer will display a paper jam. Make sure the flag is operating freely.
Replace the fuser if the sensor is damaged.
Input/duplex sensor Make sure the input paper feed sensors are working properly. A stuck or incorrectly installed
Manual feed sensor sensor causes a paper jam indication.
Media picks but stops halfway through the printer
FRU Action
Input/duplex sensors Make sure the input sensors are working properly.
(under print cartridge assembly)
Input sensor (manual) Check for a broken or stuck flag on the input sensors. Clear anything that keeps
the flags from rotating freely.
Make sure the cables are seated on the controller board at J27 (input/duplex
sensor) and J23 (manual input).
Check for +5 V dc on pin 2 and 5 at J27 (input/duplex sensors) and pin 2 at J23
(Input sensor). Voltages on pins 1 and 4 at J27 pin 1 at J23 should change as the
flags intersect with the sensor.
If correct, then replace the input paper feed sensor.
If these voltages are not correct, then replace the controller board.
Check the pick tires. Clean or replace as necessary.
2-28 Service Manual

4513-630, -63W, -6EW
Media never picks
FRU Action
Paper feed (pick tires) tray 1 Open the left cover, and verify that the solenoids and clutches are functioning
Paper feed (pick tires) tray 2 when an attempt is made to feed the media.
Media drive ASM
Media feed clutch ASM Make sure the rubber tires on the ACM are installed and clean.
Manual feed clutch ASM Replace the tires, ACM drive, clutch assemblies, solenoids, or drive shaft as
P/U and manual feed solenoid necessary.
ACM drive shaft
Media occasionally mispicks or picks multiple sheets at once
FRU Action
Tray 1 Check tray for media catch points.

Tray 2 (option)
If the sheet being fed stops momentarily, then the ACM applies additional vertical force,
causing additional sheets to feed.
Do not mix media types in one tray.
Paper pick tires Check the tires in the ACM assembly for signs of wear or damage.
(Tray 1 or tray 2)
Replace the tires as necessary.
ACM clutch Open left cover, and observe the solenoid and clutch actions at the ACM and manual
Manual feed clutch feed shafts as a print job is attempted.
Media feed clutch ASM
(tray 1 only) Replace the faulty part.
Manual feed clutch
solenoid
Controller board Disconnect the solenoid cable at J26 on the controller board and measure the resistance
P/U and manual feed across cable pins 1 and 2.
solenoid ASM.
The resistance should be approximately 70 ohms.
If it is not, then replace the solenoid.
If the resistance is approximately 70 ohms, then check the controller board. Pin 1 at
J26 should be +24 V dc. See Controller board service check on page 2-23 for
more information.
Replace controller board as necessary.
Media skews
FRU Action
Paper feed (pick tires) tray 1 Check tires for debris. If tires are new, then try reversing each on its hub.
Paper feed (pick tires) tray 2
Tray 1 Check side guides on Tray 1 and Tray 2. Guides set for a full stack of media may
Tray 2 (option) be too wide when the stack is short.

4513-630, -63W, -6EW
Media trees, wrinkles, stacks poorly, or curls
FRU Action
Fuser This problem is most likely due to a worn backup roll. It causes the printer to run hotter than
required for the media being printed. Excessive heat can cause media treeing problems,
poor stacking, or curl.
Print the menu sheet found under Utilities.
Look at the media settings. Some, such as card stock or rough texture, may require a
higher fuser temperature, which leads to more of these problems (except stacking) in plain
paper.
Change settings using the printer driver.
Use the local printer setup utility (included on the CD) to change the NVRAM
settings.
Try a different ream of paper. Moist media has a higher tendency to crease (treeing) and
curl.
Parallel or USB port service check
1. Perform a print test to make sure the printer prints correctly. Verify that the indicator light is on, then print
the menu settings by selecting Print Menu under Utilities.
2. Be sure the printer parallel cable is designed for bidirectional printing.
3. Be sure the users application is set up correctly.
4. If the internal print test page prints correctly, then the users application/printer driver is set up correctly,
and the correct bidirectional parallel cable is installed, but the printer still fails to print on command from the
host computer, replace the controller board.
5. Check the USB cable for continuity.
2-30 Service Manual

4513-630, -63W, -6EW
Print quality service checks
Note: Ensure the cover closes tightly. A gap in the opening may allow light to expose the photoconductor,
resulting in a dirty print. Extreme environmental conditions, temperatures, and humidity will affect the print
quality.
Using print quality test pages
To help isolate print quality problems, like streaking, print test pages using the print quality test pages. To print
the print quality test pages:
1. Enter Configuration Menu.

a. Turn off the printer.
b. Turn on the printer while pressing and holding and .
c. Release the buttons when Performing Self Test displays.
d. The message CONFIG MENU displays.
e. Press to Prt Quality Pgs.
f. Press to print the pages.
Four pages print to help evaluate print quality. The first page has various fonts and a graphic, the
second page is gray with graphics, the third page is black, and the last page is blank.
2. Use the test pages to isolate problems such as light or toner streaks. See POST symptom table on
page 2-21 for solutions to these problems.
3. Press to Exit Config Menu, and press .
To exit configuration, turn the printer off.
Note: Refer to the print defects guide at the end of the manual for repeating defects.
Blank page
FRU Action
Toner cartridge (not a Remove the toner cartridge, and gently shake it to evenly distribute the toner.
FRU)
Check for cartridge damage.
Blank pages can be caused by a defective printhead assembly,

LVPS/HVPS, or controller board.
Printhead errors typically result in printer service errors unless there is blockage of the
beam or dust on the lens. Check the lens and opening for blockage.
Blank pages typically are caused by the PC roll not being properly charged. Try a
Printhead different PC kit.
LVPS/HVPS With the cartridge out, check the spring loaded contacts on the right side for free motion.
Controller board None should be ground except for #4 contact from the front.
Unplug the printer, and check the cable continuity between the LVPS/HVPS connector
marked OPC (at CN202) and the corresponding wire form (spring) found about 14 mm
above and to the right of the transfer roll gear.
If there is not continuity, then call the next level of service.
Try a different toner cartridge and PC kit.
If those fail, then replace the LVPS/HVPS, controller board, or the printhead in that
order.

4513-630, -63W, -6EW
Black page
Note: Incorrect laser exposure or incorrect charging of the photoconductor causes an all black page. Always
verify the same results from a different print cartridge assembly and developer before proceeding.
FRU Action
Toner electrodes (not Check the three rearward electrodes below the toner cartridge assembly for contamination,
a FRU) damage, or a short to ground. Correct as necessary.
Check continuity between the cable (DEV, TAR, and doctor blade) connection PCN3 and
on the contact tips below the toner cartridge assembly.
If continuity fails, then call the next level of service.
With the printer off, disconnect the LVPS/HVPS cable from J502 on the controller board.
Turn the printer on, and verify +24 V dc on pins 17 and 19 of the cable.
Verify +5 V dc on pins 1, 3, 5, 13, and 15.
Verify ground on pins 10, 12,14, 16, and 18.
LVPS/HVPS board If any of the values are incorrect, then replace LVPS/HVPS board.
Controller board
Miscellaneous cables If the grounds are incorrect, then check ground paths.
Check continuity in the cable. If the cable is bad, then call the next level of support.
If the values are correct and the toner electrodes are good, then replace the controller
board.
See the LVPS/HVPS service check on page 2-26 and the Controller board
service check on page 2-23, if necessary.
Heavy background
Poor development or poorly charged toner particles cause excessive background. This is more noticeable as
the toner cartridge nears end-of-life.
FRU Action
Toner cartridge (not a Check the toner darkness setting in the driver. Try a lower setting.
FRU)
Photoconductor kit (not Make sure the toner cartridge and photoconductor kit are correctly installed and the high
a FRU) voltage contacts are clean.
If the toner cartridge and photoconductor kit are installed correctly, then try a new
photoconductor kit first and then toner cartridge.
Check the contacts for correct installation and contamination where contact is made
between the print cartridge assembly and spring contacts which connect to the LVPS/HVPS
board at CN203. Clean as necessary.
If this does not correct the problem, then replace the following FRUs one at a time in the
order shown:
LVPS/HVPS LVPS/HVPS board (See Black page on page 2-32 for pin values.)
Controller board Controller board
2-32 Service Manual

4513-630, -63W, -6EW
Partial blank image/white spots (no repeating pattern)
FRU Action
Toner cartridge (not a Remove the toner cartridge assembly, and gently shake the assembly to evenly distribute
FRU) the toner.
Check to make sure that the laser light path is not blocked.
If toner cartridge is low, then try a new one.
Paper (not a FRU) Make sure recommended media is being used.

Check the media settings in the printer driver. A heavier media may require higher heat to
properly fuse.
Variation in image density horizontally across page
FRU Action
Photoconductor kit (not The charge roll may have an unbalanced force against the PC (photoconductor) drum.
a FRU)
Try a new photoconductor kit.
Transfer roll Note: Do not touch the transfer roll except at its ends. Place a sheet of paper over the roll to
prevent damage from finger oils or hand lotion.
Check the springs in the left and right transfer roll bearings. The bearing assemblies should
support the transfer roll, applying evenly distributed forces to the PC drum.
Replace the transfer roll assembly if the springs or bearings show signs of damage or
fatigue.
Inspect the transfer roll for signs of wear, damage, or contamination.
Replace as necessary.
Poor fusing of image
FRU Action
Fuser The fuser may not be operating at the proper temperature to fuse the toner to the paper.
SeeLVPS/HVPS service check on page 2-26 for more information. Try changing the
setting to heavier paper or even card stock.
Media (not a FRU) Make sure recommended media is being used.

Check the media settings in the printer driver.

4513-630, -63W, -6EW
Light print
FRU Action
Toner cartridge (not a Make sure the toner cartridge and photoconductor kit are installed correctly and that the
FRU) toner cartridge is not low on toner.
If the problem continues, then install a new toner cartridge.
Recheck condition before replacing photoconductor kit, if necessary.
Check the transfer roll for signs of toner buildup and contamination.
Inspect the HVPS contact (transfer roll) for contamination.
Verify the high voltage cable is plugged into the LVPS/HVPS.
If all components appear free of contamination, then replace the following FRUs one at a
Transfer roll time in the order shown:
LVPS/HVPS card Transfer roll
LVPS/HVPS card
White or black lines or bands
FRU Action
Print cartridge Banding appears as light or dark horizontal lines on a uniformly gray page or on a page with
assembly (not a FRU) a large area of graphics. Banding is primarily due to a variation in the speed of the media as
Developer drive it feeds through the printer, especially in the developer and transfer process. It may also be
coupling assembly a result of overly dry or moist environments.
Main motor gear drive
With the printer off, check to make sure that the laser beam is not blocked.
Inspect the toner cartridge and paper feed components, especially the drive coupler and
drive gears for debris, binds, or damage.
Toner on back of page
FRU Action
Photoconductor kit (not Print a menu page found under Utilities, and check settings for media type.
a FRU)
Inspect the overall paper path for signs of spilled toner.
Gently clean the contaminated areas with a soft cloth.
Fuser Inspect the fuser for signs of contamination.

Replace the fuser as necessary.
Transfer roll A transfer roll contaminated with toner can cause toner to transfer to the back of pages.
Inspect the transfer roll for contamination and its cable for continuity.
HVPS or controller Loss of the proper high voltages can cause excessive toner to contaminate the transfer
board roller. None of these voltages can be measured, but the contacts and continuities can be
checked. To check the lower voltage, see J502 on the wiring diagram. Replace the LVPS/
HVPS or controller board as necessary.
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Solving print quality problems
Note: Refer to the print defects guide at the end of the manual for repeating defects.
Print quality problems
Problem Cause / action
Light or blurred Light print

characters.
See Light print on page 2-34.
The toner cartridge may be getting low on toner:
Remove the toner cartridge and print cartridge assembly.
Shake it from side to side to redistribute the toner.
Reinstall it, and recheck for condition.
Make sure to use the recommended print media (see media types and sizes in the
Users Guide).
Use MarkVision Professional to define the custom type setting for media type, media
texture, or media weight.
The toner cartridge or photoconductor kit may be defective. Replace the
photoconductor kit first, and recheck.
Blurred characters
Blurred images, including characters, are usually caused by a defective printhead.
Vertical white lines
See Vertical streaks below.
Vertical white lines may be caused by the laser beam, which may be partially blocked. With
the printer off, clear the path or clean the lens. The toner cartridge or fuser may be
defective. Try a different toner cartridge. Inspect the fuser at its entry for debris.
Toner smudges Make sure the media is straight and unwrinkled.

appear on the front or Replace the photoconductor kit, and recheck before replacing the toner cartridge. See
back of the page. Toner on back of page on page 2-34 for more information.
Vertical or horizontal Vertical streaks

streaks appear on the
page. Something could be caught between the photoconductor kit and the fuser. Check the paper
path around the fuser entry. Try a different toner cartridge.
Vertical white lines may be caused by the laser beam, which may be partially blocked. With
the printer off, clear the path or clean the lens. The toner cartridge or fuser may be
defective. Try a different toner cartridge. Inspect the fuser at its entry for debris.
Horizontal streaks
The toner cartridge or the fuser may be the cause due to excessive page count or defect.
Replace as needed.
If the lines are parallel and match the two intended ghost images, then the Form Type may
be incorrectly set. Check those settings.
The PC cleaner sump may be full. Replace the photoconductor kit.

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Print quality problems (Continued)
Toner smears or rubs Toner is not being fused to the paper. Replace the fuser.
off the page. Change the media texture setting in the driver. If special media is being used, such as
card stock or labels, then be sure to select the correct media type.
Try a different kind of paper. Paper designed for copiers gives the best quality fusing.
The print is getting Toner is becoming low in the cartridge.

light, but the printer The Toner Low message does not display if the 1,500-page toner cartridge is installed.
has not indicated it is Remove the toner cartridge, and gently shake it from side to side to redistribute the
low on toner. toner.
Replace the toner cartridge.
The Toner Low Remove the toner cartridge, and gently shake it from side to side to redistribute the
message displays. toner.
Solid black areas on There is a mismatch in the transparency and what the software is expecting.
transparencies Choose a different fill pattern in the software program.
Remove the toner cartridge, and gently shake it from side to side to redistribute the
toner.
Try a different type of transparency.
Faint images or Select a different media type or form type setting from the printer driver.
repetitive spots appear Try a different type of paper. Media designed for copiers gives the best quality.
on the page. Replace the toner cartridge.
Pages are blank. The print cartridge may be out of toner or defective. Replace the cartridge.
There may be a software error. Re-initialize the printer by turning it off and back on.
With the printer off, check the printhead beam path. If clear, then check for a printhead
error on POR. See Printhead service check on page 2-38.
Also, see Blank page on page 2-31.
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The printer is on and Make sure the parallel or USB cable is not damaged and is firmly plugged into the
indicates ready, but connector on the back of the printer.
nothing prints. Make sure the toner cartridge assembly is installed properly.
Print the menu page found under Utilities.
- If a menu settings page cannot be printed, then contact the next level of support.
- If a menu settings page can be printed, then the problem is one of the following:
Computer
Software program
Cable
(USB only) A failed controller board. Replace card.
Note: Test by unplugging USB and plugging it with the printer on. If the computer indicates
unknown device, replace the controller board.
Toner Low light is on If a 3.5K or more page toner cartridge is being used and the Toner Low alarm is set to on,
and printing stops. then the printer stops printing until the toner cartridge is replaced.
The Error light alone is Make sure the front printer cover is closed.
on.
The Toner Low light is Make sure the toner cartridge is installed correctly.
blinking, and the Error Install a new toner cartridge.
light is on.
The media skews or Tray is overfilled or media is too loose.

buckles. Dont overfill Tray 1 or the optional Tray 2 (see media capacities in the media types and
sizes table in the Users Guide).
Make sure the paper guides are flush against the edges of the media.
The media sticks The friction between sheets is too high.

together, resulting in Remove the media from Tray 1 or Tray 2, and fan it.
the printer feeding Dont overfill Tray 1 or the optional Tray 2 (see media capacities in the media types and
multiple sheets. sizes chart in the Users Reference).
The media fails to feed Frictional force between tires and media is less than resisting force.
from Tray 1. Remove the media from Tray 1, and fan it.
Make sure Tray 1 is selected from the printer driver. Do not overfill the tray.
Check the condition of the rubber on the paper feed rolls. Replace if worn or
contaminated.
Verify that the ACM clutch is functioning correctly.
The media fails to feed Incorrect tray selection or inadequate picking force by tires.
from the optional Make sure the correct tray and media type are selected from the driver.
Tray 2. Make sure the tray is pushed all the way in.
Remove the media from the optional Tray 2, fan it, and reload.
Check the rubber on the paper feed tires for dirt or any other debris. Replace as
necessary.
Check the paper path in the tray for burrs or debris that may hinder media movement.
Make sure the media does not exceed the stack height indicator.
Load Paper displays The input sensor does not sense media after picking.
even though there is Make sure the tray is pushed all the way in.
media loaded in the Press .
optional Tray 2.
Check the feed tires. (See two preceding actions.)
The printer does not The printer is waiting on the next command.
print after a paper jam Clear all jams.
has been cleared. Press and release , or open and close the printer cover to restart the printer.
Make sure the print cartridge assembly is installed properly.

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Unexpected Ensure correct printer driver is being used.

characters print, or Select hex trace mode to determine what the problem is.
characters are Restore factory defaults.
missing.
Make sure the parallel cable or USB cable is firmly plugged in at the back of the printer.
Jobs are not printing, The printer is waiting for an appropriate command.
and an error message Make sure the print cartridge assembly is installed properly.
is displayed. Make sure the printer front cover is closed.
While in PostScript 3 Ensure the correct PostScript driver is being used.

emulation, the printer The printer doesnt have enough memory to print the job. Install more memory.
is flushing data (an
error message is
displayed).
Printhead service check
FRU Action
Turn the printer off.

Disconnect the printhead cables from J8 and J100 on the controller board.
Turn the printer on with the front door closed.
On the controller board, verify +5 V dc on pin 10 at J8 and +5 V dc on pins 1, 2, and 3 at
Printhead J100.
Note: New printhead Verify grounds on pins 2, 4, and 7 at J8 and on pin 4 at J100.
must be aligned. See If voltages or grounds are incorrect, then check the controller board. See Controller
Printhead assembly board service check on page 2-23 for more information.
electronic
adjustment on If voltages are correct, then replace the printhead (comes with cables).
page 3-18.
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Service software service check
There are different types of 900.xx errors that can occur. There may be a communication problem (Bad cable,
network connection, and so on) software issue, or a hardware problem with the controller board, or ISP (Internal
solutions port). The communication and software aspects should be checked first. Determine if the problem is
constant or intermittent. Use the troubleshooting procedure below to isolate the issue. Take any notes as
instructed. You will need that information in the event you need to contact your next level support.
Note: Before troubleshooting, determine the operating system used when the error occured. If possible
determine whether a PostScript or PCL file was sent to the device when the error occured. Ask the customer
which Lexmark Solutions applications are installed on the device.
1 POR the device. Go to step 2. Problem resolved.

Does the error reoccur?
2 Write down the exact 900.xx error Go to step 3. Go to step 6.

code displayed on the device.
Turn the device off.
Clear the print queues.
Disconnect all communication cables,
and remove all memory options.
Remove all ISP and modem cards.
Restart the device into diagnostic
mode.
Does the 900.xx error reoccur during

startup?
3 Check all the cables connected to the RIP Go to step 5. Go to step 4.

board for proper connectivity.
Are the cables properly connected?
4 Properly connect the cables to the RIP Go to step 5. Go to step 6.

board. Restart the device into diagnostic
mode.
Does the 900.xx error reoccur during
startup?
5 Replace the RIP board, and restart the Problem resolved. Go to step 31.
device.
Does this fix the problem?
Note: If an error, different from the
original 900.xx, is displayed, consult the
service check for that error.
6 Print the following: Go to step 31. Go to step 7.

Error log
Menu settings page
Network settings page
Does the 900.xx error reoccur while

these pages were printing?

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7 Re-attach the communications cable. Go to step 8. Go to step 10.

Restart the printer to operating mode.
Send the printer a print job.
Does the 900.xx error reoccur?
Note: Before performing this step, write
down this information about the file being
sent to the printer:
Application used
Operating system
Driver type
File type (PCL, PostScript, XPS, etc.)
8 Restart the printer to operating mode. Go to step 9. Go to step 10.

Send a different print job to the device.
9 Upgrade the firmware. Contact your next Go to step 31. Go to step 10.
level of support for the correct firmware
level to use.
10 Is the device a Multi Function Printer? Go to step 11. Go to step 13.
11 Run a copy job. Go to step 31. Go to step 12.

12 Run a scan to PC job. Go to step 31. Go to step 13.

13 Is there optional memory installed? Go to step 14. Go to step16.
14 Reinstall the memory, and send a print job Go to step 15. Go to step 16.
to the device.
15 Install a Lexmark recommended memory Go to step 31. Problem resolved.

option. Send a print job to the device.
16 Is there a modem installed on the device? Go to step 17. Go to step 21.
17 Reinstall the modem. Restart the device. Go to step 18. Go to step 20.
18 Upgrade the firmware. Contact your next Go to step 19. Problem resolved.
level to use.
19 Replace the modem. Restart the device. Go to step 31. Problem resolved.
20 Run a fax job. Go to step 31. Go to step 21.

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21 Are there any ISP (internal solutions port) Go to step 22. Problem resolved.
options installed?
22 Reinstall the first ISP option. Restart the Go to step 24. Go to step 23.
device.
23 Run a job to test the option. Go to step 24. Go to step 26.

24 Upgrade the firmware. Contact your next Go to step 25. Problem resolved.
level to use.
25 Replace the faulty ISP option. Restart the Go to step 31. Go to step 26.
device.
26 Are there any more ISP options to install? Go to step 27 Problem resolved.
27 Install the next ISP option. Restart the Go to step 29. Go to step 28.
device.
28 Run a job to test the option. Go to step 29. Go to step 26.

29 Upgrade the firmware. Contact your next Go to step 30. Go to step 26.
level to use.
30 Replace the faulty ISP option. Restart the Go to step 31. Go to step 26.
device.
31 Contact your next level of support. You will need the following information for them:
Exact 900.xx error digits and complete error message
Printed menu settings page
Printed network settings page
Device error log
A sample print file if error appears to be isolated to a single file
File/Application used if error is related to specific print file
Device Operating System
Driver used (PCL/PS)
Frequency of the occurrence of the error

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Transfer roll service check
FRU Action
Note: Do not touch the transfer roll except at its ends. Place a sheet of paper over the roll to
prevent damage from finger oils or hand lotion.
Check the springs in the left and right transfer roll bearings. Do not try to move the left
spring. The bearing assemblies should support the transfer roll, applying evenly distributed
forces to the PC drum.
Transfer roll Replace the transfer roll assembly if the springs or bearings show signs of damage, or
fatigue.
Inspect the transfer roll for signs of wear, damage, or contamination.
Replace as necessary.
Tray 2 service check
FRU Action
Tray 2 Turn the printer off.

Separate the printer from Tray 2.
Turn the printer on and check the voltages on connector J28 on the controller board. See
the wiring diagram at the end of the service manual, or Lexmark E460dn, E460dw
controller board connector pin values on page 5-4 for the J28 connector.
Pins 1, 4: 3.3 V
Pin 2: 24 V
Pin 6: Ground
If the voltages are incorrent, then replace the controller board. If the voltages are correct,
then try using Tray 2 again. If the printer error persists, then replace Tray 2.
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3. Diagnostic aids
This chapter explains the tests and procedures to identify printer failures and verify repairs have corrected the
problem.
Accessing service menus

There are different test menus that can be accessed during POR to identify problems with the printer.
Configuration Menu 1. Turn off the printer. The Configuration Menu group contains a set of
2. Press and hold and . menus, settings, and operations which are
3. Turn on the printer. infrequently required by a user. Generally, the
options made available in this menu group are
4. Release the buttons when the used to configure a printer for operation.
clock displays.
See Configuration menu (CONFIG MENU) on
page 3-2 for more information.
Diagnostics Mode 1. Turn off the printer. The Diagnostics Mode group contains the settings
2. Press and hold and . and operations used while manufacturing and
3. Turn on the printer. servicing the printer.
4. Release the buttons when the See Diagnostics menu on page 3-6 for more
clock displays. information.
To run the printer diagnostic tests described in this chapter, the printer must be in Diagnostic Mode.
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Configuration menu (CONFIG MENU)

Entering Configuration Menu
1. Turn off the printer.

2. Press and hold and .
3. Turn on the printer.
4. Release the buttons when the clock displays.
Available menus
The menus display on the operator panel in the order shown:
Maintenance Count Value See Maintenance Count Value (Maint Cnt Value) on page 3-3.
Reset Maintenance Count See Reset Maintenance Count Value (Reset Maint Cnt) on
page 3-3.
Reset Photoconductor Maintenance See Reset Photoconductor Maintenance Counter (Reset PC
Count Cnt) on page 3-3.
Print Quality Pages See Print Quality Pages on page 3-3.
Reports See Reports on page 3-4.
Panel Menus See Panel Menus on page 3-4.
PPDS Emulation See PPDS Emulation on page 3-4.
Demo Mode See Demo Mode on page 3-4.
Factory Defaults See Factory Defaults on page 3-4.
Action for Prompts See Action For Prompts on page 3-5.
Energy Conserve See Energy Conserve on page 3-5.
Font Sharpening See Font Sharpening on page 3-5.
Exit Config Menu See Exit Configuration Menu (Exit Config Menu) on page 3-5.
Note: Menus may vary depending on the features and options of the printer.
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Maintenance Count Value (Maint Cnt Value)
The Maintenance Count Value displays the current value of the Maintenance Kit counter which provides a rough
gauge of the printers usage. A simplex print job increases the counter by one, and a duplex print job increases
the counter by two. Press to enter this setting. The following displays:
Maintenance Count Value

[Value]
Press to return to the Configuration Menu.
Note: When the Maintenance Count Value is equal to the Maintenance Kits rated life, the operator panel
displays the 80 Scheduled Maintenance message. Perform the required maintenance, and then reset the
Maintenance Kit counter to 0.
Reset Maintenance Count Value (Reset Maint Cnt)
This setting resets the maintenance count value to 0.
1. Press to enter the Reset Maintenance Count Value setting. The following displays:
Reset Cnt
Reset
2. Select Reset.
3. Resetting Maintenance Counter displays.
Once initiated, the reset operation cannot be canceled. Press or to return to the Configuration Menu.
Reset Photoconductor Maintenance Counter (Reset PC Cnt)
This setting resets the photoconductor kit page counter and clears any warnings or photoconductor exhausted
messages. This operation should be performed only after a new photoconductor unit has been installed.
Print Quality Pages
This setting is a limited version of the Print Quality Pages setting that appears in the Diagnostics menu. This
setting reports the values of a broad range of printer settings and tests the printers ability to generate
acceptable printed output. Press to print the report. Printing Quality Test Pages will display. Once started,
the printing cannot be canceled and no buttons are active until the printing completes.
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Reports
The Reports menu contains two selections: Menu Settings Page and Event Log.
Menu Settings Page
To print the Menu Settings page, press . Press to return to the Configuration menu.
Event Log
The event log provides a history of printer errors. The event log can only be printed in the Configuration
menu. Additional options are available in the Diagnostics menu. See Reports on page 3-16.
To print the event log:
1. Select Print Event Log from the Event Log menu.
2. Press to return to the Configuration menu.
Note: An event log printed from the CONFIG MENU will not contain debug information or secondary
codes for 900 service errors. However, the event log printed from DIAGNOSTICS mode does include this
information.
Panel Menus
The settings are On and Off. The default is On.
PPDS Emulation
This menu item activates or deactivates the PPDS emulation data stream. The selections are Deactivate
(default) and Activate. When PPDS emulation is activated, the following settings are also changed:
SmartSwitch settings for each port are turned off.

The printer language is changed to PPDS Emulation.
Users can still switch languages on the operator panel and through the PJL data stream.
Demo Mode
This setting contains a built-in demonstration mode. The settings allow you to turn the Demo Mode Off (default)
or On. While Demo Mode is set, the printer will start in Demo Mode until you change the setting.
Note: While Demo Mode is set to On, only demonstration files can print. Files received across the network or
from the host computer are ignored.
Factory Defaults
This setting enables a user to restore all the printer settings to the original factory settings. The selections are
Do not restore (default) and Restore now. Network does not appear unless you have a network printer. The
following settings are not changed:
Display language
Settings in the NETWORK/PORTS MENU group.
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Action For Prompts
This setting determines which input source receives paper-related or envelope-related change prompts when
they occur. Press to enter Action For Prompts from the Configuration Menu. The following displays:
Action For Prompts

*Prompt user
Continue
Use Current
Press to select a prompt. Submitting Selection displays. The screen automatically returns to the
Configuration Menu.
Press to exit the Env Prompts setting at anytime.
Energy Conserve
This menu controls what values appear on the Power Saver menu. If Off is selected in the Energy Conserve
menu, then the Power Saver can be turned off. If On (default) is set in Energy Conserve, then the Power Saver
feature cannot be turned off.
Font Sharpening
This menu allows a user to set a text point-size value below which the high-frequency screens will be used when
printing font data. For example, if this settings value is 24, then all fonts sized 24 points or less will use the
high-frequency screens. To increase this settings value by 1, press . To decrease this settings value by 1,
press .
Exit Configuration Menu (Exit Config Menu)
Press to exit the Configuration menu. The printer performs a POR and restarts in normal mode.
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Diagnostics menu
Entering Diagnostics menu
1. Turn off the printer.

2. Press and hold and .
3. Turn on the printer.

4. Release the buttons when the clock displays.
Available tests
The tests display on the operator panel in the order shown:
Registration See Registration on page 3-7.

Print tests See Print Tests on page 3-8.
Hardware tests See Hardware Tests on page 3-9.
Duplex tests See Duplex Tests on page 3-10.
Input Tray Tests See Input Tray Tests on page 3-11.
Output Bin Tests See Output bin tests on page 3-12.
Base Sensor Test See Base Sensor Test (B. Sensor Test) on page 3-12.
Printer setup See Printer Setup on page 3-13.
EP Setup See EP Setup on page 3-15.
Reports See Reports on page 3-16.
Event Log See Reports on page 3-16.
Exit Diagnostics See Exit Diagnostics on page 3-17.
Note: Menus may vary depending on the features and options of the printer.
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Registration
The Registration menu settings adjust the black planes margins. To set print registration, select
REGISTRATION from the Diagnostics menu. The following will display:
REGISTRATION
Top Margin
Bottom Margin
Left Margin
Right Margin
Quick Test
Press or to move to the desired setting, and then press .
Margins
To change the value of any margin setting, press or to increase or decrease the margin setting value,
and then press to save. The panel displays Submitting changes... and returns to the initial
REGISTRATION menu screen. To exit the margin setting menu without changing the settings value, press .
Top Margin
This setting moves the black planes top margin up or down. Increasing the margin value moves text down the
page and increases the amount of space between the pages top edge and the top margin. Decreasing the
margin value moves text up the page and narrows the amount of space between the pages top edge and the
top margin. The default margin is 1/6 inch.
Note: Modifying the top margin moves the entire image either up or down on the physical page. In order to
preserve the bottom margin, changing the top margin does not compress or expand the image.
Bottom Margin
This setting moves the black planes bottom margin up or down. Increasing the margin value moves text down
the page and narrows the amount of space between the bottom edge of the page and the bottom margin.
Decreasing the margin value moves text up the page and widens the amount of space between the bottom edge
of the page and the bottom margin. The default margin is 1/6 inch.
Note: Modifying the bottom margin affects the rate of the stepper motor and may cause the page image to
be compressed or expanded.
Left Margin
This setting moves the position of the black plane to the right or left. Increasing the margin value moves the
plane to the right. Decreasing the margin value moves the plane to the left. The default margin is 1/4 inch.
Note: The left margin adjustment is used to center the image from left to right. The image will remain the
same width.
Right Margin
This setting is used to adjust the printhead, but only after determining that it is out of adjustment by observing
the Quick Test Page.
Note: The right margin setting is not a margin adjustment and should not be used unless a new printhead
is installed. To adjust a new printhead, see Printhead assembly electronic adjustment on page 3-18
or Printhead assembly mechanical adjustment on page 3-19.
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Quick Test page
Print a Quick Test page to verify that the REGISTRATION margin values are set appropriately. The Quick Test
page consists of the following:
Alignment diamonds
Horizontal lines used for skew adjustment
General device information (current page count, installed memory, etc.)
The printers serial number, code levels, and print registration settings
While the Quick Test page prints, Printing... will display. No buttons are active while the Quick Test page
prints. When the Quick Test page is finished printing, the display returns to the initial REGISTRATION menu
screen.
Note: Print the Quick Test page on Letter- or A4-sized media.
Print Tests
This setting tests the printers ability to generate printed output from each of its installed input sources and to
test the printers current print quality.
Input sources
PRINT TESTS contains the following installed input sources:
Tray1
Tray 2
Multi-Purpose Feeder
Print Quality Pages
Press or to scroll through the PRINT TESTS menu, and then press to select the desired input
source. Single or Continuous is displayed on the screen. A Single test feeds one sheet of media from the
selected input and prints a test page on it. No buttons are active during the Single test. The Continuous test
feeds media from the selected input and prints test pages until is pressed. The printer always generates a
simplexed version of the Print Test page in its default resolution. While the Single or Continuous tests print,
Printing... will display. After the Single test prints or the Continuous test is canceled, the display returns to the
PRINT TESTS menu screen.
Note: The type of media installed in the selected input source will affect the contents of the page.
Print Quality Pages (Prt Quality Pgs)
This setting reports the values of a broad range of printer settings and tests the printers ability to generate
acceptable printed output. Press to print the report. Printing Quality Test Pages will display. Once started,
the printing cannot be canceled, and no buttons are active until the printing completes.
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Hardware Tests
This setting contains the following tests:
Panel Test
Button Test
DRAM Test
CACHE Test
Press or to scroll through the Hardware Tests menu, and then press to select the desired test.
Panel Test
Once the Panel Test setting is selected, the printer automatically performs the operator panel test. This test
toggles each pixel in the operator panel through every contrast level, beginning with the darkest and ending with
the lightest. Once the pixels are toggled, the backlight of the operator panel comes on and then goes off. Non-
functioning pixels will appear as blank spaces during the tests darker stages. Press anytime to cancel
the LCD Test. Once the test is canceled, the display returns to the initial Hardware Tests screen.
Button Test
The Button Test verifies the operation of each button on the operator panel. Press to select the Button Test
from the HARDDWARE TESTS menu. All of the buttons and the backlight illuminate, and PANEL TEST Press
Count: 0 displays. Press , , or to increase the value of the Press count field by one. If the final Press
count does not match the total number of buttons that are pressed, then one or more buttons are malfunctioning.
Press to return to the HARDWARE TESTS menu screen.
DRAM Test
The purpose of this test is to check the validity of DRAM, both standard and optional. The test writes patterns of
data to SDRAM to verify that each bit in memory can be set and read correctly.
To run the SDRAM Memory Test:
1. Select DRAM Test from the menu. The power indicator blinks, indicating the test is in progress.
DRAM Test xxxMb
P:###### F:#####
xxxMB represents the amount of installed DRAM memory in MB.
P:###### represents the number of times the memory test has passed and finished successfully. Initially, 000000
displays with the maximum pass count being 999,999.
F:##### represents the number of times the memory test has failed and finished with errors. Initially, 00000
displays with the maximum fail count being 999,999.
2. Once the maximum pass count or fail count is reached, the test stops, the power indicator is turned on
solid, and the final results display. If the test fails, then the message DRAM Error displays for approximately
three seconds, and the failure count increases by 1.
3. To stop the test before it completes, turn off the printer. The test does not terminate.
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Duplex Tests
The following tests are used to determine if the duplex is working correctly:
Quick Test
Top Margin
Left Margin
Sensor Test
Duplex Feed 1
Quick Test
The Quick Test contains the following information on a duplexed page:
Print registration settings

Alignment diamonds at the top and bottom
Horizontal lines to check for skew
General printer information, including current page count, installed memory, serial number,
and code level.
To print the duplexed Quick Test page:
1. Select Quick Test from the DUPLEX TESTS menu.

2. Select Single or Continuous by pressing or .
3. Press to print the page.
Top Margin
1. Select Top Margin from the DUPLEX TESTS menu.

2. To change the margin value, press to increase the value or to decrease the value.
3. Press to save the desired margin value.
Left Margin
1. Select Left Margin from the DUPLEX TESTS menu.

2. To change the margin value, press to decrease the value or to increase the value.
3. Press to save the desired margin value.
Sensor Test
This test is used to determine if the input sensor is operating correctly.
If the sensor is operating correctly, then OP (Open) will appear on the display:
Sensor Test
Input=OP
Press to return to the DUPLEX TESTS menu.
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Duplex Feed 1
1. Select Duplex Feed 1 from the DUPLEX TESTS menu. The following will appear on the display:
Duplex Feed 1
Feeding...
2. A blank page will feed through the printer. The following will appear on the display:
Duplex Feed 1
Clear Paper...
3. Remove the blank page from the printer, and press to return to the DUPLEX TESTS menu.
Input Tray Tests
The INPUT TRAY TESTS setting is used to test the printers installed input trays and their sensors.
Feed Tests
The Feed Test observes the paper path of media as it passes through the printer. This setting contains the
following tests:
Tray 1
Tray 2
MP Feeder, if installed
To observe the paper path, open the upper rear door during the feed test.
Note: The upper front door cannot be opened during the feed test.
The feed test can be performed by using media from any of the installed input sources. All pages used during
this test drop into the default output bin. For each installed input source, press to select Single, or press
and to select Continuous. The Single test feeds one sheet of media to the default output bin. The
Continuous test feeds media to the default output bin until is pressed. The operator panel displays
[Select Input Tray] Feeding... while either of these tests perform.
Sensor Test
The Sensor Test verifies that the Tray 1, Tray 2, and MP Feeder (if installed) sensors are working correctly.
Press to select this test from the INPUT TRAY TESTS menu. [Select Input Tray...] Tray Present will
display on the operator panel.
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Output bin tests
The Output bin tests setting is used to test the printers output bins and its sensors.
Feed Tests
This test verifies that the media from the printers default input source feeds to the specific output bin. Press
to select Single, or press and to select Continuous. The Single test feeds one sheet of media to the
default output bin. No buttons are active during this test. The Continuous test feeds media to the default output
bin until is pressed. The indicator light blinks green, and the operator panel displays [Select Output Bin]
Feeding... while either of these tests perform.
Sensor Test
This test verifies that the selected output bins sensors are working correctly. The following sensors are available
in each output bin:
Output bin Full sensor Near full sensor Passthru 1 Passthru 2 Level sensor*
sensor sensor
Standard bin x x x x
-bin Mailbox x x
*This sensor will register the following levels: empty, normal, near full, and full.
Press to select this test from the Output bin tests menu, and then press again to select the desired
output bin. Closed will display on the operator panel if the sensor is closed. Open will display on the operator
panel if the sensor is open. If the wrong message is displayed, then the sensor is malfunctioning. To exit the
Sensor Test, press or .
Base Sensor Test (B. Sensor Test)
The Base Sensor Test verifies the correct functioning of the following sensors:
Toner level open

Input open
Exit open
Narrow media open
Front door open
This test toggles each of these sensors. If a sensor does not toggle, then the sensor is malfunctioning. To exit
the Base Sensor Test, press or .
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Printer Setup
Printer Setup displays the following selections:
Defaults (U.S.*, Non-U.S.)

Printed Page Count
Perm Page Count
Serial Number
Engine Setting (1 through 4)
Model Name
Configuration ID
Edge to Edge
Par S Strobe Adj (displayed only if the printer has a standard parallel port)
Defaults
The value of this setting determines whether the printer uses the U.S. or Non-U.S. factory default value for the
settings listed below:
Device Setting U.S. value Non-U.S. value

Paper sizes Letter A4
Envelope size 10 DL Envelope
PCL Symbol Set PC-8 PC-850
PPDS Code Page 437 850
Universal Units of Measure Inches Millimeters
If the value of a setting is changed, then Submitting Changes... displays. Press to exit the Defaults setting
and return to the Printer Setup menu.
Printed Page Count (Page Count)
The value of this setting gauges the amount of usage on the printer. The Page Count settings value will equal
the values of the Picked Sides meter. After all print tests have been completed, the value will reset to 0.
Note: The value of this setting cannot be changed manually.
Press to exit the Page Count setting and return to the Printer Setup menu.
Permanent Page Count (Perm Page Count)
The value of this setting indicates the total number of pages that have been printed. After all print tests have
been completed, the value will reset to 0.
Note: The Permanent Page Counts value cannot be reset.
Press to exit the Permanent Page Count and return to the Printer Setup menu.

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Serial Number
The serial number can only be viewed and cannot be changed.
To view the serial number:
1. Select Serial number from PRINTER SETUP.

2. Press Return to return to PRINTER SETUP.
Service Tag (only on some printers)
The service tag number can only be viewed and cannot be changed.
1. Select Service Tag from the PRINTER SETUP menu.

2. Press Back to return to PRINTER SETUP.
Engine Setting 1 through 4
Warning: Do not change these settings unless requested to do so by your next level of support.
Model Name
The serial number can only be viewed and cannot be changed.
Configuration ID
The configuration ID is used to communicate characteristics of certain areas of the printer that cannot be
determined by hardware sensors. The configuration ID was originally set when the printer was manufactured
and is located on the printer label.
Edge to Edge
When Edge to Edge is set to On, text and graphics are printed with all margins set to the physical edges of the
page. This feature does not work in PPDS emulation.
Par S Strobe Adj (parallel strobe adjustment)
This setting adjusts the factory setting for the amount of time the strobe is sampled to determine that valid data
is available on the parallel port. Incrementing this value by one means the strobe is sampled 50 nanoseconds
longer. The range of values are between -4 and +6, in increments of one. A value of zero indicates no change is
made from the factory setting.
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EP Setup
EP Setup displays the following selections:
EP Defaults
Fuser Temperature (Fuser Temp)
Fuser Page Count
Warm up Time
Transfer
Print Contrast
Charge Roll
Gap Adjust
Automatic Darkness Adjustment (Auto Dark Adj)
EP Defaults
Restores all EP settings to factory default values. Selections are Restore and Do Not Restore.
Fuser Temperature (Fuser Temp)
Changing this setting can reduce media curl or melting of some letterhead images. Selections are Normal
(default), Lower, and Lowest.
Transfer
The transfer can be adjusted to Low, Medium, or High. The default setting is Medium.
Print Contrast
The print contrast can be adjusted to Low, Medium, or High. The default setting is Medium.
Charge Roll
The charge roll can be adjusted to Low, Medium, or High. The default setting is Medium.
Gap Adjust
Adjusts the minimum gap between sheets during printing. This setting reduces speed (pages per minute), but
can be used to reduce curl of printed media and improve stacking in the output bin.
The range is 0 (default) to 255. Adjusting by one results in 9 mm of increased gap.

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Automatic Darkness Adjustment (Auto Dark Adj)
This setting attempts to optimize the amount of toner used when printing with a specific operating point. Each
time this setting executes, the printer performs the following:
Calibrates its toner density sensor

Measures the reflectivity of its bare drum
Prints patches on the drum and measures the drums reflectivity through the patches
Cleans the transfer roll
Calculates reflectivity ratios and operating points in order to attain each operating points
darkness target
Modifies the EP mechanism as necessary to adjust toner darkness
No messages are displayed on the operator panel to give any indication that this test is running. When
deactivated, the printer disables.
Reports
This setting prints the Diagnostic menu settings page. Press to print the menu settings page.
Event log
Display Log
Selecting EVENT LOG provides a history of printer errors. The most recent error displays in position 1, and the
oldest error displays in position 10 (if 10 errors have occurred). If an error occurs after the log is full, then the
oldest error is discarded. Identical errors in consecutive positions in the log are entered. All 2xx and 9xx error
messages are stored in the event log as well as the photoconductor kit and maintenance counter resets and
NVRAM resets initiated by the Factory Defaults setting in the UTILITIES menu.
To view the display log:
1. Select Display Log from the EVENT LOG menu.

The error log is displayed one error per display screen. For example:
Event 1/6
936 Svc Error
This error is the first of six errors (it is also the latest error). This error was a 936 service error. To see the
second service error, press . Pressing will display the sixth error as shown:
Event 6/6
202.01 Paper Jam
2. Press Back once to exit the Display log, or press twice to exit the EVENT LOG.
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Print Log
Additional diagnostic information is available when you print the error log. Some of the additional information
includes:
Detailed printer information, including model and serial number

Time and date stamps
Page counts for each error
The printed error log can be faxed to Lexmark or your next level of support for verification or diagnosis. This
report can also be printed from the Configuration Menu. Because you can clear error logs, the contents of this
log may not match the contents when you view the error log.
To print the error log:
1. Press to enter Print Log from the EVENT LOG menu.

2. Press Back to exit the EVENT LOG menu.
Clear Log
1. Select Clear Log from the Error Log menu.

Clear Log
=Yes
2. Select No to exit without clearing the log. Press Yes to confirm. The log is immediately erased, and the
display indicates No Events Logged.
3. Press Return to exit the Clear Log menu after clearing the log.
Exit Diagnostics
Selecting EXIT DIAGNOSTICS exits the Diagnostics menu, and Resetting the Printer displays. The printer
performs a POR, and the printer returns to normal mode.

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Printhead assembly electronic adjustment

Note: Before aligning the printhead electronically, first align the printhead mechanically, if needed. See
Printhead assembly mechanical adjustment on page 3-19.
1. Enter the Diagnostics menu. See Entering Diagnostics menu on page 3-6.
2. Press to enter the Registration menu.
3. Press to print the Quick test page.
Quick Test page

(sample only; use actual sheet)
4. In the Registration menu, select the right margin setting.

5. To determine the margin setting, choose the value that is closest to the darkest bar on the center graph of
the margin page. Add that value to the current right margin setting printed on the left hand side of the
margin page. (The right margin setting will also appear on the operator panel display.) For example, if the
right margin setting on the page is -2, and the number that is closest to the darkest line on the graph is 3
(-2+3), then the right margin setting will be equal to +1.
6. Press or to the desired setting, and press .
7. Print the Quick Test page again and check that the darkest line in the center graph is equal to zero. If it is,
then check to see if the left, top, and bottom margins are detected. If it is not, then repeat step 5.
Note: The alignment of the left margin positions the black plane to the right or left. The alignment of the right
margin does not alter the margins and should only be used to adjust the printhead.
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Printhead assembly mechanical adjustment

A printhead needs to be correctly positioned after it has been removed. Use a pencil to mark the screw locations
of the old printhead on the metal frame. Align the new printhead relative to the location of the old printhead.
Note: Skew is caused by a sheet being fed through the printer while misaligned. The entire image is rotated
relative to the sheet edges. However, a mechanically misaligned printhead causes the horizontal lines to appear
skewed, while the vertical lines remain parallel to the vertical edges.There are no adjustments for skew. Check
the pick roll (paper pick assembly) for wear, the paper path for obstructions, the fuser for proper setting, and the
tray paper guides for fit to the media.
Paper feed Printhead

skew misalignment
To adjust the printhead:
1. Enter the Diagnostics Menu. See Entering Diagnostics menu on page 3-6.
2. Select PRINT TESTS.
3. Select Tray 1.
4. Select Single.
5. Fold the printed test page on the left side so that a few millimeters of grid lines wrap around the outside of
the fold. See photo below.
6. Fold a second vertical fold near the center so that the left side top edge aligns with the right side top edge.

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7. If the grid lines of the right flap align below the corresponding lines on the left flap, then adjust the printhead
clockwise relative to the printer, and recheck. (See the left side of the figure below.) If the grid lines of the
left flap align below the corresponding lines of the right side, then adjust the printhead counterclockwise.
(See the right side of the figure below.)
8. After obtaining a properly adjusted image on the paper, tighten all three screws.
Note: The printhead must be aligned electronically. See Printhead assembly electronic adjustment on
page 3-18.
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4. Repair information
Warning: Read the following before handling electronic parts.
Handling ESD-sensitive parts

Many electronic products use parts that are known to be sensitive to electrostatic discharge (ESD). To prevent
damage to ESD-sensitive parts, follow the instructions below in addition to all the usual precautions, such as
turning off power before removing logic cards:
Keep the ESD-sensitive part in its original shipping container (a special ESD bag) until the
part is ready to be installed into the printer.
Make the least-possible body movements to prevent an increase of static electricity from
clothing fibers, carpets, and furniture.
Put the ESD wrist strap on your wrist. Connect the wrist band to the system ground point. This
discharges any static electricity in your body to the printer.
Hold the ESD-sensitive part by its edge connector shroud (cover); do not touch its pins. If a
pluggable module is being removed, then use the correct tool.
Do not place the ESD-sensitive part on the MFP cover or on a metal table; if the ESD-
sensitive part needs to be put down for any reason, then first put it into its special bag.
Machine covers and metal tables are electrical grounds. They increase the risk of damage,
because they make a discharge path from your body through the ESD-sensitive part. (Large
metal objects can be discharge paths without being grounded.)
Prevent ESD-sensitive parts from being accidentally touched by other personnel. Install
machine covers when the machine is not being worked on, and do not put unprotected ESD-
sensitive parts on a table.
If possible, keep all ESD-sensitive parts in a grounded metal cabinet (case).
Be extra careful in working with ESD-sensitive parts when cold-weather heating is used,
because low humidity increases static electricity.
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Removal procedures
Note:
Remove the toner cartridge and media tray before removing other printer parts. The toner cartridge should
be protected from light while out of the printer.
We recommend disconnecting all external cables from the printer to prevent damage during service.
Unless otherwise stated, reinstall the parts in reverse order of removal.
When reinstalling a part held with several screws, start all screws before final tightening.
Remove the paper tray and print cartridge before proceeding with a removal.
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ACM pick tire roller removal
1. Place the printer on its side.

Note: Be careful to not mar the finish of the printer.
2. Open the duplex jam door just far enough to pull out the ACM pick tires.
Warning: Open the duplex door only far enough to remove the ACM pick tires. If the door is opened too far,
then it can become disengaged and interfere with the paper tray. The tray may go in but will not come
out, and will render the printer as non-serviceable.
3. After the ACM pick tires have been pulled out, close the duplex door.

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4. Remove the ACM pick tire roller (A).

Note:
If the left hub is gray, then disconnect the old right and left tire/hub assemblies from the ACM, and replace
with the new right and left tire/hub assemblies.
If the left hub is black, then remove the old right and left tires from the ACM hubs, and replace with the new
tires. Do not attempt to remove the hubs.
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Bezel removal
1. Open the front access door.

2. Flex the top of the bezel, and disconnect the latch (A) from the upper front cover.
A
3. Disconnect the bezel from the upper front cover.
4. Remove the bezel.

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Controller board removal
CAUTION
This product contains a lithium battery. THERE IS A RISK OF EXPLOSION IF THE BATTERY
IS REPLACED BY AN INCORRECT TYPE. Discard used batteries according to the battery
manufacturers instructions and local regulations.
Warning:
Always touch a ground before touching the board.
Handle the board carefully by the edges.
Never replace the operator panel and controller board without a successful POR in between.
Never replace the operator panel and the controller board at the same time. Each card contains the printer
settings. When either of these cards is new, it obtains its settings from the other card. Critical factory
settings are lost when both cards are new and are replaced at the same time.
1. Remove the right side cover. See Right side cover assembly removal on page 3-62.
2. Remove the three screws (A) from the USB port.
Note: The E460dw printer has a wireless antenna and does not have a parallel port.
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3. Disconnect all of the cables from the controller board.

Note: A drip guard (B) has been added below the controller board. The drip guard may need to be removed to
access to the controller board.
B
4. Remove the five screws (C) from the controller board.
C
5. Lift the controller board, and remove.
Note: When installing the controller board, place the USB port and parallel port screws first, and then place the
other controller board screws.

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Cover open sensor
2. Disconnect the cable (A) from the controller board.
3. Use a #1 Phillips screwdriver to remove the screw (B) holding the sensor.
B A
4. Remove the cover open sensor.
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Door mount removal
1. Open the front cover.

2. Remove the lower front cover. See Lower front cover removal on page 3-27.
3. Remove the left side cover. See Left side cover removal on page 3-25
5. Disconnect the operator panel cable (A).
6. Remove the cable through the opening.

7. Remove the three screws (B) from the right side of the printer.

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8. Disconnect the fuser link (C).
C
9. Remove the three screws (D) from the left side of the printer.
10. Remove the door mounts.
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Duplex removal
2. Remove the LVPS/HVPS. See LVPS/HVPS removal on page 3-29.
3. Remove the three screws (A) from the shield.
A
4. Remove the four screws (B) from the duplex.

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5. Lift the duplex slightly, push to the left, and tilt to clear the right side of the printer.
6. Remove the duplex.
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Duplex/main motor gear drive interface removal

2. Remove the duplex. See Duplex removal on page 3-11.
3. Remove the main motor gear drive. See Main motor gear drive removal on page 3-32.
4. Remove the e-clip (A) from the gear.
5. Remove the gear (B) and gear shaft (C).

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6. Remove the screw (D) from the gear (E).
7. Remove the plastic bushing (F).
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8. Use a screwdriver to pop the retainer clip (G) loose from the gear.
9. Remove the gear (H).

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Fan removal
2. Disconnect the cable (A) from the controller board, and remove the two screws (B) holding the fan to the
right side frame.
B A B
3. Remove the fan.
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Front access door removal
1. Remove the operator panel. See Operator panel removal on page 3-55.
2. Remove the left side cover. See Left side cover removal on page 3-25.
3. Remove the upper front guide assembly. See Upper front guide assembly removal on page 3-68,
steps 1-3.
4. Close the front access door.
5. While closing the MPF cover, pull up on the MPF by the steel shaft until the MPF lifts from its hinges.

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6. Disconnect the MPF from the lower front cover.
7. Disconnect the fuser link (A) from the front access door.
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8. Disconnect the front access door cable (B), and pull it through the opening to clear the side frame.
B
9. Disconnect the front access door from its hinges, and remove.
Installation note:
a. Install a new front access door at its hinges.

b. Push the cable (C) through the side frame and into the controller board area.
c. Connect the fuser link.
d. Remove the two screws (D).
e. Slide the latch to the left to free it, and then rest it on the door. Keep the spring in place.
f. Remove the two screws (E), and lift off the cable cover.
g. Connect the operator panel to the cable, and pull the cable through the front access door until the
operator panel can be held lightly with the four screws (F).
Note: Do not over pull the cable.

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h. Reinstall the cable cover and latch, assuring that the tab (G) is in place.
i. Pull all the excess cable through the frame opening at the hinge and into the controller board area.
j. Connect the cable to the controller board and loop it so that the closing and opening of the front
access door does not cause bending.
k. Finish tightening the screws (F), and reinstall the remaining parts.
G D C E
F F
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Fuser removal
1. Remove the rear exit guide. See Rear exit guide assembly with sensor and reversing solenoid
2. Remove the two screws (A).
3. Partially pull the fuser forward for better access.
4. Push in on the cable connector cover (B), and remove.

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5. Disconnect the AC cable (C).
C B
6. Disconnect the thermistor cable (D).
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7. Disconnect the exit sensor cable (E) from the controller board.
8. Remove the fuser.

Note:
Be careful to not damage the gears during the fuser installation.
Be sure to reinstall the AC cable during the fuser installation.

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Left print cartridge guide removal
1. Open the front door and remove the print cartridge.

3. Swing the front edge of the print cartridge guide to the right, and then toward the front of the printer.
4. Remove the left print cartridge guide.
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Left side cover removal
Note:
Leave the front door closed when removing the left side cover.
Make sure that the fuser cables are out of the way when removing the left side cover.
1. Remove the paper tray.
2. Remove the screw (A) from the rear left side of the printer.
A
3. Remove the screw (B), and press the two latches (C) on the bottom of the left side cover.
B C

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4. Swing the cover open, and lift to remove the left side cover.
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Lower front cover removal
1. Open the lower front cover.

2. Disconnect the MPF pins (A) from the right and left sides of the lower front cover.
Note: The picture below shows the E260d, E260dn printer. The lower front cover removal is the same for all
models.
A
3. Flex the lower front cover, and disconnect it first from its right hinge and then from its left hinge.
Note: An alternative to step 3 is to remove the front access door, and remove the three screws from the right
door mount. See Front access door removal on page 3-17 and Door mount removal on page 3-9.

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Installation note: Use a flathead screw driver to press in on the door mount (B) while pulling on the front access
door to connect the cover to the hinge (C).
C B
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LVPS/HVPS removal
1. Remove the rear door cover. See Rear door and rear cover removal on page 3-58.
3. Place the printer on its top with the rear facing you.
4. Remove the two screws (A) from the right rear foot assembly.
A
5. Disconnect the fuser power cable (B).

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6. Remove the four screws (C) from the LVPS/HVPS shield.
C
7. Lift the LVPS/HVPS, and disconnect the three cables (D).
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Note: Squeeze the clip to remove the cables from their connectors (E).
E
8. Disconnect the transfer roll cable (F).
F
9. Lift and remove the LVPS/HVPS.

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Main motor gear drive removal
2. Disconnect the fuser link (A) from the front access door.
A
3. Place the printer on its right side.
4. Remove the four screws (B) from the main motor gear drive.
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5. Lift the gear drive, and disconnect the main motor gear drive cable (C).
6. Remove the main motor gear drive.

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Manual feed clutch removal
2. Open the front access door, and disconnect the fuser link (A).
A
4. Remove the four screws (B) from the main motor gear drive.
B
5. Rotate the main motor gear drive enough to access the manual feed solenoid.
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6. Use a screwdriver to remove the e-clip (C) from the manual feed clutch.
Note: The picture below shows the E260d, E260dn printer. The manual feed clutch removal is the same for all
models.
C
7. Remove the manual feed clutch (D).

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Manual feed solenoid removal
1. Remove the right side cover. See Left print cartridge guide removal on page 3-24.
3. Open the front access door, and place the printer on its right side.
Note: The picture below shows the E260d, E260dn printer. The manual feed solenoid removal is the same for
all models.
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5. Remove the three screws (B) from the left door mount.

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6. Lift the left door mount (C) away from the side frame, and unroute the cable (D) with a spring hook.
7. Reinstall the left door mount, and place the printer on its top.
8. Disconnect the cable (D) from J25 on the controller board, and remove the manual feed solenoid.
Installation note:
Install the two screws holding the new solenoid in place, and route the cable (D) behind the MPF clutch (E).
D E C
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Media ACM ASM feeder removal
5. Loosen the media feed clutch. See Media feed clutch removal on page 3-42.
Warning: Do not cut the cable (leave the media feed clutch hanging).
6. Use a screwdriver to pop the shaft retainer tab (A) loose from the ACM feed shaft.
7. Use a small pair of pliers to remove the shaft retainer tab.

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8. Use a screwdriver to pop the inner shaft lock (B) loose.
9. Remove the inner shaft lock (C).
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10. Pull out the auto compensator shaft, and remove the spring (D).
11. Remove the auto compensator shaft.

12. Disconnect the spring (E) from the cylinder.
13. Remove the media ACM ASM feeder.

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Media feed clutch removal
1. Remove theleft cover. See Left side cover removal on page 4-25.
3. Carefully remove the e-clipthat secures the clutch to the ACM shaft.
4. Pull up the clutch from the cavity, exposingthe white tape.

5. Cut the tape to expose the wire connectionto the clutch, and cut the cables at the copper leads.
6. Clean any adhesive residue from the wires.
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7. Pull the clutch cable into the motor cavity. Pull up the cable to remove any slack.
8. Remove any shrink tubing that is holding the wires together.

Warning: Do not strip the insulation off the red and black wires. The connectors will not work if the insulation is
removed.

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Installation notes:
1. Remove the new clutch from its packaging.

2. Measure 4 inches (100 mm) from the clutch, and cut the clutch cable.
3. Install the new media clutch on the ACM drive shaft.

4. Insert the red wire from the printer into the wire splice connector.
5. Insert the red wire from the clutch into the wire splice connector.
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6. Using a pair of pliers, squeeze the connector to secure the red wires in place.
Note: Check the connector to make sure that the gray connector is pressed flush to the bottom of the wire
splice.
7. Repeat steps four through six for the black wires on the clutch and printer.
8. Tuck the connectors securely above the duplex guide.
Note: If needed, use a wire tie to secure the cable in place. Make sure the tie does not interfere with the
paper path.
9. Reinstall the gear drive.

10. Print the menu pages to test the printer.
11. Reinstall the left cover.

4513-630, -63W, -6EW
Media manual input sensor removal
2. Place the machine on its top.
3. Disconnect the sensor cable (A) from J23 (MPFS) on the controller board.
A
4. Remove the screw (B) holding the sensor.
B
5. Free the cable from its retainers, and pull it through the opening toward the sensor mount.
4-46

4513-630, -63W, -6EW
Re-installation note:
Prop open the duplex door, and insert the hook end of the spring hook through the frame opening (C) from
the controller board side. Extend the hook until the sensor connector can be hooked.
Hook the spring hook (D) to the connector (E), and pull it through the opening.
C D E
Place the sensor into position, and reconnect the cable on the controller board.
Using the spring hook, be sure to reroute the cable through the three retainers (F) between the sensor and
side frame.
F
Note: If the cable is not properly installed in its retainers, then the loose cable will obstruct the paper path.

4513-630, -63W, -6EW
Warning: Check to make sure the duplex paper jam door is in its proper position. If it is not, then the paper tray
will become lodged and the printer will need to be replaced.
4-48

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Multipurpose feeder (MPF) removal

2. Remove the four screws (A) from the upper front guide.
A
3. Remove the upper front guide.
4. Remove the two screws (B).

4513-630, -63W, -6EW
5. Close the front access door, and pull up on the MPF by the steel shaft until the MPF lifts from its hinges.
6. Disconnect the MPF from the lower front cover.
4-50

4513-630, -63W, -6EW
7. Open the front access door, and remove the lower paper guide.

4513-630, -63W, -6EW
Multipurpose feeder (MPF) feed clutch removal
3. Disconnect the cable (A) from the controller board.

Note: Be careful to not damage any cables or mar the finish of the printer.
4-52

4513-630, -63W, -6EW
5. Remove the three screws (B) from the left side of the printer.
6. Disconnect the left hinge (C) from the feed clutch, and remove the e-clip (D).
7. Lift and remove the multipurpose feeder (MPF) feed clutch.

4513-630, -63W, -6EW
Nameplate removal

2. Remove the three screws (A).
Note: The picture below shows the E260d, E260dn printer. The nameplate removal is the same for all models.
3. Remove the nameplate.
4-54

4513-630, -63W, -6EW
Operator panel removal
1. Remove the nameplate. See Nameplate removal on page 3-54.

2. Remove the bezel. See Bezel removal on page 3-5.
3. Remove the four screws (A) from the display plate.
4. Lift the operator panel cover, and disconnect the operator panel cable (B).
B
5. Remove the operator panel.

4513-630, -63W, -6EW
Paper input and duplex sensor assembly removal
3. Remove the two screws (A) from the sensors.
A
4. Disconnect the sensor cable (B) from the controller board.
B
5. Remove the paper input and duplex sensor assembly.
4-56

4513-630, -63W, -6EW
Printhead removal
1. Remove the top cover. See Top cover assembly removal on page 3-65.
2. Remove the right side cover. See Right side cover assembly removal on page 4-62
3. Disconnect the two cables (A), and unroute them back through the frame toward the printhead.
4. Remove the three screws (B).

Note: Use a pencil to mark the screw locations of the printhead on the metal frame. Align the new printhead
relative to the location of the old printhead. See Printhead assembly mechanical adjustment on page 3-19.
B
5. Remove the printhead.

4513-630, -63W, -6EW
Rear door and rear cover removal
1. Open the rear door.

2. Pull the rear door up at an angle, disconnect the door from the notch (A), and remove.
A
3. Remove the two screws (B) from the top of the rear cover.
4-58

4513-630, -63W, -6EW
4. Tilt the rear cover, and remove.

4513-630, -63W, -6EW
Rear exit guide assembly with sensor and reversing solenoid removal
1. Remove the top cover. See Top cover assembly removal on page 3-65.
2. Remove the rear door and rear cover. See Rear door and rear cover removal on page 3-58.
3. Disconnect the narrow media sensor cable and the reversing solenoid cable (A).
4. Remove the six screws (B) from the rear exit guide assembly.
B B B
4-60

4513-630, -63W, -6EW
5. Remove the solenoid cable (C) through the opening.
6. Remove the narrow media sensor cable (D) through the opening.
7. Remove the rear exit guide assembly.

Note: Be careful to not damage the gears during the rear exit guide assembly removal and reinstallation.

4513-630, -63W, -6EW
Right side cover assembly removal
Note: Leave the front cover closed when removing the right side cover assembly.
1. Remove the one screw (A) from behind the paper tray.
A
2. Remove the screw (B) from the bottom right side of the printer.
4-62

4513-630, -63W, -6EW
3. Press the latches (C).
C
4. Rotate the right side cover assembly out, and remove.

4513-630, -63W, -6EW
Toner level sensor removal

3. Disconnect the toner level sensor cable (A) from the controller board.
4. Squeeze the lower tabs (B) of the toner level sensor, and push it from its holder.
B A
5. Remove the toner level sensor through the inside of the printer.
Note: The toner level sensor must be installed properly, or the printer will not function.
4-64

4513-630, -63W, -6EW
Top cover assembly removal

4. Remove the rear door and rear cover. See Rear door and rear cover removal on page 3-58.
5. Remove the two screws (A) from the left side of the printer.
6. Remove the two screws (B) from the right side of the printer.

4513-630, -63W, -6EW
7. Lift the top cover, and remove.
Note:
Be sure to lift the top cover assembly from the front to remove.
During reinstallation, be sure the exit guide and the paper bin align correctly. A mismatch can cause paper
jams.
4-66

4513-630, -63W, -6EW
Transfer roll removal
Note: A flashlight may be useful to remove the transfer roll.

2. At the right side of the transfer roll, squeeze the holder arms (A) with the left hand while lifting. Stop when
the holder is unlatched.
3. At the left side of the transfer roll, squeeze the holder arms with the right hand while lifting with the left
hand. Stop when the left holder is unlatched.
4. With a hand at each end, lift the transfer roll out.
Note: Do not try removing the spring on the left; it is not removeable but can be dislodged. The spring included
with the FRU is to be used only if the old right-side spring is damaged or lost. Both springs must be positioned
on posts that cannot be seen. If the old springs are moved, then feel the base of the springs to assure that they
are on the posts. The top of the springs must be captured in the bearings of the transfer roll.

4513-630, -63W, -6EW
Upper front guide assembly removal

2. Remove the four screws (A) from the upper front guide.
A
3. Remove the upper front guide.
4-68

4513-630, -63W, -6EW
Wear strip (tray 1 and 250-sheet tray 2) removal
1. Hold the tray with the bottom up.

2. Use a spring hook to disconnect the strip from the top of the tray.
3. Remove the strip from inside the tray.

4513-630, -63W, -6EW
Wear strip (550-sheet tray 2) removal
1. Use a spring hook to disconnect the strip from the top of the tray.
2. Life the strip, and remove.

Note: When replacing the strip (for all trays):
Carefully insert the strip from the top of the tray, and push it down through the opening until it snaps
into place.
Turn the tray over to view the bottom of the strip. Using the spring hook, check to make sure that the
end of the strip is fastened tightly.
Be sure that the drafted edge of the strip is installed toward the bottom of the tray.
4-70

4513-630, -63W, -6EW
5. Locations and connections
Locations
Front view
Front door
release
button Operator
panel
Paper
stop
Front
door
Standard
output
Multi-purpose bin
feeder door
System
board
door
Standard 250-sheet tray (Tray 1)
Rear view
Rear
door
Ethernet Locking
port device
USB Printer power

port cord socket Power
switch
Locations and connections 5-1

4513-630, -63W, -6EW
Lexmark E460dn controller board
5-2 Service Manual

4513-630, -63W, -6EW
Lexmark E460dw controller board

4513-630, -63W, -6EW
Lexmark E460dn, E460dw controller board connector pin values
Note: See the wiring diagram at back of book.
These values were measured with all connections made (plugged) or with only one connector at a time
unplugged to expose the pins. Always disconnect and connect with the printer power off. Otherwise, the values
below may not match.
Connector Pin # Value Value Comments

cable plugged cable unplugged
(if different)
J2 1, 2, 3, 4 0 V dc Wireless card (E460 dw only)
5 5 V dc
6 3.3 V dc
J4 1 Ground Cartridge
(The front access door must be closed.)
2 1.7 V dc
3, 4 3.3 V dc
J5 1, 3, 5, 6 3.3 V dc Operator panel
2 5.0 V dc
4, 7 Ground
J100 1 > 0 V dc 5 V dc Printhead
2, 3 5 V dc
4, 5, 6, 7 Ground
J7 1 5 V dc (door closed) Open door sensor
0 V dc (door open)
2 5 V dc
3 Ground
J8 1, 10 5 V dc LSU
9 2.9 V dc
J9 1 24 V dc 0 V dc Cooling fan
2 24 V dc
J10 1 24 V dc 24 V dc Duplex solenoid
2 24 V dc 0 V dc
J11 1 5 V dc Narrow media sensor
2 5 V dc 5 V dc
3 Ground
J12 1 5 V dc Thermistor
2 Ground
J13 1 0.6 V dc Toner level sensor
2 Ground
3 0 V dc
J14 1 > 0 V dc 5 V dc Fuser exit sensor
2 5 V dc
3 Ground
5-4 Service Manual

4513-630, -63W, -6EW
Connector Pin # Value Value Comments

cable plugged cable unplugged
(if different)
J17 1, 4 0.1 V dc 5 V dc Main gear drive motor
2, 3, 6 5 V dc
5 Ground
7, 8, 9 24 V dc
J19 USB port
J21 Parallel port
J23 1 1.1 V dc 5 V dc Manual feed sensor
2 5 V dc
3 Ground
J24 1 24 V dc MPF clutch
2 24 V dc 0 V dc
J25 1 24 V dc Manual feed solenoid
2 24 V dc 0 V dc
J26 1 24 V dc Media feed clutch
2 24 V dc 0 V dc
J27 1, 4 1.1 V dc 5 V dc Input and duplex sensor
2, 5 5 V dc
3, 6 Ground
J28 1, 4 3.3 V dc Tray 2
2 24 V dc
6 Ground
J501 1 5 V dc Toner patch (density) sensor
3 1 V dc 0 V dc
4 Ground
5 5 V dc 0V dc
J502 1, 3, 5, 7, 11, 5V dc LVPS/HVPS
13, 15
4 5 V dc
6 24 V dc
17, 19 24 V dc
Other 0 V dc

4513-630, -63W, -6EW
5-6 Service Manual

4513-630, -63W, -6EW
6. Preventive maintenance
This chapter describes procedures for printer preventive maintenance. Follow these recommendations to help
prevent problems and maintain optimum performance.
Safety inspection guide

The purpose of this inspection guide is to aid you in identifying unsafe conditions.
If any unsafe conditions exist, then find out how serious the hazard could be and if you can continue before you
correct the hazard.
Check the following items:
Damaged, missing, or altered parts, especially in the area of the On/Off switch and the power supply
Damaged, missing, or altered covers, especially in the area of the top cover and the power supply cover
Possible safety exposure from any non-Lexmark attachments
Lubrication specifications
FRUs are typically lubricated as needed from the factory. If not, then lubricate only when parts are replaced or
as needed, not on a scheduled basis. Use of lubricants other than those specified can cause premature failure.
Some unauthorized lubricants may chemically attack parts. Use P/N 99A0394 (Nyogel 744) to lubricate
appropriate areas. Lubricate gears that were lubricated in the original part.
Maintenance kits
Maintenance kits include:
Fuser (P/N 40X5344, 40X5345, or 40X5346)

Exit guide (P/N 40X5372)
Tray 1 ACM feed tires (P/N 40X5451)
Transfer roll (P/N 40X5364)
Maintenance kits
Description Part number

Low voltage (110 V) maintenance kit 40X5400
High voltage (220 V) maintenance kit 40X5401
100 V maintenance kit 40X5402
Preventive maintenance 6-1

4513-630, -63W, -6EW
6-2 Service Manual

4513-630, -63W, -6EW
7. Parts Catalog
How to use this parts catalog

The following legend is used in the parts catalog:
Asm- Part Units/ Units/

Description
Index number mach FRU
Asm-index: identifies the assembly and the item in the diagram. For example, 3-1 indicates
assembly 3 and the item number 1.
Part number: identifies the unique number that identifies this FRU.
Units/mach: refers to the number of units actually used in the machine or product.
Units/FRU: refers to the number of units packaged together and identified by the part number.
NS: (Not shown) in the Asm-Index column indicates that the part is procurable but is not
pictured in the illustration.
PP: (Parts Packet) in the parts description column indicates the part is contained in a parts
packet.
Model information used in the parts catalog.
Machine type
Description
and model
4513-630 Lexmark E460dn
4513-63W Lexmark E460dw

4513-6EW
Parts Catalog 7-1

4513-630, -63W, -6EW
Assembly 1: Covers
13
12
3
11
10
7-2 Service Manual

4513-630, -63W, -6EW
Assembly 1: Covers
Description
1-1 40X5373 1 1 Top cover assembly
2 40X5377 1 1 Rear upper and lower cover assembly
3 40X5375 1 1 Right side cover
4 40X5398 1 1 Optional 250-sheet tray
4 40X5399 1 1 Optional 550-sheet tray
5 40X5394 1 1 250-sheet (Tray 2) assembly
5 40X5395 1 1 550-sheet (Tray 2) assembly
6 40X2855 1 4 Tray 2 wear strips (550-sheet tray only)
7 40X5382 1 6 Wear strips (250-sheet trays, optional and primary)
8 40X5381 1 1 Primary tray
9 40X5379 1 1 Front door cover
10 40X5359 1 1 Nameplate cover
11 40X5378 1 1 Front access door assembly
12 40X5374 1 1 Left side cover
13 40X5357 1 1 LCD bezel cover, E460dn
13 40X5391 1 1 LCD bezel cover, E460dw
13 40X2899 1 1 LCD bezel cover, ES460dn
13 40X2900 1 1 LCD bezel cover, EG460dn
13 40X2868 1 1 LCD bezel cover, E462dtn
Parts Catalog 7-3

4513-630, -63W, -6EW
Assembly 2: Electronics
2
15
14 4
5
13
12
6
11
7
8
9
10
7-4 Service Manual

4513-630, -63W, -6EW
Assembly 2: Electronics
Description
2-1 40X5356 1 LCD operator panel assembly, E460dn/E460dw
2 40X5344 1 Fuser assembly, 115 V
3 40X5365 1 1 Duplex and media sensor assembly
4 40X5360 1 1 Access door open sensor assembly
5 40X5392 1 1 Cooling fan (screws included)
6 40X5385 1 1 Toner low sensor
7 40X5036 1 1 Wireless card, E460dw
8 40X5350 1 1 Controller board, E460dn/E462
8 40X5351 1 1 Controller board, E460dw
9 40X5320 1 1 Antenna (11 inch cable)
10 40X5361 1 LVPS/HVPS card assembly, 110 V/100 V
10 40X5362 1 LVPS/HVPS card assembly, 220 V
11 40X5366 1 1 Manual input sensor assembly
12 40X5369 1 1 Manual feed solenoid
13 40X5371 1 1 MPF feed clutch
14 40X5370 1 1 Media feed (ACM) clutch
15 40X5387 1 LSU, E460dn/E460dw (printhead)
Parts Catalog 7-5

4513-630, -63W, -6EW
Assembly 3: Frame
1
12
2
11
10
3
8 9
See instruction
6
sheet in the FRU.
7-6 Service Manual

4513-630, -63W, -6EW
Assembly 3: Frame
Description
31 40X5364 1 Transfer roll, bearings, gear, spring (CBM)
2 40X5372 1 Media exit guide assembly (redrive)
3 40X5397 1 1 Front mounts
4 40X5396 N/A Screws, miscellaneous
4 TP2NCX3X6PF-Ni
4 TP2C-4.0+8PF-Ni
4 M3.0*0.5+6PF-Ni
2 M3.0*0.5+4PF-Ni
2 M3.5*0.6+6P-Ni
5 40X5380 1 1 Complete duplex assembly
6 40X5453 1 1 Media (ACM) drive assembly
7 40X5451 2 2 Paper feed, ACM tires
7 40X5440 1 2 Tray 2 paper feed tires
8 40X5358 1 1 MPF tray assembly
9 40X5383 1 1 Upper front frame assembly
10 40X5368 1 1 Manual feed clutch CBM
11 40X5367 1 1 Main drive gearbox (in motor)
12 40X5363 1 1 Duplex gear drive CBM
NS 40X5400 1 1 110 V maintenance kit
Note: Kit contains the following:
Fuser (40X5344, 40X5345, or 40X2802)
Tray 1 ACM feed tires (40X5451)
Transfer roll CBM (40X5364)
NS 7470094 1 Field relocation package assembly
NS 40X0407 1 Left print cartridge guide
Parts Catalog 7-7

4513-630, -63W, -6EW
Assembly 4: Options

Description
NS 40X5972 1 1 Japanese font card assembly
NS 40X5970 1 1 Simplified Chinese font card assembly
NS 40X5971 1 1 Traditional Chinese font card assembly
NS 40X5969 1 1 Korean font card assembly
NS 40X5952 1 1 Print cryption card assembly
NS 40X5951 1 1 Korean KS/KSSM/KSP
NS 40X5940 1 1 Bar code and forms
NS 40X5937 1 1 128MB DIMM
NS 40X5938 1 1 256MB DIMM
NS 40X5939 1 1 512MB DIMM
NS 40X5704 1 1 256MB flash
NS 40X1367 1 1 Parallel cable, packaged (3 m) (E460dn only)
NS 40X1368 1 1 USB cable, packaged (2 m)
7-8 Service Manual

4513-630, -63W, -6EW
Assembly 5: Power cords

Description
NS 40X0297 1 1 Power cord, 1.8M (straight)USA, Canada
NS 40X0278 1 1 Power cord, 6 foot (straight)Europe and others
NS 40X0288 1 1 Power cord, 8 foot (straight)Argentina
NS 40X0286 1 1 Power cord, 8 foot (straight)United Kingdom
NS 40X0275 1 1 Power cord, 6 foot (straight)Israel
NS 40X0274 1 1 Power cord, 6 foot (straight)Switzerland
NS 40X0276 1 1 Power cord, 6 foot (straight)South Africa
NS 40X0287 1 1 Power cord, 6 foot (straight)Traditional Italy
NS 40X0279 1 1 Power cord, 6 foot (straight)Denmark
NS 40X0277 1 1 Power cord, 6 foot (straight)Brazil
NS 40X0282 1 1 Power cord, 1.8M (straight)PRC
NS 40X0270 1 1 Power cord, 2.5M (straight)Japan
NS 40X0280 1 1 Power cord, 1.8M (straight)Korea
NS 40X0281 1 1 Power cord, 1.8M (straight)Taiwan
NS 40X0296 1 1 Power cord, 1.8M (straight)Australia
NS 40X7229 1 1 Power cord, 2.5M (straight)India
Parts Catalog 7-9

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7-10 Service Manual

4513-630, -63W, -6EW
Index
A EP Defaults 3-15
abbreviations 1-9 error log
acronyms 1-9 clear log (diagnostics mode) 3-17
display log (diagnostics mode) 3-16
B Print Log 3-17
buttons error messages
accessing service menus 3-1 service error codes 2-15
user attendance messages 2-5
C ESD-sensitive parts 4-1
Charge Roll, diagnostics mode 3-15
compatibility 1-4 F
configuration ID 3-14 fan
configuration menu parts catalog 7-5
accessing 3-1, 3-2 service check 2-24
available menus 3-2 frame, parts catalog 7-6
Demo Mode 3-4 fuser
Energy Conserve 3-5 parts catalog 7-5
Factory Defaults 3-4 service check 2-26
Panel Menus 3-4 Fuser Temp 3-15
PPDS Emulation 3-4
control panel 1-2 G
controller card Gap Adjust 3-15
service check 2-23
H
D handling ESD-sensitive parts 4-1
defaults History
factory defaults 3-4 see error log 3-17
diagnostics mode 3-6
L
accessing 3-1
lithium battery v-xiii, 4-6
available tests 3-6
locations
diagnostics mode
front views 5-1
EP Setup
rear views 5-1
Charge Roll 3-15
lubrication specifications 6-1
EP Defaults 3-15
LVPS/HVPS
Fuser Temp 3-15
parts catalog 7-5
Gap Adjust 3-15
service check 2-26
Print Contrast 3-15
Transfer 3-15 M
Event Log maintenance approach 1-1
Clear Log 3-17 maintenance kits 6-1
Display Log 3-16 menus
Print Log 3-17 accessing service menus 3-1
Hardware Tests messages
DRAM Test 3-9 service error codes 2-15
Printer Setup user attendance messages 2-5
Configuration ID 3-14 Model Name 3-14
Edge to Edge 3-14 models
Engine Settings 3-14 comparison 1-1
Model Name 3-14 diagrams 5-1
Par S Strobe Adj 3-14 operator panels 1-2
Registration 3-7 trays available 1-5
DRAM Test 3-9
N
E navigation buttons 2-2
Edge to Edge 3-14
Index I-1

4513-630, -63W, -6EW
O parallel port 2-30

operator panel print quality 2-31
LCD 2-2 black page 2-32
LED blank page 2-31
service check 2-28 heavy background 2-32
LEDE238/E240(n) image density 2-33
overview 1-2 light print 2-34
partial blank image 2-33
P poor fusing of image 2-33
panel, control 1-2 toner on back of page 2-34
paper jams white or black lines 2-34
tips on preventing 1-7 printhead 2-38
parallel port service check 2-30 transfer roll 2-42
parts catalog service error codes 2-15
covers 7-2 special tools 1-8
electronics 7-4 specifications
frame 7-6 connectivity 1-4
options 7-8 input trays 1-5
power-on self test (POST) 2-1 memory 1-3
symptoms 2-21 operating systems 1-4
Print Contrast 3-15 photoconductor capacity 1-5
print media print media 1-6
preventing jams 1-7 toner capacity 1-5
trays by model 1-5 start 2-1
types and sizes 1-6 strobe adjustment 3-14
print quality pages symptom tables 2-21
using 2-31 POST 2-21
print quality problems printer 2-22
print media 1-7
service check 2-31 T
solving 2-35 tools 1-8
printer symptom table 2-22 Top Margin 3-7
printhead Transfer 3-15
service check 2-38 transfer roll
parts catalog 7-7
R service check 2-42
registration 3-7
removals U
covers user attendance messages 2-5
front access cover 4-6
procedures 4-2
S
safety information v-xiii
safety inspection guide 6-1
service checks 2-23
controller card 2-23
cooling fan 2-24
cover interlock switch 2-24
dead machine 2-25
fuser 2-26
LVPS/HVPS 2-26
main motor 2-27
operator panel 2-28
paper feed 2-28
paper jam during POST 2-28
paper never picks 2-29
paper picks but stops 2-28
paper picks sheets 2-29
paper trees, curls 2-30
I-2 Service Manual

4513-630, -63W, -6EW
Part number index
P/N Description Page
40X0270 Power cord, 1.77M (straight)Japan - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-9

40X0274 Power cord, 6 footSwitzerland - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-9
40X0275 Power cord, 6 foot (straight)Israel - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-9
40X0276 Power cord, 6 footSouth Africa - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-9
40X0277 Power cord, 6 foot (straight)Brazil - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-9
40X0278 Power cord, 6 foot (straight)Europe and others - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-9
40X0279 Power cord, 6 foot (straight)Denmark - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-9
40X0280 Power cord, 1.77M (straight)Korea - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-9
40X0281 Power cord, 1.77M (straight)Taiwan - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-9
40X0282 Power cord, 1.77M (straight)PRC - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-9
40X0286 Power cord, 6 footUnited Kingdom - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-9
40X0287 Power cord, 6 foot (straight)Traditional Italy - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-9
40X0288 Power cord, 6 footArgentina - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-9
40X0296 Power cord, 1.8M (straight)Australia - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-9
40X0297 Power cord, 1.77M (straight)USA, Canada - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-9
40X0407 Left print cartridge guide - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-7
40X1367 Parallel cable, packaged (3 m) (E460dn only) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-8
40X1368 USB cable, packaged (2 m) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-8
40X2855 Tray 2 wear strips (550-sheet tray only) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-3
40X2868 LCD bezel cover, E462dtn - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-3
40X2899 LCD bezel cover, ES460dn - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-3
40X2900 LCD bezel cover, EG460dn - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-3
40X5036 Wireless card, E460dw - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-5
40X5320 Antenna (11 inch cable) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-5
40X5344 Fuser assembly, 115 V - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-5
40X5350 Controller board, E460dn/E462 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-5
40X5351 Controller board, E460dw - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-5
40X5356 LCD operator panel assembly, E460dn/E460dw - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-5
40X5357 LCD bezel cover, E460dn - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-3
40X5358 MPF tray assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-7
40X5359 Nameplate cover - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-3
40X5360 Access door open sensor assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-5
40X5361 LVPS/HVPS card assembly, 110 V/100 V - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-5
40X5362 LVPS/HVPS card assembly, 220 V - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-5
40X5363 Duplex gear drive CBM - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-7
40X5364 Transfer roll, bearings, gear, spring (CBM) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-7
40X5365 Duplex and media sensor assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-5
40X5366 Manual input sensor assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-5
40X5367 Main drive gearbox (in motor) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-7
40X5368 Manual feed clutch CBM - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-7
40X5369 Manual feed solenoid - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-5
40X5370 Media feed (ACM) clutch - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-5
40X5371 MPF feed clutch - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-5
40X5372 Media exit guide assembly (redrive) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-7
40X5373 Top cover assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-3
40X5374 Left side cover - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-3
40X5375 Right side cover - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-3
40X5377 Rear upper and lower cover assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-3
40X5378 Front access door assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-3
40X5379 Front door cover - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-3
40X5380 Complete duplex assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-7
40X5381 Primary tray - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-3
Part number index I-3

4513-630, -63W, -6EW
40X5382 Wear strips (250-sheet trays, optional and primary) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-3

40X5383 Upper front frame assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-7
40X5385 Toner low sensor - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-5
40X5387 LSU, E460dn/E460dw (printhead) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-5
40X5391 LLCD bezel cover, E460dw - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-3
40X5392 Cooling fan (screws included) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-5
40X5394 Tray 2 assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-3
40X5395 550-sheet (Tray 2) assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-3
40X5396 Screws, miscellaneous - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-7
40X5397 Front mounts - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-7
40X5398 Optional 250-sheet tray - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-3
40X5399 Optional 550-sheet tray - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-3
40X5400 110 V maintenance kit - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-7
40X5400 Low voltage (110 V) maintenance kit - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-1
40X5401 220 V maintenance kit - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-7
40X5401 High voltage (220 V) maintenance kit - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-1
40X5402 100 V maintenance kit - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-1, 7-7
40X5440 Tray 2 paper feed tires - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-7
40X5451 Paper feed, ACM tires - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-7
40X5453 Media (ACM) drive assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-7
40X5704 256MB flash - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-8
40X5937 128MB DIMM - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-8
40X5938 256MB DIMM - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-8
40X5939 512MB DIMM - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-8
40X5940 Bar code and forms - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-8
40X5951 Korean KS/KSSM/KSP - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-8
40X5952 Print cryption card assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-8
40X5969 Korean font card assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-8
40X5970 Simplified Chinese font card assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-8
40X5971 Traditional Chinese font card assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-8
40X5972 Japanese font card assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-8
40X7229 Power cord, 2.5M (straight)India - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-9
7470094 Field relocation package assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-7
I-4 Service Manual

38.8
48.3
52.4
80.0
98.3

E460d/E460dn
70S
CN102
TAT201
(0V)
5V
Open
( 0V) 5V
( 0V) 5V
0V (24V)
0V (24V)
(0V) 5V
1.7V
3.3V
3.3V
3.3V
3.3V
3.3V
3.3V
2.5V
0.6V
Gnd
Gnd
Gnd
Gnd
Gnd
Gnd
Gnd
Gnd
Gnd
Gnd
Gnd
Gnd
24V
24V
5V
5V
5V
5V
5V
Closed
5V
5V
5V
5V
5V
Toner Patch J4 J5 J100 J7 J8 J9 J10 J11 J12
Sensor With printer off, unplug this cable
and turn printer back on. Check
0V (5V) J13 values on the cable pins. J14
Gnd
0V (1V)
J501
(5V)
21V
(24V)
21V (24V)
5V (5V)
(>0V) 5V
J17
5V (5V)
5V (5V)
(>0V) 5V Wireless Battery
5V
5V
3V
5.0V
5V
5V
24V
5V
1 19
5V
J2
2 20 2 1
Parallel
CN203 CN202 CN201 J502
5V
With printer off, unplug this cable port
5V
and turn printer back on. Check (E460dn only)
values on the cable pins.
20 19
5V
24V
24V J24 J26
J23 J27 J28

J25
3.3V
Gnd
5V
24V
24V
24V
Gnd
5V
Gnd
5V
Gnd
24V
3.3V
5V (1.1V)
0V (24V)
0V (24V)
0V (24V)
5V (1.1V)
5V (1.1V)
Plugged voltage (if different) = ( )

70S
MPF Manual MPF Paper Feed Paper In Duplex Tray 2 Connector

Sensor Clutch Clutch Clutch Sensor Sensor
Solenoid

E460dn Service Manual

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Revision Date: July 1, 2013

Safety and notices

Lexmark and Lexmark with diamond design are

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Edition: July 1, 2013

2008 Lexmark International, Inc.

UNITED STATES GOVERNMENT RIGHTS

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

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

Diagnostics information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

Table of contents iii

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Media occasionally mispicks or picks multiple sheets at once . . . . . . . . . . . . . . . . . . . . . . . . .2-29

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

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Duplex Feed 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11

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

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Multipurpose feeder (MPF) removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-49

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

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

Parts Catalog ........................................................................... 7-1

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Notices and safety information

The following laser notice labels may be affixed to this printer.

Avis relatif lutilisation de laser

Avvertenze sui prodotti laser

Notices and safety information vii

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Avisos sobre el lser

Declarao sobre Laser

Os produtos laser da Classe I no so considerados perigosos. Internamente, a impressora contm um produto

viii Service Manual

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VARO! Avattaessa ja suojalukitus ohitettaessa olet alttiina nkymttmlle lasersteilylle. l katso

Notices and safety information ix

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Avs sobre el Lser

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Notices and safety information xi

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xii Service Manual

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Lithium warning -xiii

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-xiv Service Manual

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Safety information -xv

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Revision date Updates

There are several types of caution statements:

A caution identifies something that might cause a servicer harm.

-xvi Service Manual

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This type of caution indicates a hot surface.

This type of caution indicates a tipping hazard.

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-xviii Service Manual

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