E120TECH

Technical Instructions Printer Supplies. OEM Info Tools 1

CORPORATE 12015SA Part Number: 23S0300 Tools Needed:
LOS ANGELES, USA 2,000 page Return Program Toner Technology: Laser Needle nose pliers
US 1 800 394.9900 Cartridge Print Speed: Up to 20ppm Small Phillips screwdriver
Int’l +1 818 837.8100 Resolution: 1200 image quality #2 Phillips screwdriver
FAX 1 800 394.9910 12035SA printing Small flat blade screwdriver
Int’l +1 818 838.7047 2,000 page Toner Cartridge First page out: As fast as 8 seconds
Processor: 183 MHz Supplies Needed:
ATLANTA, USA 12026XW Memory: 16MB (std./max) 99% Alcohol
US 1 877 676.4223 25000 page Photoconductor Kit Footprint: 15.3W x 14D x 9.8H Lint-free cloth
Int’l +1 678 919.1189 Duty Cycle: Up to 10,000 pages Cotton swabs
FAX 1 877 337.7976 per month Toner
Int’l +1 770 516.7794 Doctor bar (if needed)
Drum (if needed)
KANSAS CITY, USA
US 1 913 871.1700
FAX 1 913 888.0626
Photo 1
MIAMI, USA Toner Hopper Remanufacturing Instructions:
US 1 800 595.4297
Int’l +1 305 594.3396
FAX 1 800 522.8640
Int’l +1 305 594.3309

NEW YORK, USA

US 1 800 431.7884
Int’l +1 631 588.7300
FAX 1 800 431.8812
Int’l +1 631 588.7333
Step 1
TORONTO, CAN Remove the small Phillips screw that holds the
CAN 1 877 848.0818 doctor blade positioning plate.
Int’l +1 905 712.9501
FAX 1 877 772.6773 (See Photo 1)
Int’l +1 905 712.9502

BUENOS AIRES, ARG Photo 2

ARG 0810 444.2656 Step 2
Int’l +011 4583.5900
FAX +011 4584.3100
The doctor blade positioning plate has two align-
ment pins on each side of the plate that holds the
MELBOURNE, AUS doctor blade in the correct position. Carefully
AUS 1 800 003. 100 bend the plate and slide the alignment pins from
Int’l +62 03 9561.8102
FAX 1 800 004.302
the gear side of the toner hopper.
Int’l +62 03 9561-7751 (See Photo 2)

SYDNEY, AUS
AUS 1 800 003.100
Int’l +62 02 9648.2630
FAX 1800 004.302
Int’l +62 02 9548.2635

MONTEVIDEO, URY Photo 3

URY 02 902.2001
Int’l +5982 902.2001
Step 3
FAX +5982 900.0858 Slide the positioning plate toward the gear side
JOHANNESBURG, S.A. of the hopper to remove the alignment pins from
S.A. +27 11 974.6155 the contact side of the toner hopper.
FAX +27 11 974.3593 (See Photo 3)
SÃO PAULO, BRAZIL
Int’l +55 11 5524.8000

RAANANA, ISRAEL
ISR 09 760.12.39
Int’l +972 9760.12.39
ISR 052.38.555.82
Int’l +972 5238.555.82

E-mail: info@futuregraphicsllc.com Website: www.futuregraphicsllc.com

REV. 9/14/06
 2 E120 Technical Instructions
Step 4
Using needle nose pliers, grab the
leaf spring towards its center.
Carefully press downward, removing
the spring from the spring’s locking
cradle. (See Photo 4) Remove the
leaf spring.
Photo 4
Step 5
Lift the doctor blade from the gear
side of the toner hopper. (See Photo
5) Slide the contact end of the doctor
blade out from the contact side of
the toner hopper. (See Photo 5)
NOTE: Be careful not to bend the
doctor blade contact while removing
the blade.
Photo 5
Photo 6
Photo 7
Step 6
Clean the doctor blade using dry compressed
air. (Lexmark is using the new style doctor
blades in the E120n cartridges. These blades
have a foam core with a textured coated strip
on the working edge.) Clean the blade using a
lint-free cloth and alcohol. (See Photo 7)
Photo 8
Step 7
Rotate the toner hopper so the gear end is
facing you. Using a spring hook, remove the
locking washer and the washer that holds the
black drive gear to the toner hopper.
(See Photo 8)
Photo 9
Step 8
Remove the gear.
(See Photo 9)
Photo 10
Step 9
Using a small flat blade screwdriver, remove
the locking bar that holds developer roller
bushing. (See Photo 10)
Photo 11
Step 10
Rotate the developer roller bushing counter-
clockwise. (See Photo 11)
Photo 12
Step 11
Lift up the end of the roller and slide the
developer roller bushing from the shaft of the
roller. (See Photo 12)
 Lexmark E120 Technical Instructions 3
Photo 13
Step 12
Holding the developer roller in place, rotate the
developer roller drive gear clockwise. This will
unlock the drive gear from the shaft of the Step 18
developer roller. (See Photo 13) NOTE: You may While holding the developer roller
need to hold the shaft of the developer roller by the shaft, install the keyed end
using needle nose pliers and rotate while hold- of the shaft into the gear end of the
ing the drive gear in order to remove the rollers toner hopper. (See Photos 19)
drive gear.

Photo 14
Photo 19
Step 13
Remove the developer roller drive gear from the
shaft of the roller.
(See Photo 14)

Step 14
Photo 15 Lift up the shaft of the developer roller on the
contact side of the toner hopper. Slide the
shaft of the developer roller from the gear end
of the toner hopper. (See Photo 15). Clean the
developer roller using distilled water and a
lint-free cloth. (See Photo 16).
NOTE: Make sure the developer roller is com-
pletely dry before it is reinstalled in the toner
hopper.
Step 19
Lift up on the shaft of the developer
roller. Install the bushing on to the
end of the developer roller. Rotate
the developer roller clockwise,
locking the bushing in place.
(See Photo 20)

Photo 20
Photo 16

Step 15
Photo 17 Remove the warranty sticker covering the toner
hopper fill plug. Remove the fill plug from the Step 20
toner hopper. (See Photo 17) Place the locking bar onto the end
of the developer roller bushing.
Step 16 (See Photo 21)

Dump the remaining toner from the toner

hopper. Clean the hopper using dry,
compressed air or a vacuum. Photo 21

Photo 18
Step 17
Clean the developer roller end seals using a
cotton swab and alcohol.
(See Photo 18)
 4 Lexmark E120 Technical Instructions
Step 21
Install the white developer roller
drive gear onto the shaft of the
roller. Rotate the gear counter-
clockwise to lock the gear onto the
shaft of the developer roller.
(See Photo 22)
Photo 22
Step 22
Place the black drive gear onto the
alignment post on the gear end of
the toner hopper. Install the washer
and locking washer onto the align-
ment post. (See Photo 23)
Photo 23
Step 23
Install the cleaned or new doctor bar
onto the toner hopper, making sure
the positioning post on the doctor
bar is properly seated into the end
of the toner hopper. (See Photo 24)
NOTE: Make sure the doctor blade
contact is touching the doctor
blade.
Photo 24
E-mail: info@futuregraphicsllc.com
Photo 25
Step 24
Position one end of the leaf spring onto the
doctor bar. Using needle nose pliers, carefully
place the opposite end of the spring onto the
doctor bar. (See Photo 25)
Photo 26
Step 25
Slide the two alignment pins on the left side of
the positioning plate into the two holes on the
contact side of the toner hopper. (See Photo 26)
Photo 27
Step 26
Carefully bend the plate and slide the two
alignment pins into the two alignment holes on
the gear end of the toner hopper.
(See Photo 27)
Photo 28
Step 27
Install the small Phillips screw that holds the
positioning plate in place. (See Photo 28)
Photo 29
Step 28
Fill the toner hopper with toner. Place the fill
plug back onto the toner hopper.
Step 29
Remove the Phillips screw that holds the
cartridge chip that sits atop the toner hopper.
Remove the chip.
(See Photo 29)
Website: www.futuregraphicsllc.com
 Lexmark E120 Technical Instructions 5

Photo 30
Step 30
Place a new chip onto the toner hopper and
install the screw that holds the chip in place.
(See Photo 30) Post-test your cartridge.
Step 5
Remove the two screws that hold
the wiper blade. (See Photo 6)

Remanufacturing the E120n Drum Unit:

Photo 1 Photo 6

Step 1
Using a small flat blade screwdriver remove
the E-ring from the drum axle.
(See Photo 1)
Step 6
Lift out the wiper blade. (See Photo
Photo 2 7) Clean the wiper blade and the
Step 2 waste hopper using dry compressed
air or a vacuum.
Slide the drum axle from the drum on the
NOTE: Be careful not to lose the
opposite side of the waste hopper.
wiper blade end foams that sit on
(See Photo 2)
each side of the waste hopper.

Photo 7

Photo 3
Step 3
Carefully lift out the drum. (See Photo 3) Clean
the drum using a soft cloth. Place the drum in
a protected area away from the light.

Step 4
Photo 4
Carefully lift out the PCR. (See Photo 4)
Remove the two spacers from the shaft of the
PCR. (See Photo 5). Clean the PCR using a
lint-free cloth and distilled water.
Step 7
Apply padding powder to the wiper
blade. Place the wiper blade onto
the waste hopper and install the two
screws that hold the blade in place.
(See Photo 8)

Photo 5 Photo 8
 6 Lexmark E120 Technical Instructions

Photo 12
Step 11
Install the loop of the drum’s torsion spring,
located on the non-gear side of the drum, into
Step 8 the slot on the side of the waste hopper.
Clean the PCR saddles using a (See Photo 12)
cotton swab and alcohol.
(See Photo 9)

Photo 9

Photo 13
Step 12
Slide the drum axle through the drum starting
on the non-gear side of the drum.
(See Photo 13)

Step 9
Place the spacers onto the shaft of
the PCR (See Photo 10)
Photo 14
Step 13
Install the E-ring onto the end of the drum axle.
(See Photo 14)
Photo 10

Photo 15
Step 14
Post-test the drum unit.

Step 15
Step 10 Rotate the spacers on each end of the PCR so
the legs of the spacer are facing up.
Install the PCR into the saddles. (See Photo 15) This will pull the PCR away
(See Photo 11) from the drum and prevent flat spots for form-
ing on the PCR.

Drum Reset Procedures:

Photo 11
Step 1: Open the front door and hold the
Cancel button until all lights begin to cycle.

Step 2: Close the front door. The warning

clears and the counter resets to zero.

Step 3: Press Continue to resume printing.

E-mail: info@futuregraphicsllc.com Website: www.futuregraphicsllc.com