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MedleyTM

4012-0XX

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

4012-0XX

Second Edition (July, 1995)
The following paragraph does not apply to the United Kingdom or 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 of the publication. Improvements or changes in the products or the programs described in this publication may be made at any time. Publications are not stocked at the address given below; requests for publications should be made to your point of purchase. Comments may be addressed to Lexmark International, Inc., Department D22A/035-3, 740 New Circle Road, Lexington, Kentucky 40550, U.S.A. Lexmark may use or distribute any of the information you supply in any way it believes appropriate without incurring any obligation to you. Lexmark and Medley are trademarks of Lexmark International, Inc. ExecJet is a registered trademark of International Business Machines Corporation

© Copyright Lexmark International, Inc. 1995. All Rights Reserved.
UNITED STATES GOVERNMENT RESTRICTED RIGHTS This software and documentation are provided with RESTRICTED RIGHTS. Use, duplication or disclosure by the Government is subject to restrictions as set forth in subparagraph (c)(1)(ii) of the Rights in Technical Data and Computer Software clause at DFARS 252.227-7013 and in applicable FAR provisions: Lexmark International, Inc., Lexington, KY 40550.

4012-0XX

Contents

1

Preface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . vi Safety Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . vii General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Maintenance Approach. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Diagnostic Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Symptom Table. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Service Checks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Communications Service Check . . . . . . . . . . . . . . . . . . . . . 7 Envelope Feed Service Check . . . . . . . . . . . . . . . . . . . . . . . 8 First Print Line Service Check . . . . . . . . . . . . . . . . . . . . . . . 8 Maintenance Station Service Check . . . . . . . . . . . . . . . . . . 9 Operator Panel Service Check. . . . . . . . . . . . . . . . . . . . . . 10 Power Service Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Printer Paper Feed Service Check. . . . . . . . . . . . . . . . . . . 12 Printer Paper Path Service Check . . . . . . . . . . . . . . . . . . . 15 Print Quality Service Check . . . . . . . . . . . . . . . . . . . . . . . . 16 Printing Problem Service Check. . . . . . . . . . . . . . . . . . . . . 18 Scanner Document Feed Service Check . . . . . . . . . . . . . . 19 Scanner Service Check . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Transport Service Check . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Diagnostic Aids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Call Monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Error Report . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Frame Service Position. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Hex Print Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Machine Checkout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Memory Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Operator Panel Service Position. . . . . . . . . . . . . . . . . . . . . . . . 23 Operator Panel Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Reset Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Print Engine Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Purge Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Scanner Feed Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Setting the Machine Serial Number . . . . . . . . . . . . . . . . . . . . . 26 Test Print . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

iii

4012-0XX Repair Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27 Handling ESD-Sensitive Parts . . . . . . . . . . . . . . . . . . . . . . . . . 28 Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 Bidirectional Alignment Adjustment . . . . . . . . . . . . . . . . . . 29 Removal Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Auto Sheet Feed (ASF) Assembly Removal . . . . . . . . . . . 30 ASF Envelope Buckler and Pick Roller Hub Removal. . . . 31 ASF Right and Left Edge Guide Assemblies Removal . . . 31 Battery Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 Carrier Guide Rod Removal . . . . . . . . . . . . . . . . . . . . . . . 31 Carrier Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 Carrier Transport Belt Removal. . . . . . . . . . . . . . . . . . . . . 32 Carrier Transport Motor Removal . . . . . . . . . . . . . . . . . . . 33 Carrier Transport Motor Frame Removal . . . . . . . . . . . . . 33 Covers Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 Front Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34 Rear Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34 Top Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34 Right Side Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34 Left Side Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34 Operator Panel and Cover . . . . . . . . . . . . . . . . . . . . . .34 Encoder Strip Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 End-of-Forms Flag Removal . . . . . . . . . . . . . . . . . . . . . . . 35 Exit Roller Assembly Removal . . . . . . . . . . . . . . . . . . . . . 35 EPROM Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 Fax Board, Printer Board, and LCU Board Removal. . . . . 37 Feed Arm Assembly Removal . . . . . . . . . . . . . . . . . . . . . . 37 Inside Idler Gears Removal . . . . . . . . . . . . . . . . . . . . . . . . 37 Large Feed Roller Assembly Removal . . . . . . . . . . . . . . . 38 Left Side Frame Removal . . . . . . . . . . . . . . . . . . . . . . . . . 38 Maintenance Drive and Rocker Assemblies Removal. . . . 39 Memory Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 Middle Frame Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 Outside Idler Gears Removal . . . . . . . . . . . . . . . . . . . . . . 40 Paper Ejectors Removal . . . . . . . . . . . . . . . . . . . . . . . . . . 40 Paper Feed Motor Removal . . . . . . . . . . . . . . . . . . . . . . . 40 Paper Guide Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 Paper Release Lever Removal . . . . . . . . . . . . . . . . . . . . . 41 Power Supply Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 Print Engine Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 Printhead Cable Removal . . . . . . . . . . . . . . . . . . . . . . . . . 43 Releasing Plastic Latches . . . . . . . . . . . . . . . . . . . . . . . . . 44 Right Side Frame Removal . . . . . . . . . . . . . . . . . . . . . . . . 45 iv

4012-0XX Repair Information, Removal Procedures (continued) Rubber Backer Removal . . . . . . . . . . . . . . . . . . . . . . . . . . Small Feed Roller Assembly Removal . . . . . . . . . . . . . . . . Star Roller Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Scanner and Speaker Removal . . . . . . . . . . . . . . . . . . . . . Subframe Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Parts and Test Point Locations . . . . . . . . . . . . . . . . . . . . . . . . . . LCU Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fax Board. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Printer Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Preventive Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Lubrication Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . Scanner Cleaning Procedure . . . . . . . . . . . . . . . . . . . . . . . Parts Catalog . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . How To Use This Parts Catalog . . . . . . . . . . . . . . . . . . . . . Assembly 1: Covers . . . . . . . . . . . . . . . . . . . . . . . . . . Assembly 2: Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . Assembly 3: Operator Panel . . . . . . . . . . . . . . . . . . . . Assembly 4: Printer Paper Feed Assembly . . . . . . . . Assembly 4: Printer Paper Feed Assembly (cont.) . . . Assembly 5: Carrier . . . . . . . . . . . . . . . . . . . . . . . . . . Assembly 6: Carrier Transport . . . . . . . . . . . . . . . . . . Assembly 7: Maintenance Station . . . . . . . . . . . . . . . Assembly 8: Scanner . . . . . . . . . . . . . . . . . . . . . . . . . Assembly 9: Electronics . . . . . . . . . . . . . . . . . . . . . . . Assembly 10: Automatic Sheet Feed (ASF) . . . . . . . . Assembly 11: Options . . . . . . . . . . . . . . . . . . . . . . . . . Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

47 47 47 48 48 49 49 50 52 54 54 55 56 56 57 59 61 63 65 67 69 71 73 75 77 79 80

v

4012-0XX

Preface
This manual is divided into the following chapters: 1. General Information contains a general description of the printer and the maintenance approach used to repair it. Special tools and test equipment are listed in this chapter, as well as general environmental and safety instructions. 2. Diagnostic Information contains the symptom table 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. Parts and Test Point Locations uses illustrations to identify the major components and test points on the printer. 6. Preventive Maintenance contains recommendations to help prevent problems and maintain optimum performance. 7. Parts Catalog contains illustrations and part numbers for individual FRUs.

vi

4012-0XX

Safety Information · ·
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. The safety features of some parts may not always be obvious. Therefore, replacement parts must have the identical or equivalent characteristics as the original parts.

·

Sicherheitshinweise · ·
Die Wartungsinformationen fuer dieses Produkt wurden zur Verwendung durch einen Wartungsfachmann entwickelt und sollten nicht von anderen benuetzt werden. Zusaetzliches Risiko eines elektrischen Schlags und koerperlicher Verletzung existiert waehrend des Auseinandernehmens und der Wartung des Geraets. Fachpersonal sollte im vollen Verstaendnis der Lage entsprechende VorsichtsmaBnahmen ergreifen. Ersatzteile muessen gleiche oder gleichwertige Merkmale wie die Originalteile aufweisen, da Sicherheitsvorkehrungen nicht immer offensichtlich sind.

·

Consignes De Securite · · ·
Les consignes d'entretien et de reparation de ce produit s'adressent uniquement a un personnel de maintenance qualifie. Le demontage et l'entretien de ce produit pouvant presenter certains risques electriques, le personnel d'entretien qualifie devra prendre toutes les precautions necessaires. Les normes de securite de certaines pieces n'etant pas toujours explicites, les pieces de rechange doivent etre identiques ou conformes aux caracteristiques des pieces d'origine.

vii

4012-0XX

Norme Di Sicurezza · ·
Le informazioni riguardanti la manutenzione di questo prodotto sono indirizzate soltanto al personale dell'assistenza autorizzato. Durante lo smontaggio e il manutenzionamento di questo prodotto, e possibile il rischio accresciuto di scosse elettriche e danni personali. Il personale di assistenza autorizzato, consapevole di cio, deve adottare le precauzioni necessarie. E possibile che le funzioni di sicurezza di alcuni elementi non siano cosi ovvie, quindi, i pezzi di ricambio devono avere caratteristiche identiche o equivalenti a quelle dei pezzi originali.

·

Pautas De Seguridad · ·
La informacion sobre el mantenimiento de este producto fue escrita para el personal de mantenimiento cualificado y no para cualquier otro usuario. Existen mayores riesgos de descargas electricas y danos personales durante el desmontaje y la reparacion de la maquina. El personal cualificado comprende esto y toma las precauciones necesarias. Los dispositivos de seguridad de algunas partes quiza no siempre puedan ser reconocidas a simple vista. Por lo tanto, las partes de reemplazo deben poseer caracteristicas identicas o equivalentes a las partes originales.

·

Sikkerhedsoplysninger · · ·
Oplysningerne om vedligeholdelse af dette produkt er forberedt med henblik pa professionelt servicepersonale, og bor derfor ikke benyttes af andre. Risikoen for elektrisk stod oges under demontering og service af dette produkt, hvorfor der bor tages de nodvendige forholdsregler. Sikkerhedsforanstaltningerne er ikke altid lige apenbare for alle reservedele. Der bor derfor kun anvendes originale reservedele eller reservedele med samme egenskaber som de oprindelige.

viii

4012-0XX

Chinese Safety Information

Korean Safety Information

ix

4012-0XX

General Information

8

This manual is used to service the Lexmark Medley 4012. Medley is a multifunction product which can connect to an IBM-compatible personal computer. It acts as an all-in-one color-capable printer, G3 fax machine, scanner, and convenience copier. It will send and receive faxes, scan documents, print from the PC, and make convenience copies. It uses 300 x 300 pels per inch inkjet technology for high quality text and graphics. Print Quality Enhancement Technology (PQET) smooths the edges of lines and characters. Medley uses the same black or color print cartridges as the IBM ExecJet II and ExecJet IIc by Lexmark. Medley uses a 300 x 300 dpi scanner for fast, high quality scanning, personal copying, and faxing. Scanning software for the PC is included with the Medley. There are three models: Medley 4c (4012-005) which does not include a handset, Medley 4x (4012-006) which does include a handset, and the Medley 4sx (4012-009) which is the same as the 4x but is shipped standard with the battery backup. Other than in the Parts Catalog, there are no service differences. All models can handle a variety of paper sizes as well as envelopes and other media using an integrated automatic sheet feed and manual feed. The machine contains the following circuit boards:

· · · ·

Fax Board--controls the scanner and most of the machine's functions Printer Board--runs the printer motors, sensors, and printhead Line Connect Unit (LCU) Board--printer parallel port and telephone connections Operator Panel Board

General Information 1

4012-0XX

Options
The following options are available. Contact your point of purchase for options available in your country.

· · ·

1MB Memory Expansion 3MB Memory Expansion Battery Backup (standard on Medley 4sx)

Maintenance Approach
The diagnostic information in this manual leads you to the correct field replaceable unit (FRU) or part. Use the error code charts, symptom table, service checks, and diagnostic aids to determine the symptom and repair the failure. Medley can be serviced without being connected to a host computer. After you complete the repair, perform tests as needed to verify the repair.

General Information 2

4012-0XX

Abbreviations
CCD CE CSU DRAM ESD FRU G3 LCD LCU LED NVRAM OEM PCA PICS PIXEL POST PQET SRAM UPR V ac V dc ZIF Charge Coupled Device Customer Engineer Customer Setup Dynamic Random Access Memory Electrostatic Discharge Field Replaceable Unit Group 3 (Digital Facsimile Protocol) Liquid Crystal Display Line Connect Unit Light-Emitting Diode Nonvolatile Random Access Memory Original Equipment Manufacturer Printed Circuit Assemblies Problem Isolation Charts Picture Element Power-On Self Test Print Quality Enhancement Technology Static Random Access Memory Used Parts Replacement Volts alternating current Volts direct current Zero Insertion Force

3

4012-0XX

Diagnostic Information

9

Use the symptom table and service checks in this chapter to determine the failing part in a malfunctioning machine.

Diagnostic Information 4

4012-0XX

Symptom Table
Symptom
Printer Code 1,4 Printer Code 1,6 Printer Code 1,8 Printer Code 1,10 Printer Code 1,12 Printer Code 1,14 Printer Code 3,4 Printer Code 3,8 Printer Code 9,2 Printer Code 9,4 Power Problem No LEDs or LCD pixels light up during POR, no machine activity: Maintenance Station Problem Maintenance station does not move, or fails to clean or cap the printhead: Carrier Transport Problem No carrier movement, slow carrier movement, carrier stops: Operator Panel Problem Incorrect or no lit LEDs or LCD display, or buttons do not work properly:

Action
Replace the printer board EPROM; if necessary replace the printer board. Go to "Transport Service Check" on page 21. Replace the printer board EPROM; if necessary replace the printer board. Go to "Maintenance Station Service Check" on page 9. Replace the printer board EPROM; if necessary replace the printer board. Go to "Maintenance Station Service Check" on page 9. Go to "Transport Service Check" on page 21. Go to "Transport Service Check" on page 21. Replace the printer board EPROM; if necessary replace the printer board. Go to "Transport Service Check" on page 21.

Go to "Power Service Check" on page 11.

Go to "Maintenance Station Service Check" on page 9. Go to "Transport Service Check" on page 21.

Go to "Operator Panel Service Check" on page 10.

5

4012-0XX

Symptom
Printer paper feed, misfeed, or jam problem Paper fails to stop at first print line: Envelopes fail to feed: Paper misfeeds, multifeeds, jams, picks but fails to feed, or fails to exit: Paper skews: Scanner paper feed, misfeed, or jam problem Printing Problem Test prints, faxes, or printer jobs do not print correctly (not a print quality problem). Print Quality Problem Test prints, faxes, and printer jobs print but output has voids or uneven density or is fuzzy, smudged, or faint. Scanning Problem No scanned image or incorrect scanned image: Communications Problem Cannot send fax, cannot receive fax, or cannot connect with remote machine:

Action

Go to "First Print Line Service Check" on page 8. Go to "Envelope Feed Service Check" on page 8. Go to "Printer Paper Feed Service Check" on page 12. Go to "Printer Paper Path Service Check" on page 15. Go to "Scanner Document Feed Service Check" on page 19.

Go to "Printing Problem Service Check" on page 18.

Go to "Print Quality Service Check" on page 16. Go to "Scanner Service Check" on page 20.

Go to "Communications Service Check" on page 7.

Diagnostic Information 6

4012-0XX

Service Checks
Communications Service Check
FRU
1 Fax or LCU Card Cannot make telephone connection to other fax machine.

Action
No dialtone Verify correct dialing method (tone or pulse). TEL and LINE connections reversed. Verify phone number and availability of other fax machine. Turn Call Monitoring on and listen to the speaker during dial. You should hear the ring and a 0.5 second 1000Hz calling tone from your machine, a 1 second pause, then the 3 second 2100Hz fax response tone and a 1650Hz-1850Hz "warbling" handshaking tone from the called machine. Check the connections of LCU card J2 to fax card J11. If the problem still exists, replace the LCU board, and then if necessary, the fax board. Machine not set for auto-answer. TEL and LINE connections reversed. A telephone on the same line is already off-hook. Machine connected to the wrong telephone line. Damaged telephone line to machine. Check memory; faxes received during paper jams are stored and printed after jam is cleared. Make sure "Receive into memory" is set to No. If handshaking between fax machines can be established, the LCU board should be OK. If necessary, replace the fax board.

2

Cannot receive faxes.

7

4012-0XX

Envelope Feed Service Check
FRU
1 Envelope Loading

Action
Be sure the envelope guides have been turned to the envelope load positions. Be sure the envelope guides are against the envelopes. Go to and perform the "Printer Paper Feed Service Check" on page 12.

First Print Line Service Check
FRU
1 2 3 Printer End-of-Forms Flag Printer End-of-Forms Sensor Printer Board

Action
Check the flag for binds or damage. Check the sensor for dirt. Check the End-of-Forms sensor, measure the voltage at pin 2 of U28 on the printer board. The voltage should change from 0 to 5 V dc as you block and unblock the End-ofForms sensor S1. Check all parts of the feed arm assembly for binds, wear, or damage. Use Toolkit, one of the setup programs installed on the PC, to adjust the Top of Form setting. Go to "Operator Panel Service Check" on page 10.

4 5

Feed Arm Assembly Software Setting

6

Operator Panel

Diagnostic Information 8

4012-0XX

Maintenance Station Service Check
The maintenance station has two functions: 1. Cleans the printhead nozzles during the print operation. 2. Seals the printhead when it is not being used to prevent the nozzles from drying.
FRU
1 Maintenance Drive Assembly

Action
Warning: Disconnecting the maintenance motor while the machine is plugged in can damage the printer board. Voltage is present on the board even with the power switch off. Disconnect J4 from the printer board. Check for 18 ohms (±4 ohms) between pins 1 and 2 at the motor. If the reading is incorrect, replace the maintenance drive assembly. Check for motor pins shorted to the motor housing. If you find a shorted pin, replace the maintenance drive assembly. If the symptom remains, replace the printer board. A bind in the drive assembly can prevent the motor from turning. Check for binds and loose or worn parts in the drive assembly. Also check the motor gear.

2

Printer Board

Turn the machine off and disconnect J4 from the printer board. Turn the machine on and check for a pulse of 15 V dc between J4-1 and ground on the system board as the printer goes through POST. Check for binds or wear. A worn wiper causes degraded print quality just after a maintenance cleaning. Check for loose or worn wiper. A worn cap causes the printhead nozzles to dry and clog. Check for loose or worn cap.

3 4

Maintenance Rocker Asm Wiper

5

Cap

Note: If the failure remains, replace the printer board.

9

4012-0XX

Operator Panel Service Check
FRU
1 Power Supply

Action
Disconnect J2 from the fax board and check the following voltages on the power supply cable: J2-1 to GND = +5 V dc J2-3 to GND = +34 V dc If you do not have correct voltage, replace the power supply. Be sure to unplug the machine before you reconnect the power supply to the fax board.

2

Operator Panel Board Operator Panel Cable

Perform the Operator Panel Test; see "Operator Panel Test" on page 24. If some of the buttons do not work, check the contacts on the back of the keypads and the surface of the lands on the operator panel board. Replace the keypads as necessary. Check the continuity of the operator panel cable before replacing the operator panel board. Turn the printer on. Check for +5 V dc at J4-3 on the fax board.

3

Fax Board

Diagnostic Information 10

4012-0XX

Power Service Check
The operator panel power key does not control line power. With the machine turned off the power supply is still active and there is voltage to both the fax and printer boards. To remove power you must unplug the machine.
FRU
1 Power Supply

Action
Disconnect J2 from the fax board, J11 from the printer board and check the following voltages on both power supply cables: Pin-1 to GND = +5 V dc Pin-3 to GND = +34 V dc If you do not have correct voltage, replace the power supply. Be sure to unplug the machine before you reconnect the power supply to the boards.

2

Printhead Cable Parallel Cable

Unplug the machine. Disconnect one of the listed components and plug in the machine. Look for a symptom change. Check the failing part for shorts and replace as necessary. Repeat this procedure for the remaining listed parts. Disconnect the fax board from the printer board. Run the Print Engine Test. If the test does not run and there are no mechanical problems, replace the printer board. Check for +5 V dc at the fax board J9-4, and check for +34 V dc at J9-2. If the voltages are incorrect replace the fax board.

3

Printer Board

4

Fax Board

11

4012-0XX

Printer Paper Feed Service Check
If your machine does not have paper jam problems, go on to the service check. If your machine does have a paper jam problem, examine it for the following before you begin the service check.

· · · · ·

Check the entire paper path for obstructions. Make sure there is not too much paper in the Automatic Sheet Feed (150 sheets or less depending on the thickness). Make sure the correct type of paper is in the machine. Check for static in the paper. Make sure the rear of the carrier guide is on top of the paper guide.

FRU
1 Printer Board

Action
With J5 disconnected and power on, check for +24 V dc between J5-3 and ground, and between J5-4 and ground on the printer board. If the voltage is not present, check for motor pins shorted to the motor housing. If you find a shorted pin, replace the motor. If you still have a failure after replacing the motor, replace the printer board.

Diagnostic Information 12

4012-0XX

FRU
2 Paper Feed Motor

Action
A noisy or chattering motor or a motor that fails to turn, can be caused by: · An open or short in the motor · An open or short in the motor driver on the printer board · A bind in the paper feed mechanism Warning: Disconnecting the paper feed motor while the machine is plugged in can damage the printer board. Voltage is present on the board even with the power switch off. Check for 100 ohms (±20 ohms) between the following pins on the motor: Pin 1 to Pin 4 Pin 2 to Pin 4 Pin 3 to Pin 5 Pin 3 to Pin 6. If the readings are incorrect, replace the motor. Check for motor pins shorted to the motor housing. If you find a shorted pin, replace the motor. If the failure remains, replace the printer board. Although the paper feeds in a forward direction only, the paper feed motor turns in two directions. If the paper feed motor turns in one direction only, replace the printer board. Binds in the paper feed motor or gear train can cause intermittent false paper jam errors. Remove the paper feed motor and check the shaft for binds. Also check for loose or worn motor gears.

3

Gears

Check for binds in the gear train and paper feed mechanism. To do this, rotate the largest gear by hand. If you notice a bind, isolate it by removing the small idler gear on the outside of the right side plate and rotate the gears again. Replace any worn or binding gears, rollers, or bearings.

13

4012-0XX

FRU
4 Feed Arm Assembly

Action
At the beginning of the paper feed operation, the paper feed motor reverses momentarily to allow the feed arm pawl to drop off the home position notch in the ASF side plate. If the pawl fails to drop off the notch, check the feed arm assembly for binds, and worn or broken parts. Check the following for wear or damage: · Pick Rollers · Envelope Bucklers · All parts inside the left and right edge guides.

5

Auto Sheet Feed (ASF)

6 7 8

End-of-Forms Flag Star Rollers Ejectors

Check for binds or damage. Check for worn or binding rollers. Check for broken star roller springs. After the paper exits from the exit rollers, the paper feed motor reverses causing the feed arm pawl to restore to the home position in the ASF side plate. At the same time, the paper ejectors move the last sheet of paper into the exit tray. If the ejectors do not move or restore, check them for worn, loose, or broken parts; also check for interference with the front cover.

Diagnostic Information 14

4012-0XX

Printer Paper Path Service Check
Examine the machine for the following before you begin this service check:

· · · ·

Check the entire paper path for obstructions. Be sure the paper guides are not worn or broken and are positioned against the paper without binding or buckling the paper. Be sure the correct type of paper is in the machine. Be sure the rear of the carrier guide is on top of the paper guide.
FRU Action
Check for wear and binds. Check for damage. Check for equal pressure between the left and right pick rolls and their pads; this can be caused by the paper load shaft gears being misaligned by one tooth in the ASF frame. Check the following for wear or damage: · Envelope Bucklers · All parts inside the left and right edge guides.

1 2 3

Large and Small Feed Rollers Large Feed Roller Springs Auto Sheet Feed (ASF)

4 5 6 7

End-of-Forms Flag Exit Roller Star Rollers Ejectors

Check for binds or damage. Check for wear or binds. Check for wear or binds. Check for broken star roller springs. Check the front cover; if it is installed incorrectly it can interfere with the ejectors. Make sure the front bottom cover is installed correctly. If the front bottom cover is not installed correctly, the ejectors can hang on the cover possibly causing severe paper jams. After the paper exits from the exit rollers, the paper feed motor reverses causing the feed arm pawl to restore to the home position in the ASF side plate. At the same time, the paper ejectors move the last sheet of paper into the exit tray. If the ejectors do not restore, check them for worn, loose, or broken parts.

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Print Quality Service Check
FRU
1 2 Print Cartridge Printhead Carrier Assembly

Action
Be sure the machine has a known good print cartridge. Reseat the printhead cables in the printer board and check the following parts for wear or damage: · Print Cartridge Latch · Latch Spring · Carrier

3

Printer Board

Perform the "Purge Test" on page 25. Look for a break in the diagonal line at the bottom of the test pattern. A broken line indicates one or more print nozzles are clogged. Run the test again to verify the failure. If there are even breaks in the diagonal line similar to the pattern shown below, replace the printer board.

If there is a single break or random breaks in the diagonal line check the following: Printhead Cable Check the gold-plated contacts on the end of the cable that connects to the carrier for dirt and wear. Use only a clean dry cloth to clean the contacts. Also check the cable for damage. You may need to remove the cable from the carrier to inspect it. A worn rubber backer will result in poor contact between the printhead cable and the print cartridge. Check the rubber backer for wear. Intermittent nozzle failures can be caused by worn parts in the maintenance station. Go to and perform the "Maintenance Station Service Check" on page 9, then return to this check.

Rubber Backer

4

Maintenance Station

Diagnostic Information 16

4012-0XX

FRU
5 Paper Feed

Action
Ink smudging and smearing can be caused by paper problems or problems in the paper feed area. Check the following: · Correct type of paper is in the machine. Also check the paper for curl and wrinkles. · Feed roller for wear, dirt, or looseness. · Gears for wear or binds. · Paper path for obstructions. · Star rollers for binds or dirt. The exit roller and star rollers keep tension on the paper by moving slightly faster than the feed rollers. A binding star roller can put vertical marks on the paper. · Subframe is properly snapped into position.

6

Transport

Blurred print and voids can be caused by problems in the transport area. Check the following: · Transport belt for wear. · Carrier guide and carrier guide rod for wear or dirt. · Idler pulley parts for wear, damage, or looseness. · Encoder strip for wear or dirt. · Subframe is properly snapped into position.

7

Bidirectional Alignment

Uneven vertical lines can be adjusted by performing the "Bidirectional Alignment Adjustment" on page 29.

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4012-0XX

Printing Problem Service Check
If test prints, faxes, or printer jobs do not print correctly (not a print quality problem), run the Print Engine Test.
FRU
1 Machine does not start the test:

Action
Make sure all the pins of connector J7 are shorted together and try to run the test again. If the test still does not start, go to "Power Service Check" on page 11. Refer to the appropriate service check for the symptom. There is a problem with the print job, the parallel cable, the LCU board, the fax board, the fax/LCU cables, or the printer/ fax cable. Check the cables and their continuity. If no problem is found, replace the fax board and then the LCU board.

2 3

The machine responds but does not complete the test: The tests prints correctly:

Diagnostic Information 18

4012-0XX

Scanner Document Feed Service Check
Before beginning service, examine the following:

· · · · · ·

Are the pages damaged or dog-eared, are pages stuck together? Is the paper being fed too thin (less than 16 lb paper), or too thick (greater than 24 lb paper)? Are the pages too small to feed properly? Too many pages being fed (greater than 20)? Are the scanner entry guides set properly? Are both sides of the scanner front frame latched?

The scanner document feeder can be checked using the "Scanner Feed Test" on page 25.
FRU
1 Feed Rollers & Restraint Pad

Action
Check for dirty, worn, or damaged rollers. Make sure the restraint pad and its spring are in good condition. Make sure the pick springs and all roller springs are undamaged. Refer to "Scanner Cleaning Procedure" on page 55. The operator panel message should change when a document is fed into the scanner. Check for fax board J6-3 to change from 0 V dc to +5 V dc as the entry sensor flag is toggled. Check for fax board J6-6 to change from 0 V dc to +5 V dc as the second sensor flag is toggled. Fax board J3-5 and J3-6 should have +15 V dc. Warning: Disconnecting scanner motor while the machine is plugged in can damage the fax board. Voltage is present on the board even with the power switch off. Unplug the machine before proceeding. Disconnect the motor from the fax board. Motor pins 1 through 4 should not have continuity to each other or to ground.

2

Paper Sensors

3

Motor

4 5

Gear Train Fax Board or Connections

Inspect the gear teeth for damage. Rotate the gear train to check for binds. Check scanner motor (J3) and paper sensor (J6) cable connections to fax board.

19

4012-0XX

Scanner Service Check
FRU
1 LED Array

Action
A failed LED array results in either black or very dark output. If a single LED fails, the output will have a black or dark vertical fuzzy stripe. The voltage at fax board J7-3 should be +12 V dc during a scan. Replace the array if the voltage is correct. If there is no image (all white image), check the connection of the scanner data cable to both the scanner (J1) and the fax board (J8). A scanner CCD unit failure results in either a white image, a black image, or an image with one or more thin vertical black lines. Replace the scanner CCD unit. It is not possible to be certain whether an all-black or all-white scan failure is due to the CCD unit or the fax board. In general, if the machine performs non-scanning functions involving the fax board (for example, receiving a fax, exchanging stored data with the PC, or accepting data entered from the operator panel) the fax board is probably OK. If replacing the CCD unit does not correct the problem, reinstall the old CCD unit and replace the fax board. If the machine sends faxes properly but does not create a scanned image file on the PC, there is a problem with the PC scanner software installation or configuration.

2

Scanner and Fax Board

3

PC Scanner Software

Diagnostic Information 20

4012-0XX

Transport Service Check
FRU
1 Transport Motor

Action
Check the motor for binds, or loose motor pulley. Warning: Disconnecting the transport motor while the machine is plugged in can damage the printer board. Voltage is present on the board even with the power switch off. Unplug the machine before proceeding. Disconnect the transport motor (J6) from the printer board. Check for 8 to 18 ohms between pins 1 and 2 on the motor cable. If the reading is incorrect, replace the motor. Check for motor pins shorted to the motor housing. If you find a pin shorted to the housing, replace the motor. If the failure remains, replace the printer board.

2

Printer Board

Unplug the machine and disconnect J6 from the printer board. Plug the machine in and check for a pulse of 3 to 5 V dc between J6-1 and ground and between J6-2 and ground on the printer board as the machine goes through POST. Check for worn, loose or broken parts. Clean the carrier guide rod. Do not lubricate the rod or the carrier rod bearings. Check for obstructions blocking carrier movement. Check for wear and dirt. Be sure the printer board connectors J1 and J2 are fully seated. Check the cables for damage. A problem with the maintenance station can cause carrier movement problems at the right margin: Go to the "Maintenance Station Service Check" on page 9.

3

Transport Belt Carrier Guide or Guide Rod Idler Pulley Parts Cable Clip Encoder Strip Printhead Cables

4 5

6

Maintenance Station

21

4012-0XX

Diagnostic Aids Call Monitoring

3

Call Monitoring plays tones during the call connection. This is helpful in diagnosing communication problems. To invoke this aid, press Setup, then select SPK. Press an arrow key to turn the speaker on or off, press OK to save the setting and then press Stop.

Error Report
When a fax transmission cannot be completed, the machine prints an Error Report. This is useful in determining whether service is required to correct the communication problem.

Frame Service Position
For ease of access to the electronic boards, the frame can be pivoted out of the way without being removed. Remove the covers. Disconnect the cables from the frame on the right side of the printer and fax boards. Unsnap the right front and right rear frame supports from the machine base. Pivot the printer frame up 90 ° on the left feet.

Hex Print Mode
Perform this test with a black print cartridge installed. Use hex mode to help evaluate data stream problems. All data (including both control and character data) print in hexadecimal digits instead of ASCII. To activate, press Setup, then select PRT. Use the right arrow to move the cursor to Diag and press OK. Select HEX. Then send the PC job to be printed in hexadecimal. Press Stop to return to ASCII mode, and press Stop again to exit from the service menus.

Diagnostic Aids 22

4012-0XX

Machine Checkout
Use the standard functions of the machine to verify the correct operation of its subsystems. Copying a document confirms that the scanner and the printer engine is working. Sending a fax verifies that the scanner and the telephone connection are OK. Printing a job from the PC verifies that the parallel port and the print engine are OK. Receiving a fax to memory confirms that the telephone connection and the memory on the fax board are good.

Memory Test
Use the Memory Test for testing both system memory and document memory. 1. 2. 3. 4. 5. Press Setup. Press 2104 to enter the Service Functions menu. Press the right arrow key to select Testing, then press OK. Select MEM. Press Stop several times to exit the test.

Operator Panel Service Position
To operate the machine with the covers removed, the operator panel can be positioned on a table at the left of the machine and the cable connected to the fax board.

23

4012-0XX

Operator Panel Test
This test activates each LED in sequence and cycles all pels of the LCD display. It also allows the servicer to test each button. 1. Press Setup. 2. Press 2104 to activate the Service Functions menu. 3. Press the right arrow to move the pointer to Testing, then press OK. 4. Select PNL. 5. Press any button (except Stop) to start the button test. Follow the instructions on the display to press and test each button. 6. Press Stop at any time to end the test. Press Stop several times to exit the menus.

Reset Button
This recessed button on the operator panel is covered with a shield and must be pressed with a small tool or straightened paper clip. The Reset button does a hardware reset of the fax board and operator panel. Pressing Reset does not erase stored faxes or the contents of the phone book. The Reset button does not reset the printer board; unplugging the machine resets the printer board.

Print Engine Test
Use the Print Engine test for testing the printer board and inkjet printer engine independent of the other machine subsystems. This test can be run with the fax, LCU, or operator panel boards disconnected or defective. 1. Unplug the machine. 2. Remove the right cover and locate printer board header J7. 3. Short all four pins together with a screwdriver and plug the machine in. The test print will run continuously until the machine is unplugged. The pins do not need to stay shorted after the test starts.
Diagnostic Aids 24

4012-0XX

Purge Test
This test prints out a nozzle test pattern followed by several gray lines and another nozzle test pattern. Use this test to check the function of all the nozzles in the print cartridge. This test also checks the electronic connection to the print cartridge. During the test, the printhead cartridge goes through a maintenance cleaning at the maintenance station. Run this test with either the black or the color cartridge installed. 1. 2. 3. 4. Press Setup. Select PRT. Select PUR. Press Stop several times to exit the menus.

Scanner Feed Test
This test exercises the scanner Automatic Document Feed to allow you to verify the paper pick and scanner motor function. This test feeds paper but does not test scanning. 1. 2. 3. 4. 5. Press Setup. Press 2104 to activate the Service Functions menu. Use the right arrow to select Testing and press OK. Select ADF. Insert one or more sheets into the scanner ADF and follow the panel instructions. 6. Press Stop several times to exit the service menus.

25

4012-0XX

Setting the Machine Serial Number
When the fax board is replaced, the machine serial number needs to be saved into memory. Press Setup. Press 2104 to activate the Service Functions menu. Press OK to enter the Service Setup menu. Select SRN. Enter the machine serial number (4012 followed by 10 characters) found on the rear label. 6. Press OK to save the number. Press Stop several times to exit the service menus. 1. 2. 3. 4. 5.

Test Print
From the operator panel, print the Setup Conditions report (press Setup, then press the button for LST) to determine that the operator panel, the fax board, the printer board, the ASF, and the print engine are performing correctly. There are two other test prints available. Press Setup, then the button for PRT. Press the right arrow to select Diag and then press OK. On this menu, FON prints the fonts available in the printer. TST prints a test print which can show a non-functioning printhead nozzle. Press Stop several times to exit the service menus.

Diagnostic Aids 26

4012-0XX

Repair Information

7

This chapter explains how to make adjustments to the printer and how to remove defective parts. Read page 28 before handling electronic parts. Warning: Medley has a soft power key which does not remove machine power; it shuts down visible machine activity. When the machine is plugged in power is always present on the fax board and printer board. Before connecting or disconnecting any machine components always unplug the machine from the wall outlet.

Repair Information 27

4012-0XX

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 boards:

· · · · · ·

·

· ·

Keep the ESD-sensitive part in its original shipping container (a special "ESD bag") until you are ready to install the part into the machine. Make the least-possible movements with your body to prevent an increase of static electricity from clothing fibers, carpets, and furniture. Put the ESD wrist strap on your wrist. Connect the wrist band to the system ground point. This discharges any static electricity in your body to the machine. Hold the ESD-sensitive part by its edge connector shroud (cover); do not touch its pins. If you are removing a pluggable module, use the correct tool. Do not place the ESD-sensitive part on the machine cover or on a metal table; if you need to put down the ESD-sensitive part for any reason, first put it into its special bag. 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 you are not working on the machine, 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 coldweather heating is used because low humidity increases static electricity.

Repair Information 28

4012-0XX

Adjustments
Bidirectional Alignment Adjustment
Perform this adjustment with the black print cartridge installed. Note: For machines at software version 5.15.5.2 or lower (press Setup LST to print the report listing the version number), this adjustment affects only Letter quality mode and Step 5 and its note do not apply. If bidirectional alignment in Draft mode is a problem on a machine at this level, enter Setup PRT Setup and either set Printing Quality to Letter or set Printing Direction to Unidir. 1. Press Setup. 2. Select PRT, select Diag (diagnostics), and then select Bidi. 3. Open the top cover to see the alignment test print. A page loads and the bidirectional alignment pattern prints. The pattern consists of three lines of vertical bars. The bars are aligned when the adjustment is correct. The following sample requires the center vertical bars to be moved to the right.

4. The center bars can be aligned in increments of 1/1200 (0.02 mm). If the lines are not straight, press the left arrow key () to move the center of the lines to the left, or press the right arrow key () to move them to the right. Each time you press an arrow key the three lines print. 5. When the alignment is correct, press the top right key under the display to switch to Draft mode. Follow the same procedures as above to align the bars in Draft mode. Note: Single left and right arrows are printed while in Letter mode, and triple left and right arrows are printed while in Draft mode. 6. When the adjustment is complete press Stop to save the setting then press Stop again to exit the Setup menu.

29

4012-0XX

Removal Procedures
The following procedures are arranged according to the name of the part discussed. When there is artwork to support a procedure, it follows the text. Note: Unplug the machine before beginning any electrical service. The power key does not remove power from the electronics.

Auto Sheet Feed (ASF) Assembly Removal
1. 2. 3. 4. 5. 6. Remove the paper load lever. Remove the left and right side covers. Remove the clip from the right side subframe, if installed. Remove the top cover. Release the latches holding the subframe to the ASF. Push in the two latches [A] that secure the ASF to the side frame, then lift up the sheet feed to remove it from the machine.

A

A

When you reinstall the ASF, be sure the feed arm assembly is vertical, with the feed pawl at the top.

Repair Information 30

4012-0XX

ASF Envelope Buckler and Pick Roller Hub Removal
1. Remove the ASF assembly. 2. Remove the inside C-clip from the pick roller shaft and pull the shaft to the right far enough to remove the envelope bucklers and pick rollers. 3. Remove the pick roller hubs from the bucklers.

ASF Right and Left Edge Guide Assemblies Removal
1. Remove the ASF assembly. 2. Remove the manual insert tray by prying one of the side frames away from it. 3. Remove the inside C-clip from the pick roller shaft and pull the shaft out to the right. 4. Remove the pick roller and buckler assemblies. 5. Remove the paper load lever and shaft by pulling them out from the right side of the ASF assembly. Be careful not to lose the small gear on the left end of the shaft. When you reinstall this shaft, it must be parallel with the ASF housing. 6. Pivot the guide assembly up and pry it off the back plate.

Battery Option
1. Unplug the machine. 2. Open the access door on the left side cover. The battery option is attached to the door. 3. Disconnect the battery option cable from the fax board. 4. Remove the battery board mounting screw. Note: If the battery option is being replaced, install the jumper on the new battery option board. If the battery option is being removed, install the jumper at J9 (2 center pins) of the fax board. Failure to install the jumper will cause a dead machine condition.

Carrier Guide Rod Removal
1. Open the top cover. 2. Remove the print cartridge. 3. With the carrier centered, carefully release the two carrier guide rod latches and lift the shaft slightly. 4. Unlatch the two carrier guide rod latches by pushing the latches to the rear. 5. Gently push the carrier to the extreme right and remove the carrier guide rod. 31

4012-0XX

Carrier Removal
Open the top cover. Remove the right side cover Remove the print cartridge. Disconnect the printhead cables from the printer board. Cut the cable tie and remove the toroid. Move the carrier in line with the opening in the carrier transport motor frame. 7. Reach through the opening and pull the belt from the carrier. 8. To unlock the carrier guide rod latches, rotate the rod top-to-rear. Gently push the carrier guide rod latches, at each end of the rod, to the rear and lift up the rod until the sensor on the carrier clears the encoder strip. Move the rod to the left until the right end can be lifted above the frame. Remove the carrier guide rod to the right, above the carrier motor. Be careful not to damage the encoder strip. 9. Pull the ends of the printhead cables into the machine, then remove the cables from the four retainers in the paper guide starting from the right. 1. 2. 3. 4. 5. 6.

Carrier Transport Belt Removal
1. Open the top cover and then remove the left and right side covers. 2. Move the carrier in line with the opening in the carrier transport motor frame. 3. Reach through the opening and pull the belt from the carrier. 4. Remove the belt from the carrier transport motor pulley. 5. Remove the belt from the idler pulley and pull it through the opening in the left side frame. Note: When you reinstall the belt be sure to insert the bottom of the belt into both the lower and upper belt grips on the carrier. DO NOT INSERT THE TOP OF THE BELT INTO THE UPPER GRIP.

Repair Information 32

4012-0XX

Carrier Transport Motor Removal
1. Open the top cover and then remove the left and right side covers, then the lower front cover. 2. Disconnect the carrier transport motor (J6) from the printer board. 3. Remove the two motor mounting screws and remove the motor.

Carrier Transport Motor Frame Removal
1. 2. 3. 4. 5. 6. 7. 8. Remove the top cover and then the left and right side covers. Remove the rear and front covers. Disconnect J6 from the printer board. Disconnect the four scanner connectors and the speaker connector from the fax board. Remove the scanner and subframe. Move the carrier in line with the opening in the carrier transport motor frame. Reach through the opening and pull the belt from the carrier. To unlock the carrier guide rod latches, rotate the rod top-to-rear. Gently push the carrier guide rod latches, at each end of the rod, to the rear and lift up the rod until the sensor on the carrier clears the encoder strip. Remove the carrier guide rod through the opening in the left side frame. Be careful not to damage the encoder strip. A latch on the top front end of each side frame holds the transport motor frame in place. Push up the latches on the front of the side frames and pivot the carrier transport motor frame down and out of the side frames.

9.

33

4012-0XX

Covers Removal
Front Cover 1. Remove the left and right side covers. 2. Flex the front cover to release the latches on each end. 3. Lift the cover to free the lower latch and remove the cover. Note: When reinstalling the front cover, make sure the lower latch and side latches are installed properly to prevent the cover from interfering with the paper ejectors. Rear Cover 1. Remove the left and right side covers. 2. Flex the tabs on the subframe to release both latches. 3. Lift the cover to free the lower latch and remove the cover. Top Cover 1. Bend the subframe slightly to free the top cover pivot pin. 2. Remove the top cover. Right Side Cover 1. Remove the paper load lever. 2. Open the operator panel cover and the top cover. 3. Remove the screw from inside the subframe just above scanner. 4. Lift on the top inner edge of the cover to free the top latches. 5. Rotate the cover to the right to free the lower latches. Left Side Cover Open the operator panel cover and the top cover. Remove the screw from inside the subframe just above scanner. Lift the top inner edge of cover to free the top latches. Rotate the cover to the left to free the lower latches. If the battery option is installed, disconnect its cable from the fax board (J9). Operator Panel and Cover Remove the left and right side covers. Flex the subframe to free one of the pivot pins. Remove the two screws and the ESD shield. Disconnect the operator panel cable from the back of the operator panel. 5. Unsnap the operator panel from the cover. 1. 2. 3. 4. 1. 2. 3. 4. 5.

Repair Information 34

4012-0XX

Encoder Strip Removal
The encoder strip can be easily damaged; use care when removing or installing. 1. Open the top cover. 2. Move the carrier in line with the opening on the carrier transport motor frame. 3. Reach through the opening and pull the belt from the carrier. 4. To unlock the carrier guide rod latches, rotate the rod top to rear. Gently push the carrier guide rod latches at each end of the rod to the rear and lift up the rod until the sensor on the carrier clears the encoder strip. Place the carrier on top of the paper guide. 5. Remove the encoder strip from the left mounting peg. To do this, push the right latch slightly to the left. 6. Remove the encoder strip from the right latch. When you install the encoder strip, be sure it is fully seated on the left mounting peg.

End-of-Forms Flag Removal
Remove the covers. Disconnect the printer board connectors: J1, J2, J4, J5, and J6. Disconnect the fax board connectors: J3 and J8. Raise the machine frame into the service position. Pivot the weighted end of the end-of-forms flag through the opening in the middle frame. 6. Unsnap the flag by moving it to the rear. 1. 2. 3. 4. 5.

Exit Roller Assembly Removal
1. Remove the covers. 2. Remove the carrier transport frame. 3. Pivot the paper ejector pusher toward the front then pull it to remove the paper ejector from the shaft. 4. Remove the bushing from the left end of the exit shaft. To do this, pull the tab and rotate the bushing. 5. Slide the exit roller to the left and lift it out of the machine.

35

4012-0XX

EPROM Removal
1. Unplug the machine before beginning any electrical service. The power key does not remove power from the electronics. 2. Remove the top cover. 3. Disconnect the printhead cables from the printer board. 4. Disconnect connectors J4, J5, and J6 from the printer board. 5. Disconnect the scanner motor connector J3 from the fax board. 6. Release the latches at the right-front and right-rear legs of the frame, then lift and pivot the frame 90 ° to the left into the service position. 7. Gently pry the EPROM from the board. 8. To install the EPROM: a. Ensure the orientation notch is to the right for the fax board or to the front for the printer board. Refer to: "Parts and Test Point Locations" on page 49. b. Ensure that each module pin aligns with each socket, so there are no bent pins. c. Apply even pressure on the top of the module until it is seated against the socket.

Repair Information 36

4012-0XX

Fax Board, Printer Board, and LCU Board Removal
1. Unplug the machine before beginning any electrical service. The power key does not remove power from the electronics. 2. Remove the left and right side covers, the front cover and the rear cover, and disconnect J1, J2, J4, J5 and J6 from the printer board. 3. Disconnect the scanner motor cable from J3 and scanner data cable J8 from the fax board. 4. Unsnap the two print engine feet at the right side of the machine. 5. Pivot the print engine up around the left pivots, being sure no cables are being strained, until the left side of the print engine is resting on the table. 6. Disconnect the remainder of the cables required to remove the board. 7. Cut the cable tie around the support posts. 8. Remove the EPROM (see "EPROM Removal" on page 36) for installation on the new board. Remove the ground screw and remove the board. Note: If the printer board is replaced, check the bidirectional alignment. If the fax board is replaced, inspect the LCU board for physical damage. Replace the LCU board if damage is present. The machine serial number needs to be saved into memory, if the fax board is replaced. Refer to "Setting the Machine Serial Number" on page 26.

Feed Arm Assembly Removal
1. Remove the covers. 2. Remove the ASF. 3. Remove the C-clip from the center of the large gear and remove the feed arm assembly.

Inside Idler Gears Removal
1. 2. 3. 4. 5. Remove the covers. Remove the ASF. Disconnect the printhead cables from the printer board. Remove the paper guide. Remove the C-clip from the feed arm assembly and remove the feed arm assembly. 6. Pull the idler gears off the mounting studs.

37

4012-0XX

Large Feed Roller Assembly Removal
1. 2. 3. 4. 5. Remove the top cover. Disconnect the printhead cables from the system board. Disconnect connectors J4, J5, and J6 from the system board. Disconnect scanner motor connector J3 from the fax board. Release the latches at the right front and right rear legs of the frame, then lift and pivot the frame 90 ° to the left into the service position. 6. Disconnect the 3 springs from the bottom of the middle frame assembly. 7. Remove the large feed roller assembly.

Left Side Frame Removal
1. 2. 3. 4. 5. 6. 7. Remove the covers. Remove the print cartridge. Remove the subframe. Remove the ASF. Disconnect the printhead cables from the printer board. Disconnect connectors J4, J5, and J6 from the printer board. Remove the machine from the base. To do this, release the latches at the right-front and right-rear legs of the frame, then lift and pivot the frame 90 ° to the left. Lift the frame to disengage the left legs from the base. Move the carrier in line with the opening in the carrier transport motor frame. Reach through the opening and pull the belt from the carrier. To unlock the carrier guide rod latches, rotate the rod top-to-rear. Gently push the carrier guide rod latches, at each end of the rod, to the rear and lift up the rod until the sensor on the carrier clears the encoder strip. Remove the carrier guide rod through the opening in the left side frame. Be careful not to damage the encoder strip. Pull the ends of the printhead cables into the machine, then remove the cables from the four retainers in the paper guide starting from the right. Disengage the left paper guide latch by carefully moving the rear of the left side frame to the left. Disengage the right side of the paper guide from the latch and lift it from the machine.

8. 9. 10.

11.

12. 13.

Repair Information 38

4012-0XX 14. A latch on the top front end of each side frame holds the transport motor frame in place. Push up the latches on the front of the side frames, then pivot the carrier transport motor frame down and out of the side frames. 15. Place the machine on its back and push the left side frame latch to the rear and remove the frame from the machine. 16. Unsnap the feet from the left side frame. When you reinstall the paper guide, be sure the front edge goes under the rear of the carrier guide. If the paper guide is on top of the carrier guide, push down the front, bottom edge. The paper guide will snap under the carrier guide. To install the left side frame onto the middle frame, align the right side frame latch with the latching surface on the middle frame before you align the roller shafts and carrier guide. It may be easier to do this with the machine on its right side.

Maintenance Drive and Rocker Assemblies Removal
1. 2. 3. 4. 5. Remove the covers. Remove the ASF. Remove the right side frame. Gently unlatch the maintenance assembly latches. Slide out the maintenance drive assembly and then the rocker assembly.

When you reassemble the drive assembly, be sure the forks engage the pins on the rocker assembly.

Memory Option
1. Unplug the machine. 2. Open the access door in the left side cover. 3. Lift up the memory board to remove it. Note: The 1MB option consists of two modules and the 3MB option has six modules. 4. From the operator panel, print the Setup Conditions report (press Setup, then select LST) to verify the installed memory is recognized by the machine.

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4012-0XX

Middle Frame Removal
1. 2. 3. 4. 5. 6. 7. Remove the covers. Remove the print cartridge. Remove the subframe. Remove the ASF. Disconnect the printhead cables from the printer board. Disconnect J4, J5, and J6 from the printer board. Remove the machine from the base. To do this, release the latches at the right front and right rear legs of the frame, then lift and pivot the frame 90 ° to the left. Lift the frame to disengage the left legs from the base. Remove the paper ejectors from the middle frame. Remove the left side frame. Remove the exit shaft. Remove the small feed roller shaft. Remove the large feed roller shaft and springs. Remove the end-of-forms flag. Remove the right side frame. Remove the maintenance station.

8. 9. 10. 11. 12. 13. 14. 15.

Outside Idler Gears Removal
1. Remove the right cover. 2. Disconnect the printhead cables from the printer board. 3. Each gear is latched in place. Push up the latch and remove the gear from the side frame stud by pulling the gear from the bottom.

Paper Ejectors Removal
1. Remove the covers. 2. Pivot the paper ejector pusher toward the front then pull it to remove the paper ejector from the shaft. 3. Unsnap the paper ejectors from the middle frame.

Paper Feed Motor Removal
1. Remove the right cover. 2. Disconnect the paper feed motor connector from printer board J5. 3. Remove the two mounting screws.

Repair Information 40

4012-0XX

Paper Guide Removal
Remove the covers. Remove the ASF. Remove the subframe. Disconnect the printhead cables from the printer board. Pull the ends of the printhead cables into the machine, then remove the cables from the four retainers in the paper guide starting from the right. 6. Disengage the left paper guide latch by carefully moving the rear of the left side frame to the left. 7. Disengage the right side of the paper guide from the latch and lift it from the machine. When you reinstall the paper guide, be sure the front edge goes under the rear of the carrier guide. If the paper guide is on top of the carrier guide, push down the front, bottom edge. It w