Lexmark Medley 4sx, Medley 4x, Medley 4c Service Manual

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Page 1

• Table of Contents

• Start Diagnostics

• Safety and Notices

• Trademarks

Medley

4012-0XX

• Index

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

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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; thesechangeswillbe 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 Corpora-

tion

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.

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Contents 1

Preface........................................... vi

SafetyInformation................................... vii

GeneralInformation....................................1

Options............................................2

Maintenance Approach................................2

Abbreviations.......................................3

DiagnosticInformation .................................4

SymptomTable......................................5

ServiceChecks......................................7

CommunicationsServiceCheck .....................7

EnvelopeFeedServiceCheck.......................8

FirstPrintLineServiceCheck.......................8

MaintenanceStationServiceCheck ..................9

Operator Panel Service Check......................10

PowerServiceCheck.............................11

Printer Paper Feed Service Check. ..................12

Printer Paper Path Service Check . ..................15

PrintQualityServiceCheck........................16

PrintingProblemServiceCheck.....................18

Scanner Document Feed Service Check ..............19

Scanner Service Check ...........................20

TransportServiceCheck..........................21

DiagnosticAids ......................................22

CallMonitoring.....................................22

Error Report . . . ....................................22

FrameServicePosition...............................22

HexPrintMode.....................................22

MachineCheckout..................................23

MemoryTest.......................................23

Operator Panel Service Position........................23

Operator Panel Test .................................24

ResetButton.......................................24

PrintEngineTest...................................24

PurgeTest........................................25

ScannerFeedTest..................................25

SettingtheMachineSerialNumber.....................26

TestPrint .........................................26

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RepairInformation.....................................27

Handling ESD-Sensitive Parts ......................... 28

Adjustments....................................... 29

Bidirectional Alignment Adjustment. . ................ 29

RemovalProcedures................................ 30

Auto Sheet Feed (ASF) Assembly Removal ........... 30

ASFEnvelopeBucklerandPickRollerHubRemoval.... 31

ASF Right and Left Edge Guide Assemblies Removal . . . 31

BatteryOption.................................. 31

CarrierGuideRodRemoval....................... 31

CarrierRemoval ................................ 32

CarrierTransportBeltRemoval..................... 32

CarrierTransportMotorRemoval................... 33

CarrierTransportMotorFrameRemoval ............. 33

CoversRemoval................................ 34

FrontCover .................................34

RearCover..................................34

TopCover ..................................34

RightSideCover .............................34

LeftSideCover ..............................34

Operator Panel and Cover ......................34

EncoderStripRemoval........................... 35

End-of-FormsFlagRemoval....................... 35

ExitRollerAssemblyRemoval ..................... 35

EPROMRemoval............................... 36

FaxBoard,PrinterBoard,andLCUBoardRemoval..... 37

FeedArmAssemblyRemoval...................... 37

InsideIdlerGearsRemoval........................ 37

LargeFeedRollerAssemblyRemoval............... 38

LeftSideFrameRemoval......................... 38

Maintenance Drive and Rocker Assemblies Removal.... 39

MemoryOption................................. 39

MiddleFrameRemoval........................... 40

OutsideIdlerGearsRemoval...................... 40

Paper Ejectors Removal . ......................... 40

Paper Feed Motor Removal ....................... 40

Paper Guide Removal. . . ......................... 41

Paper Release Lever Removal ..................... 41

Power Supply Removal. . ......................... 42

PrintEngineRemoval............................ 42

Printhead Cable Removal ......................... 43

ReleasingPlasticLatches......................... 44

RightSideFrameRemoval........................ 45

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Repair Information, Removal Procedures (continued)

Rubber Backer Removal ..........................47

SmallFeedRollerAssemblyRemoval................47

StarRollerRemoval..............................47

Scanner and Speaker Removal . . . ..................48

SubframeRemoval...............................48

PartsandTestPointLocations..........................49

LCUBoard.....................................49

FaxBoard......................................50

PrinterBoard...................................52

Preventive Maintenance ...............................54

Lubrication Specifications..........................54

Scanner Cleaning Procedure.......................55

PartsCatalog ........................................56

HowToUseThisPartsCatalog.....................56

Assembly1:Covers ..........................57

Assembly2:Frame...........................59

Assembly3:OperatorPanel....................61

Assembly 4: Printer Paper Feed Assembly ........63

Assembly 4: Printer Paper Feed Assembly (cont.) . . . 65

Assembly5:Carrier ..........................67

Assembly6:CarrierTransport ..................69

Assembly 7: Maintenance Station ...............71

Assembly 8: Scanner .........................73

Assembly9:Electronics .......................75

Assembly 10: Automatic Sheet Feed (ASF) ........77

Assembly11:Options.........................79

Index ...............................................80

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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.

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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.

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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.

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Chinese Safety Information

Korean Safety Information

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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 tele-

phone connections

• Operator Panel Board

General Information 1

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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

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Abbreviations

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

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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

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Symptom Table

Symptom Action

Printer Code 1,4 Replace the printer board EPROM;

Printer Code 1,6 Go to “Transport Service Check” on page

Printer Code 1,8 Replace the printer board EPROM;

Printer Code 1,10 Go to “Maintenance Station Service

Printer Code 1,12 Replace the printer board EPROM;

Printer Code 1,14 Go to “Maintenance Station Service

Printer Code 3,4 Go to “Transport Service Check” on page

Printer Code 3,8 Go to “Transport Service Check” on page

Printer Code 9,2 Replace the printer board EPROM;

Printer Code 9,4 Go to “Transport Service Check” on page

Power Problem No LEDs or LCD pixels light up during POR, no machine activity:

if necessary replace the printer board.

21.

if necessary replace the printer board.

Check” on page 9.

if necessary replace the printer board.

Check” on page 9.

21.

if necessary replace the printer board.

21.

Go to “Power Service Check” on page 11.

Maintenance Station Problem Maintenance station does not move,orfailstocleanorcap 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:

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.

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Symptom Action

Printer paper feed, misfeed, or jam problem Paper fails to stop at first print line:

Go to “First Print Line Service Check” on

page 8.

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 butoutputhasvoidsor uneven density or is fuzzy, smudged, or faint.

Scanning Problem No scanned image or incorrect scanned image:

Communications Problem Cannot send fax,cannotreceive fax, or cannot connect with remote machine:

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

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Service Checks

Communications Service Check

FRU Action

1 Fax or LCU Card

Cannot make telephone connection to other fax machine.

2 Cannot receive faxes. Machine not set for auto-answer.

No dialtone Verifycorrect dialing method (tone or pulse). TEL and LINE connections reversed. Verifyphone 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.

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.

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Envelope Feed Service Check

FRU Action

1 Envelope Loading 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 Action

1 Printer End-of-Forms Flag Check the flag for binds or damage. 2 Printer End-of-Forms Sensor Check the sensor for dirt. 3 Printer Board Check the End-of-Forms sensor, measure

4 Feed Arm Assembly Check all parts of the feed arm assembly for

5 Software Setting Use Toolkit, one of the setup programs

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.

binds, wear, or damage.

installed on the PC, to adjust the TopofForm setting.

6 Operator Panel Go to “Operator Panel Service Check” on

page 10.

Diagnostic Information 8

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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 Action

1 Maintenance Drive Assembly Warning: Disconnecting the maintenance

2 Printer Board Turn the machine off and disconnect J4 from

3 Maintenance Rocker Asm Check for binds or wear. 4 Wiper A worn wiper causes degraded print quality

5 Cap A worn cap causes the printhead nozzles to

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.

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.

just after a maintenance cleaning. Check for loose or worn wiper.

dry and clog. Check for loose or worn cap.

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

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Operator Panel Service Check

FRU Action

1 PowerSupply Disconnect J2 from the fax board and

2 Operator Panel Board

Operator Panel Cable

3 Fax Board Turn the printer on. Check for +5 V dc at

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.

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.

J4-3 on the fax board.

Diagnostic Information 10

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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 Action

1 PowerSupply Disconnect J2 from the fax board, J11

2 Printhead Cable

Parallel Cable

3 Printer Board Disconnect the fax board from the printer

4 Fax Board Check for +5 V dc at the fax board J9-4,

from the printer board and check the following voltages on both power supply cables:

Pin-1toGND=+5Vdc 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.

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.

board. Run the Print Engine Test. If the test does not run and there are no mechanical problems, replace the printer board.

and check for +34 V dc at J9-2. If the voltages are incorrect replace the fax board.

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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 Action

1 Printer Board 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

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FRU Action

2 Paper Feed Motor 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:

Pin1toPin4 Pin2toPin4 Pin3toPin5 Pin3toPin6.

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 forbinds 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.

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FRU Action

4 Feed Arm Assembly At the beginning of the paper feed opera-

5 Auto Sheet Feed (ASF) Check the following for wear or damage:

6 End-of-Forms Flag Check for binds or damage. 7 Star Rollers Check for worn or binding rollers. Check

8 Ejectors After the paper exits from the exit rollers,

tion, 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.

• Pick Rollers

• Envelope Bucklers

• All parts inside the left and right edge guides.

for broken star roller springs.

the paper feed motor reversescausing 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

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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 posi-

tioned against the paper without binding or buckling the paper.

• Be sure the correct type of paper is in the m achine.

• Be sure the rear of the carrier guide is on top of the paper guide.

FRU Action

1 Large and Small Feed Rollers Check for wear and binds. 2 Large Feed Roller Springs Check for damage. 3 Auto Sheet Feed (ASF) Check for equal pressure between the left

4 End-of-Forms Flag Check for binds or damage. 5 Exit Roller Check for wear or binds. 6 Star Rollers Checkfor wear or binds. Check for broken

7 Ejectors Check the front cover; if it is installed

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.

star roller springs.

incorrectly it can interfere with the ejectors. Make sure the front bottom cover is installed correctly.Ifthe 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 reversescausing 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 Action

1 Print Cartridge Be sure the machine has a known good

2 Printhead Carrier Assembly Reseat the printhead cables in the printer

3 Printer Board

Printhead Cable

Rubber Backer

print cartridge.

board and check the following parts for wear or damage:

• Print Cartridge Latch

• Latch Spring

•Carrier Performthe“PurgeTest” 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 evenbreaks 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:

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. Youmay 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.

4 Maintenance Station Intermittent nozzle failures can be caused

by worn parts in the maintenance station. Go to and perform the “Maintenance Sta-

tion Service Check” on page 9, then return

to this check.

Diagnostic Information 16

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FRU Action

5 Paper Feed Ink smudging and smearing can be

6 Transport Blurred print and voids can be caused by

7 Bidirectional Alignment Uneven vertical lines can be adjusted by

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.

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.

performing the “Bidirectional Alignment

Adjustment” on page 29.

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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 Action

1 Machine does not start the test: Make sure all the pins of connector J7 are

2 The machine responds butdoes

not complete the test:

3 The tests prints correctly: There is a problem with the print job, t he

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.

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.

Diagnostic Information 18

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Scanner Document Feed Service Check

Before beginning ser vice, 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 entr y 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 Action

1 Feed Rollers & Restraint Pad Check for dirty, worn, or damaged rollers.

2 Paper Sensors The operator panel message should

3 Motor Fax board J3-5 and J3-6 should have

4 Gear Train Inspect the gear teeth for damage. Rotate

5 Fax Board or Connections Check scanner motor (J3) and paper sen-

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 Proce-

dure” on page 55.

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.

+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.

the gear train to check for binds.

sor (J6) cable connections to fax board.

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Scanner Service Check

FRU Action

1 LED Array A failed LED array results in either black or

2 Scanner and Fax Board If there is no image (all white image),

3 PC Scanner Software If the machine sends faxes properly but

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.

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 probablyOK.If replacing the CCD unit does not correct the problem, reinstall the old CCD unit and replace the fax board.

does not create a scanned image file on the PC, there is a problem with the PC scanner software installation or configuration.

Diagnostic Information 20

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Transport Service Check

FRU Action

1 Transport Motor Check the motor for binds, or loose motor

2 Printer Board Unplug the machine and disconnect J6

3 Transport Belt

Carrier Guide or Guide Rod Idler Pulley Parts Cable Clip

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.

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. 4 Encoder Strip Check for wear and dirt. 5 Printhead Cables Be sure the printer board connectors J1

6 Maintenance Station A problem with the maintenance station

and J2 are fully seated. Check the cables

for damage.

can cause carrier movement problems at

the right margin:

Go to the “Maintenance Station Service

Check” on page 9.

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Diagnostic Aids 3

Call Monitoring

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 faxboards. 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

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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 memor y 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. Press Setup.

2. Press 2104 to enter the Service Functions menu.

3. Press the right arrow key to select Testing, then press OK.

4. Select MEM.

5. 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.

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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. Followthe instructions on the display to press and test each button.

6. Press Stop at any time to end the test. Press Stop s everal 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 pr inter board and inkjet printer engine independent of the other machine subsystems. T his 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

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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. Press Setup.

2. Select PRT.

3. Select PUR.

4. 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. Press Setup.

2. Press 2104 to activate the Service Functions menu.

3. Use the right arrow to select Testing and press OK.

4. Select ADF.

5. Insert one or more sheets into the scanner ADF and follow the panel instructions.

6. Press Stop several times to exit the service menus.

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Setting the Machine Serial Number

When the fax board is replaced, the machine serial number needs to be saved into memory.

1. Press Setup.

2. Press 2104 to activate the Service Functions menu.

3. Press OK to enter the Service Setup menu.

4. Select SRN.

5. 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.

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 areperformingcorrectly.

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 pr ints 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

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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

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Handling ESD-Sensitive Parts

Many electronic products use par ts 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 ri sk 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 cab-

inet (case).

• Be extra careful in working with ESD-sensitive parts when cold-

weather heating is used because low humidity increases static electricity.

Repair Information 28

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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.

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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. Remove the paper load lever.

2. Remove the left and right side covers.

3. Remove the clip from the right side subframe, if installed.

4. Remove the top cover.

5. Release the latches holding the subframe to the ASF.

6. 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.

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

Repair Information 30

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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.

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Carrier Removal

1. Open the top cover.

2. Remove the right side cover

3. Remove the print cartridge.

4. Disconnect the printhead cables from the printer board.

5. Cut the cable tie and remove the toroid.

6. 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.

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

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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. Remove the top cover and then the left and right side covers.

2. Remove the rear and front covers.

3. Disconnect J6 from the printer board.

4. Disconnect the four scanner connectors and the speaker connector from the fax board.

5. Remove the scanner and subframe.

6. 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. Remove the carrier guide rod through the opening in the left side frame. Be careful not to damage the encoder strip.

9. 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.

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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 l ower 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 l ower 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

1. Open the operator panel cover and the top cover.

2. Remove the screw from inside the subframe just above scanner.

3. Lift the top inner edge of cover to free the top latches.

4. Rotate the cover to the left to free the lower latches.

5. If the battery option is installed, disconnect its cable from the fax board (J9).

Operator Panel and Cover

1. Remove the left and right side covers.

2. Flex the subframe to free one of the pivot pins.

3. Remove the two screws and the ESD shield.

4. Disconnect the operator panel cable from the back of the operator panel.

5. Unsnap the operator panel from the cover.

Repair Information 34

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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

1. Remove the covers.

2. Disconnect the printer board connectors: J1, J2, J4, J5, and J6.

3. Disconnect the fax board connectors: J3 and J8.

4. Raise the machine frame into the service position.

5. 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.

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. Removethe bushing from the left end of the exit shaft. Todo this, pull the tab and rotate the bushing.

5. Slide the exit roller to the left and lift it out of the machine.

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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

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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 l eft 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 thefeedarmassembly.

Inside Idler Gears Removal

1. Remove the covers.

2. Remove the ASF.

3. Disconnect the printhead cables from the printer board.

4. Remove the paper guide.

5. Remove the C-clip from the feed ar m assembly and remove the feed arm assembly.

6. Pull the idler gears off the mounting studs.

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Large Feed Roller Assembly Removal

1. Remove the top cover.

2. Disconnect the printhead cables from the system board.

3. Disconnect connectors J4, J5, and J6 from the system board.

4. Disconnect scanner motor connector J3 from the fax board.

5. 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. Remove the covers.

2. Remove the print cartridge.

3. Remove the subframe.

4. Remove the ASF.

5. Disconnect the printhead cables from the printer board.

6. Disconnect connectors J4, J5, and J6 from the printer board.

7. 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.

8. Move the carrier in line with the opening in the carrier transport motor frame.

9. Reach through the opening and pull the belt from the carrier.

10. 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.

11. 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.

12. Disengage the left paper guide latch by carefully moving the rear of the left side frame to the left.

13. Disengage the right side of the paper guide from the latch and lift it from the machine.

Repair Information 38

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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. Remove the covers.

2. Remove the ASF.

3. Remove the right side frame.

4. Gently unlatch the maintenance assembly latches.

5. 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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Middle Frame Removal

1. Remove the covers.

2. Remove the print cartridge.

3. Remove the subframe.

4. Remove the ASF.

5. Disconnect the printhead cables from the printer board.

6. Disconnect J4, J5, and J6 from the printer board.

7. 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.

8. Remove the paper ejectors from the middle frame.

9. Remove the left side frame.

10. Remove the exit shaft.

11. Remove the small feed roller shaft.

12. Remove the large feed roller shaft and springs.

13. Remove the end-of-forms flag.

14. Remove the right side frame.

15. Remove the maintenance station.

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

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Paper Guide Removal

1. Remove the covers.

2. Remove the ASF.

3. Remove the subframe.

4. Disconnect the printhead cables from the printer board.

5. 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.

Paper Release Lever Removal

1. Remove the left cover.

2. Pull the paper release lever forward.

3. Place a screwdriver into the slot [A] of the paper release lever. Push the screwdriver down to release the latch, then remove the lever.

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Power Supply 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.

3. Remove the front and rear covers.

4. Disconnect the scanner motor cable from J3 on the right side of the fax board.

5. Disconnect the five cables connecting the printer board to the print engine (J1, J2, J4, J5, J6).

6. Unsnap the two print engine feet at the right side of the machine.

7. 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.

8. Disconnect the power leads from the fax board (J2) and the printer board (J11).

9. Remove the ground screw holding the power supply to the bottom shield.

Note: Make sure the ground screw is secure when reinstalling the power supply.

10. Unsnap the front latch and lift the power supply from the machine. Make sure the power supply insulator remains in place when reinstalling the power supply.

Print Engine 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.

3. Remove the front and rear covers.

4. Disconnect the six cables connecting the fax board to the print engine (J3, J4, J5, J6, J7, J8); cut the cable tie on the scanner cable.

5. Disconnect the five cables connecting the printer board to the print engine (J1, J2, J4, J5, J6).

6. Unsnap the two print engine feet at the right side of the machine.

7. 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.

8. Lift the print engine to free the left pivot feet from the bottom cover.

Repair Information 42

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4012-0XX

Printhead Cable Removal

1. Unplug the machine before beginning any electrical service. The power key does not remove power from the electronics.

2. Open the top cover.

3. Remove the print cartridge.

4. Remove the carrier.

5. Remove the cable clip [A] from the left side of the carrier.

6. Remove the pointer from the front of the carrier.

7. Remove the two sensor mounting screws.

8. Push down the two latches that secure the cradle to the carrier and pull the cradle up from the carrier.

9. Remove the printhead cable from the alignment pins.

The new cable comes without the folds in it. Place the new cable next to the old cable and fold the new cable in the appropriate places.

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Releasing Plastic Latches

Many of the parts are held in place with plastic latches. To remove such parts, press the hook end of the latch away from the par t to which it is latched. The latches break easily. Release them carefully.

Never apply excessive force

Hook

when releasing the hook.

Repair Information 44

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Right Side Frame Removal

1. Remove the covers.

2. Remove the print cartridge.

3. Remove the subframe.

4. Remove the ASF.

5. Disconnect the printhead cables from the printer board.

6. Disconnect connectors J4, J5, and J6 from the system board.

7. 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.

8. Move the carrier in line with the opening in the carrier transport motor frame.

9. Reach through the opening and pull the belt from the carrier.

10. To unlock the carrier guide rod latches, rotate the rod top-to-rear. Gently push the carrier rod guide 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 rod guide through the opening in the left side frame. Be careful not to damage the encoder strip.

11. 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.

12. Disengage the left paper guide latch by carefully moving the rear of the left side frame to the left.

13. Disengage the right side of the paper guide from the latch and lift the guide from the machine.

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15. Place the machine on its back, then unlatch the right frame latch from the middle frame and remove the side frame.

Note: For reassembly you may want to remove the carrier guide and reinstall it after you install the paper guide.

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 will snap under the carrier guide.

To install the right side frame onto the middle frame, align the right side frame latch with the latching surface on the mid frame before you align the roller shafts and carrier guide. It may be easier to do this with the machine on its left side.

Repair Information 46

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Rubber Backer Removal

1. Open the top cover.

2. Remove the print cartridge.

3. Remove the printhead cable.

4. Remove the rubber backer from the carrier.

Small Feed Roller Assembly Removal

1. Remove the covers.

2. Remove the ASF.

3. Remove the paper guide.

4. Carefully remove the paper release lever.

5. Remove the bushing from the left end of the small feed roller shaft. To do this, pull the tab and rotate the bushing.

6. Slide the small feed roller assembly to the left and lift it out of the machine.

Star Roller Removal

1. Remove the covers.

2. Remove the subframe.

3. Move the carrier in line with the opening on the carrier transport motor frame.

4. Reach through the opening and pull the belt from the carrier.

5. 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.

6. 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. Place the carrier transport motor frame face down in front of the machine.

7. Removethe star roller by pushing it forward off the mounting peg in the carrier transport motor frame.

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Scanner and Speaker 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.

3. Remove the front cover.

4. Disconnect the scanner motor cable from J3 on the right side of the fax board.

5. Disconnect the scanner paper sensor and LED/microswitch cables from J6 and J7 on the left side of the fax board.

6. Cut the tie wrap and disconnect the scanner data cable J8 from the left side of the fax board.

7. Unsnap the large tab holding the left end of the scanner to the subframe.

8. Lift the scanner from the machine.

9. Disconnect the speaker from the fax board J5.

10. Slide the speaker toward the front to remove it.

Subframe Removal

1. Remove the left and right side covers.

2. Remove the rear cover.

3. Remove the top cover, the operator panel cover, and the front cover.

4. Disconnect the four scanner cables (J3, J6, J7, J8) and the speaker cable (J5) from the fax board.

5. Cut the cable tie.

6. Remove the clip from the right side.

7. Spread the tabs at the sides of the sheet feed to free the pins. Warning: To avoid damage to the encoder strip, make sure the

carrier transport motor frame does not come unsnapped during the next step.

8. Lift the tabs, rotating the subframe toward you to release the subframe where it is snapped to the printer frame.

Repair Information 48

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Parts and Test Point Locations 9

LCU Board

TJ2TJ1

LCU Board

Connector Name

J1 Handset J2 Phone Data to Fax Board J3 Parallel Port J4 Parallel Data to Fax Board TJ1 Phone Line In TJ2 External Phone

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Fax Board

J12

J11

J10

Parts and Test Point Locations 50

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Fax Board

Connector Name

J1 Printer Board J2 PowerSupply J3 Scanner Motor J4 Operator Panel J5 Speaker J6 Scanner Paper Sensors J7 LED Array & Scanner Closed

Switch J8 Scanner Data J9 Battery Backup Option J10 Memory Option J11 Phone Data from LCU Board J12 Parallel Data from LCU Board

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Printer Board

J11

EPROM

Printer Board

Connector Name

J1 Printhead J2 Printhead J3 Not Used J4 Maintenance Motor J5 Paper Feed Motor

Parts and Test Point Locations 52

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Printer Board

Connector Name

J6 Carrier Motor J7 POR Test Jumper J8 Not Used J9/J9A Fax Board J10 Not Used J11 Power Supply

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Preventive Maintenance 10

Following these recommendations can help prevent problems and maintain optimum performance.

Lubrication Specifications

Lubricate only when parts are replaced or as needed, not on a scheduled basis.

Warning: Petroleum-basedgreases can attack polycarbonate parts causing premature failure. Use only mineral oil-based grease.

Use a mineral oil-based grease to lubricate the following:

• All gear mounting studs

• Right end of the exit roller at the right side frame

• Right end of the small feed roller at the right side frame

• Left end of the large feed roller at the left side frame

• Both ends of the ASF pick roll shaft at the ASF side frames

• Transport belt idler pulley hole

• Inside surface of the transport idler pulley tension wedge where it

touches the left side frame.

Do not lubricate the carrier guide rod or carrier guide rod bearings.

Preventive Maintenance 54

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Scanner Cleaning Procedure

The scanner restraint pad and paper feed rollers should be cleaned when necessary to avoid feed problems.

1. Clean the pad with isopropyl alcohol, wiping downward in the paper movement direction.

2. Clean the three paper feed rollers using isopropyl alcohol. Turn the gear train with your thumb to clean the entire surface of

the rollers.

3. Wipe paper dust, ink, or foreign material off the scanner white reference strip inside the front frame with a clean cloth. If necessary, use isopropyl alcohol.

The scanner lenses and mirrors do not normally require cleaning; the microcode compensates for dust on the optical surfaces. If, however, these surfaces become unusually dirty or the scanned image becomes fuzzy, remove the scanner and clean the mirrors and lenses with isopropyl alcohol.

Caution: Do not hold the scanner by the mirrors or supports. If the supports are bent it can change alignment in the scanner. Hold the scanner by the plastic.

Note: Do not disassemble any optical components of the scan-

ner.

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Parts Catalog 4

How To Use This Parts Catalog

• SIMILAR ASSEMBLIES: If two assemblies contain a majority of

identical parts, they are broken down on the same list. Common parts are shown by one index number. Parts peculiar to one or the other of the assemblies are listed separately and identified by description.

• AR: (As Required) in the Units column indicates that the quantity

is not the same for all machines.

• NS: (Not Shown) in the Asm-Index column indicates that the part

is procurable but is not pictured in the illustration.

• PP: Parts Packet

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Assembly 1: Covers

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Description 4012-005 P/N

1 Top Cover Asm w/guides 69G6828 69G6828 2 FrontCover 69G6875 69G6875 3 Rear Cover 69G6874 69G6874 4 Right Side Cover 69G6869 69G6869 NS Screw, Right Side Cover

PP 69G6846 5 Memory/Battery Access Door 69G6899 69G6899 6 PaperLoad Lever 69G6888 69G6888 7 Left Side Cover 69G6870 69G6893 NS Screw, Left Side Cover

PP 69G6846 8 Bezel, front 69G6861 69G6861 9 Handset w/Cable N/A 69G6822 10 Cradle, Handset N/A 69G6894 NS Screw, Cradle Mounting

PP 69G6846 11 Left output Guide 1367493 1367493 15 Extender, Input Tray, Printer 69G6890 69G6890 19 Panel, Scan Input Tray 69G6889 69G6889 20 Tray, Scan Input 69G6891 69G6891 21 Extender, Scan Input Tray 69G6871 69G6871 22 Tray, Scanner Output 69G6830 69G6830

4012-006 4012-009 P/N

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Assembly 2: Frame

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Description 4012-005 P/N

1 Base Asm 69G6900 69G6900 2 Left Side Frame 1367209 1367209 3 MIddle Frame Asm 1367219 1367219 4 Right Side Frame 1367229 1367229 5 Carrier Transport Motor Frame 1367309 1367309 6 Exit Tray Asm 69G6824 69G6824 7 Carrier Guide 1367079 1367079 8 Foot 69G6860 69G6860 9 Leg, left Rear 69G6882 69G6882 10 Leg, left Front 69G6883 69G6883

4012-006 4012-009 P/N

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Assembly 3: Operator Panel

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Description 4012-005 P/N

1 Operator Panel Cover 69G6901 69G6902 1 Operator Panel Cover 4012-009 69G6905 2 Overlay, Operator Panel 69G6885 69G6886 3 Overlay, Sm Operator Panel 69G6897 69G6898 NS Shield, Reset Button

4 Keypad, Left 69G6896 69G6896 5 Keypad, Center 69G6895 69G6895 6 Keypad, Right 69G6884 69G6884 7 Operator Panel Board 69G6806 69G6806 8 Lens, Display 69G6831 69G6831 9 Door,Button 69G6887 69G6887 10 Shield, Directory

NS Cable, Operator Panel Cable

11 Shield, EMC 69G6903 69G6903

PP 69G6846

69G6878 69G6878

to Fax Board

4012-006 4012-009 P/N

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Assembly 4: Printer Paper Feed Assembly

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Description 4012-005 P/N

1 Paper Release Lever 1367179 1367179 2 Bushing, PP 1367169 3 Paper Guide 1367339 1367339 4 Small Feed Roller Asm 1367279 1367279 5 Exit Roller Asm 1367289 1367289 6 Ejector B/M 1367266 1367266 7 Spring, PP 1367169 8 End-of-Form Flag 1367049 1367049 9 Large Feed Roller Asm 1367269 1367269

4012-006 4012-009 P/N

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Assembly 4: Printer Paper Feed Assembly (cont.)

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Description 4012-005 P/N

10 Paper Feed Motor 1367239 1367239 NS Toroid, Paper Feed Motor 1374338 1374338 11 Gears B/M 1367249 1367249 12 Feed Arm Asm 1367259 1367259 13 C-Clip, PP 1367169 14 Screw,PP 1367169

4012-006 4012-009 P/N

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Assembly 5: Carrier

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Description 4012-005 P/N

1 Carrier Asm 1367299 1367299 2 Printhead Cable 1367149 1367149 NS Toroid, Printhead Cable 1374338 1374338 3 Screw, PP 1367169 4 Rubber Backer 1367109 1367109 5 Carrier Guide Rod 1367089 1367089 6 Clip, PP 1367169

4012-006 4012-009 P/N

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Assembly 6: Carrier Transport

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Description 4012-005 P/N

1 Carrier Motor 1367319 1367319 2 Screw, PP 1367169 3 Carrier Belt 1367359 1367359 4 Encoder Strip 1367379 1367379 5 Star Roller Asm 1425705 1425705 6 Spring PP 1367169 7 Idler Pulley B/M 1367329 1367329

4012-006 4012-009 P/N

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Assembly 7: Maintenance Station

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Description 4012-005 P/N

1 Maintenance Station

Rocker Asm 2 Maintenance Station Drive Asm 1367399 1367399 3 Wiper & Cap B/M 1367389 1367389 4 Screw PP 1367169

1425669 1425669

4012-006 4012-009 P/N

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Assembly 8: Scanner

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Description 4012-005 P/N

1 Scanner,Complete 69G6836 69G6836 2 CCD Asm. 69G6857 69G6857 3 FrontFrame Asm 69G6843 69G6843 4 Feed Roller Kit 69G6840 69G6840 5 Gear Kit (3 Gears) 69G6844 69G6844 6 PadUnit 69G6845 69G6845 7 LED/FrameSwitch Asm. 69G6841 69G6841 8 Motor Assembly 69G6842 69G6842 9 L/P Sensor 69G6839 69G6839 NS Screws, PP 69G6846 10 Paper Path Cover 69G6855 69G6855 12 Subframe, Scanner 69G6833 69G6833 13 Cap & Bracket Asm 69G6835 69G6835 14 Speaker 69G6838 69G6838 NS Jumper, Front Frame ESD Gnd. 69G6862 69G6862 NS Shield, Scanner 69G6863 69G6863

4012-006 4012-009 P/N

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Assembly 9: Electronics

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Description 4012-005 P/N

1 Power Supply 69G6805 69G6805 2 PS Insulator 69G6879 69G6879 NS Screw, PS Mounting 1624852 1624852 4 FaxCard, W/O EPROM 69G6800 69G6800 5 EPROM, Fax Card 69G6810 69G6810 6 Printer Card, W/O EPROM 69G6802 69G6802 7 EPROM, Printer Card 1375418 1375418 8 LCU Card w/Bezel 69G6808 69G6801 9 Shield, LCU Card 69G6880 69G6880 10 Shield, Printer 69G6881 69G6881 11 Shield Asm, Bottom 69G6837 69G6837 14 Line Cord, U.S. 69G6868 69G6868 15 Cable, Telephone 69G6892 69G6892 NS Toroid, Printer/Fax Cable 69G6906 69G6906 16 Cable, Printer to Fax 69G6872 69G6872 17 Cable, Scanner to Fax 69G6873 69G6873 18 Cable, Fax to LCU Digital 69G6876 69G6876 19 Cable, Fax to LCU Analog 69G6877 69G6877 NS Jumper, Fax Card J9

PP 69G6846

4012-006 4012-009 P/N

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Assembly 10: Automatic Sheet Feed (ASF)

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Description 4012-005 P/N

1 R. Edge Guide & Strip 1425574 1425574 2 L. Edge Guide Asm 1425578 1425578 3 Pick Roll & Paper Load B/M 1367469 1367469 4 Pick Roll Hub Asm 1367463 1367463 5 Paper Load Arm 1425580 1425580 6 Envelope Buckler B/M 1367019 1367019 7 Side & Back Plate B/M 1425582 1425582 8 Gears, B/M 1367249 1367249 9 E-Ring, PP 1367169 10 Screw,PP 1367169 11 Manual Insert Tray, Printer 1425585 1425585

4012-006 4012-009P/N

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Assembly 11: Options

Description 4012-005 P/N

1 Memory Option, 1MB

(2 modules)

2 Memory Option, 3MB

(6 modules) 3 Battery Option 69G6807 69G6807 NS Screw, Battery

Mounting

PP 69G6846 4 Demo code ROM,

4012-011,4012-012

69G6803 69G6803

69G6804 69G6804

69G6811 69G6811

4012-006 4012-009 P/N

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Index

Abbreviations 3 Adjustments 29 ASF Envelope Buckler And Pick

Roller Hub Removal 31

ASF Right And Left Edge Guide

Assemblies Removal 31

Auto Sheet Feed Removal 30

Battery Option 31 Bidirectional Alignment

Adjustment 29

Call Monitoring 22 Carrier Belt Removal 32 Carrier Guide Removal 31 Carrier Removal 32 Carrier Transport Motor Frame

Removal 33

Carrier Transport Motor

Removal 33 CCD 20 CommunicationsServiceCheck

Covers Removal 34

Diagnostic Aids 22 Diagnostic Information 4

Encoder Strip Removal 35 End-of-Forms Flag Removal 35 Envelope Feed Service Check

EPROM Removal 36 Error Report 22 Exit Roller Assembly Removal

Fax Board, Printer Board, and

LCU Board 37

Feed Arm Assembly Removal

First Print Line Service Check 8 Frame Service Position 22

General Information 1

Handling ESD-Sensitive Parts

Hex Print Mode 22 How To Use This Parts Catalog

Inside Idler Gears Removal 37

Large Feed Roller Assembly

Removal 38 Left Side Frame Removal 38 Lubrication Specifications 54

Machine Checkout 23 Maintenance Approach 2 Maintenance Drive And Rocker

Assemblies Removal 39 Maintenance Station Service

Check 9 Memory Option 39 Memory Test 23

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Middle Frame Removal 40

Operator Panel Service Check

OperatorPanelServicePosition

Operator Panel Test 24 Options 2 Outside Idler Gears Removal

Paper Ejectors Removal 40 Paper Feed Motor Removal 40 Paper Feed Service Check 12 Paper Guide Removal 41 Paper Path Service Check 15 Paper Release Lever Removal

Parts and Test Point Locations

Parts Catalog 56 Power Service Check 11 Power Supply Removal 42 Preventive Maintenance 29, 54 Print Engine Removal 42 Print Engine Test 24 Print Quality Service Check 16 Printer Paper Feed Service

Check 12 Printer Paper Path Service

Check 15 Printhead Cable Removal 43 PrintingProblemServiceCheck

Purge Test 25

Reset Button 24 Right Side Frame Removal 45 Rubber Backer Removal 47

Safety Information vii ScannerAnd Speaker Removal

Scanner Cleaning Procedure

Scanner Document Feed

Service Check 19 Scanner Feed Test 25 Scanner Service Check 20 Service Checks 7 Setting the Machine Serial

Number 26 Small Feed Roller Assembly

Removal 47 Star Roller Removal 47 Subframe Removal 48 Symptom Table 5

Test Print 26 Transport Service Check 21

Releasing Plastic Latches 44 Removal Procedures 30 Repair Information 27

Lexmark Medley 4sx, Medley 4x, Medley 4c Service Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

General Information 1

Options

Maintenance Approach

Abbreviations

Diagnostic Information 4

Symptom Table

Service Checks

Communications Service Check

Envelope Feed Service Check

First Print Line Service Check

Maintenance Station Service Check

Operator Panel Service Check

Power Service Check

Printer Paper Feed Service Check

Printer Paper Path Service Check

Print Quality Service Check

Printing Problem Service Check

Scanner Document Feed Service Check

Scanner Service Check

Transport Service Check

Call Monitoring

Error Report

Frame Service Position

Hex Print Mode

Diagnostic Aids 22

Machine Checkout

Memory Test

Operator Panel Service Position

Operator Panel Test

Reset Button

Print Engine Test

Purge Test

Scanner Feed Test

Setting the Machine Serial Number

Test Print

Repair Information 27

Handling ESD-Sensitive Parts

Adjustments

Bidirectional Alignment Adjustment

Removal Procedures

Auto Sheet Feed (ASF) Assembly Removal

ASF Envelope Buckler and Pick Roller Hub Removal

ASF Right and Left Edge Guide Assemblies Removal

Battery Option

Carrier Guide Rod Removal

Carrier Removal

Carrier Transport Belt Removal

Carrier Transport Motor Removal

Carrier Transport Motor Frame Removal

Covers Removal

Encoder Strip Removal

End-of-Forms Flag Removal

Exit Roller Assembly Removal

EPROM Removal

Fax Board, Printer Board, and LCU Board Removal

Feed Arm Assembly Removal

Inside Idler Gears Removal

Large Feed Roller Assembly Removal

Left Side Frame Removal

Maintenance Drive and Rocker Assemblies Removal

Memory Option

Middle Frame Removal

Outside Idler Gears Removal

Paper Ejectors Removal

Paper Feed Motor Removal

Paper Guide Removal

Paper Release Lever Removal

Power Supply Removal

Print Engine Removal

Printhead Cable Removal

Releasing Plastic Latches

Right Side Frame Removal

Rubber Backer Removal

Small Feed Roller Assembly Removal

Star Roller Removal

Scanner and Speaker Removal