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

• 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.

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.

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 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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