Lexmark Medley Service Repair Manual

4012-0XX Medley TM Lexmark and Medley are trademarks of Lexmark International, Inc., registered in the United States and/or other countries. • Table of Contents • Safety and Notices • Trademarks • Index • Start Diagnostics

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 INTERNA- TIONAL, INC. PROVIDES THIS PUBLICATION “AS IS” WITHOUT WAR- RANTY 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 dis- claimer of express or implied warranties in certain transactions, therefore, this statement may not apply to you. This publication could include technical inaccuracies or typographical errors. Changes are periodically made to the information herein; these changes will be incorporated in later editions of the publication. Improvements or changes in the products or the programs described in this publication may be made at any time. Publications are not stocked at the address given below; requests for publications should be made to your point of purchase. Comments may be addressed to Lexmark International, Inc., Department D22A/035-3, 740 New Circle Road, Lexington, Kentucky 40550, U.S.A. Lex- mark 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 © Copyright Lexmark International, Inc. 1995. All Rights Reserved. UNITED STATES GOVERNMENT RESTRICTED RIGHTS This software and documentation are provided with RESTRICTED RIGHTS. Use, duplication or disclosure by the Government is subject to restrictions as set forth in subparagraph (c)(1)(ii) of the Rights in Technical Data and Computer Software clause at DFARS 252.227-7013 and in applicable FAR provisions: Lexmark International, Inc., Lexington, KY 40550. 4012-0XX

iii 4012-0XX C ontents 1 Preface ........................................... vi Safety Information................................... vii General Information .................................... 1 Options ............................................ 2 Maintenance Approach ................................ 2 Abbreviations ....................................... 3 Diagnostic Information ................................. 4 Symptom Table...................................... 5 Service Checks ...................................... 7 Communications Service Check ..................... 7 Envelope Feed Service Check ....................... 8 First Print Line Service Check ....................... 8 Maintenance Station Service Check .................. 9 Operator Panel Service Check ...................... 10 Power Service Check ............................. 11 Printer Paper Feed Service Check ................... 12 Printer Paper Path Service Check ................... 15 Print Quality Service Check ........................ 16 Printing Problem Service Check..................... 18 Scanner Document Feed Service Check .............. 19 Scanner Service Check ........................... 20 Transport Service Check .......................... 21 Call Monitoring ..................................... 22 Error Report ....................................... 22 Frame Service Position............................... 22 Hex Print Mode ..................................... 22 Machine Checkout .................................. 23 Memory Test ....................................... 23 Operator Panel Service Position........................ 23 Operator Panel Test ................................. 24 Reset Button ....................................... 24 Print Engine Test ................................... 24 Purge Test ........................................ 25 Scanner Feed Test .................................. 25 Setting the Machine Serial Number ..................... 26 Test Print ......................................... 26 Diagnostic Aids ...................................... 22

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

v 4012-0XX Repair Information, Removal Procedures (continued) Rubber Backer Removal .......................... 47 Small Feed Roller Assembly Removal ................ 47 Star Roller Removal .............................. 47 Scanner and Speaker Removal ..................... 48 Subframe Removal............................... 48 Parts and Test Point Locations .......................... 49 LCU Board ..................................... 49 Fax Board ...................................... 50 Printer Board ................................... 52 Preventive Maintenance ............................... 54 Lubrication Specifications.......................... 54 Scanner Cleaning Procedure ....................... 55 Parts Catalog ........................................ 56 How To Use This Parts Catalog ..................... 56 Assembly 1: Covers .......................... 57 Assembly 2: Frame ........................... 59 Assembly 3: Operator Panel .................... 61 Assembly 4: Printer Paper Feed Assembly ........ 63 Assembly 4: Printer Paper Feed Assembly (cont.) . . . 65 Assembly 5: Carrier .......................... 67 Assembly 6: Carrier Transport .................. 69 Assembly 7: Maintenance Station ............... 71 Assembly 8: Scanner ......................... 73 Assembly 9: Electronics ....................... 75 Assembly 10: Automatic Sheet Feed (ASF) ........ 77 Assembly 11: Options ......................... 79 Index ............................................... 80

vi 4012-0XX Preface This manual is divided into the following chapters: 1. General Information contains a general description of the printer and the maintenance approach used to repair it. Special tools and test equipment are listed in this chapter, as well as general environmental and safety instructions. 2. Diagnostic Information contains the symptom table and service checks used to isolate failing field replaceable units (FRUs). 3. Diagnostic Aids contains tests and checks used to locate or repeat symptoms of printer problems. 4. Repair Information provides instructions for making printer adjustments and removing and installing FRUs. 5. Parts and Test Point Locations uses illustrations to identify the major components and test points on the printer. 6. Preventive Maintenance contains recommendations to help prevent problems and maintain optimum performance. 7. Parts Catalog contains illustrations and part numbers for indi- vidual FRUs.

vii 4012-0XX Safety Information • The maintenance information for this product has been prepared for use by a professional service person and is not intended to be used by others. • There may be an increased risk of electric shock and personal injury during disassembly and servicing of this product. Profes- sional service personnel should understand this and take neces- sary precautions. • The safety features of some parts may not always be obvious. Therefore, replacement parts must have the identical or equiva- lent 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.

viii 4012-0XX Norme Di Sicurezza • Le informazioni riguardanti la manutenzione di questo prodotto sono indirizzate soltanto al personale dell’assistenza autorizzato. • Durante lo smontaggio e il manutenzionamento di questo prodotto, e possibile il rischio accresciuto di scosse elettriche e danni personali. Il personale di assistenza autorizzato, consapevole di cio, deve adottare le precauzioni necessarie. • E possibile che le funzioni di sicurezza di alcuni elementi non siano cosi ovvie, quindi, i pezzi di ricambio devono avere caratteristiche identiche o equivalenti a quelle dei pezzi originali. Pautas De Seguridad • La informacion sobre el mantenimiento de este producto fue escrita para el personal de mantenimiento cualificado y no para cualquier otro usuario. • Existen mayores riesgos de descargas electricas y danos personales durante el desmontaje y la reparacion de la maquina. El personal cualificado comprende esto y toma las precauciones necesarias. • Los dispositivos de seguridad de algunas partes quiza no siempre puedan ser reconocidas a simple vista. Por lo tanto, las partes de reemplazo deben poseer caracteristicas identicas o equivalentes a las partes originales. Sikkerhedsoplysninger • Oplysningerne om vedligeholdelse af dette produkt er forberedt med henblik pa professionelt servicepersonale, og bor derfor ikke benyttes af andre. • Risikoen for elektrisk stod oges under demontering og service af dette produkt, hvorfor der bor tages de nodvendige forholdsregler. • Sikkerhedsforanstaltningerne er ikke altid lige apenbare for alle reservedele. Der bor derfor kun anvendes originale reservedele eller reservedele med samme egenskaber som de oprindelige.

ix 4012-0XX Chinese Safety Information Korean Safety Information

General Information 1 4012-0XX General Information 8 This manual is used to service the Lexmark Medley 4012. Medley is a multifunction product which can connect to an IBM-compatible personal computer. It acts as an all-in-one color-capable printer, G3 fax machine, scanner, and convenience copier. It will send and receive faxes, scan documents, print from the PC, and make convenience copies. It uses 300 x 300 pels per inch inkjet technology for high quality text and graphics. Print Quality Enhancement Technology (PQET) smooths the edges of lines and characters. Medley uses the same black or color print cartridges as the IBM ExecJet II and ExecJet IIc by Lexmark. Medley uses a 300 x 300 dpi scanner for fast, high quality scanning, personal copying, and faxing. Scanning software for the PC is included with the Medley. There are three models: Medley 4c (4012-005) which does not include a handset, Medley 4x (4012-006) which does include a handset, and the Medley 4sx (4012-009) which is the same as the 4x but is shipped standard with the battery backup. Other than in the Parts Catalog, there are no service differences. All models can handle a variety of paper sizes as well as envelopes and other media using an integrated automatic sheet feed and manual feed. The machine contains the following circuit boards: • Fax Board—controls the scanner and most of the machine’s functions • Printer Board—runs the printer motors, sensors, and printhead • Line Connect Unit (LCU) Board—printer parallel port and tele- phone connections • Operator Panel Board

Lexmark Medley Service Repair Manual

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