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Medley 4012-0XX • Table of Contents • Start Diagnostics • Safety and Notices • Trademarks • Index • Main Menu Lexmark and Medley are trademarks of Lexmark International, Inc., registered in the United States and/or other countries.
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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.
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.
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.
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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.
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4012-0XX Chinese Safety Information Korean Safety Information...
4012-0XX General Information This manual is used to service the Lexmark Medley 4012. Medley is a multifunction product which can connect to an IBM-compatible per- sonal 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.
4012-0XX Options The following options are available. Contact your point of purchase for options available in your country. • 1MB Memory Expansion • 3MB Memory Expansion • Battery Backup (standard on Medley 4sx) Maintenance Approach The diagnostic information in this manual leads you to the correct field replaceable unit (FRU) or part.
4012-0XX Abbreviations Charge Coupled Device Customer Engineer Customer Setup DRAM Dynamic Random Access Memory Electrostatic Discharge Field Replaceable Unit Group 3 (Digital Facsimile Protocol) Liquid Crystal Display Line Connect Unit Light-Emitting Diode NVRAM Nonvolatile Random Access Memory Original Equipment Manufacturer Printed Circuit Assemblies PICS Problem Isolation Charts...
4012-0XX Diagnostic Information Use the symptom table and service checks in this chapter to deter- mine the failing part in a malfunctioning machine. Diagnostic Information...
4012-0XX Symptom Table Symptom Action Printer Code 1,4 Replace the printer board EPROM; if necessary replace the printer board. Printer Code 1,6 Go to “Transport Service Check” on page Printer Code 1,8 Replace the printer board EPROM; if necessary replace the printer board. Printer Code 1,10 Go to “Maintenance Station Service...
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4012-0XX Symptom Action Printer paper feed, misfeed, or jam problem Paper fails to stop at first print Go to “First Print Line Service Check” on line: page Envelopes fail to feed: Go to “Envelope Feed Service Check” on page Paper misfeeds, multifeeds, Go to “Printer Paper Feed Service Check”...
4012-0XX Service Checks Communications Service Check Action Fax or LCU Card No dialtone Cannot make telephone con- Verify correct dialing method (tone or nection to other fax machine. pulse). TEL and LINE connections reversed. Verify phone number and availability of other fax machine.
4012-0XX Envelope Feed Service Check Action 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 First Print Line Service Check Action Printer End-of-Forms Flag...
4012-0XX Maintenance Station Service Check The maintenance station has two functions: 1. Cleans the printhead nozzles during the print operation. 2. Seals the printhead when it is not being used to prevent the noz- zles from drying. Action Maintenance Drive Assembly Warning: Disconnecting the maintenance motor while the machine is plugged in can damage the printer board.
4012-0XX Operator Panel Service Check Action Power Supply Disconnect J2 from the fax board and check the following voltages on the power supply cable: J2-1 to GND = +5 V dc J2-3 to GND = +34 V dc If you do not have correct voltage, replace the power supply.
4012-0XX Power Service Check The operator panel power key does not control line power. With the machine turned off the power supply is still active and there is volt- age to both the fax and printer boards. To remove power you must unplug the machine.
4012-0XX Printer Paper Feed Service Check If your machine does not have paper jam problems, go on to the ser- vice check. If your machine does have a paper jam problem, exam- ine it for the following before you begin the service check. •...
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4012-0XX Action 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 •...
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4012-0XX Action Feed Arm Assembly At the beginning of the paper feed opera- 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.
4012-0XX Printer Paper Path Service Check Examine the machine for the following before you begin this service check: • Check the entire paper path for obstructions. • Be sure the paper guides are not worn or broken and are posi- tioned against the paper without binding or buckling the paper.
4012-0XX Print Quality Service Check Action Print Cartridge Be sure the machine has a known good print cartridge. Printhead Carrier Assembly Reseat the printhead cables in the printer board and check the following parts for wear or damage: • Print Cartridge Latch •...
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4012-0XX Action Paper Feed Ink smudging and smearing can be caused by paper problems or problems in the paper feed area. Check the following: • Correct type of paper is in the machine. Also check the paper for curl and wrin- kles.
4012-0XX Printing Problem Service Check If test prints, faxes, or printer jobs do not print correctly (not a print quality problem), run the Print Engine Test. Action Machine does not start the test: Make sure all the pins of connector J7 are shorted together and try to run the test again.
4012-0XX Scanner Document Feed Service Check Before beginning service, examine the following: • Are the pages damaged or dog-eared, are pages stuck together? • Is the paper being fed too thin (less than 16 lb paper), or too thick (greater than 24 lb paper)? •...
4012-0XX Scanner Service Check Action LED Array A failed LED array results in either black or very dark output. If a single LED fails, the output will have a black or dark vertical fuzzy stripe. The voltage at fax board J7-3 should be +12 V dc during a scan.
4012-0XX Transport Service Check Action Transport Motor Check the motor for binds, or loose motor pulley. Warning: Disconnecting the transport motor while the machine is plugged in can damage the printer board. Voltage is present on the board even with the power switch off.
4012-0XX Diagnostic Aids 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.
4012-0XX Machine Checkout Use the standard functions of the machine to verify the correct oper- ation of its subsystems. Copying a document confirms that the scan- ner 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.
4012-0XX Operator Panel Test This test activates each LED in sequence and cycles all pels of the LCD display. It also allows the servicer to test each button. 1. Press Setup. 2. Press 2104 to activate the Service Functions menu. 3.
4012-0XX Purge Test This test prints out a nozzle test pattern followed by several gray lines and another nozzle test pattern. Use this test to check the func- tion of all the nozzles in the print cartridge. This test also checks the electronic connection to the print cartridge.
4012-0XX 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.
4012-0XX Repair Information This chapter explains how to make adjustments to the printer and how to remove defective parts. Read page 28 before handling elec- tronic 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.
4012-0XX Handling ESD-Sensitive Parts Many electronic products use parts that are known to be sensitive to electrostatic discharge (ESD). To prevent damage to ESD-sensitive parts, follow the instructions below in addition to all the usual pre- cautions, such as turning off power before removing logic boards: •...
4012-0XX Adjustments Bidirectional Alignment Adjustment Perform this adjustment with the black print cartridge installed. Note: For machines at software version 5.15.5.2 or lower (press Setup LST to print the report listing the version number), this adjust- ment affects only Letter quality mode and Step 5 and its note do not apply.
4012-0XX Removal Procedures The following procedures are arranged according to the name of the part discussed. When there is artwork to support a procedure, it fol- lows 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.
4012-0XX ASF Envelope Buckler and Pick Roller Hub Removal 1. Remove the ASF assembly. 2. Remove the inside C-clip from the pick roller shaft and pull the shaft to the right far enough to remove the envelope bucklers and pick rollers. 3.
4012-0XX 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.
4012-0XX Carrier Transport Motor Removal 1. Open the top cover and then remove the left and right side covers, then the lower front cover. 2. Disconnect the carrier transport motor (J6) from the printer board. 3. Remove the two motor mounting screws and remove the motor. Carrier Transport Motor Frame Removal 1.
4012-0XX Covers Removal Front Cover 1. Remove the left and right side covers. 2. Flex the front cover to release the latches on each end. 3. Lift the cover to free the lower latch and remove the cover. Note: When reinstalling the front cover, make sure the lower latch and side latches are installed properly to prevent the cover from interfering with the paper ejectors.
4012-0XX Encoder Strip Removal The encoder strip can be easily damaged; use care when removing or installing. 1. Open the top cover. 2. Move the carrier in line with the opening on the carrier transport motor frame. 3. Reach through the opening and pull the belt from the carrier. 4.
4012-0XX EPROM Removal 1. Unplug the machine before beginning any electrical service. The power key does not remove power from the electronics. 2. Remove the top cover. 3. Disconnect the printhead cables from the printer board. 4. Disconnect connectors J4, J5, and J6 from the printer board. 5.
4012-0XX Fax Board, Printer Board, and LCU Board Removal 1. Unplug the machine before beginning any electrical service. The power key does not remove power from the electronics. 2. Remove the left and right side covers, the front cover and the rear cover, and disconnect J1, J2, J4, J5 and J6 from the printer board.
4012-0XX 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.
4012-0XX 14. A latch on the top front end of each side frame holds the trans- port 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.
4012-0XX 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.
4012-0XX 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.
4012-0XX 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.
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.
4012-0XX 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 part to which it is latched. The latches break easily. Release them carefully. Never apply excessive force when releasing the hook.
4012-0XX 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.
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4012-0XX 14. A latch on the top front end of each side frame holds the trans- port 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.
4012-0XX 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.
4012-0XX 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.
4012-0XX Parts and Test Point Locations LCU Board LCU Board Connector Name Handset Phone Data to Fax Board Parallel Port Parallel Data to Fax Board Phone Line In External Phone...
4012-0XX Fax Board Parts and Test Point Locations...
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4012-0XX Fax Board Connector Name Printer Board Power Supply Scanner Motor Operator Panel Speaker Scanner Paper Sensors LED Array & Scanner Closed Switch Scanner Data Battery Backup Option Memory Option Phone Data from LCU Board Parallel Data from LCU Board...
4012-0XX Preventive Maintenance 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-based greases can attack polycarbonate parts causing premature failure. Use only mineral oil-based grease. Use a mineral oil-based grease to lubricate the following: •...
4012-0XX 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.
4012-0XX Parts Catalog 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.
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4012-0XX 4012-006 Description 4012-005 P/N 4012-009 P/N Top Cover Asm w/guides 69G6828 69G6828 Front Cover 69G6875 69G6875 Rear Cover 69G6874 69G6874 Right Side Cover 69G6869 69G6869 Screw, Right Side Cover PP 69G6846 Memory/Battery Access Door 69G6899 69G6899 Paper Load Lever 69G6888 69G6888 Left Side Cover...
4012-0XX Index Error Report 22 Exit Roller Assembly Removal Abbreviations 3 Adjustments 29 ASF Envelope Buckler And Pick Roller Hub Removal 31 Fax Board, Printer Board, and ASF Right And Left Edge Guide LCU Board 37 Assemblies Removal 31 Feed Arm Assembly Removal Auto Sheet Feed Removal 30 First Print Line Service Check 8 Frame Service Position 22...
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4012-0XX Memory Option 39 Removal Procedures 30 Repair Information 27 Memory Test 23 Middle Frame Removal 40 Reset Button 24 Right Side Frame Removal 45 Rubber Backer Removal 47 Operator Panel Service Check Operator Panel Service Position Safety Information vii Scanner And Speaker Operator Panel Test 24 Removal 48...
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