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IBM 3112 Service Manual

IBM 3112 Service Manual

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S544-5256-00
3112 and 3116 Page Printer:
Service Manual

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  • Page 1 S544-5256-00 3112 and 3116 Page Printer: Service Manual...
  • Page 2 Information Development PO Box 1900 Boulder CO, USA 80301-9191 IBM Printing Systems may use or distribute any of the information you supply in any way it believes appropriate without incurring any obligation to you. © Copyright International Business Machines Corporation 1994, 1995.

  • Page 3: Notices And Safety Information

    Notices and Safety Information References in this publication to products, programs, or services do not imply that the manufacturer intends to make these available in all countries in which it operates. Any reference to a product, program, or service is not intended to state or imply that only that product, program, or service may be used.

  • Page 4: Industry Canada Compliance Statement

    To assure compliance with FCC regulations for a Class B computing device, use a properly shielded and grounded IBM cable. Part numbers for the various interface cables are: part number 1525612 for parallel interface, and part number 8509386 for serial interface.

  • Page 5: European Community (Ec) Electromagnetic Compatibility Directive

    European Community (EC) Electromagnetic Compatibility Directive This product is in conformity with the protection requirements of EC Council directive 89/336/EEC on the approximation of the laws of the Member States relating to electromagnetic compatibility. Japanese VCCI Notice German Statement of Acoustic Emissions A declaration of conformity with the requirements of the Directive has been signed by the Director of Manufacturing and Technical Support, Lexmark International, Ltd., Boigny, France.

  • Page 6: Trademarks

    Trademarks IBM is a trademark of International Business Machines Corporation. The following terms, denoted by a double asterisk (**) in this publication are trademarks or registered trademarks of other companies. AppleTalk Apple Computer, Inc. LocalTalk Apple Computer, Inc. Optra and Lexmark Lexmark International, Inc.

  • Page 7: Safety Information

    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.

  • Page 8: Ozone Information

    danni personali. Il personale di assistenza autorizzato, consapevole di ciò, deve adottare le precauzioni necessarie. • È possibile che le funzioni di sicurezza di alcuni elementi non siano così ovvie, quindi, i pezzi di ricambio devono avere caratteristiche identiche o equivalenti a quelle dei pezzi originali. Pautas de Seguridad •...

  • Page 9: Preface

    Preface This manual is divided into the following chapters: • “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.
  • Page 10 Service Manual...

  • Page 11: Table Of Contents

    Table of Contents Notices and Safety Information ........... iii Electronic Emission Notices ............. iii Federal Communications Commission (FCC) Statement .... iii Industry Canada Compliance Statement ........iv The United Kingdom Telecommunications Act 1984 ....iv European Community (EC) Electromagnetic Compatibility Directive ..................
  • Page 12 Honeycomb .................21 Horizontal Void or Streak ............21 Host Printing Problems..............22 LAN Problems ................24 Light Print ..................24 Network Card 977 Errors.............25 Network Wrap Tests..............25 Output Bin Sensor ...............26 Operator Panel Problem..............26 Paper Feed Problem, 500-Sheet Second Tray ......27 Paper Feed, Base Printer............27 Paper Feed, Duplex Unit .............28 Paper Feed Problem, Envelope+ Feeder/ 100-Sheet Auxiliary Feeder............29...
  • Page 13 Fuser Temperature .............. 44 Fuser Warm-up Time ............44 LCD Test ..................44 Maintenance Kit Count..............45 Memory Tests ................45 Page Count ................. 45 Paper Feed Tests................ 46 Permanent Page Count............... 46 Print Contrast ................46 Print Registration................. 47 Print Test 1..................
  • Page 14 Right Cover Removal ..............62 Front Cover Removal ..............62 Left Cover Removal..............64 Top Cover Removal ..............64 14 in. 200-Sheet Paper Tray Top Cover ........65 14 in. 500-Sheet Paper Tray Top Cover ........65 Transfer Roll Removal..............65 D-roll Assembly Removal ............66 Drive Motor Removal..............67 Fan/Redrive Removal..............68 Fuser Removal ................69 Fuser Input Guide Removal ............70...
  • Page 15 Gear Train ................. 104 HVPS ..................105 Transfer Roller Housing ............105 Engine Board Connectors ............106 RIP Board.................. 108 Board Installation Hardware............109 Printhead Connector Locations..........110 Mirror Motor/Fan Cable ............. 111 Operator Panel/Output Bin Sensor Cable ......... 112 Duplex Autoconnect Cable............
  • Page 16 Service Manual...

  • Page 17: General Information

    General Information The 3112 and 3116 are designed to attach to IBM**-compatible PC’s and to most types of computer networks including a twinax or coax system. All models come standard with PostScript** Level 2 emulation and PCL** 5 emulation, and SCS capability (IPDS is optional).

  • Page 18: Power Consumption

    Power Consumption 3112 3116 Power Saver Mode Printing (average) 260W 310W Max. A/C draw 110V 6.8A 9.8A Max. A/C draw 220V 3.4A 5.0A Options The following options are available. Some options are not available in every country. Contact your point of purchase for options available in your country.

  • Page 19: Maintenance Approach

    Maintenance Approach The diagnostic information in this manual will lead you to the correct field replaceable unit (FRU) or part. Use the error code charts, symptom index, service checks, and diagnostic aids to determine the symptom and repair the failure. Begin with “Start” on page 2-2. This printer can be serviced without being connected to a host.

  • Page 20: Abbreviations

    Abbreviations ASIC Application-Specific Integrated Circuit Customer Setup DRAM Dynamic Random Access Memory EEPROM Electrically Erasable Programmable Read-Only Memory Electrophotographic Process Electrostatic Discharge Field Replaceable Unit HVPS High Voltage Power Supply Integrated Network Access Local Area Network LASER Light Amplification by Stimulated Emission of Radiation Liquid Crystal Display Light-Emitting Diode...

  • Page 21: Diagnostic Information

    Diagnostic Information Two-digit codes are messages for the user, but if they recur frequently or at inappropriate times they may be symptomatic of a service prob- lem. Refer to the diagnostics Error log for the last six machine errors. Error Code Explanation 20 Paper Jam The input sensor was not unmade in...

  • Page 22: Service Manual

    Error Code Explanation 38 Memory Full Memory used to store pages is full. To verify that the printer recognizes all the installed memory, go to the user menus and print the “Print Menus” test page. Make sure the memory shown on the printout matches the installed memory.
  • Page 23 Error Code Explanation 64 Defective Disk The printer will ignore a disk it senses as defective. Run the Quick Disk Test. If the test fails, the disk is defective or the data on track 1 is bad. If the Quick Disk Test passes but the disk does not work, run the Disk Test/Clean (2 hour test).
  • Page 24 Error Code Explanation 918 Transfer Roll Error Servo Failure. Verify correct cable connections from the Engine board to the HVPS. Make sure there is continuity between the transfer roller and its contact on the HVPS; replace the transfer roll if the continuity is correct.
  • Page 25 Error Code Explanation 944 RIP Board RIP processor failure. Replace the RIP Board. 945 RIP Board ASIC 1 failure. Replace the RIP Board. 946 RIP Board ASIC 2 failure. Replace the RIP Board. 947 Engine Board Engine ASIC RAM failure. Replace the engine board.
  • Page 26 Error Code Explanation 972 Network Card 2 Network card 2 ROS/FLASH failure. Replace network card 2. 973 Network Card 1 Go to “Host Printing Problems” on page 22. 973 Network Card 2 Network card 2 EEPROM/NVRAM failure. Replace network card 2. 974 Network Card 1 Go to “Host Printing Problems”...
  • Page 27 Error Code Explanation 979 Network Card 2 General network 2 card software error. Verify that the network card is installed and grounded correctly. If this error returns after a POR, there is a software or microcode incompatibility problem. Do Not replace the card. Contact your next level of support.

  • Page 28: Power-On Self Test (Post)

    Power-On Self Test (POST) When you turn the printer on, it performs a Power-On Self Test. Check for correct POST functioning by observing the following: 1. 1 1/2 rows of pels appear on the display and then clear. 2. Diamonds fill the display and then clear. 3.

  • Page 29: Symptom Table

    Symptom Table Symptom Action or Service Check Dead Machine Dead Machine Service Check Machine Hangs Displaying Machine Hangs Displaying Diamonds Diamonds Service Check Repeats a pattern of 5 beeps and Operator Panel Service Check a pause. Operator Panel Operator Panel Service Check Paper Feed, Base Printer Paper Feed, Base Printer Service Check Paper Feed, Duplex Unit...

  • Page 30: Banding

    Symptom Action or Service Check Horizontal Void or Streak Horizontal Service Check Vertical Void or Streak Vertical Service Check Banding Banding Service Check Banding Banding appears as light and dark horizontal lines on a page that is supposed to be uniformly gray. It is due to variation in the speed of the paper as it moves from roll to roll during development or transfer.

  • Page 31: Black Page

    voltages; then stop the test and check the voltages again: Voltage while Connector Voltage while Idling Printing J13-1 Less than 5VDC 0VDC J13-2 Less than 5VDC 0VDC J13-3 (Fluctuates 0VDC between pages) +1.5VDC J13-8 Less than 1VDC +6VDC If any voltages are not correct replace the engine board. If no problem is found, enter the diagnostics mode and change the Charge Roll setting.

  • Page 32: Blank Page

    correct, replace the engine board. Voltage while Voltage while Connector Printing Idling J13-1 to J13-4 +4.5VDC 0VDC J13-2 to J13-4 +4VDC 0VDC If no other trouble is found replace the HVPS. Blank Page Inspect the printhead shutter for proper operation and make sure the actuator on top of the cartridge is present and extends into the print- head shroud when the printer top cover is closed.

  • Page 33: Dead Machine

    feed roll or transfer roll. Also see Banding. Inspect the HVPS contacts; make sure each spring-loaded contact returns when pressed and released. Inspect the transfer roll housing contacts for damage or contamination. Check the gear train for dam- age, binds, or wear. When using the 100-sheet auxiliary feeder, some blurring may occur at the point where the feeder’s friction rollers release the paper.
  • Page 34 If the duplexer does not home immediately but homes after 5 or 6 sec- onds, the duplexer is receiving +34VDC from the printer but is not com- municating with the printer. The duplexer homes on its own as a signal that it is functional.

  • Page 35: Fan (927 Error)

    the paper path. Make sure the flags of the duplex unit input and exit sensors move freely. While the 23 is displayed, press and hold the Return button while press- ing the second button from the top, and note the 7th and 8th digits from the left.

  • Page 36: Fuser Theory

    Fuser Theory The fuser lamp operates off line voltage from the LVPS. The thermistor is in contact with the fuser hot roll. The system board reads the ther- mistor resistance and toggles a TRIAC in the LVPS which cycles the lamp on and off to maintain the proper hot roll temperature.

  • Page 37: Fuser: 923 Or 924 Error

    engine board, the fuser, and the fuser wiper. Next, measure the voltage to the fuser lamp during a POR; it should be line voltage until the 922 Error is displayed, if it does not, replace the LVPS, the fuser, and the fuser wiper.

  • Page 38: Host Printing Problems

    Host Printing Problems You are here for one of the following reasons: 1. Host (twinax or coax) printing problems. 2. 97x errors (if 977, go to “Network Card 977 Errors” on page 25) 3. An IPDS card error, such as “RAM Check”, printed out on a sheet of paper.
  • Page 39 READY RINT ENUS HEN PRESS THE BUTTON Mark the first page with a 2. If IPDS, there is another page which you should mark 3. If you replace a Host Card (coax or twinax) or an IPDS card, you will need to reset the settings on these Printouts 2 and 3.

  • Page 40: Lan Problems

    • For coax, ensure that other devices on or attached to the controller are OK. Also ensure that the configu- rations are correct. Do not continue until you have verified all of this. If the printer has an IPDS card: 1.

  • Page 41: Network Card 977 Errors

    printer on for about two minutes each time. Other causes are the same as for “Blank Page”. See “Blank Page” on page 16. Make sure Print Darkness on the customer Setup menu is set to Nor- mal or Dark. Increasing the diagnostics mode Print Contrast setting will darken print further.

  • Page 42: Output Bin Sensor

    Note: There is an output bin sensor on the 3116-002 and 3116-003. It is not on the 3112-001 or the 3116-001. Make sure the plastic bails and guide are in good condition and that they guide the sensor flag out of and into the sensor as paper passes into the bin.

  • Page 43: Paper Feed Problem, 500-Sheet Second Tray

    If the printer beeps 5 times at POR, or if the operator panel is blank: check for +5VDC at pin 4 of the cable connector at the operator panel, and also at engine board J1-4. Replace the operator panel or the cable if they are the problem.

  • Page 44: Paper Feed, Duplex Unit

    • The D-roll will not move at all. Check the paper feed magnet adjustment. If the adjustment is correct, either the paper feed magnet is defective or the engine board signal is incorrect. Check the resistance of the paper feed magnet J14-1 to J14-2 for 100-250 ohms.

  • Page 45: Paper Feed Problem, Envelope+ Feeder

    board J15-10. The voltage will change from 0VDC to +5VDC as the selector lever is moved. Also see “23 Paper Jams” on page 18. Paper Feed Problem, Envelope+ Feeder/ 100-Sheet Auxiliary Feeder Check for the following: paper or envelope jammed in the feed path; missing hold-down weight;...

  • Page 46: Paper Size Sensing Problem

    board. If the voltage is correct, check the continuity of the fan/mirror motor cable. Replace the printhead if the cable is good. Paper Size Sensing Problem (The printed area does not fit on the page, or the paper size cannot be changed from the operator panel.) Make sure the paper tray and its stops are undamaged.

  • Page 47: Residual Image

    Component Print Defect Spacing on Page PC Drum (part of print cartridge) 125.7 mm Transfer Roll 53.1 mm Fuser Hot Roll 78.9-79.2 mm Fuser Backup Roll 69.1 mm Charge Roll (part of print cartridge) 37.1-37.7 mm Developer Roll (part of print cartridge) 40.0mm Prealigner Feed Roller 68.5 mm...

  • Page 48: Skew, Top And Bottom Only

    If the test print frame is not parallel to the left and right edges of the paper, the paper has skewed in the paper path. Check the paper path for obstructions. Make sure the paper in the tray is loaded properly and is undamaged.

  • Page 49: Vertical Void Or Streak

    Vertical Void or Streak Do a developed image test to determine if the defect is occurring before or after the transfer process. If you see the defect on the photoconductor, check the operation of the printhead shutter and clean the printhead window with a lint-free cloth folded over a cotton swab;...
  • Page 50 Service Manual...

  • Page 51: Diagnostic Aids

    Diagnostic Aids Diagnostics Mode To run the remainder of the printer diagnostic tests described in this chapter, you must put the printer in Diagnostics mode. To enter Diagnostics mode: 1. Turn the printer off. 2. Press and hold the Ready and Return buttons. Then turn the printer on.
  • Page 52 HARDWARE TESTS LCD Test Sensor Tests Toner Low Output Bin Input Exit Cover Open Button Test Wrap Tests Parallel Serial Memory Tests DRAM PAGE COUNTS Page Count Permanent Page Count Maintenance Count PAPER FEED TESTS Tray 1 Tray 2 Feeder Manual Service Manual...
  • Page 53 DUPLEX TESTS Top Margin Duplex Quick Test Duplex Feed 1 Duplex Feed 2 DEVICE TESTS Disk Test/Clean Quick Disk Test Flash Test PRINTER SETUP Fuser Temperature Warm-Up Time Envelope Enhance Auto Clean Auto Clean Frequency Auto Clean Delay Transfer Print Contrast Charge Roll Defaults ERROR LOG...

  • Page 54: Diagnostics Mode Tests

    Diagnostics Mode Tests Auto Clean Auto Clean needs to be turned on if there is an unacceptable amount of toner being deposited on the back of the page. When Auto Clean is on, after printing the number of pages specified in Auto Clean Frequency, the printer will pause the number of seconds specified in Auto Clean Delay.

  • Page 55: Button Test

    Button Test To test the operator panel buttons: 1. Enter Diagnostics mode. 2. Select [HARDWARE TESTS]. 3. Select [Button Test]. 4. Press each button. [Closed] is displayed until the button is released. Then [Open] is displayed. 5. Press Return to return to the Diagnostics mode main menu. Charge Roll This setting varies the charge roll bias.

  • Page 56: Defaults

    Defaults Allows setting the following defaults to U.S. or Non-U.S. values. U.S. NON U.S. Letter size paper A4 paper # 10 envelopes DL envelopes Symbol Set Roman-8 Symbol Set PC-850 1. Enter Diagnostics mode. 2. Select [PRINTER SETUP]. 3. Select [Defaults]. 4.

  • Page 57: Duplex Feed 1 Test

    Duplex Feed 1 Test This test checks for slipping paper problems. It verifies that the paper is entering the duplex unit far enough for the trailing edge to clear the selector fingers before the paper reverses direction. 1. Enter Diagnostics mode. 2.

  • Page 58: Envelope Enhance

    8. Carefully remove the duplex unit from the printer without disturbing the position of the paper on the top of the duplex tray. 9. Without changing the position of the page, hold it to the top of the paper tray and remove the paper tray. 10.

  • Page 59: Error Log

    Error Log The error log records the last 6 “2X Paper Jam” or “9XX Service” errors. In a full log, position 6 is the oldest error. If more than 6 errors are received, the oldest error is discarded. If the same error occurs consecutively it is recorded only once.

  • Page 60: Service Manual

    Paper curl in which the edges of the paper curl toward the printed side (cold paper curl) can corrected by increasing the fuser warm-up time. Use the lowest setting that corrects the problem. Setting “0” is the factory default and is the shortest warm-up time. Setting “5” increases warm-up time by 90 seconds;...

  • Page 61: Maintenance Kit Count

    Maintenance Kit Count This non-displayed counter must be reset after the maintenance kit is replaced to prevent the [80 Scheduled Maintenance] message from displaying when the machine is turned on. 1. Enter Diagnostics mode. 2. Select [PAGE COUNTS]. 3. Select [Maintenance Count]. 4.

  • Page 62: Paper Feed Tests

    Paper Feed Tests This test allows you to observe the drive gear train and feed paper through the printer to check for broken gear teeth, watch the paper path, or check the erase lamps. Note: You may want to remove the gear cover before starting this test so you can observe the motor gears.

  • Page 63: Print Registration

    Print Registration Use Print Test 1 or the Quick Test to evaluate print registration. Adjust the registration so the tips of the diamonds are at the top and bottom edges of the page and the printout is centered left to right. Verify that the top margin is correct before adjusting the bottom margin.

  • Page 64: Print Test 1

    Print Test 1 Print Test 1 generates one printout similar to the test page. This test uses paper from tray 1 only. Print Test 1 will not duplex. To run Print Test 1: 1. Enter Diagnostics mode. 2. Select [PRINT TESTS]. 3.

  • Page 65: Quick Disk Test

    4. Select [Single] or [Continuous]. 5. Select [Cancel] to stop continuous print. 6. Press Return to return to Diagnostics mode main menu. Quick Disk Test This is a one minute test which performs a non-destructive write/ read on one block per track on the disk. It tests the printer-to-disk communications, and the disk hardware and circuitry, but does only incidental testing of the disk surface itself.

  • Page 66: Top Margin And Duplex Quick Tests

    Top Margin and Duplex Quick Tests The Top Margin and Duplex Quick Test are used together to adjust the duplex front-to-back registration. Make sure the non-duplex page registration is correct before adjusting the duplex top margin. 1. Enter Diagnostics mode. 2.

  • Page 67: Wrap Tests

    Wrap Tests The Wrap Tests check the circuits used to communicate with the host computer. To run the Wrap Test: 1. Turn the printer off. 2. Disconnect the interface cable. 3. Install the wrap plug in one of the interface cable connectors. Note: Install the parallel wrap plug part no.

  • Page 68: Other Tests

    Other Tests Developed Image Test Use the Developed Image Test to isolate print quality problems. You might have to practice this procedure several times to get the timing correct. To run the Developed Image Test: 1. Open the front exit tray. 2.

  • Page 69: Print Test Page

    Print Test Page You can run the Print Test even if the printer is not attached to a computer. Use this test to check print and graphics quality and the version numbers of printer microcode. The first page of this test feeds from tray 1.
  • Page 70 Service Manual...

  • Page 71: Repair Information

    Repair Information This chapter explains how to make adjustments to the printer and how to remove defective FRUs. 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 precau- tions, such as turning off power before removing logic boards: •...

  • Page 72: Adjustments

    Adjustments Envelope Restraint Spring On The Envelope+ Feeder 1. Loosen the mounting screw [A]. 2. Position the spring [B] so it clears the separator roller by 1.9 +/- 0.2 mm (0.075 +/- 0.008 in.). 3. Tighten the mounting screw. Paper Restraint Spring On The 100-Sheet Auxiliary Feeder 1.

  • Page 73: Envelope+ Feeder Magnet And 100-Sheet Auxiliary Feeder Magnet

    Envelope+ Feeder Magnet And 100-Sheet Auxiliary Feeder Magnet 1. Hold the armature [A] in the closed (coil active) position. 2. Loosen the mounting screw [B], and rotate the magnet assembly so the armature clears the clutch gear by 0.30 +/- 0.20 mm (0.012 +/- 0.008 in.).

  • Page 74: Paper Feed Magnet

    Paper Feed Magnet 1. Remove the RIP board. (See “RIP Board, Inner EMC Shield, and Engine Board Removal” on page 91.)The magnet is accessed through the holes in the right frame. 2. With the armature latched on the cam step check for 0.60 mm +/- 0.07 mm (0.024 in +/- 0.003) between the foam pad and the magnet pole piece.
  • Page 75 be affected if the gears are too tight. 1. Remove the fuser cover. 2. Locate gear #2. It is the white adjustable gear-mounted to the side frame below the fuser gear. 3. Rotate the adjustable gear in one direction to check for backlash.

  • Page 76: Fuser Solenoid

    Fuser Solenoid Note: The fuser solenoid must be mounted on the fuser for this adjustment and should be at room temperature. 1. Loosen screw [A]. 2. Remove the rubber washer. 3. Rotate shaft [B] (eccentric) to obtain 4.2 mm +/- 0.2 mm (0.165 in.

  • Page 77: Printhead Skew

    Printhead Skew 1. 3112-001 and 3116-001: Remove the plug in the top cover. 3112-002 and 3112-003: Open the paper exit stop. Unlatch and remove the spring-loaded exit stacker. 2. Loosen the screws [A]. 3. Run Print Test 1 or the Quick Test on the Diagnostics Menu.

  • Page 78: Removals

    Removals Note: When there is artwork to support a procedure, it follows the text. Covers Right Cover Removal 1. Turn the printer off. 2. Remove all external trays. 3. Open the top cover. 4. Depress the latch and open the right cover. 5.
  • Page 79 Repair Information...

  • Page 80: Left Cover Removal

    Left Cover Removal 1. Unplug the power cord. 2. Open the top cover and remove the print cartridge. 3. Remove the front cover. 4. Locate the latch [E] and lift the end to release it. 5. Push the top of the cover to the left. 6.

  • Page 81: 14 In. 200-Sheet Paper Tray Top Cover

    14 in. 200-Sheet Paper Tray Top Cover 1. Push the tab where the left corner of the tray cover pivots. 2. Move the left tray cover pivot pin forward and then upward. 3. Remove the cover from the tray. 14 in. 500-Sheet Paper Tray Top Cover 1.

  • Page 82: D-Roll Assembly Removal

    D-roll Assembly Removal 1. Unplug the power cord. 2. Remove the paper tray. 3. Remove the print cartridge. 4. Remove the fuser input guide. 5. Remove the transfer roll housing assembly. 6. Pull the D-roll firmly to the left to remove it. Note: The D-roll is designed to be installed only once;...

  • Page 83: Drive Motor Removal

    Drive Motor Removal 1. Unplug the power cord. 2. Remove the RIP board and inner EMC shield together. 3. Remove the engine board. 4. Remove the fuser input guide. 5. Remove the transfer housing assembly. 6. Remove the gear cover by releasing the rear latch and lifting up. 7.

  • Page 84: Fan/Redrive Removal

    Fan/Redrive Removal 1. Open the top cover. 2. Remove the print cartridge. 3. Remove the top cover. 4. Remove the lower redrive shaft by disengaging the right end to the rear of the machine. 5. Disconnect the long redrive belt [A] and slip it off the lower shaft. 6.

  • Page 85: Fuser Removal

    Fuser Removal Note: The heater lamp is fragile and may be damaged if you are not careful when you remove or replace the fuser unit. CAUTION: THE TEMPERATURE OF THE HOT ROLLER IS 150 ˚-230 ˚ C (302 ˚- 446 ˚ F). USE EXTREME CAUTION WHEN REMOVING THIS UNIT.

  • Page 86: Fuser Input Guide Removal

    Fuser Input Guide Removal 1. Remove the fuser input guide [B] by lifting the rear end of the guide and unsnapping both sides from the fuser. 2. Lift the fuser input guide upward at both sides near the fuser and slide the guide toward the rear of the machine to release.

  • Page 87: Fuser Solenoid Removal

    TO COOL FOR 5 MINUTES. Note: The fuser lamp is a glass heater. Do not touch the lamp with your hands; skin oils and acids can reduce the life of the heater lamp. Use a soft cloth to handle the heater lamp at all times if the lamp is to be reinserted.

  • Page 88: Fuser Thermistor Removal

    3. Disengage the solenoid bracket from the plunger. Note: When a new solenoid assembly is installed, the fuser sole- noid must be adjusted. Fuser Thermistor Removal 1. Disconnect the thermistor cable connector [A] from the exit sensor card. 2. Remove the fuser cover and wiper. 3.
  • Page 89 Repair Information...

  • Page 90: Hvps Removal

    HVPS Removal 1. Unplug the power cord. 2. Remove the left cover 3. Remove the fuser input guide. 4. Remove the transfer roll housing. 5. Remove the fuser cover. 6. Disconnect the cable from the HVPS connector. 7. Remove the power switch rod. 8.
  • Page 91 Repair Information...

  • Page 92: Input Sensor Board Removal

    Input Sensor Board Removal 1. Remove the fuser input guide. 2. Remove the transfer roll housing. 3. Remove the D-roll. 4. Disconnect the input sensor cable from the input sensor board. Note: Use care, the flag can be damaged while removing the board.
  • Page 93 Repair Information...

  • Page 94: Lower Frame Assembly Removal

    Lower Frame Assembly Removal 1. Remove the right, front, and left covers 2. Remove the LVPS and the rod for the on/off switch. 3. Remove gear cover and the fuser input guide [A]. 4. Remove the transfer roll housing. 5. Disconnect the cable from the HVPS. 6.
  • Page 95 Repair Information...

  • Page 96: Lvps Removal

    LVPS Removal 1. Disconnect the power cord. 2. Remove all external feed trays. 3. Remove the left and right side covers. 4. Remove the RIP board and the inner EMC shield together. 5. Remove the left and right LVPS mounting screws and the screw for the cable tie.

  • Page 97: Lvps Cover Removal

    LVPS Cover Removal 1. Form tabs [D] away from the power supply to create clearance for tabs [A] to move downward. 2. Release the top latches [A]. 3. Release the side latches [B]. 4. Release the bottom latches [C]. Repair Information...

  • Page 98: Operator Panel Removal

    Operator Panel Removal 1. Remove the top cover. 2. Disconnect the operator panel cable. 3. Remove the operator panel mounting screws from the inside of the top cover. INA or Hard Disk Removal 1. Open the top cover. 2. Open the right cover. 3.
  • Page 99 4. Open the top cover. Then open the right side cover. 5. Remove the Host Attachment Card grounding screw. 6. With host attachment card, but no IPDS card, unplug the connector. With IPDS, pop the cards off the plastic standoffs as you unplug the connector.

  • Page 100: Host Attachment Card / Ipds Card Replacement

    Host Attachment Card / IPDS Card Replacement Note: The following directions also apply when you are installing a new IPDS card. 1. With IPDS, attach the Host Attachment Card to the IPDS Card (2 screws). 2. Connect the Host Attachment Card onto the system board. With IPDS, snap the IPDS Card onto the standoffs.
  • Page 101 Repair Information...

  • Page 102: Paper Feed Magnet Assembly

    Paper Feed Magnet Assembly Paper Feed Magnet Assembly Removal 1. Remove the print cartridge. 2. Remove the right cover. (See “Covers” on page 62). 3. Remove the RIP board. (See “RIP Board, Inner EMC Shield, and Engine Board Removal” on page 91). 4.
  • Page 103 5. Separate the side frames. 6. Pull the guides [C] out of the side frames. 7. Use a flat-blade tool to snap the gears and rollers [D] off the shaft. Repair Information...

  • Page 104: Paper Size Switch Removal

    Paper Size Switch Removal 1. Remove the paper tray. 2. Remove the front cover. 3. Unplug the cable [B] from the switch connector [C]. 4. Remove the two screws [A]. 5. Rotate the switch about 90 ˚ and pull it out of the printer. Service Manual...

  • Page 105: Printhead Removal

    Printhead Removal IMPORTANT: The Printhead is ESD-sensitive. It is not serviceable and should be replaced as a unit. 1. Turn the printer off. 2. Remove the print cartridge. 3. Remove the right and top covers. 4. Remove the exit redrive and its belt. 5.
  • Page 106 Service Manual...

  • Page 107: Rip Board, Inner Emc Shield, And Engine Board Removal

    RIP Board, Inner EMC Shield, and Engine Board Removal Note: Note: The RIP Board and Inner EMC shield MUST be removed together. This prevents damage to the Engine Board pins. 1. Turn the printer off. 2. Remove the right cover (1 E-Clip from the rear pivot pin). 3.
  • Page 108 5. Remove the 4 nuts (N), 1 standoff(ST), and the screw/lock washer. Note: Note: In the following step, the Engine Board to RIP board connector will be damaged if the assembly is not pulled straight out of the printer. 6. Remove the inner EMC shield and RIP board straight out from the printer as an assembly.

  • Page 109: Fuser/Sensor Cable Removal

    • Unsnap the board from the plastic standoff. Fuser/Sensor Cable Removal 1. Turn the printer off. 2. Remove the RIP board and the inner EMC shield together. 3. Disconnect the cable from the exit sensor board. 4. Remove the front cover. 5.
  • Page 110 4. Lift the transfer roll housing far enough to disconnect the erase lamp cable. 5. Lift the transfer roll housing out of the machine. Service Manual...

  • Page 111: Upper Frame Removal

    Upper Frame Removal 1. Unplug the power cord. 2. Remove the print cartridge. 3. Remove the right, left, and top covers. 4. Remove the RIP board and the inner EMC shield together. 5. Remove the engine board. 6. Remove the load box latches [A]. 7.
  • Page 112 Service Manual...

  • Page 113: Duplex Option Top Cover And Table Cover Removal

    Duplex Option Top Cover And Table Cover Removal 1. Open the top cover by pulling up at [A] and pivoting 90 ˚. 2. Pry the top cover from the bottom cover at [B]. 3. Release latches [C] on the table cover and lift up. 4.

  • Page 114: Duplex Option Exit Card And Cover Removal

    Duplex Option Exit Card And Cover Removal 1. Pry up on tabs [A]. After the tabs are released, lift up on the cover, rotate the cover out, and slide it to the right to completely remove it. 2. Disconnect the exit sensor card cables. 3.

  • Page 115: Duplex Option Bottom Cover And Entry Sensor Card Removal

    Duplex Option Bottom Cover And Entry Sensor Card Removal 1. Remove the duplexer top cover. 2. Remove the exit card cover and exit card. 3. Pry off the cover for the blind connector. 4. Pry up on the blind connector to remove it from the bottom cover. 5.
  • Page 116 Service Manual...

  • Page 117: Duplex Option System Card And Motor Removal

    Duplex Option System Card And Motor Removal 1. Disconnect all cables. 2. Release latches [A] and lift the system board out. 3. Remove the two motor mounting screws [B]. 4. Lift the motor out of the frame assembly. Note: Reinstall the motor so the belt is not tight but will not jump teeth on the timing pulley.
  • Page 118 Service Manual...

  • Page 119: Connector Locations

    Connector Locations This chapter shows the locations of major printer assemblies, gears, connectors, and ground straps. Major Assembly Locations Connector Locations...

  • Page 120: Service Manual

    Gear Train Service Manual...

  • Page 121: Hvps

    HVPS Transfer Roller Housing Connector Locations...

  • Page 122: Engine Board Connectors

    Engine Board Connectors Service Manual...
  • Page 123 Engine Board Connectors Connector Name Operator Panel/Output Bin Sensor Printhead Mirror Motor/Fan Duplex LVPS Reserved Paper Drive Motor Board-to-Board Connector (Rip Board/Engine Board) Exit/Paper Size Sensor/Fuser Solenoid Input/Toner Sensor Board/Erase Lamps Envelope Feeder Magnet Printhead Hsync Printhead Laser HVPS Paper Feed Magnet 500 Sheet Feed Option Connector Locations...

  • Page 124: Rip Board

    RIP Board RIP Board Connectors Connector Name Font Card (on back of board) Parallel Port Board-to-Board Host (Coax or Twinax) With IPDS option, an IPDS Card is connected to the Host Card. ROMM SIMM (flash memory option) ROMM SIMM (printer microcode) DRAM SIMM (printer memory) DRAM SIMM (printer memory) Serial Port...

  • Page 125: Board Installation Hardware

    Board Installation Hardware Connector Locations...

  • Page 126: Printhead Connector Locations

    Printhead Connector Locations Service Manual...

  • Page 127: Mirror Motor/Fan Cable

    Mirror Motor/Fan Cable Mirror Motor/Fan Cable Connections Motor J2-1 J2-2 J2-3 J2-4 J2-5 J2-6 J2-7 J2-8 Connector Locations...

  • Page 128: Operator Panel/Output Bin Sensor Cable

    Operator Panel/Output Bin Sensor Cable Operator Panel/Output Bin Sensor Cable Connectors Sensor (3116- Op Panel 002, -003) * J1-1 J1-2 J1-3 J1-4 J1-5 Service Manual...

  • Page 129: Duplex Autoconnect Cable

    Operator Panel/Output Bin Sensor Cable Connectors Sensor (3116- Op Panel 002, -003) * J1-6 J1-7 J1-8 J1-9 No connection * The same cable is used on the 3312-001 and 3116-001, but the output bin sensor leads are not used. Duplex Autoconnect Cable Duplex Autoconnect Cable Connectors Engine Board...

  • Page 130: Printer Ground Straps

    Printer Ground Straps Service Manual...

  • Page 131: Preventive Maintenance

    Use of lubricants other than those specified can cause premature failure. Some unauthorized lubricants may chemically attack polycarbonate parts. Use IBM no. 10 oil, p/n 1280443 (Approved equivalents: Mobil DTE27, Shell Tellus 100, Fuchs Renolin MR30) to lubricate the areas of contact between: •...
  • Page 132 The fixed-center idler gear in the 500 sheet base and its shaft • The idler gear in the 500 sheet base and its shaft Use IBM no. 23 grease (Approved equivalent Shell Darina 1) to lubricate: • Front pivot latch studs •...
  • Page 133 Use grease, p/n 1384076 to lubricate: • [A] Areas of contact between the two shafts and the grounding spring. Use grease, p/n 1383586 to lubricate: [B] on the duplex unit. Preventive Maintenance...

  • Page 134: Printhead Window Cleaning Procedure

    Printhead Window Cleaning Procedure Do not use cleaning fluids on the printhead window. Do not use a bare cotton swab. The swab deposits lint on the window. Note: The printhead window is a coated glass. Do not push too hard and scratch or break the glass. 1.

  • Page 135: Usage Kit Information

    Order as Feature Codes through your IBM Marketing Representative (Feature Code 4920 for 110V; Feature Code 4921 for 220 V). • Contact IBM DIRECT within the country and order ber listed above. the part num Outside these locations, customers contact their point of pur- chase or Lexmark.
  • Page 136 Service Manual...

  • Page 137: Parts Catalog

    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.

  • Page 138: Assembly 1: Covers

    Assembly 1: Covers Service Manual...
  • Page 139 Top Cover, 3116-001 69G5055 Top Cover, 3116-002, -003 1381631 Operator Panel Asm Screw, Operator Panel-Parts Packet 1381663 1381656 Tray Asm, Stacker, 3112-002, -003 Spring, Stacker-Parts Packet 1381666 1408176 Right Cover Asm 1408163 Latch, Right Cover 1408233 Spring, Right Cover Latch...

  • Page 140: Assembly 2: Lower Frame

    Assembly 2: Lower Frame Service Manual...
  • Page 141 Part Units Description Index Number 1381667 Lower Frame Assembly 1381632 Motor, Brkt. and Gear Asm, 3112-001 1381633 Motor, Brkt. and Gear Asm, 3116-001, -002, -003 1408572 Plate Asm. Gear Box Mtg. 1408779 Clip, Ground, Motor Mtg. Mtg. Screw, Motor Asm-Parts Packet 1381663 Mtg.

  • Page 142: Assembly 3: Upper Frame

    Assembly 3: Upper Frame Service Manual...
  • Page 143 Asm- Part Units Description Index Number 1325196 Cover Hinge Asm 3112-001, 3116-001 (does not include the load box) 1381045 Cover Hinge Asm 3116-002, -003 (does not include the load box) Screw, Cover Hinge Parts Packet 1381663 1325103 Upper Plate Asm 3112-001, 3116-001...

  • Page 144: Assembly 4: Printhead

    Assembly 4: Printhead Service Manual...
  • Page 145 Asm- Part Units Description Index Number 1381635 Printhead 1328431 Printhead Shroud Assembly 1408033 Cable, Fan/Mirror Motor 1408034 Cable, hsync 1038199 Cable, Tie 1425284 Cable, Laser (Install with marked end to Printhead) Pin, Parts Packet 1381666 Spring, Parts Packet 1381666 Screw, Printhead Mtg., Parts Packet 1381663 Screw, Hex Headed Parts Packet 1381663 Pointer, Parts Packet 1381663 Clip, Hex Screw Ground, Parts Packet...

  • Page 146: Assembly 5: Paper Feed

    Assembly 5: Paper Feed Service Manual...
  • Page 147 Deflector, Redrive, 3112-001, 3116-001 1408804 Deflector, Redrive 3116-002, -003 1042206 Shaft Asm, Upper Redrive 1328169 Shaft Asm, Auxiliary Shaft 3116-002, -003 1042207 Shaft Asm, Middle Redrive 3112-001, 3116- 1328173 Shaft Asm, Middle Redrive 3116-002, -003 1381073 Toner Sensor 1328323 Shaft, 3116-002, -003 1328322...
  • Page 148 Assembly 5: Paper Feed (Continued) Service Manual...
  • Page 149 Output Bin Sensor 3116-002, -003 1408064 Cable, Output Bin/Op Panel (Output Bin lead has no connection on 3112-001, 3116-001) 1381567 Guide, Bail, and Minibail Kit (3112-001, 3116- 001 uses Minibail only) 1408061 Cable, Tray 2 Blind Mate 1408792 Cover, Tray 2 Cable Opening...

  • Page 150: Assembly 6: Paper Feed Alignment Gears

    Assembly 6: Paper Feed Alignment Gears Service Manual...
  • Page 151 Asm- Part Units Description Index Number 1427307 Bellcrank, Metering o Shaft o Bellcrank o Roll o Thrust Washer 1381145 Kit, Prealigner and Auxiliary Rollers 1039278 Gear, Idler, Prealigner Spring, Prealigner and Metering Bellcranks, Parts Packet 1381666 1328384 Bellcrank, Prealigner o Shaft o Roll o Bellcrank o Thrust washer...

  • Page 152: Assembly 7: Paper Feed Drive

    Assembly 7: Paper Feed Drive Service Manual...
  • Page 153 Asm- Part Units Description Index Number 69G5480 D-Roller Asm 1328279 Washer, Thrust 1126832 Clip, D-Roll 1408703 Rail Assembly, Right (W/O gears) 1328313 Shield, D-Roll 1381790 Shaft, D-Roll (with Gear 11 and D-Roller Asm) Bushing, Parts Packet 1383315 Must be installed properly. Align slot in bushing with notch in frame assembly.

  • Page 154: Assembly 8: Standard Paper Tray (200-Sheet)

    Assembly 8: Standard Paper Tray (200-sheet) Service Manual...
  • Page 155 Asm- Part Units Description Index Number 1427375 Paper Tray Assembly, 11 in. (200-sheet) 1427376 Paper Tray Assembly, 14 in. (200-sheet) 1427361 Paper Tray Assembly for Labels, 11 in. (200- sheet) 1427364 Paper Tray Assembly for Labels, 14 in. (200- sheet) 1427379 Paper Tray Assembly, A5 1408170...

  • Page 156: Assembly 9: Paper Tray (500-Sheet)

    Assembly 9: Paper Tray (500-Sheet) Service Manual...
  • Page 157 Asm- Part Units Description Index Number 1427377 Paper Tray Assembly, 11 in. 1427378 Paper Tray Assembly, 14 in. 1427424 Paper Tray Assembly, Light Weight Labels (550g spring), 11 in. 1427372 Paper Tray Assembly, Light Weight Labels (550g spring), 11 in. 1427367 Paper Tray Assembly, Heavy Weight Labels (650g spring), 11 in.

  • Page 158: Assembly 10: Base For Paper Drawer (500-Sheet)

    Assembly 10: Base for Paper Drawer (500-Sheet) Service Manual...
  • Page 159 Asm- Part Units Description Index Number 10-1 1408289 Housing 1039558 Roll 1409146 Plate Assembly, Gear 1039170 Pad, Machine 1328674 Clip, Ground Parts Catalog...

  • Page 160: Assembly 11: Optional Paper Drawer (500-Sheet)

    Assembly 11: Optional Paper Drawer (500-Sheet) Service Manual...
  • Page 161 Asm- Part Units Description Index Number 11-1 1408161 Base Assembly 1328630 Deflector 1039170 Feet 1039596 Bellcrank Assembly Spring, Bellcrank--Parts Packet 1381666 1039603 Drive Roller 1039540 D-Roller Tire 1381306 Torquer Motor Spring--Parts Packet 1381666 1381638 Drive Assembly 1039558 Roller 1183299 Switch Assembly Screws--Parts Packet 1381663 Parts Catalog...

  • Page 162: Assembly 12: Fuser

    Assembly 12: Fuser Service Manual...
  • Page 163 1328132 Fuser Cover Spring Redrive Exit, Parts Packet 1381666 Screw, Parts Packet 1381663 1381523 Fuser Lamp 110V 3112-001. Install lamp with color-coded end away from gear. 1381524 Fuser Lamp 220V 3112-001. Install lamp with color-coded end away from gear. 1381011 Fuser Lamp 110V 3116-001, -002, -003.
  • Page 164 Assembly 12: Fuser (Continued) Service Manual...
  • Page 165 Asm- Part Units Description Index Number 12-24 Screw, Mtg., Parts Packet 1381663 1039316 Detack Fingers 1039317 Detack Finger Springs Parts Catalog...

  • Page 166: Assembly 13: Electronics

    Assembly 13: Electronics Service Manual...
  • Page 167 Plate, On/Off Actuator 1408276 Lever, Pivot 1408272 Latch, On/Off 1381645 HV Power Supply 1381653 Cable, HVPS 1381713 RIP Board, 3112-001 1381711 RIP Board, 3116-001, -002, -003 1381694 Engine Board, 3112-001 1381695 Engine Board, 3116-001, -002, -003 1408063 Cable, Erase Lamps/Input Sensor 1321882...
  • Page 168 Assembly 13: Electronics (Continued) Service Manual...
  • Page 169 Part Asm- Numbe Units Description Index 1381664 Standoff Kit, Board Mounting 13-13 1408106 Guide, Font Card 30H3274 Host Card (Twinax) 30H3278 Host Card (Coax) 30H3719 IPDS W/3916 Font Set. See note 1 and 2. 30H3720 IPDS Card W/3812 Font Set. See note 1 and 57G2126 Twinax T-cable IPDS memory (See “Options”...

  • Page 170: Assembly 14: Transfer Roll

    Assembly 14: Transfer Roll Service Manual...
  • Page 171 Asm- Part Units Description Index Number 14-1 1381008 Roll Asm, Transfer 1381652 Housing, Transfer o Rear Lens Asm, Erase o Contact, Transfer Roll o Lamp Asm, Erase 1328356 Cover, Clip Bearing Parts Catalog...

  • Page 172: Assembly 15: Duplex Option

    Assembly 15: Duplex Option Service Manual...
  • Page 173 Asm- Part Units Description Index Number 15-1 1381551 Top Cover Asm 1381552 Duplex System Card 1381554 Bottom Cover 1408940 Exit Sensor Cover 1381555 Exit Sensor Asm 1408906 Bellcrank 1408905 Table Cover (Floor) 1408949 Paper Stop/Slide 1381558 Gear Block Frame Asm 1381559 Input Sensor Card 1326042...

  • Page 174: Assembly 16: Envelope+ And 100-Sheet Auxiliary Feeder

    Assembly 16: Envelope+ and 100-Sheet Auxiliary Feeder Service Manual...
  • Page 175 Asm- Part Units Description Index Number 1408893 Envelope+ Feeder 1408894 100-Sheet Auxiliary Feeder 1408862 Weight Assembly 1622529 Screw 1039615 Spring 1383944 Magnet Assembly 1622303 Washer 1622536 Screw, Mtg 1408869 Cover, Right 1408868 Guide, Large 1408861 Latch, Guide 1408863 Guide, Small 1183273 Spring, Override Lever (100-Sheet Auxiliary Feeder Only)

  • Page 176: Options

    Options Asm- Part Units Description Index Number 1328585 2MB Flash SIMM 1376461 4MB Flash SIMM 1328589 2MB DRAM SIMM (printer memory) 1321882 4MB DRAM SIMM 1321883 8MB DRAM SIMM 1427322 16MB DRAM SIMM 1427323 32MB DRAM SIMM Option Cards 1381050 o INA-LocalTalk 1402219 o INA-Ethernet 10Base2, high memory...

  • Page 177: Miscellaneous

    Grease, 2g 1384076 Grease, conductive 1 oz. 1383586 Grease, damping, 1 oz. 9900692 Grease, IBM #23 1280443 Oil, IBM #10 4 oz. 1381035 Duplex Gears parts packet 1381048 Duplex Flags parts packet 1381669 Jumpers/Flags parts packet 1381664 Standoffs parts packet...
  • Page 178 Service Manual...

  • Page 179: Index

    Index blank page 16 blurred or fuzzy print 16 button test 39 Numerics 100-sheet auxiliary feeder charge roll 39 magnet adjustment 57 connector locations 103 paper feed problem 29 connectors paper restraint spring duplex option autoconnect adjustment 56 cable 113 parts assembly 158 engine board 106 200-sheet paper tray...
  • Page 180 disk test/clean 40 drive motor removal 67 fan (927 error) 19 D-roll assembly fan/redrive removal 66 removal 68 duplex features 1 23 paper jam 18 flash test 43 933 error 18 frame diagnosis 17 lower frame assembly removal paper feed problem 28 duplex feed 1 test 41 lower frame parts assembly duplex feed 2 test 41...
  • Page 181 connectors 105 Token-Ring 25 removal 74 operator panel INA removal 82 problems 26 inner EMC shield removal 91 removal 82 input sensor board removal 76 operator panel//output bin sensor cable connectors 112 optional paper drawer (500-sheet) parts assembly 144 information 52 options problems 24 available 2...
  • Page 182 power-on self test (POST) 12 sensor test 49 preventive maintenance 115 skew print contrast 46 all edges 31 print registration 47 top and bottom only 32 bottom margin 47 stalled printer 32 left margin 47 streaks 33 top margin 47 symptom table 13 print test 1 48 print test 2 48...
  • Page 183 Readers 3112/3116 Printer Service Manual Comment SA40-0843-00 9/94 Form You may use this form to communicate your comments about this publication, with the understanding that Lexmark may use or distribute whatever information you supply in any way it believes appropriate without incurring any obligation to you.
  • Page 184 NO POSTAGE NECESSARY IF MAILED IN THE UNITED STATES BUSINESS REPLY MAIL FIRST CLASS MAIL PERMIT NO. 2659 LEXINGTON, KY POSTAGE WILL BE PAID BE ADDRESSEE LEXMARK INTERNATIONAL INC DEPARTMENT F95 BUILDING 035 3 740 NEW CIRCLE ROAD NW LEXINGTON KY 40511 9954 | | | | | | | | | |...

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