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3112 and 3116 Page Printer: Service Manual

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1. 1 the printer off 2 Remove the right cover 1 E Clip from the rear pivot pin 3 Disconnect all the cables near the RIP board coax twinax serial parallel LAN feeder 4 Remove the Host Card from J6 E gs Ta AA ioe 8 J12 o 9 e IPDS Host 3 Card Card 5 9 ch _ C 7 7 Plastic Screw Standoffs Remove the INA card or hard disk option if present from the upper connector J12 Repair Information 91 5 Remove the 4 nuts 1 57 and the screw lock washer RIPBoard NO 1 50001 InnerEMC Shield DE Screw and ST Lockwasher 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 You need to pull hard but carefully 7 Ifthe RIP board is being replaced remove the ROM SIMM and all options for installation on the new board 8 Remove the 4 nuts N and the standoff ST to separate the RIP board from the inner EMC shield N NO RIP Board 57 E en 8 5 InnerEMC Shield zl 9 If you are here to remo
2. 78 Fuser Sensor Cable Removal Toner Sensor Removal 93 Bee 93 PRENNENT 95 MMC ORE 97 Duplex Option Exit Card And Cover 98 And Entry Sensor Card Removal 99 Duplex Option System Card And Motor Removal 101 Connector Locations 103 Major Assembly Locations 103 XiV Service Manual Gear Train Usage Kit Information 119 Parts Catalog hs deu 121 121 122 Assembly 2 Lower Frame 124 Assembly 3 Upper Frame 126 Table of Contents XV XVI Service Manual 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 The following briefly describes the differences between the models 3112 001 3116 001 3116 002 Maximum print 12 16 16 speed pages min Paper input 200 200 500 capacity pages min Paper output 250 250 500 capacity pages Output bin full No No Yes sensing Standard Memory 2 4 4 MB There is al
3. dix Number Units Description 16 1408893 1 Envelope Feeder 1408894 1 100 Sheet Auxiliary Feeder 1 1408862 1 Weight Assembly 2 1622529 1 Screw 3 1039615 1 Spring 4 1383944 1 Magnet Assembly 5 1622303 1 Washer 6 1622536 1 Screw 7 1408869 1 Cover Right 8 1408868 1 Guide Large 1408861 1 Latch Guide 9 1408863 1 Guide Small 10 1183273 1 Spring Override Lever 100 Sheet Auxiliary Feeder Only NS 1383934 1 Roller Pack Envelope Feeder Only NS 1383935 1 Roller Pack 100 Sheet Auxiliary Feeder Only Parts Catalog 159 Options Asm Part 160 Service Manual index Number Units Description NA 1328585 1 2MB Flash SIMM 1376461 1 4MB Flash SIMM 1328589 1 2MB DRAM SIMM printer memory 1321882 1 4MB DRAM SIMM 1321883 1 8MB DRAM SIMM 1427322 1 16MB DRAM SIMM 1427323 1 32MB DRAM SIMM 1 Option Cards 1381050 1 o INA LocalTalk 1402219 1 INA Ethernet 10Base2 high memory 1402217 1 INA Token Ring high memory 1402218 1 INA Ethernet 10BaseT high memory 1328563 1 Thumbscrew INA 1325231 1 Font Card Adapter 1425267 1 Hard Disk 40MB 1321882 1 4MB IPDS memory 1321883 1 8MB IPDS memory Miscellaneous geg aL Units Description NA 1319128 1 Parallel Wrap Plug 1329048 1 Serial Wrap Plug 1381663 1 Fasteners parts packet 1381666 1 Springs parts packet 1381665 1 Gears 7 14 parts packet 1381145 1 Metering and Prealigner rolls parts packet 1329301 1 Grease 2g 13
4. 63 Unformatted Disk Format the disk 6 Service Manual 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 Replace the disk if instructed by the operator panel 7X Network Card Codes These user codes are documented in the For example 71 X Network Printer Utility Guide SA40 0822 See Network Wrap Tests on page 25 Note 7X codes are normal when an INA 15 installed but no LAN cable is attached Press Disable to continue 80 Scheduled Maintenance Printer has reached 200 000 prints without maintenance count reset 88 Toner Low Toner sensor detects low toner 90X Software Error Unrecoverable software error If one of these errors appeared during POST or while the printer was idle not printing or receiving data or while trying to print one of the internal test pages replace the RIP Board If the error appeared while sending a job from the host to the printer turn the printer off then turn it on and try again If the error appears again call the next level service support for assistance 917 Transfer Roll Error Cannot start servo operation Verify correct cable connections from the engine board to the HVPS Make sure there is continuity be
5. di Number Units Description 11 1 1408161 1 Base Assembly 2 1328630 1 Deflector 3 1039170 1 Feet 4 1039596 1 Bellcrank Assembly NS 1 Spring Bellcrank Parts Packet 1381666 6 1039603 1 Drive Roller 7 1039540 1 D Roller Tire 8 1381306 1 Torquer Motor 11 1 Spring Parts Packet 1381666 12 1381638 1 Drive Assembly 14 1039558 1 Roller 15 1183299 1 Switch Assembly 16 1 Screws Parts Packet 1381663 Parts Catalog 145 Assembly 12 Fuser 146 Service Manual Index Number Units Description 12 1 1381639 1 Fuser and Lamp 110V 3112 001 1 1381641 1 Fuser and Lamp 220V 3112 001 1 1381640 1 Fuser and Lamp 110V 3116 001 002 003 1 1381642 1 Fuser and Lamp 220V 3116 001 002 003 2 4 Screw Fuser Mounting Parts Packet 1381663 3 1382287 1 Fuser Wiper Assembly supply item 4 1328132 1 Fuser Cover 6 1 Spring Redrive Exit Parts Packet 1381666 7 2 Screw Parts Packet 1381663 8 1381523 1 Fuser Lamp 110V 3112 001 Install lamp with color coded end away from gear 8 1381524 1 Fuser Lamp 220V 3112 001 Install lamp with color coded end away from gear 8 1381011 1 Fuser Lamp 110V 3116 001 002 003 Install lamp with color coded end away from gear 8 1381037 1 Fuser Lamp 220V 3116 001 002 003 Install lamp with color coded end away from gear 1381146 1 Hot Roll assembly NS 1329928 1 Backup Roll 9 1381637 1 Thermistor Sensor Asm 10 1328458 1 Redrive Idle Arm Asm 11 132839
6. Enter Diagnostics mode Select PRINTER SETUP Select Auto Clean Frequency Select or to display the frequency desired Select Save Press Return to return to Diagnostics mode main menu Auto Clean Delay This can be set from 1 to 60 seconds with a default of 1 On PON gt Enter Diagnostics mode Select PRINTER SETUP Select Auto Clean Delay Select or to display the delay desired Select Save Press Return to return to Diagnostics mode main menu 38 Service Manual Button Test To test the operator panel buttons PO NS 5 Enter Diagnostics mode Select HARDWARE TESTS Select Button Test Press each button Closed is displayed until the button is released Then Open is displayed Press Return to return to the Diagnostics mode main menu Charge Roll This setting varies the charge roll bias It is used to reduce background on the output In general if there is background and the environment is hot and humid change the setting to low if the environment is cool and dry change the setting to high If the background is not reduced try changing the setting the other way St So D Enter Diagnostics mode Select PRINTER SETUP Select Charge Roll Select High Medium or Low Press Return to return to the Diagnostics mode main menu Diagnostic Aids 39 Defaults Allows setting the following defaults to U S or Non U S values
7. Machine Hangs Displaying Diamonds Service Check Operator Panel Service Check Operator Panel Operator Panel Service Check Paper Feed Base Printer Paper Feed Base Printer Service Check Paper Feed Duplex Unit Paper Feed Duplex Unit Service Check Paper Feed Problem 500 Sheet Second Tray Paper Feed Problem Envelope Feeder 100 Sheet Auxiliary Feeder Automatic Paper Size Sensing Problem Paper Feed Problem 500 Sheet Second Tray Service Check Paper Feed Problem Envelope Feeder 100 Sheet Auxiliary Feeder Service Check Automatic Paper Size Sensing Problem Service Check Host Printing Problems LAN Problems Blank Page Black Page Random Marks Regularly Spaced Marks Skew all edges Skew top and bottom only Light Print Blurred or Fuzzy Print Residual Image Honeycomb Background Go to Host Printing Problems on page 22 Go to LAN Problems on page 24 Blank Page Service Check Black Page Service Check Random Marks Service Check Regularly Spaced Marks Service Check Skew Service Check Skew top and bottom Service Check Light Print Service Check Blurred Fuzzy Print Service Check Residual Service Check Honeycomb Service Check Background Service Check Diagnostic Information 13 Symptom Action or Service Check Horizontal Void or Streak Horizontal Service Check Vertical Void or Streak Vertical Service Check Banding Banding Service Check Banding
8. Press Return to return to the main diagnostic menu Print Test 3 This test generates 2 printouts a solid black page and a dot pattern that can be used to evaluate print quality Print Test 3 will not duplex 1 2 3 Enter Diagnostics mode Select PRINT TESTS Select Print Test 3 48 Service Manual 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 The Quick Disk Test does not destroy data on the disk existing data is read and stored prior to the testing of each track and then rewritten after the track is tested Enter Diagnostics mode Select DEVICE TESTS Select Quick Disk Test The display will indicate Test Passed or Test Failed Press Return to return to Diagnostics mode main menu gum ox m Quick Test The Quick Test is activated by pressing Ready from any screen while in Diagnostics mode as well as being an entry under PRINT REGISTRATION It provides a simple page alignment pattern that prints faster than the other print tests Sensor Test 1 Enter Diagnostics mode 2 Select HARDWARE TESTS 3 Select Sensor Test 4 Select on
9. 5VDC on B24 of J6 If the voltage is incorrect replace the engine board See RIP Board Inner EMC Shield and Engine Board Removal on page 91 f The host attachment card receives the correct voltage but the printer is not communicating with the host e For twinax ensure that other devices on the line are OK Diagnostic Information 23 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 Remove the IPDS card from the host attachment card or an IPDS memory SIMM problem 2 Install the host attachment card without the IPDS card 3 Ifthe lights are OK now you have an IPDS card problem Ensure that the memory SIMM on the IPDS card is seated If this does not fix the problem try new IPDS memory If you still have a problem install a new IPDS card Then tailor the configuration information using printout 3 you made at the beginning of the MAP LAN Problems You cannot find a printer or network problem but jobs still do not print If the network card checks out successfully the problem may be with the hardware or software outside of the network card Below are some suggestions to the customer for checking hardware and software for possible problems Refer the customer to the Network Printer Utility Guide SA40 0822 to find the problem This guide is shipp
10. 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 It is undetectable when printing text and is most noticeable on fine dot or horizontal line patterns such as the second page of Print Test 2 or Print Test 3 Inspect the gear train and the paper feed rollers for wear dam age dirt or binds Background Areas that are supposed to stay blank are getting small amounts of toner deposited on them Clean the erase lamps and the printhead win dow Verify that all the erase lamps are working by powering on or off with the top cover open Verify that there is 24VDC on engine board 9 1 land between 15 and 20VDC on engine board J9 2 Shorting engine board J9 2 to ground should turn on all the erase lamps Check the erase lamp cable continuity Replace the transfer roll housing if the volt age and the cable are good Inspect the contacts on the HVPS make sure each spring loaded tact returns when pressed and released Rough Paper mode can cause background on some papers if Rough Paper mode is on turn it off and run the print test again Printing on coated paper or using refilled print cartridges can also cause background Run the Print Test with the RIP Board removed and check the following 14 Service Manual voltages then stop the test and check the voltages again
11. Note Please direct all requests for copies of publications to your point of purchase Publications are not stocked at the location to which this form is addressed IF MAILED INU FUSTAGE NECESSARY 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 Fold Here eur m9
12. PCL is a registered trademark of the Hewlett Packard Company PCL 5 is Hewlett Packard Company s designation of a set of printer commands language and functions included in its printer products This printer is designed and manufactured by Lexmark International Inc to be compatible with the PCL 5 language This means the printer recognizes PCL 5 commands used in various applications programs and that the printer emulates the functions corresponding to the commands PostScript is a registered trademark of Adobe Systems Incorporated PostScript is Adobe Systems designation of a set of printer commands language and functions included in its software products This printer is designed and manufactured by Lexmark International Inc to be compatible with the PostScript Level 2 language This means the printer recognizes PostScript Level 2 commands used in the various application programs and that the printer emulates the functions corresponding to the commands Service Manual 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 part
13. Print Cartridge Contacts Transfer Roll Contacts Transfer Roller Housing Erase Lamp Window Transfer Roll Connector Locations 105 Engine Board Connectors 106 Service Manual Engine Board Connectors Connector Name J1 Operator Panel Output Bin Sensor J2 Printhead Mirror Motor Fan J3 Duplex 4 LVPS J5 Reserved J6 Paper Drive Motor J7 Board to Board Connector Rip Board Engine Board J8 Exit Paper Size Sensor Fuser Solenoid J9 Input Toner Sensor Board Erase Lamps J10 Envelope Feeder Magnet J11 Printhead Hsync J12 Printhead Laser J13 HVPS J14 Paper Feed Magnet J15 500 Sheet Feed Option Connector Locations 107 RIP Board J7 8 O OD co JT2 Jio 3e a rn to a Oo c3 EM I ra E es co 2 0 J J3 a OO ou pri Connector J1 J2
14. 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 Select U S or NON U S 5 Press Return to return to Diagnostics mode main menu Disk Test Clean This is two hour test that should be performed only on disk that contains bad data and is therefore unusable This test destroys all data on the disk by doing multi pass write read on every block of the disk Bad blocks are flagged and removed from use If over 2000 bad blocks are found the test stops and the display indicates the disk must be replaced message describing test progress is displayed during the test Enter Diagnostics mode Select DEVICE TESTS Select Disk Test Clean Select CONTINUE to start the test or CANCEL to return to Diagnostics mode main menu Select CANCEL to interrupt the test 6 Press Return to return to Diagnostics mode main menu ci e 40 Service Manual 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 2 3 4 Enter Diagnostics mode Select DUPLEX TESTS Select Duplex Feed 1 Select Tray 1 or Tray 2 Note Paper feeds all the way into the duplex unit and stop 5 6 7 The me
15. Voltage while Printing Less than 5VDC OVDC Less than 5VDC OVDC Fluctuates OVDC between pages 1 5VDC Less than 1VDC 6VDC Connector Voltage while Idling 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 Users who run large jobs with very dense graphics in high humidity environments may get some print quality improvement from increasing the Transfer setting users with more normal jobs will see no difference Make sure the HVPS contacts to the transfer roll housing are in good condition Black Page Black output is usually caused by an incorrect high voltage in the print ing process resulting in toner development on the entire photoconduc tor drum Check the condition of each HVPS contact and make sure they spring back when pressed Check the continuity of the HVPS cable Make sure the following voltages are correct if they are not replace the engine board Connector Voltage J13 5 to J13 4 24VDC J13 6 to J13 4 24VDC Run the Print Test with the RIP Board removed Make the following volt age checks while printing and again while idling If the voltages are not Diagnostic Information 15 correct replace the engine board Voltage while Voltage while Printing Idling J13 1 to J13 4 4 5VDC 13 2 10 13 4 4VDC OVDC Connector If no other trouble is found rep
16. 82 Service Manual e Open the top cover Then open the right side cover Remove the Host Attachment Card grounding screw 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 You will need to pinch the standoffs With IPDS separate the Host Attachment Card and the IPDS Card Remove the 2 screws from the host attachment card Each card is a separate FRU Transfer the IPDS memory to the new IPDS card Repair Information 83 Host Attachment IPDS Card Replacement IPDS Card Twinoxor Coax Card Note The following directions also apply when you are installing a new IPDS card 1 2 With IPDS attach the Host Attachment Card to the IPDS Card 2 screws Connect the Host Attachment Card onto the system board With IPDS snap the IPDS Card onto the standoffs Ensure that the connector is seated Install the grounding screw washer Close the right side cover and the top cover Connect the host attachment cable Twinax or Coax Use the printouts to return all host settings and non host settings to the original customer values Note To avoid losing Host settings at power off ensure that you select Save Settings within the SAVE RESTORE menu in Network Menu 1 Exit Sensor Board Removal SUSEN Remove the front cover Disconnect the fuser sensor cable Disconnect th
17. Copyright International Business Machines Corporation 1994 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 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 Any functionally equivalent product program or service that does not infringe any existing intellectual property rights may be used instead Evaluation and verification of operation in conjunction with other products programs or services except those expressly designated by the manufacturer are the user s responsibility Electronic Emission Notices Consult the following list for any emission that may apply in your country Federal Communications Commission FCC Statement This printer has been tested and found to comply with the limits for a Class B digital device pursuant to Part 15 of the FCC Rules These limits are designed to provide reasonable protection against harmful interference in a residential installation This equipment generates uses and can radiate radio frequency energy and if not installed
18. Denmark 3 1342536 1 Power Cord Set New Zealand Australia Argentina Paraguay 3 1342537 1 Power Cord Set Israel 3 1342543 1 Power Cord Set UK Malaysia Singapore 4 1408274 1 Rod on off 4A 1408277 1 Support Rod on off 4B 1408198 1 Actuator On Off 4C 1408275 1 Plate On Off Actuator 4D 1408276 1 Lever Pivot 4E 1408272 1 Latch On Off 5 1381645 1 HV Power Supply 1381653 1 Cable HVPS 6 1381713 1 RIP Board 3112 001 6 1381711 1 RIP Board 3116 001 002 003 7 1381694 1 Engine Board 3112 001 7 1381695 1 Engine Board 3116 001 002 003 NS 1408063 1 Cable Erase Lamps Input Sensor 9 1321882 1 DRAM SIMM 4 MB 9 1328589 1 DRAM SIMM 2 MB 9 1321883 1 DRAM SIMM 8MB 11 1381651 1 Inner EMC Shield Parts Catalog 151 Assembly 13 Electronics Continued 152 Service Manual pan es Index hai Units Description NS 1381664 1 Standoff Kit Board Mounting 13 13 1408106 1 Guide Font Card 14 30H3274 1 Host Card Twinax 14 30H3278 1 Host Card Coax 15 30H3719 1 IPDS W 3916 Font Set See note 1 and 2 15 30H3720 1 EE Card W 3812 Font Set See note 1 and 16 5702126 1 Twinax T cable NS IPDS memory See Options on page 160 NS 2 Screw HVPS Mtg Parts Packet 1381663 18 2 Screw LVPS Mtg Parts Packet 1381663 19 1383513 1 Switch On Off 20 1039456 1 Switch Pivot 21 1381714 1 ROM SIMM Note 1 If you are unsure of the font set see PN label on the IPDS card
19. Moving the number ina negative direction moves the text up the page and narrows the top margin e Bottom Margin can set between 20 and 20 Moving the number in a positive direction moves the margin down and narrows the bottom margin Moving the number in a negative direction moves the text up the page and leaves a wider bottom margin Select to move the number in a positive direction or select to move the number in a negative direction Select SAVE to save your settings when they are correct Select Quick Test to check your settings Press Return to return to the Diagnostics mode menu Diagnostic Aids 47 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 ONS Enter Diagnostics mode Select PRINT TESTS Select Print Test 1 Select Single or Continuous Select CANCEL to stop continuous print Press Return to return to the main Diagnostics mode menu Print Test 2 Print Test 2 generates two printouts a page similar to the test page and a fine dot pattern which can be used to evaluate banding or other print quality problems Print Test 2 will duplex if the duplex option is installed To run Print Test 2 o grde o Ww Enter Diagnostics mode Select PRINT TESTS Select Print Test 2 Select Single or Continuous Select Cancel to stop continuous print
20. 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 39 Complex Page 43 Font Card Not Supported 44 Defective Font Card 47 Font Card Removed While Printing Page too complex to print 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 Font card format not supported by printer Defective font card installed in font slot Printer needs data on removed card 51 Defective Flash The printer detects a defective Flash SIMM If the error recurs replace the Flash SIMM 52 Flash Full 53 Unformatted Flash Not enough flash memory for data requested to be stored Flash problem at POR or while attempting to write 54 Serial Error Framing or parity error on serial 57 Check Duplex Connection The duplex unit has been electrically disconnected from the printer but the printer top cover is not open Check the auto connect plugs on the duplex unit and the printer 58 Duplex Not Attached 59 Duplex Cover Open 62 Disk Full Duplex is no longer connected and printer top cover 15 closed Top cover of duplex unit is sensed open Not enough disk space for data that has been requested to be written to disk
21. 2 Detent Box 8 1329013 1 Right Cartridge Latch 9 1 Spring Parts Packet 1381666 11 1039271 1 Shaft Gear 2 12 1 Nut Gear 2 Parts Packet 1381663 13 1 Lockwasher Gear 2 Parts Packet 1381663 14 1329144 1 Left Cartridge Latch 15 1408645 1 Gear Train Cover 18 1328428 1 LH Bracket Duplex 19 1328427 1 RH Bracket Duplex NS 1 Screw Duplex Bracket Parts Packet 1381663 20 1039476 1 Grommet Printhead Cable 22 1408623 2 Cable Clamp 23 1408721 1 Guide Cable NS 4 Screw Cable Clamp Parts Packet 1381663 Parts Catalog 125 Assembly 3 Upper Frame 126 Service Manual Part Index Number Units Description 3 1 1325196 1 Cover Hinge Asm 3112 001 3116 001 does not include the load box 1 1381045 1 Cover Hinge Asm 3116 002 003 does not include the load box 1A 1 Screw Cover Hinge Parts Packet 1381663 2 1325103 1 Upper Plate Asm 3112 001 3116 001 2 1328218 1 Upper Plate Asm 3116 002 003 3 1427306 1 Cartridge Load Box 4 1 Right Cam Button Parts Packet 1381663 5 1039693 1 Right Bellcrank 6 1 Left Cam Button Parts Packet 1381663 7 1 Spring Bellcrank Parts Packet 1381666 8 1039692 1 Left Bellcrank 9 1383998 1 Fan Asm NS 1424481 1 Pad Acoustic Fan 10 1328222 1 Plenum Asm 11 1 Retainer Parts Packet 1381663 12 1 Spring Parts Packet 1381666 16 2 Screw Plenum Mtg Parts Packet 1381663 18 1408616 1 Handle Latch with Grip 3112 001 3116 001
22. Information Vii danni personali personale di assistenza autorizzato consapevole di ci 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 informaci n 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 el ctricas y dafios personales durante el desmontaje y la reparaci n de la m quina El personal cualificado comprende esto y toma las precauciones necesarias Los dispositivos de seguridad de algunas partes quiz no siempre puedan ser reconocidas a simple vista Por lo tanto las partes de reemplazo deben poseer caracter sticas id nticas o equivalentes a las partes originales Sikkerhedsoplysninger Oplysningerne om vedligeholdelse af dette produkt er forberedt med henblik p professionelt servicepersonale og ber derfor ikke benyttes af andre Risikoen for elektrisk st d eges under demontering og service af dette produkt hvorfor der b r tages de n dvendige forholdsregler Sikkerhedsforanstaltningerne er ikke altid lige penbare for alle reservedele Der ber derfor kun anvendes originale reservedele eller reservedele med samme egenskaber som de oprindelige Ozone Information This product does
23. N 4 AY 4 be SN Mies LC EE Ee SQL Right Front View Left Rear View Repair Information 87 Paper Size Switch Removal 1 Remove the paper tray 2 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 88 Service Manual Printhead Removal IMPORTANT The Printhead is ESD sensitive It is not serviceable and should be replaced as a unit 1 Turn the printer off Remove the print cartridge Remove the right B nd top Covers Remove the exit redrive and its belt Remove the air plenum Remove the screws A and the pointer Cut and discard the Printhead cable clamp Disconnect the connectors B 9 Remove the Printhead and the Printhead shroud 10 Pry off the grip rings holding the Printhead to the shroud Note After replacing the Printhead perform the Printhead skew adjustment N Repair Information 89 Y ASE WZ A 0 1 90 Service Manual 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 22225 pit gee Prod X RIP Board 1 2 Engineboard J6 LA isconnected 7 behind RIP board Inner EMC Shield
24. PRINT TESTS Print Tests 1 Print Tests 2 Print Tests 3 Envelope Print Tests PRINT REGISTRATION Left Margin Top Margin Bottom Margin Quick Test Diagnostic Aids 35 HARDWARE TESTS LCD Test Sensor Tests Toner Low Output Bin Input Exit Cover Open Button Test Wrap Tests Parallel Serial Memory Tests DRAM ROM PAGE COUNTS Page Count Permanent Page Count Maintenance Count PAPER FEED TESTS Tray 1 Tray 2 Feeder Manual 36 Service Manual 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 RESET PRINTER Diagnostic Aids 37 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 This pause minimizes the toner accumulating on the fuser cleaner IO Enter Diagnostics mode Select PRINTER SETUP Select Auto Clean Select On or Off Press Return to return to Diagnostics mode main menu Auto Clean Frequency This can be set from 10 to 255 pages with a default of 50 Hr BW o
25. Press Return to return to the Diagnostics mode main menu AN R DE 50 Service Manual Wrap Tests The Wrap Tests check the circuits used to communicate with the host computer To run the Wrap Test 1 2 3 nor rcm 9 Turn the printer off Disconnect the interface cable Install the wrap plug in one of the interface cable connectors Note Install the parallel wrap plug part no 1319128 for the allel test or install the 25 pin serial wrap plug part no 1329048 for the serial test Enter Diagnostics mode Select HARDWARE TESTS Select Wrap Test Select Parallel for the parallel port or Serial for the 25 pin serial port Select Single or Continuous Select CANCEL to stop continuous A Passed message indicates the printer connection to the printer cable connector is good A Failed message indicates a defective RIP board Note Ignore the number displayed after a failure is displayed 10 Press Return to return to the Diagnostics mode main menu 11 Turn the printer off then remove the wrap plug from the interface connector Diagnostic Aids 51 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 Print the test page 3 As soon as the leading edge of the paper is vi
26. Remove the engine board Remove the load box latches A Release the latches B Pivot the upper frame to the rear to release the spring tension Unsnap the plastic insert D holding the upper frame cables in the right side frame 10 Remove the screws 11 Remove the upper frame cables through the side frame 12 Lift the upper frame off the machine NO BR D Repair Information 95 96 Service Manual 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 Release latch D and lift the table cover out of the front assembly Repair Information 97 Duplex Option Exit Card And Cover Removal Pry up on tabs A After the tabs are released lift up on the 1 cover rotate the cover out and slide it to the right to completely remove it 2 Disconnect the exit sensor card cables 3 Depress the exit sensor flag actuator B and lift out the exit sensor card 98 Service Manual 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 Release the two latches A on the frame assembly and lift it out of the bottom cover
27. and used in accordance with the instructions may cause harmful interference to radio communications However there is no guarantee that interference will not occur in a particular installation If this equipment does cause harmful interference to radio or television reception which can be determined by turning the equipment off and on the user is encouraged to try to correct the interference by one or more of the following measures e Reorient or relocate the receiving antenna e Increase the separation between the equipment and receiver e Connect the equipment into an outlet on a circuit different from that to which the receiver is connected e Consult your point of purchase or service representative for additional suggestions Notices and Safety Information iii The manufacturer is not responsible for any radio television interference caused by using other than recommended cables or by unauthorized changes or modifications to this equipment Unauthorized changes or modifications could void the user s authority to operate the equipment Note To comply with FCC regulations on electromagnetic interfer ence for a Class B computing device the printer cable must be shielded 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 int
28. are working correctly If the cus tomer still has a problem printing see LAN Problems on page 24 Output Bin Sensor Examine the bin area for obstructions or damage Run the diagnostic sensor test Note There 15 an output bin sensor on the 3116 002 and 3116 003 Itis 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 On the sensor the voltage from pin 2 to pin 3 pin 1 is the bottom pin should change from 0 to 5VDC as the sensor is blocked and unblocked Pin 1 should always measure 5VDC Replace the sensor the sensor card or the operator panel bin sensor cable as necessary Operator Panel Problem Note If the printer is in Menus Disabled mode you can activate the menus by powering on the printer with the Return button and the top button pressed Repeat the POR procedure to disable the menus again after service If you need to change the displayed language use the Setup Menu Possible causes failed LCD or operator panel card cable or connector problem or engine board problem Replace the operator panel if POR stops with half rows of pels dis played Run the diagnostic tests for the LCD and for the buttons If only some buttons or pels work replace the operator panel 26 Service Manual If the printer beeps 5 times at POR or if the operator panel is blank check f
29. assembly missing or disconnected No first hsync See Printhead on page 29 932 Printhead Error Lost hsync See Printhead on page 29 934 Printhead Error 935 Printhead Error Lost lock condition See Printhead on page 29 Mirror motor unable to reach operating speed See Printhead on page 29 941 ROM SIMM Service Manual ROM SIMM failed CRC code data or font data Run the diagnostic Memory Test for ROM Replace the SIMM if the test fails or the problem recurs after POR replace the RIP Board if the SIMM does not fix the problem 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 948 Engine Board Engine ASIC electronics failure Replace the engine board 950 RIP Board SRAM failure Replace the RIP Board 951 Engine Board PQET SRAM failed verification test Replace the engine board 952 Engine Board Unable to zero PQET SRAM Replace the engine board 953 Engine Board NVRAM failure Replace the engine board 954 Engine Board Printhead crystal not functioning correctly Replace the engine board 960 Memory Error Bad or missing DRAM in the base DRAM slot Reseat the DRAM and run the diagnostic Memory Test for DRAM POR the printer If the t
30. honeycomb horizontal void or streak HVPS connectors 105 INA removal inner EMC shield removal input sensor board removal L LAN information problems LCD test light print lubrication specifications 115 LVPS cover removal removal maintenance approach maintenance kit count marks random regularly spaced vertical void or streak memory tests menu structure diagnostics mode mirror motor fan cable connectors models available N network card 977 errors network connectors network wrap tests Ethernet 10Base 2 Token Ring operator panel problems removal operator panel output bin sensor cable connectors optional paper drawer 500 sheet parts assembly options available parts assembly output bin sensor page count paper drawer base parts assembly paper feed alignment gears parts assembly parts assembly 130 rollers removal paper feed drive parts assembly paper feed problem 100 sheet auxiliary feeder 500 sheet second tray base printer duplex unit Envelope Feeder paper feed tests paper size sensing problem paper size switch removal parts catalog how to use permanent page coun power consumption 2 Index 165 power on self test POST preventive maintenance print contrast print registration bottom margin print test 1 print test 2 print test 3 print test page print test with RIP board removed printer ground straps connec
31. 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 e Front pivot latch studs e Gear no 8 teeth at gear no 7 contact points e Gear no 9 teeth at gear no 11 contact points e Gear no 9 teeth at gear no 8 and gear no 10 contact points e Cover Hinge Spring tips Cartridge ramps at top center of both sides frames Latch handle tips e Area of contact between fuser release bail and roll e All release arms areas of contact of fuser solenoid lever Use grease p n 1329301 to lubricate gear nos 2 3 4 5 6 and 12 Use all the grease in the packet Apply part of the grease rotate the gears and apply the rest The teeth of gears 3 4 and 5 should be completely coated 116 Service Manual Use grease p n 1384076 to lubricate 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 117 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 Remove the print cartridge 2 Fold a lint free cloth over a cotton swab 3 Open the shutter 4 Insert the swab and cloth combination in the printhead window slot then slide it
32. not produce measurable amounts of ozone gas viii Service Manual 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 Diagnostic Information contains error code table symptom table and service checks used to isolate failing field replaceable units FRUs Diagnostic Aids contains tests and checks used to locate or repeat symptoms of printer problems Repair Information provides instructions for making printer adjustments and removing and installing FRUs Connector Locations uses illustrations to identify the major components and test points on the printer Preventive Maintenance contains safety inspection guidelines lubrication specifications and maintenance information to prevent problems and maintain optimum performance Parts Catalog contains illustrations and part numbers for individual FRUs Preface ix X Service Manual Table of Contents Notices and Safety Information ii Electronic Emission Notices JA iii Federal Communications Commission FCC Statement iii Industry Canada Compliance Statement iv The United Kingdom Telecommunic
33. the bottom latches C Y dr Repair Information 81 Operator Panel Removal 1 Remove the top cover 2 3 Disconnect the operator panel cable Remove the operator panel mounting screws from the inside of the top cover INA or Hard Disk Removal 1 2 3 4 Open the top cover Open the right cover Remove mounting screws as required Pop the card off the plastic standoffs Host Attachment Card IPDS Card Removal Warning First read Handling ESD Sensitive Parts on page 55 These procedures can be used for all 311x but some will not have the IPDS Card 1 If the printer POSTs ok print the menu printouts which describe the customer configuration This will allow you to restore any settings that are lost when you replace electronics MENUS TEST MENU PRINT MENUS MENUS NETWORK MENU1 TEST MENU PRINT MENUS READY Explain to the customer that if he received code patches they may not be included on the new card Note The host attachment card has a code patch if a appears in the code level on the first page of the Host print test The IPDS card has a code patch if appears in the code level on the second page A higher level of code without a probably incorporates the code patch Disconnect the host attachment cable Twinax or Coax from the Host Attachment Card Remove all external trays
34. the print cartridge Remove the top cover Remove the lower redrive shaft by disengaging the right end to the rear of the machine Disconnect the long redrive belt A and slip it off the lower shaft 3116 002 Disconnect the output bin sensor cable Remove the redrive assembly screws D Remove the plenum assembly and screws B Unplug the fan cable The fan C can now be removed from the plenum assembly 68 Service Manual 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 BEFORE YOU SERVICE THIS UNIT ALLOW THE MACHINE TO COOL FOR 5 MINUTES 1 2 3 Je mb Unplug the power cord Remove the printer cartridge Through the opening for the paper output flip the metal ESD shield up out of the way and disconnect the exit sensor cable from the fuser Remove the fuser cover Disconnect the power wires A from the left side of the fuser Remove the fuser input guide Completely loosen the four fuser mounting screws Lift the fuser out of the machine Repair Information 69 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 guid
35. transfer roll surface Support the left bearing cover from the front with your left hand Useasmall screwdriver to push the rear latch forward and release the bearing cover This exposes the bearing on the end of the transfer roll 4 Grasp the bearing on the end of the transfer roll Lift slightly and move it to the left until the right end of the transfer roll shaft slides out of the right side bearing 5 Remove the transfer roll 6 Liftthe right bearing straight up and out of the machine Repair Information 65 D roll Assembly Removal 1 DURAN Unplug the power cord Remove the paper tray Remove the print cartridge Remove the fuser input guide Remove the transfer roll housing assembly Pull the D roll firmly to the left to remove it Note The D roll is designed to be installed only once if it is removed for any reason it should be replaced with a new one Note lt may take considerable force to install the new D roll 66 Service Manual Drive Motor Removal 1 Unplug the power cord Remove the RIP board and inner EMC shield together Remove the engine board Remove the fuser input guide Remove the transfer housing assembly Remove the gear cover by releasing the rear latch and lifting up Remove the motor mounting nuts B and screws D Work the motor out of the machine Repair Information 67 Fan Redrive Removal 1 B N Open the top cover Remove
36. wrist band to the system ground point This discharges any static electricity in your body to the machine Hold the ESD sensitive part by its edge connector shroud cover do not touch its pins If you are removing a pluggable module use the correct tool e Do not place the ESD sensitive part on the machine cover or on a metal table if you need to put down the ESD sensitive part for any reason first put it into its special bag Machine covers and metal tables are electrical grounds They increase the risk of damage because they make a discharge path from your body through the ESD sensitive part Large metal objects can be discharge paths without being grounded Prevent ESD sensitive parts from being accidentally touched by other personnel Install machine covers when you are not working on the machine and do not put unprotected ESD sensitive parts on a table e If possible keep all ESD sensitive parts in a grounded metal cabinet case Be extra careful in working with ESD sensitive parts when cold weather heating is used because low humidity increases static electricity Repair Information 55 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 B A Y T II T 1 940 2mm
37. 0 075 0 008in Rear View Paper Restraint Spring On The 100 Sheet Auxiliary Feeder 1 Loosen the mounting screw A 2 Position the spring B so it clears the separator roller by 1 0 0 0 2 mm 0 040 0 008 in 3 Tighten the mounting screw B A Af TT 1 0 40 2mm 0 040 0 008in Rear View 56 Service Manual Envelope Feeder Magnet And 100 Sheet Auxiliary Feeder Magnet 1 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 3 Tighten the screw 4 Check the adjustment on both sides of the gear 0 30 0 20 mm 0 012 0 008 in Repair Information 57 Paper Feed Magnet 1 P 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 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 Note Don t let the sound deadening material on the armature interfere with the adjustment Keep the armature latched and loosen the magnet mounting screw Note The flat side of the D roll is down when the feed is latched Insert feeler gage Rota
38. 08690 Toner Shield 10 1328317 1 Left Frame 11 1039175 1 Tray Frame Spring 12 1042211 1 Belt Redrive 3112 001 3116 001 12 1328192 1 Belt Redrive 3116 002 003 13 1328193 1 Belt Auxiliary 3116 002 003 14 1328172 1 Shaft Asm Lower Redrive 15 1408744 1 Deflector Redrive 3112 001 3116 001 15 1408804 1 Deflector Redrive 3116 002 003 16 1042206 1 Shaft Asm Upper Redrive 17 1328169 1 Shaft Asm Auxiliary Shaft 3116 002 003 18 1042207 1 Shaft Asm Middle Redrive 3112 001 3116 001 18 1328173 1 Shaft Asm Middle Redrive 3116 002 003 19 1381073 1 Toner Sensor 20 1328323 1 Shaft 3116 002 003 21 1328322 2 Roller backup 3116 002 003 22 1328321 1 Spring backup 3116 002 003 23 2 Jumper Ground Parts Packet 1381669 24 1381015 1 Sensor Asm Paper Size 25 1183244 1 Arm Tray Frame 26 4 Screw Deflector Mtg Parts Packet 1381663 28 1402325 1 Bearing NS 1328450 1 Spring Shaft Grd 3116 002 003 NS 1427418 1 Spring Shaft Grd 3112 001 3116 001 Parts Catalog 131 Assembly 5 Paper Feed Continued 132 Service Manual lidax Number Units Description 5 29 1408717 1 Outer Redrive Shield 29 1328381 1 Outer Redrive Shield 3116 002 003 NS Screw Backup Spring Mtg Parts Packet 1381663 30 1 Spring Arm Tray Bias Parts Packet 1381666 31 2 Screw Redrive Mtg Parts Packet 1381663 33 1038186 1 Guide Fuser Input 34 1381527 1 Redrive Assembly 3116 002 003 34 140
39. 18 1408216 1 Handle Latch with Grip 3112 002 003 19 1328308 2 Sleeve 20 1 Spring Handle Parts Packet 1381666 21 2 Ground Strap Parts Packet 1381669 23 1 Retainer E Clip Parts Packet 1381663 24 1 Pivot Handle Parts Packet 1381663 27 1 Washer Parts Packet 1381663 28 2 Screw Shaft Mtg Parts Packet 1381663 30 1328467 1 Spring Plenum Parts Catalog 127 Assembly 4 Printhead 128 Service Manual d s Number Units Description 4 1 1381635 1 Printhead 2 1328431 1 Printhead Shroud Assembly 3 1408033 1 Cable Fan Mirror Motor 4 1408034 1 Cable hsync NS 1038199 1 Cable Tie 5 1425284 1 Cable Laser Install with marked end to Printhead 6 1 Pin Parts Packet 1381666 7 1 Spring Parts Packet 1381666 8 2 Screw Printhead Mtg Parts Packet 1381663 1 Screw Hex Headed Parts Packet 1381663 8B 1 Pointer Parts Packet 1381663 8C 1 Clip Hex Screw Ground Parts Packet 1381663 9 2 Retainer Parts Packet 1381663 Parts Catalog 129 Assembly 5 Paper Feed 130 Service Manual d s Number Units Description 5 1 1039101 1 Outer Deflector 2 1183597 1 Upper Deflector 3 1381670 1 Inner Deflector with Roller 4 1381636 1 Input Sensor Board 5 1408859 1 Lower Deflector 6 1 Flag Input Sensor Parts Packet 1381669 7 1408703 1 Right Rail Asm Without Gears 7A 1408249 Extension Asm Right Rail 8 1039170 4 Machine Pad 9 14
40. 21 Assembly 1 Covers 122 Service Manual d s Number Units Description 1 1 69G5012 1 Top Cover 3112 001 1 69G5212 1 Top Cover 3116 001 1 69G5055 1 Top Cover 3116 002 003 1A 1381631 1 Operator Panel Asm NS 4 Screw Operator Panel Parts Packet 1381663 2 1381656 1 Tray Asm Stacker 3112 002 003 NS 1 Spring Stacker Parts Packet 1381666 3 1408176 1 Right Cover Asm 4 1408163 1 Latch Right Cover NS 1408233 1 Spring Right Cover Latch 5 1408184 1 Front Cover Asm 3112 001 3116 001 5 1408384 1 Front Cover Asm 3116 002 003 5A 1425457 1 Bracket Front Cover Retaining 7 1329070 1 Output Deflector 8 1408326 1 Output Deflector Lever NS 1 Spring Deflector Lever Parts Packet 1381666 12 1408188 1 Left Cover 14 1381657 1 Paper Stop Asm 3112 001 3116 001 14 1381658 1 Paper Stop Asm 3116 002 003 15 1381659 1 Cover Asm Front Exit Tray 17 1408394 1 Manual Feed Tray with guide NS 1408172 1 Plug Printhead Adjustment 3116 001 Parts Catalog 123 Assembly 2 Lower Frame 124 Service Manual sas LR Units Description 2 1 1381667 1 Lower Frame Assembly 2 1381632 1 Motor Brkt and Gear Asm 3112 001 2 1381633 1 Motor Brkt and Gear Asm 3116 001 002 003 3 1408572 1 Plate Asm Gear Box Mtg 4 1408779 1 Clip Ground Motor Mtg NS 2 Mtg Screw Motor Asm Parts Packet 1381663 NS 4 Mtg Nut Gear Asm Parts Packet 1381663 6 1328243 1 Gear 2 7 1039391
41. 5544 5256 00 3112 and 3116 Page Printer Service Manual First Edition February 1995 The following paragraph does not apply to the United Kingdom or any country where such provisions are inconsistent with local law INTERNATIONAL BUSINESS MACHINES CORPORATION 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 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 A form for reader s comments is provided at the back of this publication If the form has been removed comments may be addressed to Department 582 Building 004L IBM Printing Systems 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
42. 7 1 Paper Exit Bd Asm 12 1 Flag Parts Packet 1381669 13 1039481 1 Fuser Power Cable 14 1381662 1 Cable Fuser Paper Size Sensor 15 1381155 1 Thermal Fuse Asm 15A 1328134 2 Clips Thermal Fuse 16 1427304 1 Bail Handle 17 1381018 1 Fuser Solenoid Asm 18 2 Screw Fuser Solenoid Mtg Parts Packet 1381663 19 1328124 1 Gear No 1 Hot Roll 20 1 Gear 18T Redrive Parts Packet 1381665 21 1 Spring Redrive Idler Parts Packet 1381666 22 1328437 1 Contact Asm Right Lamp 23 1328438 1 Contact Asm Left Lamp Parts Catalog 147 Assembly 12 Fuser Continued 148 Service Manual index Number Units Description 12 24 Screw Mtg Parts Packet 1381663 25 1039316 Detack Fingers 26 1039317 Detack Finger Springs Parts Catalog 149 Assembly 13 Electronics 150 Service Manual E Units Description 13 1 1381643 1 LV Power Supply 110V 1 1381644 1 LV Power Supply 220V NS 1328463 1 Fuse LVPS SB 12A 110V NS 1328464 1 Fuse LVPS 6 3A 220V 3 1342514 1 Power Cord Set U S Canada Mexico Central and South America Saudi Arabia LV 3 1342530 1 Power Cord Set Germany France Spain Norway Finland the Netherlands Austria Belgium Brazil Greece Luxembourg Portugal Sweden Turkey Indonesia Saudi Arabia HV 3 1342532 1 Power Cord Set S Africa 3 1342533 1 Power Cord Set Switzerland 3 1342534 1 Power Cord Set Chile Italy 3 1342535 1 Power Cord Set
43. 84076 1 Grease conductive 1 oz 1383586 1 Grease damping 1 oz 9900692 1 Grease IBM 423 1280443 1 Oil IBM 10 4 oz 1381035 1 Duplex Gears parts packet 1381048 1 Duplex Flags parts packet 1381669 1 Jumpers Flags parts packet 1381664 1 Standoffs parts packet 1381661 1 Indicator parts packet 200 sheet tray Parts Catalog 161 162 Service Manual Index Numerics 100 sheet auxiliary feeder magnet adjustment paper feed problem paper restraint spring adjustment parts assembly _ 158 200 sheet paper tray parts assembly 138 top cover removal 65 500 sheet paper drawer parts assembly 500 sheet paper tra parts assembly top cover removal 500 sheet second tray A paper feed problem abbreviations adjustment 100 sheet auxiliary feeder magnet envelope restraint spring Envelope Feeder magnet fuser drive gear backlash fuser solenoid paper restraint spring printhead skew auto clean auto clean delay auto clean frequency background banding black page blank page blurred or fuzzy print button test C charge roll connector locations connectors duplex option autoconnect cable engine board gear train HVPS mirror motor fan cable operator panel output bin sensor cable printer ground straps printhead RIP board covers parts assembly right cover removal D dead machine default settings developed image test diagnostics mode diagnostics mode me
44. 8729 1 Redrive Assembly 3112 001 3116 001 35 6 Screw Frame to Paper Feed Parts Packet 1381663 NS 1328345 1 Spring Bias Transfer Housing 36 1381298 1 Output Bin Sensor 3116 002 003 37 1408064 1 Cable Output Bin Op Panel Output Bin lead has no connection on 3112 001 3116 001 38 1381567 1 Guide Bail and Minibail Kit 3112 001 3116 001 uses Minibail only 39 1408061 1 Cable Tray 2 Blind Mate 40 1408792 1 Cover Tray 2 Cable Opening 41 1408892 1 Cable Duplex Autoconnect Parts Catalog 133 Assembly 6 Paper Feed Alignment Gears RET Je LKE 134 Service Manual Index Number Units Description 6 1 1427307 1 Bellcrank Metering 1 Shaft S 1 Bellcrank 1 Roll 1 Thrust Washer 2 1381145 1 Kit Prealigner and Auxiliary Rollers 3 1039278 1 Gear Idler Prealigner 4 1 Spring Prealigner and Metering Bellcranks Parts Packet 1381666 5 1328384 1 Bellcrank Prealigner 1 Shaft 1 Roll 7 1 o Bellcrank i 1 Thrust washer NS 1383580 1 Anchor Repair Kit Metering NS 1383908 1 Anchor Repair Kit Prealigner Parts Catalog 135 Assembly 7 Paper Feed Drive 136 Service Manual index Number Units Description 7 1 69G5480 1 D Roller Asm 2 1328279 1 Washer Thrust 3 1126832 1 Clip D Roll 4 1408703 1 Rail Assembly Right W O gears 5 1328313 1 Shield D Roll 6 1381790 1 Shaft D Roll with Gear 11 and D Ro
45. Check the sensor cable continuity If the sensor and the cable are good replace the duplex system board Fan 927 Error The fan should run continuously when the printer is powered up unless the printer is in Power Saver mode Check that the fan rotates freely when spun manually and that cable connections to the fan OK The voltage at engine board J2 7 should be approximately 24VDC when the top cover is up Short J2 7 to ground J2 6 to test the fan if the fan does not run check the continuity of the fan cable before replac ing the fan A bad fan can pull down the 24V line even if it runs check between 21 and 26VDC when the fan is running if it does not replace the engine board Diagnostic Information 19 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 Inside the fuser shroud there is a thermal fuse which is in series with the lamp if the TRIAC fails and leaves the lamp on continuously the fuse melts and shuts off power to the lamp The thermistor output voltage is proportional to the fuser temperature and is on engine board J8 4 The voltage will cycle from approximately 2 0 to 2 3VDC as the lamp goes on and off during idle and will be around 2 7VDC during continuous printing w
46. J3 J4 J5 J6 J7 J8 9 10 J11 J12 Optional RIP Board Connectors 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 INA hard disk internal Network Adapter for LAN printing 108 Service Manual Board Installation Hardware Short Plastic Standoff Engine Board Female Female f ep Standoff VIN Without Groove Tall Plastic Standoff Board Medium 4X Nut With Sfamdoft Captive Star Washer Connector Locations 109 Printhead Connector Locations Print Head Cable Pin 1 Connector Mirror Motor Cable Mirror Motor Connector 110 Service Manual Mirror Motor Fan Cable Mirror Motor Fan Cable Connections Connector Locations 111 Operator Panel Output Bin Sensor Cable Op Panel Cable Connector Operator Panel Output Bin Sensor Cable Connectors Pin Op Panel e S J1 1 1 J1 2 2 J1 3 3 J1 4 4 J1 5 5 112 Service Manual Operator Panel Output Bin Sensor Cable Connectors Sensor 3116 002 003 Op Panel No connection The same cable is used on the 3312 001 and 3116 001 but the output bin sensor leads are not us
47. J8 6 with paper present Check continuity on the cable before replacing a sensor If paper is curling badly enough to cause a problem feeding or stacking see Fuser Temperature And Warm Up Time on page 43 Paper Feed Duplex Unit Check that all gears and belts are working correctly both in the duplex unit and on the tray top cover and that the gear on the tray top cover correctly engages the gear on the duplexer If paper is jamming in the table cover area make sure the table cover is properly installed Run diagnostics Duplex Test 1 to make sure the paper is feeding far enough into the duplex unit before reversing Exam ine the condition of all rollers If paper is stopping or jamming as it is fed back across the top of the paper tray run diagnostics Duplex Test 2 to make sure there is no slip page in the paper path Make sure the paper tray top cover is not dam aged Cold paper curl can also cause jams here see Fuser Temperature And Warm Up Time on page 43 If paper is jamming at the front exit of the printer inspect the duplex exit selector switch and the linkage to the printer exit deflector Check the switch by removing the duplex top cover and table cover and reinstall ing the duplexer in the printer Check for 5VDC at duplex system 28 Service Manual board 15 10 The voltage will change from OVDC to 5VDC as the selector lever is moved Also see 23 Paper Jams on page 18 Paper Feed Problem Env
48. Note When re installing the sensor lift up the flags so they will clear the sensor and not be damaged Repair Information 99 100 Service Manual 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 Note The remaining FRU is the Gear block Assembly When you replace this FRU see Lubrication Specifications on page 115 Repair Information 101 102 Service Manual Connector Locations This chapter shows the locations of major printer assemblies gears connectors and ground straps Major Assembly Locations Operator Panel Upper Frame Fan Print Cartridge Exit Redrive Print Head Transfer Roll Low Voltage High Voltage Power Supply Power Supply Fuser Engine Board Host Card Lower Frame IPDS Card Optional RIP board Output Sensor Toner Sensor Paper Tray Connector Locations 103 Gear Train Gear 10 Gear 9 o Gear 6 on shaft on motor bracket 2 ES Redrive Idler Sch AO Gear 11 Gear 1 y Molded on Fuser Gear Ve D roll shaft N Cn Gear 13 Optional Tray Drive Gear 4 Gea Gear 3 Gear 12 Routed on Motor Pin sideframe Right Rail 104 Service Manual HVPS
49. Note 2 IPDS Cards as FRUs contain no DRAM SIMM Be sure to transfer DRAM SIMM from the faulty card to the new card Parts Catalog 153 Assembly 14 Transfer Roll 154 Service Manual Index Number Units Description 14 1 1381008 1 Roll Asm Transfer 2 1381652 1 Housing Transfer 1 o Rear Lens Asm Erase 1 Contact Transfer Roll 1 o Lamp Asm Erase 3 1328356 1 Cover Clip Bearing Parts Catalog 155 Assembly 15 Duplex Option 156 Service Manual ele E Units Description 15 1 1381551 1 Top Cover Asm 2 1381552 1 Duplex System Card 3 1381554 1 Bottom Cover 4 1408940 1 Exit Sensor Cover 5 1381555 1 Exit Sensor Asm 6 1408906 1 Bellcrank 7 1408905 1 Table Cover Floor 8 1408949 1 Paper Stop Slide 9 1381558 1 Gear Block Frame Asm 10 1381559 1 Input Sensor Card 12 1326042 1 Cable Stepper Motor 13 1408918 1 Cable Sensor 14 1381025 1 Paper Feed Motor DC 15 1326113 1 Switch Asm Cover Open 16 1381570 1 Switch Asm Front Exit 17 1408969 1 Cover Corner Trim 18 1408942 1 Cover Auto connect Plug 19 1326064 1 Belt Paper Drive 20 1408889 1 Tray Asm 300 w Top Cover L Lx 20 1408884 1 Tray Asm 130 w Top Cover R Rx 22 1381560 1 Top Cover Paper Tray 23 1038708 1 Belt Paper Tray NS 1381561 1 Gear Parts Pack NS 1381048 1 Flag Parts Pack Parts Catalog 157 Assembly 16 Envelope and 100 Sheet Auxiliary Feeder 158 Service Manual
50. Setup menu b Print out your host menu settings 1page with SCS only 2 pages with IPDS MENUS MORE NETWORK MENU 1 TEST MENU 22 Service Manual PRINT MENUS THEN PRESS THE READY 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 Reseat the host card in the lower Network Menu 1 con nector J6 See RIP Board on page 108 Bad connec tion is a common cause of these problems There is a green LED on the back of the host attachment card just above the Coax or Twinax Connector It is labeled CU When this LED is ON the card is receiving and accepting POLLs from the host With the host cable twinax or coax attached and the POST complete observe the green CU LED Ifthe LED is on or blinking your host attachment card is receiving polls from the system If you have an IPDS card ensure that the connection with the Host Card is OK Then try reseating the host attach ment card again Ensure that the grounding screw is installed If you still have a problem try a new IPDS memory SIMM a new host attachment card or a new IPDS card Ifthe LED is OFF continue Note The share light is only used for special circumstances If the Share light and the CU light are both on after POST install a new host attachment card e Check
51. able from the guide clips on the right of the fuser to remove the thermistor 72 Service Manual Repair Information 73 HVPS Removal Ge Ei D gt 12 13 14 Unplug the power cord Remove the left cover Remove the fuser input guide Remove the transfer roll housing Remove the fuser cover Disconnect the cable from the HVPS connector Remove the power switch rod Remove the ground screw B Remove the mounting screws C Pull the ground strap through the hole 0 The power supply is held in place by two latches on the left side To release the latches Push one latch E in and raise one of the studs to release the latch Push the other latch E in and raise the other stud F to release the latch Lift the power supply until the studs F align with the large openings then move the power supply to the right to release it from the frame Move the front of the power supply to the right to clear the fuser power wires Tilt the front of the power supply up and lift it out of the machine 74 Service Manual Repair Information 75 Input Sensor Board Removal 1 2 3 4 Disconnect the input sensor cable from the input sensor board Note Use care the flag can be damaged while removing the board 5 Release latch B and pull the board down and forward to get it out of its mounting 6 Disconnect the toner sensor cable from the board 7 Remove t
52. ailure 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 Gear no 2 and its stud on the side plate e Gear no its stud on the motor bracket e Gear no 4 and its thrust washer e Gear no 4 and its stud on the motor bracket e Gear no 5 and its stud on the motor bracket Preventive Maintenance 115 e Gear no 6 and its stud on the motor bracket e Gear no 6 and its thrust washer e Gear no 7 and its stud on the rail e Gear no 7 and its thrust washer e Gear no 8 and its stud on the rail e Gear no 8 and its thrust washer Gear no 9 and its stud on the rail The metering roller shaft and its bushings on the rail assembly The main metering backup roller and its stud and thrust washer e D roller shaft and its bushings on the rail assembly The auxiliary metering roller and its stud on the rail including the snap in groove and the snap ridges in the roller hole Gear no 14 and its stud on the rail Gear no 13 and its stud on the rail e The auxiliary paper feed idler and its stud on the rail The prealigner drive idler and its stud on the rail The prealigner drive roller and its stud on the rail The prealigner backup roller and its shaft and thrust washer e fixed center idler gear in the 500 sheet base and
53. asher Rotate shaft B eccentric to obtain 4 2 mm 0 2 mm 0 165 in 0 008 in air gap Tighten screw A Replace the rubber washer Screw A LC 60 Service Manual 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 Run Print Test 1 or the Quick Test on the Diagnostics Menu 4 Move the pointer B to eliminate the skew Moving the pointer toward the left raises the left adjustment point on the printout Each mark is equivalent to one dot of the skew adjustment points 5 Tighten the screws and verify the adjustment e Skew Adjustment Points N Repair Information 61 Removals Note When there is artwork to support a procedure it follows the text Covers Right Cover Removal 1 OUP Turn the printer off Remove all external trays Open the top cover Depress the latch and open the right cover Remove the E clip from the rear pivot pin and lift the cover off the rear pivot pin Front Cover Removal RON Unplug the power cord Remove the paper tray Open the top cover Open the right cover Release the latches B You can reach the lower latches through the paper tray ope
54. ations Act 1984 iv European Community EC Electromagnetic Compatibilit Decent NECEM V Japanese VCCI Notice V German Statement of Acoustic Emissions V ER Trademarks id vi kee vii vii re ik Q 1 2 enke 2 HETE EE EE E 3 FENG 3 M 4 de 5 Power On Self Test POST 12 acc mM 13 EE 14 P 14 E 15 16 Lamas 16 MT EE 17 MID 17 19 ANA 20 20 O EEE 21 Table of Contents Xi Fuser Temperature And Warm Up Ti Service Manual Print Test 2 Quick Disk Test 49 Quick TEST kadett 49 KEENE E 49 Print Test Page Print Test with RIP Board Removed Repair Information ner eeeeerrersnsssrrersrerene 55 Handling ESD Sensitive Parts 55 AdiuSiments EL 56 Envelope Restraint Spring On Paper Restraint Spring On The 100 Sheet Auxiliary Feeder 1 56 Table of Contents Right Cover Removal Front Cover Removal Input Sensor Board Removal Lower Frame Assembly Removal
55. be 75 mm or less If it is larger than 75 mm there is a drive problem in the duplex unit or in the tray top cover 11 Select CONTINUE 12 Perform the test several times to verify that the measurement is accurate 13 Press Return to return to Diagnostics mode main menu Envelope Enhance Use this procedure to set the fuser solenoid power level to low medium or high Increase the level to reduce envelope wrinkling or decrease the level to reduce solenoid noise Enter Diagnostics mode Select PRINTER SETUP Select Envelope Enhance Select Low Medium or High Press Return to return to Diagnostics mode main menu SY Poo Envelope Print Test Use Envelope Print Test to test the Envelope or Auxiliary feeder Envelope Print Test generates one printout a page of ripple print Printing will occur only on the first page or envelope Enter Diagnostics mode Select PRINT TESTS Select Envelope Print Test Select Single or Continuous Select CANCEL to stop continuous print Press Return to return to the main diagnostic menu On PON gt 42 Service Manual 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 All 97X Network Card errors are logged as 977 1 Enter Diagnostic
56. 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 do not use a bare swab and do not use any cleaning fluids or water on the printhead window Inspect the HVPS contacts If the image on the photoconductor is good inspect the fuser rolls and transfer roll Make sure the left transfer roll bearing is contacting the contact from the HVPS Make sure the HVPS contacts are clean and spring back when pressed Diagnostic Information 33 34 Service Manual 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 The printer performs the Power On Self Test 3 Release the buttons when Performing Self Test is displayed 4 You can exit Diagnostics mode without a POR by selecting Reset Printer Diagnostics Mode Menu Structure The following is the Diagnostics mode menu structure The indented items are submenus available under the main menu items which are in capital letters on the operator panel Menu items referring to options will only be present if those options are installed Menus with more than four items will use MORE on the fourth operator panel button to access the next screen of selections
57. e of the following sensor tests Toner Low Output Bin Input Exit or Cover Open 5 When the sensor is blocked Open will be displayed Otherwise Closed will be displayed 6 Press Return to return to the Diagnostics mode main menu Diagnostic Aids 49 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 Enter Diagnostics mode Select DUPLEX TESTS Select Top Margin Select or to raise or lower the back image 0 01 inches per increment 5 Press Return to return to the diagnostic menu RONG The Duplex Quick Test is used to verify the Duplex Top Margin Enter Diagnostics mode Select DUPLEX TESTS Select Duplex Quick Test Press Return to return to the diagnostic menu N S There is some variation in the image position from sheet to sheet Print three or four test pages at each setting Transfer This setting varies the transfer voltage offset slightly In normal environments it will not result in a visible difference in the printout In extreme environments with unusual papers this setting may be helpful Do not change this setting unless replacing the transfer roll assembly did not correct the problem Enter Diagnostics mode Select PRINTER SETUP Select Transfer Select Low Medium or High
58. e thermistor cable Disconnect the fuser solenoid cable Release the latches A Pull the sensor board down to remove it 84 Service Manual Repair Information 85 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 Remove the inner EMC shield Warning Be careful not to damage the system cable 5 Locate the paper feed magnet mounting screw visible through the right side frame A 6 Remove the mounting screw B 7 Remove the paper feed magnet assembly from the rear slip the connector under the right frame To replace the paper feed magnet assembly perform the removal pro cedure in reverse order yor d MN pt M SN e Aj Ne SLT il Of ENS AN 5 S Y Le ANA v TINA A j SY Paper Feed Rollers Removal NOTE Replace all paper feed drive rollers at the same time 1 Remove the lower frame 2 Disconnect the cable from the input sensor 3 Remove the screws A and the outer deflector 4 Remove the screws B and the toner shield E 86 Service Manual 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 7 OS
59. e toward the rear of the machine to release 3 Lift the guide out of the machine 4 Clean the fuser input guide before installing it Fuser Lamp Removal CAUTION THE TEMPERATURE OF THE HOT ROLLER IS 150 230 C 302 446 F USE EXTREME CAUTION WHEN REMOVING THIS UNIT BEFORE YOU SERVICE THIS UNIT ALLOW THE MACHINE 70 Service Manual 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 1 Remove the fuser 2 Remove the right lamp bracket A 3 Carefully pull the lamp B out to the right using a soft cloth if the lamp is to be reinserted Install the new lamp with the color coded end away from the gear Fuser Solenoid Removal 1 Remove the fuser 2 Remove the two mounting screws A holding the solenoid housing to the fuser housing Repair Information 71 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 e Disconnect the thermistor cable connector A from the exit sensor card Remove the fuser cover and wiper Remove the tape holding the thermistor cable to the shroud Squeeze the thermistor bracket tabs B and remove the thermistor from the shroud Remove the thermistor c
60. ed Duplex Autoconnect Cable Duplex Autoconnect Cable Connectors Connector Locations 113 Printer Ground Straps Load Box Shaft to Upper Frame Operator Panel to Upper Frame Outer Deflector to Lower Frame HVPS to Frame Static Brush to Toner Shield to Lower Frame Lower Frame Toner Shield 2 d oad Box Shaft to Lower Frame 2 to Upper Frame 114 Service Manual Preventive Maintenance This chapter describes procedures for printer preventive maintenance Following these recommendations can help prevent problems and maintain optimum performance Safety Inspection Guide The purpose of this inspection guide is to aid you in identifying unsafe conditions Use good judgment to identify possible safety conditions not covered by this inspection guide Refer to the safety reminders for a general checklist If any unsafe conditions exist find out how serious the hazard could be and if you can continue before you correct the hazard Check the following items e Damaged missing or altered parts especially in the area of the On Off switch and the power supply e Damaged missing or altered covers especially in the area of the top cover and the power supply cover e Possible safety exposure from any non Lexmark attachments Lubrication Specifications Lubricate only when parts are replaced or as needed not on a scheduled basis Use of lubricants other than those specified can cause premature f
61. ed with print ers that have LAN INAs pre installed e sure that the desired network protocol is enabled from the printer operator panel e Verify proper print queue and printer driver configuration e Verify that the adapter port has been associated e Verify correct installation of software utility Single route broadcast is not supported across network bridge if bridge is used Server problem check print server installation and configuration using the appropriate system guide to operations Light Print Light print is frequently caused by worn out print cartridge Clean the transfer roll by powering on and off two or three times leaving the 24 Service Manual printer on for about two minutes each time Other causes 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 PostScript emulation output may appear lighter than PCL emulation output or a test print this is not a defect Verify on the Print Test that the print is too light before performing service Network Card 977 Errors Note Note All network card errors are recorded as 977 in the error log If you are here because there are 977 errors in the log POR several times to recreated the actual 97x error If the 97x error on the operator panel is not a 977 follow the instructions in
62. egal tray Regularly Spaced Marks This is caused by a defect on one of the rolls or gears in the print pro cess The damaged part can be determined by the spacing of the marks according to the following table Find and replace the damaged part 30 Service Manual 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 Auxiliary Feed Roller 68 5 mm Spacings other than the ones listed could be caused by damage or a bind in the gear train Residual Image Residual image the walking of a leftover image down the page is probably the result of failed erase lamps not discharging the photocon ductor or of a failed cleaner inside the print cartridge It can also be caused by a failed fuser hot roll retaining toner and redepositing it on the page Check that the erase lamp voltage at engine board J9 1 is 24VDC and that the cable has continuity To test the erase lamps jumper engine board J9 2 to ground Random Marks Random marks are nearly always due to a mechanical problem or due to foreign matter loose in the printer or in the print cartridge Inspect and clean the inside of the printer carefully and correct any problems found Skew all edges If the
63. elope Feeder 100 Sheet Auxiliary Feeder Check for the following paper or envelope jammed in the feed path missing hold down weight adjustable guide out of position feeder cable loose disconnected or plugged in the wrong connector feeder incorrectly installed worn or damaged rollers or gears warped or dam aged envelopes used envelopes improperly installed envelope flaps must rest against the paper edge guide envelopes other than 20 or 24 pound used in the Envelope Feeder paper other than 20 or 24 pound used in the 100 sheet auxiliary feeder envelopes interleaved with paper Run the diagnostics Envelope Feed test and make sure the feed mag net is being energized If not check the resistance of the magnet at J10 1 to J10 2 on the feeder cable the resistance should be from 105 Ohms to 155 Ohms If the magnet is good reconnect the cable and monitor the voltage between the two pins of the connector while running the Envelope Feed test if the voltage does not increase momentarily as the magnet is picked replace the engine board Check the adjustment of the feeder magnet If paper is being bent or double fed check the adjustment of the feeder restraint Spring Printhead Note The printhead is a sealed unit It contains no internal parts that can be replaced or adjusted Verify the presence of the following voltages 24VDC at engine board J2 1 5VDC at engine board J11 4 and 5VDC at engine board J12 8 If these vo
64. erface Use of a substitute cable not properly shielded and grounded may result in violation of FCC regulations Industry Canada Compliance Statement This digital apparatus does not exceed the Class B limits for radio noise emissions from digital apparatus as set out in the interference causing equipment standard entitled Digital Apparatus ICES 003 of Industry Canada Avis de conformit aux normes d Industrie Canada Cet appareil num rique respecte les limites de bruits radio lectriques applicables aux appareils num riques de Classe B prescrites dans la norme sur le mat riel brouilleur Appareils num riques NMB 003 dict e par Industrie Canada The United Kingdom Telecommunications Act 1984 This apparatus is approved under the approval number NS G 1234 J 100003 for the indirect connections to the public telecommunications systems in the United Kingdom iV Service Manual 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 CORA BI Sms CEB MMM AT O MEL HRI SO CHA AN SAS TEA tO RMS ES EE HEME HRA VCCI LAL RESY FURY a VRB TWH Se az tu ET Spam IES TIELOBURORLIFAN German Statement of Acoustic Emissio
65. est fails or the problem recurs replace the DRAM SIMM 961 Memory Error Bad DRAM in the optional DRAM slot Reseat the DRAM and run the diagnostic Memory Test for DRAM POR the printer If the test fails or the problem recurs replace the DRAM SIMM 970 Network Card 1 Network card 1 processor failure Go to Host Printing Problems on page 22 970 Network Card 2 Network card 2 processor failure Replace network card 2 971 Network Card 1 Go to Host Printing Problems on page 22 971 Network Card 2 Network card 2 RAM failure Replace network card 2 972 Network Card 1 Go to Host Printing Problems on page 22 Diagnostic Information 9 Error Code 972 Network Card 2 Explanation Network card 2 ROS FLASH failure Replace network card 2 973 Network Card 1 973 Network Card 2 Go to Host Printing Problems on page 22 Network card 2 EEPROM NVRAM ard 974 Network Card 1 974 Network Card 2 Go to Host Printing Problems on page 22 Network card 2 Network interface error Replace network card 2 976 Network Card 1 Host card 1 software error Verify that the network card is installed and grounded correctly If this error returns after a POR there is software or microcode incompatibility problem Do not replace the card Contact your next level of support 976 Network Card 2 Network card 2 software error Verify that the n
66. etwork 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 977 Network Card 1 Host card 1 is installed but is not communicating with the RIP Board See Network Card 977 Errors on page 25 977 Network Card 2 Network card 2 is installed but is not communicating with the RIP Board See Network 977 Errors on page 25 978 Network Card 1 978 Network Card 2 General host 1 card hardware error Go to Host Printing Problems on page 22 General network 2 card hardware error Replace network card 2 979 Network Card 1 General host 1 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 10 Service Manual 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 990 Duplex Option Duplex error See Duplex on page 17 991 Duplex System Card Failure 993 Duplex Comm Failure Dupl
67. ewdriver 2 Phillips screwdriver 5 5 mm nut driver 8 mm wrench Needlenose pliers Diagonal pliers Spring hook Feeler gauges Analog or digital multimeter Parallel wrap plug 1319128 Serial wrap plug 1329048 General Information 3 Abbreviations ASIC CSU DRAM EEPROM EP ESD FRU HVPS INA LAN LASER LCD LED LVPS NVRAM OEM PICS PIXEL POR POST PQET RIP ROM ROS SIMM SRAM UPR VDC Application Specific Integrated Circuit Customer Setup Dynamic Random Access Memory Electrically Erasable Programmable Read Only Memory Electrophotographic Process Electrostatic Discharge Field Replaceable Unit High Voltage Power Supply Integrated Network Access Local Area Network Light Amplification by Stimulated Emission of Radiation Liquid Crystal Display Light Emitting Diode Low Voltage Power Supply Nonvolatile Random Access Memory Original Equipment Manufacturer Problem Isolation Charts Picture Element Power On Reset Power On Self Test Print Quality Enhancement Technology Raster Image Processor Read Only Memory Read Only Storage Single In line Memory Module Static Random Access Memory Used Parts Replacement Volts alternating current Volts direct current 4 Service Manual 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
68. ex system board failure Replace the duplex system board Communications between the duplex unit and the printer have failed See Duplex on page 17 Diagnostic Information 11 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 2 3 1 1 2 rows of pels appear on the display and then clear Diamonds fill the display and then clear The fuser lamp and the fan turn on Performing Self Tesi appears on the display Note The printer may be idle for up to 60 seconds as the fuser warms to operating temperature Printer idle time 15 shorter if the fuser is already warm Note If the duplexer is installed the duplex drive motor turns on for about 5 seconds just before the Ready screen appears The ready screen appears on the display Note Diagnostics menu appears if you are in diagnostic mode The drive motor and the mirror motor start to run The fan starts to run at high speed The drive motor runs for approximately 10 seconds The fan runs at high speed then switches to low speed If the printer completes all these steps and no error messages are dis played the printer has successfully completed the POST 12 Service Manual Symptom Table Symptom Action or Service Check Dead Machine Dead Machine Service Check Machine Hangs Displaying Diamonds Repeats a pattern of 5 beeps and a pause
69. he sensor board 76 Service Manual Repair Information 77 Lower Frame Assembly Removal 1 Remove the right front and left covers Remove the LVPS and the rod for the on off switch Remove gear cover and the fuser input guide A Disconnect cable the HVPS Remove the RIP board and the inner EMC shield together Remove the engine board Disengage the upper frame cables from the guide in the paper feed side frame 9 Remove the screws B 10 Remove the fuser cover 11 Unplug the fuser wires C and push them below the HVPS 12 Unplug the paper size switch cable 13 Lift the lower frame assembly straight up to separate it from the paper feed assembly 78 Service Manual Repair Information 79 LVPS Removal 1 Disconnect the power cord Remove all external feed trays Remove the left and right side covers Remove the RIP board and the inner EMC shield together Remove the left and right LVPS mounting screws and the screw for the cable tie Disconnect the LVPS cable from the engine board Disconnect the LVPS connector A 8 Lift the supply up and then toward the right side frame to disconnect the On Off switch linkage D 80 Service Manual LVPS Cover Removal 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 1 4 Release
70. hen the Fuser Temperature is set to Normal In Power Saver mode the lamp is left off until a job is printed The engine board signal to the LVPS TRIAC is on J4 16 The voltage is OVDC when the lamp is to be on and 5VDC when the lamp is to be off The lamp can be tested by briefly connecting this pin to ground Fuser 920 921 or 922 Error A 922 error during a POR caused by low line voltage can usually be cleared by doing another POR If the fuser lamp is lighting very dimly check for a 220V lamp installed in a 110V machine Check all the connectors to the exit sensor card and the lamp power connections at the left end of the fuser Make sure the thermistor is making contact with the hot roll Check the continuity of the lamp the thermal fuse and the fuser power cable Check the thermistor resis tance at engine board J8 3 to J8 4 4 should be from 100K Ohms to 260K Ohms when cold it may be as low as 2 3K Ohms when hot but increases quickly as the fuser cools There should be no connection from either pin to ground If the thermal fuse has blown the fuser and the fuser wiper will be dam aged Before replacing the fuser and the fuser wiper check the voltage at engine board J4 16 as you POR again It should stay at 0 until the 922 Error is displayed and then go to 5VDC if it does not replace the 20 Service Manual engine board the fuser and the fuser wiper Next measure the voltage to the fuser lamp during a POR it shou
71. hing the printer LVPS failure blown LVPS fuse failure of the On Off switch or switch linkage or a shorted electrical component Check for the indicated voltages at the LVPS connection to the engine board If no voltages are present remove the LVPS cover and check fuse F1 and the power switch before replacing the LVPS If some voltages are present but all are not correct disconnect all cables except the LVPS from the engine board POR and verify that the LVPS voltages are correct Turn the power back off and one at a time reconnect the engine board cables powering on in between each con nection and checking the voltages The connection which causes the voltages to be wrong indicates which component is bad Repair or replace the failing component or cable as necessary Duplex The duplexer should home the front shafts should turn and the input deflector should move immediately when you install the duplexer with the printer already powered on or just before the Ready screen is displayed when you POR the printer with the duplexer installed This means the duplexer and the printer are communicating and thus the printer engine board duplexer system board and the cables between them are all good Note With twinax and coax printing the printout is always simplex unless the job specifies duplex There is no network duplex menu item like the 391x had Diagnostic Information 17 If the duplexer does not home immediately b
72. lace 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 A failed printhead will cause a 931 Service error rather than blank output Check the continuity of the HVPS cable The HVPS and transfer roll contacts should be clean and spring back when pressed Make sure the transfer roll contact under the left bearing is making contact with the HVPS Run the Print Test with the RIP Board removed Make the following volt age checks Connector Voltage while Voltage while Printing Idling Less than 5VDC J13 2 to J13 4 Less than OVDC 5VDC J13 3 to J13 4 Fluctuates OVDC between pages 1 5VDC J13 8 to J13 4 Less than 6VDC 1VDC If the voltages are not correct replace the engine board Blurred or Fuzzy Print This can be caused by a damaged gear train or by paper slippage in the 16 Service Manual 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 Dead Machine Possible causes no voltage reac
73. ld be line voltage until the 922 Error is displayed if it does not replace the LVPS the fuser and the fuser wiper If the voltage to the fuser lamp is the not the same as the line voltage replace the LVPS If the lamp fuser power cable thermal fuse thermistor and lamp volt age are OK check J4 16 to see if the engine board is sending the cor rect signal to the TRIAC At POR this signal should go to 5VDC and then immediately drop to OVDC until the fuser is warm if it does not replace the engine board the signal is OK replace the LVPS Fuser 923 or 924 Error Check the connection and continuity of the cable from the fuser exit sensor board to engine board 8 Check the thermistor condition and connection e e the O ance at eng 3 It should be from 100K Ohms to 260K Ohms when cold it may be as low as 2 3K Ohms when hot but increase quickly as the fuser cools Honeycomb Areas of the page are covered by faint 6 mm circles This print defect is usually caused by the print cartridge If it is not the problem verify that the tab on the transfer roll housing is touching the contact on the HVPS the transfer roll housing should have continuity to ground Make sure the HVPS ground lead to the side frame is in place and making good contact Horizontal Void or Streak This is usually due to the cartridge not being installed correctly Check the printhead area for obstructions and check the mechanical worki
74. left to right several times Move the swab to a clean spot on the cloth and repeat the cleaning procedure Do this procedure several times to make sure the window is clean Cleaning The Transfer Roller Power off the printer Power on and let it complete POST Do this two to three times 118 Service Manual Usage Kit Information The printer automatically displays the 80 Scheduled Maintenance message after each 200K impressions Press CONTINUE to keep printing Customers will need to purchase a Usage Kit It contains new mechanical parts to replace your worn ones The cost of the kit includes the cost of the installation Usage Kit Part Numbers Voltage 3116 110V IBM part 69G5266 IBM part 69G5264 100 to 127V 220 V IBM part 69G5267 IBM part 69G5265 200 to 240 V Notes USA only The kit part numbers listed above are available to customers by calling toll free 1 800 346 3939 Canada only The kits are available to customers in Canada by calling toll free 1 800 465 1234 x 478 and ordering the fol lowing e 3112 62469G5266 e 3116 6246995264 Europe only Customers have two options for ordering Usage kits Order as Feature Codes through your IBM Marketing Representative Feature Code 4920 for 110V Feature Code 4921 for 220 V e Contact IBM DIRECT within the country and order the part number listed above Outside these locations customers contact their point of pur chase or Lexmark Note
75. ller Asm 7 2 Bushing Parts Packet 1383315 Must be installed properly Align slot in bushing with notch in frame assembly 8 1 Spring Gear Advance Parts Packet 1383316 9 1381791 1 Paper Feed Magnet 10 Gear No 14 Sheet Feed Parts Packet 1383318 11 1 Gear No 9 Parts Packet 1383318 12 1 Gear No 7 Parts Packet 1383318 13 1 Gear No 8 Parts Packet 1383318 14 1 Gear No 10 Parts Packet 1383318 15 1 Screw Clutch Mag Mtg Parts Packet 1383314 16 1 Spring Magnet Arm Parts Packet 1383316 17 1 Washer Parts Packet 1383314 18 2 Washer Thrust Parts Packet 1383314 19 2 Bushing Gear 10 Parts Packet 1383315 20 Gear 13 Parts Packet 1383318 21 2 Clip Parts Packet 1383315 22 1039170 1 Machine Pad Parts Catalog 137 Assembly 8 Standard Paper Tray 200 sheet 138 Service Manual Number Units Description 8 1427375 1 Paper Tray Assembly 11 in 200 sheet 1427376 1 Paper Tray Assembly 14 in 200 sheet 1427361 1 Paper Tray Assembly for Labels 11 in 200 sheet 1427364 1 Paper Tray Assembly for Labels 14 in 200 sheet 1427379 1 Paper Tray Assembly A5 1 1408170 1 14 in Cover 2 1408725 1 Paper Stop 3 1408567 1 Corner Buckler 4 1408732 1 Liner 11 in 4 1408733 1 Liner 14 in 5 1408724 1 Adjustable Guide 6 1058486 1 Universal Paper Tray 7 1381661 1 Kit Paper Level Indicator Parts Catalog 139 Assembly 9 Paper Tray 500 Sheet 140 Service Ma
76. ltages are not correct replace the engine board Verify the continuity of the fan mirror motor cable the hsync cable and the laser cable 934 and 935 errors Check engine board J2 5 during a POR the volt age should be between 2VDC and 4VDC for about 7 seconds after the main motor turns on If the voltage is incorrect replace the engine Diagnostic Information 29 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 Make sure the cable to the paper size switch is connected correctly With the paper tray removed the resistance of the paper size switch should be infinite With the tray installed the resistance of the switch varies with the paper size For Tray 1 remove the front cover disconnect the cable from the sen sor and measure the resistance between the two pins on the sensor board For 500 sheet option remove the RIP Board disconnect J15 from the engine board and measure between J15 3 and J15 4 on the cable If the readings do not match the following within 5 replace the paper Tray installed and set to 5 1 4K Ohms tray 1 only B5 2 0K Ohms 10 5 3 0K Ohms 11 4 7K Ohms A4 8 0K Ohms 13 or 14 17 8K Ohms l
77. machine errors Error Code Explanation 20 Paper Jam The input sensor was not unmade in time 21 Paper Jam The exit sensor was not made in time after the input sensor was made 22 Paper Jam The exit sensor was not unmade in time 23 Paper Jam Jam at the duplex unit Paper is either not leaving the duplex entry sensor in time or not making or unmaking the duplex exit sensor in time See Duplex on page 17 24 Short Paper The defined paper size is too short to print data as formatted 25 Incorrect Manual Feed Paper fed manually while motors running and previous page in path 26 Duplex Tray Missing Duplex unit is installed but paper tray is not sensed 27 Change Envelope Paper Envelopes paper loaded are wrong size 28 Load Envelope Paper Input sensor not made after pick attempt Tray is empty or printer is requesting a manual feed 29 Output Bin Full The output bin sensor has not been unmade See Output Bin Sensor on page 26 30 Top Cover Open or Print Make sure the spring mounted pin on the Cartridge Missing printhead shroud is installed properly and that it is detected by the ramp on the print cartridge as the cover closes The pin should enter the tower on the HVPS and depress the cover switch 32 Wrong Print Cartridge installed The installed print cartridge is not supported Diagnostic Information 5 Error Code 38 Memory Full Explanation Memory used to store pages is full To
78. mation on page 119 Memory Tests ONOaArPwWN Enter Diagnostics mode Select HARDWARE TESTS Select Memory Test Select either DRAM or ROM Select Single or Continuous The display will indicate PASSED or FAILED Select CANCEL to stop continuous memory test Press Return to return to Diagnostics mode main menu Page Count To view or set the page count RON Enter Diagnostics mode Select PAGE COUNTS Select Page Count Choose any number between 0000000 and 9999999 by Selecting Next to move the cursor under each digit Select or to select the number you want in each digit Select SAVE to save the page count displayed Diagnostic Aids 45 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 Enter Diagnostics mode Select PAPER FEED TESTS Select Tray 1 Tray 2 Feeder or Manual Select Single or Continuous Select CANCEL to stop continuous Press Return to get back to Diagnostics mode main menu o grde o Ww Permanent Page Count The permanent page count can be displayed only It cannot be modified or reset by the customer or servicer Enter Diagnostics mode Select PAGE COUNTS Select Permanent Page Cou
79. ngs of the print cartridge and printhead shutter If nothing is found see Blank Page on page 16 and follow those instructions Diagnostic Information 21 Host Printing Problems You are here for one of the following reasons 1 2 3 Host twinax or coax printing problems 97x errors if 977 go to Network Card 977 Errors on page 25 An IPDS card error such as RAM Check printed out on a sheet of paper Install new IPDS memory If that does not fix the problem install a new IPDS card Follow the following steps After each step check if the problem is fixed If the problem is fixed leave this procedure and perform more verification procedures Note This procedure deals with the Host Card and the IPDS card Refer to Host Attachment Card IPDS Card Removal on page 82 as needed 1 Ask the customer to print a different host job twinax or coax that has printed on this printer before If that job prints OK there is a problem with the other job that failed For twinax check the station address For coax try another port Print out your non host menu settings MENUS MORE TEST MENU Mark the printout with a 1 If you replace an Engine Board or a RIP Board you will need to reset the settings on this Printout 1 Look at Printout 1 and ensure that a Network 1 PS SmartSwitch OFF Network 1 PCL SmartSwitch ON If either setting is wrong correct it using the SETUP MENU Network
80. ning Lift the right side of the cover to disengage latch D Slide the cover to the right to disengage the bracket from the posts Pull the front cover forward and disconnect the ground strap from the frame on the left side 62 Service Manual Repair Information 63 Left Cover Removal 1 Unplug the power cord Open the top cover and remove the print cartridge Remove the front cover Locate the latch E and lift the end to release it Push the top of the cover to the left Remove the cover by sliding it to the rear of the machine DURARON Top Cover Removal 1 3116 002 and 3116 003 Remove stacker plate by pulling upward 2 Remove the top cover screws C Lift the rear of the cover first then the front and lift the cover off 4 Rest the cover on the machine and disconnect the operator panel cable e 64 Service Manual 14 in 200 Sheet Paper Tray 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 Remove the two screws which secure the front trim panel 2 Slide the trim panel to the rear to expose the tray cover pivot pins 3 Lift the cover from the tray Transfer Roll Removal 1 Unplug the power cord 2 Remove the print cartridge 3 Remove the bearing cover from the left side of the transfer roll Note Do not touch the
81. ns 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 This product satisfies the Class B limits of EN 55022 Laser Notice The printer is certified in the U S to conform to the requirements of DHHS 21 CFR Subchapter J for Class 1 laser products and elsewhere is certified as a Class laser product conforming to the requirements of IEC 825 Class laser products are not considered to be hazardous The printer contains internally a Class 1110 3b laser that is nominally a 5 milliwatt gallium arsenide laser operating in the wavelength region of 770 795 nanometers The laser system and printer are designed so there is never any human access to laser radiation above a Class level during normal operation user maintenance or prescribed service condition Notices and Safety Information V Trademarks vi 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 PCL Hewlett Packard Company PostScript Adobe Systems Incorporated AppleTalk and LocalTalk are trademarks of Apple Computer Inc registered in the United States and other countries
82. nt Press Return to return to Diagnostics mode main menu Boo mmc Print Contrast This setting varies the developer bias to vary the print darkness If the Print Darkness setting on the customer menu does not allow the darkness to be set correctly this setting can increase or decrease the entire darkness range Enter Diagnostics mode Select PRINTER SETUP Select Print Contrast Select Low Medium or High Press Return to return to the Diagnostics mode main menu Gd 46 Service Manual 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 1 2 3 Enter Diagnostics mode Select PRINT REGISTRATION Select one of the following Left Margin Top Margin Bottom Margin The value of the margin you selected is shown Margins Left Margin can set between 23 and 23 Changing the number by one moves the margin 1 75 inches Moving the number in a positive direction moves the margin toward the right and negative moves the margin to the left Top Margin can set between 20 and 20 Changing the number by one moves the margin by 1 75 inches Moving the number in a positive direction moves the margin down the page and widens the top margin
83. nual Number Units Description 9 1427377 1 Paper Tray Assembly 11 in 1427378 1 Paper Tray Assembly 14 in 1427424 1 Paper Tray Assembly Light Weight Labels 550g spring 11 in 1427372 1 Paper Tray Assembly Light Weight Labels 550g spring 11 in 1427367 1 Paper Tray Assembly Heavy Weight Labels 650g spring 11 in 1427428 1 Paper Tray Assembly Heavy Weight Labels 650g spring 14 in 1 1408361 1 Bottom Cover 11 in 1 1408362 1 Bottom Cover 14 in 2 1381660 1 Cover Front Trim 11 2 1408369 1 Cover Front Trim 14 3 1408708 1 Paper Guide 4 1408387 1 Slide 11 in 4 1408388 1 Slide 14 in 5 1183262 1 Paper Stop 1408710 1 Slider Paper Stop 6 1408170 1 Cover 14 in 7 1195835 1 Pivot Plate with label 8 2 Retainer Parts Packet 1381663 10 1424558 1 Spring Assembly 11 1 Setscrew Parts Packet 1381663 12 1039594 1 Thumb Wheel Gear 13 1408707 1 Wheel 14 1039597 1 Detent Spring 15 2 Screw Parts Packet 1381663 16 1408389 1 Indicator Paper Level Parts Catalog 141 Assembly 10 for Paper Drawer 500 Sheet 142 Service Manual Part Index Number Units Description 10 1 1408289 1 Housing 2 1039558 1 Roll 3 1409146 1 Plate Assembly Gear 4 1039170 4 Pad Machine NS 1328674 1 Clip Ground Parts Catalog 143 Assembly 11 Optional Paper Drawer 500 Sheet 144 Service Manual
84. nus device tests duplex tests 37 hardware tests page count tests paper feed tests print registration tests print tests printer setup tests diamonds on display 32 Index 163 disk test clean drive motor removal D roll assembl removal 66 duplex 23 paper jam 933 error diagnosis paper feed problem duplex feed 1 test duplex feed 2 test 47 duplex option autoconnect cable connectors bottom cover removal entry sensor card removal exit card and cover removal parts assembly system card and motor removal top cover and table cover removal duplex quick test E electronics parts assembly engine board connectors envelope enhance envelope print test Envelope Feeder envelope restraint spring adjustment magnet adjustment paper feed problem parts assembly 158 error codes ESD sensitive parts exit sensor board removal 84 164 Service Manual F fan 927 error fan redrive removal features flash test frame lower frame assembly removal lower frame parts assembly upper frame parts assembly upper frame removal fuser 920 921 or 922 error 923 or 924 error input guide removal lamp removal 0 parts assembly removal solenoid adjustment 60 solenoid removal temperature and warm up time theory thermistor removal 72 fuser drive gear backlash fuser temperature test fuser warm up time test fuser sensor cable removal 3 G gear train connectors H hard disk removal
85. o the metal channel at the right edge of the tray cover The tray roller should move the paper forward when the tray gear is turned but allow the paper to be pulled by the D roll when it picks Make sure the belt to the duplex DC motor is in place Make sure the duplex table cover floor is correctly snapped in place at its front and rear and that the gear block assembly is correctly snapped into the bottom cover Run duplex diagnostics tests 1 and 2 to make sure there is no slippage in 18 Service Manual 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 If they are 01 or 03 there is a problem with the duplex input sensor signal Remove the duplex top cover and table cover and rein stall the duplexer on the printer Measure the voltage on J5 12 pf the duplex system board it should fluctuate from 0 to 5VDC as you toggle the sensor Check the sensor cable continuity If the sensor and the cable are good replace the duplex system board If the 7th and 8th digits are 04 there is an exit sensor problem Remove the duplex top cover and table cover and reinstall the duplexer on the printer Remove the paper tray so you can reach the sensor Measure the voltage on J5 8 of the duplex board it should fluctuate from 0 to 5VDC as you toggle the sensor
86. or 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 If the voltage at the engine system board is incorrect check that the LVPS is providing 5VDC at J4 7 J4 9 and J4 11 and replace the LVPS if its output voltages are wrong Paper Feed Problem 500 Sheet Second Tray Remove the module and inspect the tray the module D roll and the gear train Make sure the gear train is meshing with the drive gear at the bottom of the printer Look for other mechanical problems or dam age Make sure the printer and module auto connectors mate properly when the module is installed If the paper is not being picked run the Print Test with the RIP Board removed Check for 34VDC at engine board J15 2 You can test the torquer motor by shorting engine board J15 1 to ground J15 3 Paper Feed Base Printer Run the print test or the diagnostic paper feed test and carefully exam ine the area of the problem If paper is not feeding make sure the paper is in the tray correctly and is not damaged or stuck together With 500 sheet trays make sure the tension wheel is set high enough to give good contact between the D roll and the paper stack If paper is not feeding or is feeding continuously with no gaps between pages remove the paper tray and the RIP board Press switches 1 and 3 on the paper size switch assembly Watch the D roll as you run the P
87. rint Test with RIP Board removed One of the following will occur The D roll will make one complete revolution and stop with the flat side down This indicates that the paper feed magnet and gear train are working correctly e The D roll will turn continuously There is a possible short to ground of the leads between the paper feed magnet and engine board Examine the condition of the paper feed magnet leads and replace the magnet if necessary If no problem is found replace the engine board Diagnostic Information 27 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 If the resistance is correct replace the engine board e The D roll will move slightly but will not complete an entire revolution This indicates a bind or defect in the gear train If paper is jamming clean the paper path of obstructions or repair any damaged parts Very thin or thick paper labels transparencies or card stock will have a higher jam rate than regular xerographic paper Check the condition of the paper in the tray and verify that the tray is installed correctly If the paper feeds but stops undamaged in the paper path run the input and exit sensor test Check for 5VDC at the input sensor engine board J9 6 and exit sensor engine board
88. s mode 2 Select ERROR LOG 3 Select CLEAR and then CONTINUE to clear the error log 4 Press Return to return to Diagnostics mode main menu Flash Test This test writes to and reads from the flash memory It destroys all data stored in the flash SIMM 1 Enter Diagnostics mode 2 Select DEVICE TESTS Select Flash Test e The operator panel will display Passed or Failed 4 Press Return to return to Diagnostics mode main menu Fuser Temperature And Warm Up Time These settings allow adjustment of the fuser to correct problems with paper curl or melting letterheads Paper curl in which the top and bottom of the page curl toward the printed side hot paper curl can be corrected by reducing the fuser temperature Reduce the setting from Normal to No Boost if necessary reduce the setting further to Low Temperature Verify that the toner is being adequately fused to the paper at the new temperature setting Diagnostic Aids 43 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 lower settings increase the time proportionately less Settings other than 0 may reduce throughput Use the or key to change the number and then select SAVE Mel
89. s must have the identical or equivalent characteristics as the original parts Sicherheitshinweise Die Wartungsinformationen f r dieses Produkt wurden zur Verwendung durch einen Wartungsfachmann entwickelt und sollten nicht von anderen ben tzt werden Zus tzliches Risiko eines elektrischen Schlags und k rperlicher Verletzung existiert w hrend des Auseinandernehmens und der Wartung des Ger ts Fachpersonal sollte im vollen Verst ndnis der Lage entsprechende VorsichtsmaBnahmen ergreifen Ersatzteile m ssen gleiche oder gleichwertige Merkmale wie die Originalteile aufweisen da Sicherheitsvorkehrungen nicht immer offensichtlich sind Consignes de S curit Les consignes d entretien et de r paration de ce produit s adressent uniquement un personnel de maintenance qualifi Le d montage et l entretien de ce produit pouvant pr senter certains risques lectriques le personnel d entretien qualifi devra prendre toutes les pr cautions n cessaires Les normes de s curit de certaines pi ces n tant pas toujours explicites les pi ces de rechange doivent tre identiques ou conformes aux caract ristiques des pi ces d origine 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 possibile il rischio accresciuto di scosse elettriche e Notices and Safety
90. sible coming out the front exit slot turn off the printer 4 Remove the print cartridge and look at the image on the photoconductor LAN Information The printer may be connected to one of the following LAN types Token Ring Ethernet 10BaseT Ethernet 10Base2 LocalTalk The Network external connectors are pictured below The printer test page also indicates to which type of LAN the printer is connected 60000 BOT 0000 Token Ring Ethernet 10BaseT Ethernet 10Base2 LocalTalk 52 Service Manual 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 Following pages continue to feed from this tray unless you change the paper source To run the Print Test Turn the printer on Select MENUS Select TESTS MENU Select Print Test Page Select either Single for one page or Continuous for continuous test pages 6 Select Stop when you want the continuous test to end PG No Print Test with RIP Board Removed Most meter measurements required during printer service will be on the engine board connectors which are inaccessible with the RIP board in place The printer has a service mode which allows you to test the printer without the RIP board installed This verifies tha
91. so a 3116 003 model which is a 3116 002 model configured standard with a second paper drawer an Ethernet card and 8MB of memory From a service standpoint it is identical to the 3116 002 General Information 1 Power Consumption 3112 3116 Power Saver Mode 21W 20W Printing average 260W 310W Max A C draw 110V 6 8A 9 8A Max 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 Memory upgrade options of 2MB 4MB 8MB 16MB and 32MB Flash memory options of 2MB and 4MB Integrated network options Token Ring option Ethernet option AppleTalk option 200 and 500 sheet paper trays of A5 letter and legal size 500 sheet second drawer with letter size paper tray Envelope feeder 100 sheet auxiliary feeder Duplex option Font cards bitmapped or scalable fonts 40MB Hard Disk 2 Service Manual 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 After you complete the repair perform tests as needed to verify the repair Tools Required For Service Flat blade screwdriver 1 Phillips scr
92. ssage Clear Paper appears on the display Slide the tray extension all the way out until it stops Push a small screwdriver through the lower end of one of the ventilation slots and through the sheet of paper fed in under the slot Open the cover and remove the sheet of paper Measure the distance from the mark on the paper to the trailing edge of the paper If the mark or hole is more than 85 mm from the trailing edge there is a paper slipping problem with the duplex unit paper feed Duplex Feed 2 Test This test verifies that paper feeds through the duplex unit properly and tests the stop point of the page as it feeds back over the top of the duplex paper tray ON Enter Diagnostics mode Select DUPLEX TESTS Select Duplex Feed 2 Select Tray 1 or Tray 2 Note Paper feeds all the way into the duplex unit and then feeds out and stops on top of the paper tray The message Clear Paper appears on the display Open the printer top cover If you are doing the test with legal size paper open the top cover of the duplex unit Diagnostic Aids 41 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 Measure from the leading edge of the page to the leading edge of the paper stack in the tray This measurement should
93. t the motors sensors printhead and electrophotographic process are working correctly In this mode the operator panel has minimal function service codes are not displayed and most error handling is disabled during normal operation these functions are handled by the RIP board Remove the RIP board and the inner EMC shield together and power on the printer See RIP Board Inner EMC Shield and fe pen ora cep E one button active which starts and stops the print test The test consists of horizontal lines spaced about an inch apart down the page This is a continuous print test to print a single page press the start button twice Diagnostic Aids 53 54 Service Manual 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 Keep the ESD sensitive part in its original shipping container a special ESD bag until you are ready to install the part into the machine Make the least possible movements with your body to prevent an increase of static electricity from clothing fibers carpets and furniture e Put the ESD wrist strap on your wrist Connect the
94. te the magnet against the feeler gage Tighten the mounting screw The gage should pass between the foam pad and the magnet pole piece with moderate resistance Fuser Drive Gear Backlash Fuser drive gear backlash is adjusted so that when gear 2 is held still there is a slight amount of backlash in the fuser gear Print quality can 58 Service Manual 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 To adjust backlash 1 Loosen the nut on the idler stud 2 Move the idler stud downward in its slot 3 Insert a 0 95 mm 037 in feeler gage between the gear shoulders from the front of the machine You may need to use an angled or very small feeler gauge 4 With the nut snug but not tight tap the idler upward until the gage is snug between the gear shoulders 5 Tighten the locking nut 6 Check the clearance again tightening may have altered the adjustment Be sure the fuser gear can be rotated slightly when gear 2 is held still Fuser Gear Right Sideplate 0 95 0 15 037 006 Stud Idler Gear Nut Repair Information 59 Fuser Solenoid Note The fuser solenoid must be mounted on the fuser for this adjustment and should be at room temperature 1 2 3 e Loosen screw A Remove the rubber w
95. test print frame is parallel to all edges of the page but the margins are not all the same width See Print Registration on page 47 Diagnostic Information 31 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 Check the prealigner drive and auxiliary rollers springs and backup rollers for dirt wear or damage refer to the parts catalog for repair kits for broken bellcrank spring attachment hooks on the sideframe Make sure all the bellcrank assemblies pivot freely Check the gear train for damage or binds Skew top and bottom only If the test print frame is parallel to the left and right edges of the paper but not parallel to the top and bottom the printhead skew needs to be adjusted See Printhead Skew on page 61 Stalled diamonds on display Check the continuity of the cable from J1 on the engine board to the operator panel Next reseat the ROM and memory SIMMs and POR This condition can also occur if the RIP and engine board are not seated or their connectors are damaged If the problem is still present replace one at a time the 1 ROM SIMM 2 Engine board 3 RIP Board 32 Service Manual 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
96. that kits other than the part numbers listed above will not include installation in the cost Preventive Maintenance 119 120 Service Manual 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 AR As Required in the Units column indicates that the quantity is not the same for all machines NP Non Procurable in the Units column indicates that the part is non procurable and that the individual parts or the next higher assembly should be ordered NR Not Recommended in the Units column indicates that the part is procurable but not recommended for field replacement and that the next higher assembly should be ordered R Restricted in the Units column indicates that the part has a restricted availability NS Not Shown in the Asm Index column indicates that the part is procurable but is not pictured in the illustration INDENTURE The indenture is marked by a series of dots located before the parts description The indenture indicates the relationship of a part to the next higher assembly For example INDENTURE RELATIONSHIP OF PARTS No dot MAIN ASSEMBLY One dot o Detail parts of a main assembly One dot Subassembly of the main assembly Parts Catalog 1
97. the Diagnostic table See Diagnostic Information on page 5 1 Determine where the error is for the Network card in J6 the lower connector twinax or coax or for the Network 2 card in J12 the upper connector INA for LAN attachment This information should be posted with the error See RIP Board on page 108 2 Remove the suspect card coax twinax or LAN Reseat the card If this fixes the problem stop here 3 Check for 5VDC at pin B24 upper right pin at the RIP board connector J6 or J12 If the voltage is incorrect replace the engine board RIP Board Inner EMC Shield and Engine Board Removal on page 91 4 Ifthe 5VDC is OK you have a problem with the card e For Network 2 errors install a new LAN card Your customer will need to tailor his Network 2 Menu setting on the new card For Network 1 cards go to Host Attachment Card IPDS Card Removal on page 82 Network Wrap Tests Token Ring with Shielded Twisted Pair Cable Disconnect the LAN cable from the electrical outlet leaving it connected to the printer net work card Diagnostic Information 25 Ethernet 10Base 2 Attach 50 Ohm BNC terminator to each end of the T connector The customer may be able to provide this cap There is no wrap test for Token Ring with Unshielded Twisted Pair cable or for Ethernet 10Base T POR the printer If the printer completes POR successfully the printer network card and the port to the LAN
98. ting letterheads may be prevented by reducing the fuser temperature as described above for paper curl Fuser Temperature 1 Enter Diagnostics mode 2 Select PRINTER SETUP 3 Select Fuser Temperature 4 Select Normal No Boost Or Low Temperature 5 Press Return to return to the Diagnostics mode main menu Fuser Warm up Time 1 Enter Diagnostics mode 2 Select PRINTER SETUP 3 Select Warm Up Time 4 Select a setting of 0 through 5 Use the or key to change the number 0 is the shortest fuser warm up factory setting 5 is the longest fuser warm up 5 Press Return to return to the diagnostic menu LCD Test To test the operator panel display Enter Diagnostics mode Select HARDWARE TESTS Select LCD Test Select Single or Continuous The display goes through a continuous sequence of turning pels on and off Press Return to stop continuous LCD test Press Return to return to the Diagnostics mode main menu EE 44 Service Manual 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 B DE Enter Diagnostics mode Select PAGE COUNTS Select Maintenance Count Select Reset to set the count back to 0 Press Return to return to the Diagnostics mode main menu See Usage Kit Infor
99. tors printhead 934 and 935 errors connectors parts assembly 128 problem removal 89 skew adjustment printhead window cleaning Q quick disk te quick test R random marks registration regularly spaced marks removals 62 residual image RIP board connectors foa removal S safety inspection guide 166 Service Manual sensor test skew all edges top and bottom only stalled printer streaks symptom table T toner sensor removal tools used top margin and duplex quick test top margin test transfer rolle cleaning 118 parts assembly removal transfer roller housing connectors removal transfer test V vertical void W wrap tests 3112 3116 Printer Readers Service Manual SA40 0843 00 Comment 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 1 Did you find the book well organized YesO No 3 2 Was the content of the book accurate and complete Yes 9 No O 3 Was the book easy to use Yes 9 O 4 What can we do to improve the book 5 What is your job title Questions or comments about supplies service applica tions and so on will slow response time considerably Please refer those questions or comments to your authorized dealer or point of purchase
100. tween the transfer roller and its contact on the HVPS replace the transfer roll if the continuity is correct If there is no continuity make sure the HVPS contact returns to its upward limit when depressed and make sure the left bearing of the transfer roll is making proper contact Diagnostic Information 7 Error Code 918 Transfer Roll Error 920 Fuser Error 921 Fuser Error 922 Fuser Error 923 Fuser Error 924 Fuser Error Explanation 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 If there is no continuity make sure the HVPS contact returns to its upward limit when depressed and make sure the left bearing of the transfer roll is making proper contact Fuser is below temperature while printing See Fuser 920 921 or 922 Error on page 20 Fuser is below standby temperature when idle See Fuser 920 921 or 922 Error on page 20 Fuser failed to reach standb temperature See Fuser 920 921 or 922 Error on page 20 Fuser is too hot while printing or when idle See Fuser 923 or 924 Error on page 21 Open detected in thermistor circuit See Fuser 923 or 924 Error on 21 927 Fan Stalled See Fan 927 Error on page 19 928 Erase Lamps 931 Printhead Error Erase lamp
101. ut homes after 5 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 If the duplexer does not home at all it is either damaged or is not receiving 34VDC from the printer To check the connection from the printer engine board to the duplex system board remove the printer RIP Board Remove the duplex top cover and table cover and reinstall the duplexer Engine board J3 2 should have continuity with the duplex system board J5 1 J3 3 with J5 2 and so on With power on you should have the following voltages Connector Voltage to Ground Engine Board 34VDC 5VDC 5VDC Duplex System 34VDC Board 5VDC 5VDC If you do not find a cable or voltage problem replace the duplex system board If this does not fix the problem replace the printer engine board A 933 error indicates that communication between the printer and duplexer had been established but has been lost Check the cable as above if the error persists replace the duplex system board 23 Paper Jams Examine the paper path in the duplex unit and in the fuser exit area for paper or other obstructions Make sure the duplex unit is positioned correctly on the printer and that the gear at the bottom of the duplex unit meshes with the gear on the top of the paper tray Check that the paper is fed with no skew or binds from the duplexer int
102. ve the Engine board e Disconnect the engine cable connections Remove the nut and the three threaded standoffs the longer standoff is in the center 92 Service Manual Unsnap the board from the plastic standoff Engine Board OST ON ST C1PS0004 Fuser Sensor Cable Removal 1 Turn the printer off Remove the RIP board and the inner EMC shield together Disconnect the cable from the exit sensor board Remove the front cover Disconnect the cable from the paper sensor assembly Remove the cable through the right frame ES Toner Sensor Removal d Remove the transfer roll housing Lift the input sensor board far enough to disconnect the cable Remove the end of the bellcrank spring Lift the sensor to unsnap it Work the cable out of the frame and remove the sensor Transfer Roll Housing Removal 1 Remove the print cartridge 2 Remove the fuser input guide 3 Grasp the housing and pull toward the front of the machine to disconnect the housing from the mounting studs visible through openings B in the inner deflector Repair Information 93 4 Lift the transfer roll housing far enough to disconnect the erase lamp cable 5 Lift the transfer roll housing out of the machine 94 Service Manual Upper Frame Removal Unplug the power cord Remove the print cartridge Remove thelrighi ett andltop covers Remove the RIP board and the inner shield together

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