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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
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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
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©

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

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Summary of Contents for 3112

Page 1: ...S544 5256 00 3112 and 3116 Page Printer Service Manual ...

Page 2: ...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 Build...

Page 3: ...er 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 and used in accordance with the instructions may cause harmful interfer...

Page 4: ...for serial interface 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 conformité...

Page 5: ...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 I 1 laser products and elsewhere is certified as a Class I laser product conforming to the requirements of IEC 825 Class I laser products are not considered to be hazardous The printer contains internally a Class I...

Page 6: ... 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 Incorpo...

Page 7: ...nandernehmens und der Wartung des Geräts Fachpersonal sollte im vollen Verständnis der Lage entsprechende Vorsichtsmaßnahmen ergreifen Ersatzteile müssen gleiche oder gleichwertige Merkmale wie die Originalteile aufweisen da Sicherheitsvorkehrungen nicht immer offensichtlich sind Consignes de Sécurité Les consignes d entretien et de réparation de ce produit s adressent uniquement à un personnel de...

Page 8: ...o comprende esto y toma las precauciones necesarias Los dispositivos de seguridad de algunas partes quizá no siempre puedan ser reconocidas a simple vista Por lo tanto las partes de reemplazo deben poseer características idénticas o equivalentes a las partes originales Sikkerhedsoplysninger Oplysningerne om vedligeholdelse af dette produkt er forberedt med henblik på professionelt servicepersonale...

Page 9: ...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 g...

Page 10: ...x Service Manual ...

Page 11: ...VCCI Notice v German Statement of Acoustic Emissions v Laser Notice v Trademarks vi Safety Information vii Ozone Information viii Preface ix General Information 1 Power Consumption 2 Options 2 Maintenance Approach 3 Tools Required For Service 3 Abbreviations 4 Diagnostic Information 5 Power On Self Test POST 12 Symptom Table 13 Banding 14 Background 14 Black Page 15 Blank Page 16 Blurred or Fuzzy ...

Page 12: ...Printhead 29 Paper Size Sensing Problem 30 Regularly Spaced Marks 30 Residual Image 31 Random Marks 31 Skew all edges 31 Skew top and bottom only 32 Stalled diamonds on display 32 Vertical Void or Streak 33 Diagnostic Aids 35 Diagnostics Mode 35 Diagnostics Mode Menu Structure 35 Diagnostics Mode Tests 38 Auto Clean 38 Auto Clean Frequency 38 Auto Clean Delay 38 Button Test 39 Charge Roll 39 Defau...

Page 13: ...gin and Duplex Quick Tests 50 Transfer 50 Wrap Tests 51 Other Tests 52 Developed Image Test 52 LAN Information 52 Print Test Page 53 Print Test with RIP Board Removed 53 Repair Information 55 Handling ESD Sensitive Parts 55 Adjustments 56 Envelope Restraint Spring On The Envelope Feeder 56 Paper Restraint Spring On The 100 Sheet Auxiliary Feeder 56 Envelope Feeder Magnet And 100 Sheet Auxiliary Fe...

Page 14: ...r Panel Removal 82 INA or Hard Disk Removal 82 Host Attachment Card IPDS Card Removal 82 Host Attachment Card IPDS Card Replacement 84 Exit Sensor Board Removal 84 Paper Feed Magnet Assembly 86 Paper Feed Magnet Assembly Removal 86 Paper Feed Rollers Removal 86 Paper Size Switch Removal 88 Printhead Removal 89 RIP Board Inner EMC Shield and Engine Board Removal 91 Fuser Sensor Cable Removal 93 Ton...

Page 15: ...18 Usage Kit Information 119 Parts Catalog 121 How To Use This Parts Catalog 121 Assembly 1 Covers 122 Assembly 2 Lower Frame 124 Assembly 3 Upper Frame 126 Assembly 4 Printhead 128 Assembly 5 Paper Feed 130 Assembly 6 Paper Feed Alignment Gears 134 Assembly 7 Paper Feed Drive 136 Assembly 8 Standard Paper Tray 200 sheet 138 Assembly 9 Paper Tray 500 Sheet 140 Assembly 10 Base for Paper Drawer 500...

Page 16: ...xvi Service Manual ...

Page 17: ...is optional The following briefly describes the differences between the models There is also 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 3112 001 3116 001 3116 002 Maximum print speed pages min 12 16 16 Paper input capacity pages min 200 200 500 Paper output ca...

Page 18: ...lash 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 3112 3116 Power Saver Mode 21W 20W Printing average 260W 310W Max ...

Page 19: ... 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 screwdriver 2 Phillips screwdriver 5 5 mm nut driver 8 mm wrench Needlenose pliers Diagonal pliers Spring hook Feeler gauges Analog or digital multimete...

Page 20: ...ight Amplification by Stimulated Emission of Radiation LCD Liquid Crystal Display LED Light Emitting Diode LVPS Low Voltage Power Supply NVRAM Nonvolatile Random Access Memory OEM Original Equipment Manufacturer PICS Problem Isolation Charts PIXEL Picture Element POR Power On Reset POST Power On Self Test PQET Print Quality Enhancement Technology RIP Raster Image Processor ROM Read Only Memory ROS...

Page 21: ...he 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 ma...

Page 22: ...emoved While Printing 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 Not enough flash memory for data requested to be stored 53 Unformatted Flash 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 ...

Page 23: ...sor 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 agai...

Page 24: ...ach standby temperature See Fuser 920 921 or 922 Error on page 20 923 Fuser Error Fuser is too hot while printing or when idle See Fuser 923 or 924 Error on page 21 924 Fuser Error Open detected in thermistor circuit See Fuser 923 or 924 Error on page 21 927 Fan Stalled See Fan 927 Error on page 19 928 Erase Lamps Erase lamp assembly missing or disconnected 931 Printhead Error No first hsync See P...

Page 25: ...t 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 test 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 p...

Page 26: ... 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 B...

Page 27: ...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 Duplex system board failure Replace the duplex system board 993 Duplex Comm Failure Communications between the duplex unit and the printer have failed See Duplex on page 17 Error Code Explanation ...

Page 28: ...perating temperature Printer idle time is 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 4 The ready screen appears on the display Note Diagnostics menu appears if you are in diagnostic mode 5 The drive motor and the mirror motor start to run The fan starts to run at high speed 6 The dr...

Page 29: ...00 Sheet Auxiliary Feeder Paper Feed Problem Envelope Feeder 100 Sheet Auxiliary Feeder Service Check Automatic Paper Size Sensing Problem Automatic Paper Size Sensing Problem Service Check Host Printing Problems Go to Host Printing Problems on page 22 LAN Problems Go to LAN Problems on page 24 Blank Page Blank Page Service Check Black Page Black Page Service Check Random Marks Random Marks Servic...

Page 30: ...ng by powering on or off with the top cover open Verify that there is 24VDC on engine board J9 1 and 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 con tact ret...

Page 31: ...utput 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 Run the Print Test with the RIP Board removed ...

Page 32: ...d 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 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 Connector Voltage while Printing Voltage while Idl...

Page 33: ...nt 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 compo...

Page 34: ...nd 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 ...

Page 35: ...lex 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 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 p...

Page 36: ...hen 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...

Page 37: ...the fuser exit sensor board to engine board J8 Check the thermistor condition and connection Check the thermistor resistance at engine board J8 3 to J8 4 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 cartr...

Page 38: ...ost 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 2 For twinax check the station address For coax try another port 3 Print out your non host menu settings MENUS MORE TEST MENU Mark the printout with a 1 If you repla...

Page 39: ...erve the green CU LED If the 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 If the LED is ...

Page 40: ... 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 shipped with print ers that have LAN INAs pre installed Make sure that the des...

Page 41: ... 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 p...

Page 42: ...de 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 mod...

Page 43: ...er 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 th...

Page 44: ...re 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 mak...

Page 45: ...tance 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 be...

Page 46: ...es 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 size sensor Regularly Spaced Marks This...

Page 47: ...e 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 test print frame is parallel to all edges of the page but the margins are not all the same width See Print...

Page 48: ...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 oper...

Page 49: ...hutter 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 ar...

Page 50: ...34 Service Manual ...

Page 51: ...xit 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 t...

Page 52: ... 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 ...

Page 53: ...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 ...

Page 54: ...PRINTER SETUP 3 Select Auto Clean 4 Select On or Off 5 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 1 Enter Diagnostics mode 2 Select PRINTER SETUP 3 Select Auto Clean Frequency 4 Select or to display the frequency desired 5 Select Save 6 Press Return to return to Diagnostics mode main menu Auto Clean Delay This...

Page 55: ...u 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 1 Enter Diagnostics mode 2 Select PRINTER SETUP 3 Select Charge Roll...

Page 56: ... a 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 A message describing test progress is displayed during the test 1 Enter Diagnostics mode 2 Select DEVICE TESTS 3 Select Disk Test Clean 4 Select CONTINUE to start the test or CANCEL to return to Diagnost...

Page 57: ...under the slot 8 Open the cover and remove the sheet of paper 9 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 a...

Page 58: ...rn 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 1 Enter Diagnostics mode 2 Select PRINTER SETUP 3 Select Envelope Enhance 4 Select Low Medium or High 5 Press Return to return to Diagnostics mode main menu Envelope ...

Page 59: ...rom the flash memory It destroys all data stored in the flash SIMM 1 Enter Diagnostics mode 2 Select DEVICE TESTS 3 Select Flash Test 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...

Page 60: ...erature 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 th...

Page 61: ...on on page 119 Memory Tests 1 Enter Diagnostics mode 2 Select HARDWARE TESTS 3 Select Memory Test 4 Select either DRAM or ROM 5 Select Single or Continuous 6 The display will indicate PASSED or FAILED 7 Select CANCEL to stop continuous memory test 8 Press Return to return to Diagnostics mode main menu Page Count To view or set the page count 1 Enter Diagnostics mode 2 Select PAGE COUNTS 3 Select P...

Page 62: ...o Diagnostics mode main menu Permanent Page Count The permanent page count can be displayed only It cannot be modified or reset by the customer or servicer 1 Enter Diagnostics mode 2 Select PAGE COUNTS 3 Select Permanent Page Count 4 Press Return to return to Diagnostics mode main menu Print Contrast This setting varies the developer bias to vary the print darkness If the Print Darkness setting on...

Page 63: ... toward the right and negative moves the margin to the left Top Margin can be 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 Moving the number in a negative direction moves the text up the page and narrows the top margin Bottom Margin can be set between 20 and 20 Mov...

Page 64: ...touts 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 1 Enter Diagnostics mode 2 Select PRINT TESTS 3 Select Print Test 2 4 Select Single or Continuous 5 Select Cancel to stop continuous print 6 Press Return to return to the main diagnostic men...

Page 65: ...e track is tested 1 Enter Diagnostics mode 2 Select DEVICE TESTS 3 Select Quick Disk Test 4 The display will indicate Test Passed or Test Failed 5 Press Return to return to Diagnostics mode main menu 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 p...

Page 66: ...ter Diagnostics mode 2 Select DUPLEX TESTS 3 Select Duplex Quick Test 4 Press Return to return to the diagnostic menu 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 environmen...

Page 67: ...29048 for the serial test 4 Enter Diagnostics mode 5 Select HARDWARE TESTS 6 Select Wrap Test 7 Select Parallel for the parallel port or Serial for the 25 pin serial port 8 Select Single or Continuous 9 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 dis...

Page 68: ...t the test page 3 As soon as the leading edge of the paper is visible 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 pag...

Page 69: ... 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 that 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 dis...

Page 70: ...54 Service Manual ...

Page 71: ...y 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 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 a...

Page 72: ...ition the spring B so it clears the separator roller by 1 9 0 2 mm 0 075 0 008 in 3 Tighten the mounting screw Paper Restraint Spring On The 100 Sheet Auxiliary Feeder 1 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 ...

Page 73: ...Feeder Magnet 1 Hold the armature A in the closed coil active position 2 Loosen the mounting screw B and rotate the magnet assembly so the armature clears the clutch gear by 0 30 0 20 mm 0 012 0 008 in 3 Tighten the screw 4 Check the adjustment on both sides of the gear ...

Page 74: ...ning material on the armature interfere with the adjustment 3 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 4 Insert feeler gage 5 Rotate the magnet against the feeler gage 6 Tighten the mounting screw 7 The gage should pass between the foam pad and the magnet pole piece with moderate resistance Fuser Drive Gear Bac...

Page 75: ...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 ...

Page 76: ...noid must be mounted on the fuser for this adjustment and should be at room temperature 1 Loosen screw A 2 Remove the rubber washer 3 Rotate shaft B eccentric to obtain 4 2 mm 0 2 mm 0 165 in 0 008 in air gap 4 Tighten screw A 5 Replace the rubber washer ...

Page 77: ...move the spring loaded exit stacker 2 Loosen the screws A 3 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 ...

Page 78: ...r pivot pin and lift the cover off the rear pivot pin Front Cover Removal 1 Unplug the power cord 2 Remove the paper tray 3 Open the top cover 4 Open the right cover 5 Release the latches B You can reach the lower latches through the paper tray opening 6 Lift the right side of the cover to disengage latch D 7 Slide the cover to the right to disengage the bracket from the posts 8 Pull the front cov...

Page 79: ...Repair Information 63 ...

Page 80: ...nd to release it 5 Push the top of the cover to the left 6 Remove the cover by sliding it to the rear of the machine Top Cover Removal 1 3116 002 and 3116 003 Remove stacker plate by pulling upward 2 Remove the top cover screws C 3 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 ...

Page 81: ...l 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 transfer roll surface Support the left bearing cover from the front with your left hand Use a small 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...

Page 82: ...ridge 4 Remove the fuser input guide 5 Remove the transfer roll housing assembly 6 Pull the D roll firmly to the left to remove it Note The D roll is designed to be installed only once if it is removed for any reason it should be replaced with a new one Note It may take considerable force to install the new D roll ...

Page 83: ... board and inner EMC shield together 3 Remove the engine board 4 Remove the fuser input guide 5 Remove the transfer housing assembly 6 Remove the gear cover by releasing the rear latch and lifting up 7 Remove the motor mounting nuts B and screws D 8 Work the motor out of the machine ...

Page 84: ... shaft by disengaging the right end to the rear of the machine 5 Disconnect the long redrive belt A and slip it off the lower shaft 6 3116 002 Disconnect the output bin sensor cable 7 Remove the redrive assembly screws D 8 Remove the plenum assembly and screws B 9 Unplug the fan cable The fan C can now be removed from the plenum assembly ...

Page 85: ...ORE YOU SERVICE THIS UNIT ALLOW THE MACHINE TO COOL FOR 5 MINUTES 1 Unplug the power cord 2 Remove the printer cartridge 3 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 4 Remove the fuser cover 5 Disconnect the power wires A from the left side of the fuser 6 Remove the fuser input guide 7 Completely loosen t...

Page 86: ... input guide upward at both sides near the fuser and slide the guide 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 ...

Page 87: ...le 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 hou...

Page 88: ...istor Removal 1 Disconnect the thermistor cable connector A from the exit sensor card 2 Remove the fuser cover and wiper 3 Remove the tape holding the thermistor cable to the shroud 4 Squeeze the thermistor bracket tabs B and remove the thermistor from the shroud 5 Remove the thermistor cable from the guide clips on the right of the fuser to remove the thermistor ...

Page 89: ...Repair Information 73 ...

Page 90: ...he hole D 11 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 F to release the latch Push the other latch E in and raise the other stud F to release the latch 12 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 13 Move the ...

Page 91: ...Repair Information 75 ...

Page 92: ...ng 3 Remove the D roll 4 Disconnect the input sensor cable from the input sensor board Note Use care the flag can be damaged while removing the board 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 the sensor board ...

Page 93: ...Repair Information 77 ...

Page 94: ...isconnect the cable from the HVPS 6 Remove the RIP board and the inner EMC shield together 7 Remove the engine board 8 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 f...

Page 95: ...Repair Information 79 ...

Page 96: ...covers 4 Remove the RIP board and the inner EMC shield together 5 Remove the left and right LVPS mounting screws and the screw for the cable tie 6 Disconnect the LVPS cable from the engine board 7 Disconnect the LVPS connector A 8 Lift the supply up and then toward the right side frame to disconnect the On Off switch linkage ...

Page 97: ...nformation 81 LVPS Cover Removal 1 Form tabs D away from the power supply to create clearance for tabs A to move downward 2 Release the top latches A 3 Release the side latches B 4 Release the bottom latches C ...

Page 98: ...r 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 2 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...

Page 99: ... 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 7 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 8 Transfer the IPDS memory to the new IPDS card ...

Page 100: ...ding screw washer 4 Close the right side cover and the top cover 5 Connect the host attachment cable Twinax or Coax 6 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 1 Remove the front cover...

Page 101: ...Repair Information 85 ...

Page 102: ...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 Paper Feed Rollers Removal NOTE Replace all paper feed drive rollers at the same time 1 Remove the lower fram...

Page 103: ...Repair Information 87 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 ...

Page 104: ...nual Paper Size Switch Removal 1 Remove the paper tray 2 Remove the front cover 3 Unplug the cable B from the switch connector C 4 Remove the two screws A 5 Rotate the switch about 90 and pull it out of the printer ...

Page 105: ... Remove the right and top covers 4 Remove the exit redrive and its belt 5 Remove the air plenum 6 Remove the screws A and the pointer 7 Cut and discard the Printhead cable clamp 8 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 ...

Page 106: ...90 Service Manual ...

Page 107: ...vents damage to the Engine Board pins 1 Turn the printer off 2 Remove the right cover 1 E Clip from the rear pivot pin 3 Disconnect all the cables near the RIP board coax twinax serial parallel LAN feeder 4 Remove the Host Card and the attached IPDS card if present from J6 Remove the INA card or hard disk option if present from the upper connector J12 ...

Page 108: ...RIP board straight out from the printer as an assembly You need to pull hard but carefully 7 If the 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 9 If you are here to remove the Engine board Disconnect the engine cable connections Remove the nut and the ...

Page 109: ...t frame Toner Sensor Removal 1 Remove the fuser input guide 2 Remove the transfer roll housing 3 Lift the input sensor board far enough to disconnect the cable 4 Remove the end of the bellcrank spring 5 Lift the sensor to unsnap it 6 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 an...

Page 110: ...94 Service Manual 4 Lift the transfer roll housing far enough to disconnect the erase lamp cable 5 Lift the transfer roll housing out of the machine ...

Page 111: ... EMC shield together 5 Remove the engine board 6 Remove the load box latches A 7 Release the latches B 8 Pivot the upper frame to the rear to release the spring tension 9 Unsnap the plastic insert D holding the upper frame cables in the right side frame 10 Remove the screws C 11 Remove the upper frame cables through the side frame 12 Lift the upper frame off the machine ...

Page 112: ...96 Service Manual ...

Page 113: ... 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 ...

Page 114: ...al 1 Pry up on tabs A After the tabs are released lift up on the cover rotate the cover out and slide it to the right to completely remove it 2 Disconnect the exit sensor card cables 3 Depress the exit sensor flag actuator B and lift out the exit sensor card ...

Page 115: ...xit 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 Note When re installing the sensor lift up the flags so they will clear the sensor and not be damaged ...

Page 116: ...100 Service Manual ...

Page 117: ...t 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 ...

Page 118: ...102 Service Manual ...

Page 119: ...Connector Locations 103 Connector Locations This chapter shows the locations of major printer assemblies gears connectors and ground straps Major Assembly Locations ...

Page 120: ...104 Service Manual Gear Train ...

Page 121: ...Connector Locations 105 HVPS Transfer Roller Housing ...

Page 122: ...106 Service Manual Engine Board Connectors ...

Page 123: ...r Motor Fan J3 Duplex J4 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 ...

Page 124: ...ort J4 Board to Board J5 J6 Host Coax or Twinax With IPDS option an IPDS Card is connected to the Host Card J7 ROMM SIMM flash memory option J8 ROMM SIMM printer microcode J9 DRAM SIMM printer memory J10 DRAM SIMM printer memory J11 Serial Port J12 Optional INA hard disk internal Network Adapter for LAN printing ...

Page 125: ...Connector Locations 109 Board Installation Hardware ...

Page 126: ...110 Service Manual Printhead Connector Locations ...

Page 127: ...Connector Locations 111 Mirror Motor Fan Cable Mirror Motor Fan Cable Connections Motor Fan J2 1 1 J2 2 2 J2 3 3 J2 4 4 J2 5 5 J2 6 6 J2 7 2 J2 8 1 ...

Page 128: ...112 Service Manual Operator Panel Output Bin Sensor Cable Operator Panel Output Bin Sensor Cable Connectors Pin Op Panel Sensor 3116 002 003 J1 1 1 J1 2 2 J1 3 3 J1 4 4 J1 5 5 ...

Page 129: ...leads are not used Duplex Autoconnect Cable J1 6 1 J1 7 2 J1 8 3 J1 9 No connection Duplex Autoconnect Cable Connectors Engine Board Autoconnect J3 1 No connection J3 2 1 right most pin J3 3 2 J3 4 3 J3 5 4 J3 6 5 J3 7 6 Operator Panel Output Bin Sensor Cable Connectors Pin Op Panel Sensor 3116 002 003 ...

Page 130: ...114 Service Manual Printer Ground Straps ...

Page 131: ... or altered parts especially in the area of the On Off switch and the power supply Damaged missing or altered covers especially in the area of the top cover and the power supply cover 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...

Page 132: ...ve 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 The fixed center idler gear in the 500 sheet base and its shaft The idler gear in the 500 sheet base and its shaft Use IBM no 23 grease Approved equivalent Shell Darina 1 to lubricate Front pivot latch studs Gear no 8 teeth at gear no 7 contact points ...

Page 133: ...Preventive Maintenance 117 Use grease p n 1384076 to lubricate A Areas of contact between the two shafts and the grounding spring Use grease p n 1383586 to lubricate B on the duplex unit ...

Page 134: ... 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 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 print...

Page 135: ... 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 3112 62469G5266 3116 62469G5264 Europe only Customers have two options for ordering Usage kits Order as Feature Codes through your IBM Marketing Representative Feature C...

Page 136: ...120 Service Manual ...

Page 137: ...he 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 th...

Page 138: ...122 Service Manual Assembly 1 Covers ...

Page 139: ...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 ...

Page 140: ...124 Service Manual Assembly 2 Lower Frame ...

Page 141: ...Packet 1381663 6 1328243 1 Gear No 2 7 1039391 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 13...

Page 142: ...126 Service Manual Assembly 3 Upper Frame ...

Page 143: ... 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 18 1408216 1 Handle Latch with Grip 3112 002 003 19 1328308 2 Sleeve 2...

Page 144: ...128 Service Manual Assembly 4 Printhead ...

Page 145: ...4 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 8A 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 ...

Page 146: ...130 Service Manual Assembly 5 Paper Feed ...

Page 147: ...xiliary 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...

Page 148: ...132 Service Manual Assembly 5 Paper Feed Continued ...

Page 149: ...34 1381527 1 Redrive Assembly 3116 002 003 34 1408729 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...

Page 150: ...134 Service Manual Assembly 6 Paper Feed Alignment Gears ...

Page 151: ...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 o Shaft 1 o Roll 1 o Bellcrank 1 o Thrust washer NS 1383580 1 Anchor Repair Kit Metering NS 1383908 1 Anchor Repair Kit Prealigner ...

Page 152: ...136 Service Manual Assembly 7 Paper Feed Drive ...

Page 153: ...mbly 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 ...

Page 154: ...138 Service Manual Assembly 8 Standard Paper Tray 200 sheet ...

Page 155: ... 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 ...

Page 156: ...140 Service Manual Assembly 9 Paper Tray 500 Sheet ...

Page 157: ...t 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 5A 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...

Page 158: ...142 Service Manual Assembly 10 Base for Paper Drawer 500 Sheet ...

Page 159: ...Parts Catalog 143 Asm Index Part 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 ...

Page 160: ...144 Service Manual Assembly 11 Optional Paper Drawer 500 Sheet ...

Page 161: ...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 ...

Page 162: ...146 Service Manual Assembly 12 Fuser ...

Page 163: ...381011 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 8A 1381146 1 Hot Roll assembly NS 1329928 1 Backup Roll 9 1381637 1 Thermistor Sensor Asm 10 1328458 1 Redrive Idle Arm Asm 11 1328397 1 Paper Exit Bd Asm 12 1 Flag Parts Packet 1381669 13 1039481 1 Fuser Power Cabl...

Page 164: ...148 Service Manual Assembly 12 Fuser Continued ...

Page 165: ...Parts Catalog 149 Asm Index Part Number Units Description 12 24 2 Screw Mtg Parts Packet 1381663 25 1039316 5 Detack Fingers 26 1039317 5 Detack Finger Springs ...

Page 166: ...150 Service Manual Assembly 13 Electronics ...

Page 167: ... 1 Power Cord Set Chile Italy 3 1342535 1 Power Cord Set 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...

Page 168: ...152 Service Manual Assembly 13 Electronics Continued ...

Page 169: ...1 IPDS Card W 3812 Font Set See note 1 and 2 16 57G2126 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 Note 2 IPDS Cards as FRUs contain no DRAM SIMM Be sure to tr...

Page 170: ...154 Service Manual Assembly 14 Transfer Roll ...

Page 171: ...alog 155 Asm Index Part Number Units Description 14 1 1381008 1 Roll Asm Transfer 2 1381652 1 Housing Transfer 1 o Rear Lens Asm Erase 1 o Contact Transfer Roll 1 o Lamp Asm Erase 3 1328356 1 Cover Clip Bearing ...

Page 172: ...156 Service Manual Assembly 15 Duplex Option ...

Page 173: ...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 ...

Page 174: ...158 Service Manual Assembly 16 Envelope and 100 Sheet Auxiliary Feeder ...

Page 175: ... 1 Screw 3 1039615 1 Spring 4 1383944 1 Magnet Assembly 5 1622303 1 Washer 6 1622536 1 Screw Mtg 7 1408869 1 Cover Right 8 1408868 1 Guide Large 8A 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 ...

Page 176: ...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 o INA Ethernet 10Base2 high memory 1402217 1 o INA Token Ring high memory 1402218 1 o INA Ethernet 10BaseT high memory 1328563 1 o Thumbscrew INA 1325231 1 Font Card Adapter 1425267 1 Hard Disk 40MB 1321882 1 4MB IPDS memory 1321883 1 8MB IPDS memory ...

Page 177: ...5 1 Gears 7 14 parts packet 1381145 1 Metering and Prealigner rolls parts packet 1329301 1 Grease 2g 1384076 1 Grease conductive 1 oz 1383586 1 Grease damping 1 oz 9900692 1 Grease IBM 23 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 t...

Page 178: ...162 Service Manual ...

Page 179: ...uto clean delay 38 auto clean frequency 38 B background 14 banding 14 black page 15 blank page 16 blurred or fuzzy print 16 button test 39 C charge roll 39 connector locations 103 connectors duplex option autoconnect cable 113 engine board 106 gear train 104 HVPS 105 mirror motor fan cable 111 operator panel output bin sensor cable 112 printer ground straps 114 printhead 110 RIP board 108 covers f...

Page 180: ...raint spring adjustment 56 magnet adjustment 57 paper feed problem 29 parts assembly 158 error codes 5 ESD sensitive parts 55 exit sensor board removal 84 F fan 927 error 19 fan redrive removal 68 features 1 flash test 43 frame lower frame assembly removal 78 lower frame parts assembly 124 upper frame parts assembly 126 upper frame removal 95 fuser 920 921 or 922 error 20 923 or 924 error 21 input...

Page 181: ...work wrap tests 25 Ethernet 10Base 2 26 Token Ring 25 O operator panel problems 26 removal 82 operator panel output bin sensor cable connectors 112 optional paper drawer 500 sheet parts assembly 144 options available 2 parts assembly 160 output bin sensor 26 P page count 45 paper drawer base parts assembly 142 paper feed alignment gears parts assembly 134 parts assembly 130 132 rollers removal 86 ...

Page 182: ... adjustment 61 printhead window cleaning 118 Q quick disk test 49 quick test 49 R random marks 31 registration 47 regularly spaced marks 30 removals 62 residual image 31 RIP board connectors 108 removal 91 S safety inspection guide 115 sensor test 49 skew all edges 31 top and bottom only 32 stalled printer 32 streaks 33 symptom table 13 T toner sensor removal 93 tools used 3 top margin and duplex ...

Page 183: ...k well organized Yes No 2 Was the content of the book accurate and complete Yes No 3 Was the book easy to use Yes No 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 Note Please direct all requ...

Page 184: ...UNITED STATES Cut Along Line 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 BUSINESS REPLY MAIL FIRST CLASS MAIL PERMIT NO 2659 LEXINGTON KY ...

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