IBM 3112 User manual

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

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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
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.
©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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Notices and Safety Information iii
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
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:
•Reorient or relocate the receiving antenna.
•Increase the separation between the equipment and receiver.
•Connect the equipment into an outlet on a circuit different from
that to which the receiver is connected.
•Consult your point of purchase or service representative for
additional suggestions.

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iv Service Manual
The manufacturer is not responsible for any radio or 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 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 aux normes d’Industrie Canada
Cet appareil numérique respecte les limites de bruits
radioélectriques applicables aux appareils numériques de Classe B
prescrites dans la norme sur le matériel brouilleur : “Appareils
numériques”, NMB-003 édictée 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.

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Notices and Safety Information v
European Community (EC) Electromagnetic
Compatibility Directive
This product is in conformity with the protection requirements of EC
Council directive 89/336/EEC on the approximation of the laws of
the Member States relating to electromagnetic compatibility.
Japanese VCCI Notice
German Statement of Acoustic Emissions
A declaration of conformity with the requirements of the Directive
has been signed by the Director of Manufacturing and Technical
Support, Lexmark International, Ltd., Boigny, France.
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 IIIb (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 I
level during normal operation, user maintenance, or prescribed
service condition.

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

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Notices and Safety Information vii
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 parts must have the identical or
equivalent characteristics as the original parts.
Sicherheitshinweise
•Die Wartungsinformationen für dieses Produkt wurden zur
Verwendung durch einen Wartungsfachmann entwickelt und
sollten nicht von anderen benützt werden.
•Zusätzliches Risiko eines elektrischen Schlags und körperlicher
Verletzung existiert während des Auseinandernehmens und der
Wartung des Geräts. Fachpersonal sollte im vollen Verständnis
der Lage entsprechende Vorsichtsmaßnahmen ergreifen.
•Ersatzteile müssen gleiche oder gleichwertige Merkmale wie die
Originalteileaufweisen,daSicherheitsvorkehrungennichtimmer
offensichtlich sind.
Consignes de Sécurité
•Les consignes d'entretien et de réparation de ce produit
s'adressent uniquement à un personnel de maintenance
qualifié.
•Le démontage et l'entretien de ce produit pouvant présenter
certains risques électriques, le personnel d'entretien qualifié
devra prendre toutes les précautions nécessaires.
•Les normes de sécurité de certaines pièces n'étant pas toujours
explicites, les pièces de rechange doivent être identiques ou
conformes aux caractéristiques des pièces 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, è possibile il rischio accresciuto di scosse elettriche e

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viii Service Manual
danni personali. Il personale di assistenza autorizzato,
consapevole di ciò, deve adottare le precauzioni necessarie.
•È possibile che le funzioni di sicurezza di alcuni elementi non
siano così ovvie, quindi, i pezzi di ricambio devono avere
caratteristiche identiche o equivalenti a quelle dei pezzi originali.
Pautas de Seguridad
•La información 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 eléctricas y daños
personales durante el desmontaje y la reparación de la
máquina. El personal cualificado 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, og bør derfor
ikke benyttes af andre.
•Risikoen for elektrisk stød øges under demontering og service af
dette produkt, hvorfor der bør tages de nødvendige
forholdsregler.
•Sikkerhedsforanstaltningerne er ikke altid lige åpenbare for alle
reservedele. Der bør derfor kun anvendes originale reservedele
eller reservedele med samme egenskaber som de oprindelige.
Ozone Information
This product does not produce measurable amounts of ozone gas.

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Preface ix
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.

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xService Manual

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Table of Contents xi
Table of Contents
Notices and Safety Information................................................... iii
Electronic Emission Notices............................................................. iii
Federal Communications Commission (FCC) Statement............ iii
Industry Canada Compliance Statement .....................................iv
The United Kingdom Telecommunications Act 1984................... iv
European Community (EC) Electromagnetic Compatibility
Directive........................................................................................v
Japanese 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 Print .................................................................16
Dead Machine.............................................................................17
Duplex.........................................................................................17
Fan (927 Error)............................................................................19
Fuser Theory...............................................................................20
Fuser: 920, 921, or 922 Error......................................................20
Fuser: 923 or 924 Error...............................................................21

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xii Service Manual
Honeycomb.................................................................................21
Horizontal Void or Streak ............................................................21
Host Printing Problems................................................................22
LAN Problems.............................................................................24
Light Print....................................................................................24
Network Card 977 Errors.............................................................25
Network Wrap Tests....................................................................25
Output Bin Sensor.......................................................................26
Operator Panel Problem..............................................................26
Paper Feed Problem, 500-Sheet Second Tray...........................27
Paper Feed, Base Printer............................................................27
Paper Feed, Duplex Unit.............................................................28
Paper Feed Problem, Envelope+ Feeder/
100-Sheet Auxiliary Feeder.........................................................29
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
Defaults.......................................................................................40
Disk Test/Clean...........................................................................40
Duplex Feed 1 Test.....................................................................41
Duplex Feed 2 Test.....................................................................41
Envelope Enhance......................................................................42
Envelope Print Test.....................................................................42
Error Log .....................................................................................43
Flash Test....................................................................................43
Fuser Temperature And Warm-Up Time.....................................43

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Table of Contents xiii
Fuser Temperature..............................................................44
Fuser Warm-up Time...........................................................44
LCD Test.....................................................................................44
Maintenance Kit Count................................................................45
Memory Tests .............................................................................45
Page Count.................................................................................45
Paper Feed Tests........................................................................46
Permanent Page Count...............................................................46
Print Contrast..............................................................................46
Print Registration.........................................................................47
Print Test 1..................................................................................48
Print Test 2..................................................................................48
Print Test 3..................................................................................48
Quick Disk Test...........................................................................49
Quick Test...................................................................................49
Sensor Test.................................................................................49
Top Margin 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 Feeder Magnet............................................57
Paper Feed Magnet ....................................................................58
Fuser Drive Gear Backlash.........................................................58
Fuser Solenoid............................................................................60
Printhead Skew...........................................................................61
Removals........................................................................................62
Covers.........................................................................................62

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xiv Service Manual
Right Cover Removal..................................................................62
Front Cover Removal..................................................................62
Left Cover Removal.....................................................................64
Top Cover Removal ....................................................................64
14 in. 200-Sheet Paper Tray Top Cover .....................................65
14 in. 500-Sheet Paper Tray Top Cover .....................................65
Transfer Roll Removal.................................................................65
D-roll Assembly Removal............................................................66
Drive Motor Removal...................................................................67
Fan/Redrive Removal..................................................................68
Fuser Removal............................................................................69
Fuser Input Guide Removal ........................................................70
Fuser Lamp Removal..................................................................70
Fuser Solenoid Removal.............................................................71
Fuser Thermistor Removal..........................................................72
HVPS Removal ...........................................................................74
Input Sensor Board Removal......................................................76
Lower Frame Assembly Removal ...............................................78
LVPS Removal............................................................................80
LVPS Cover Removal .................................................................81
Operator 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
Toner Sensor Removal ...............................................................93
Transfer Roll Housing Removal ..................................................93
Upper Frame Removal................................................................95
Duplex Option Top Cover And Table Cover Removal.................97
Duplex Option Exit Card And Cover Removal.............................98
Duplex Option Bottom Cover
And Entry Sensor Card Removal................................................99
Duplex Option System Card And Motor Removal.....................101
Connector Locations...................................................................103
Major Assembly Locations ........................................................103

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Table of Contents xv
Gear Train.................................................................................104
HVPS ........................................................................................105
Transfer Roller Housing............................................................105
Engine Board Connectors.........................................................106
RIP Board..................................................................................108
Board Installation Hardware......................................................109
Printhead Connector Locations.................................................110
Mirror Motor/Fan Cable.............................................................111
Operator Panel/Output Bin Sensor Cable.................................112
Duplex Autoconnect Cable........................................................113
Printer Ground Straps...............................................................114
Preventive Maintenance.............................................................115
Safety Inspection Guide............................................................115
Lubrication Specifications .........................................................115
Printhead Window Cleaning Procedure....................................118
Cleaning The Transfer Roller....................................................118
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-Sheet)............142
Assembly 11: Optional Paper Drawer (500-Sheet)............144
Assembly 12: Fuser...........................................................146
Assembly 13: Electronics...................................................150
Assembly 14: Transfer Roll................................................154
Assembly 15: Duplex Option..............................................156
Assembly 16: Envelope+ and 100-Sheet Auxiliary Feeder158
Options...............................................................................160
Miscellaneous....................................................................161
Index................................................................................................163

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xvi Service Manual

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General Information 1
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** Level2
emulation and PCL**5 emulation, and SCS capability (IPDS 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
capacity (pages) 250 250 500
Output bin full
sensing No No Yes
Standard Memory
(MB) 244

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2Service Manual
Power Consumption
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
3112 3116
Power Saver Mode 21W 20W
Printing (average) 260W 310W
Max. A/C draw 110V 6.8A 9.8A
Max. A/C draw 220V 3.4A 5.0A

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General Information 3
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 screwdriver
#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

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4Service Manual
Abbreviations
ASIC Application-Specific Integrated Circuit
CSU Customer Setup
DRAM Dynamic Random Access Memory
EEPROM Electrically Erasable Programmable
Read-Only Memory
EP Electrophotographic Process
ESD Electrostatic Discharge
FRU Field Replaceable Unit
HVPS High Voltage Power Supply
INA Integrated Network Access
LAN Local Area Network
LASER Light 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 Read-Only Storage
SIMM Single In-line Memory Module
SRAM Static Random Access Memory
UPR Used Parts Replacement
VAC Volts alternating current
VDC Volts direct current