IBM 3112, 3116 Service Manual

3112 and 3116 Page Printer: Service Manual

S544-5256-00

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.

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 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.

Notices and Safety Information iii

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 interference, 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 interferencecausing 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.

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

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.

Notices and Safety Information v

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.

vi 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 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

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 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

Notices and Safety Information vii

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.

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................................................... 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

Table of Contents xi

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

xii Service Manual

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

Table of Contents xiii

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

xiv Service Manual

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

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** Level2 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 speed (pages/min.)

Paper input capacity (pages/ min.)

Paper output capacity (pages)

Output bin full sensing

Standard Memory (MB)

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.

12 16 16

200 200 500

250 250 500

No No Yes

244

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. A/C draw 220V 3.4A 5.0A

Options

The following options are available. Some options are not available in every country . Contact your point of purchase for options available in your country.

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 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

General Information 3

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

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 problem.

Refer to the diagnostics Error log for the last six machine errors.

Error Code Explanation

20 Paper Jam The input sensor was not unmade in

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

30 Top Cover Open or Print Cartridge Missing

unmade.

page 26.

Make sure the spring-mounted pin on the

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.

See

“Output Bin Sensor” on

32 Wrong Print Cartridge installed The installed print cartridge is not

supported.

Diagnostic Information 5

Error Code Explanation

38 Memory Full Memory used to store pages is full. To

verify that the printer recognizes all the installed memory, go to the user menus and print the “Print Menus” test page. Make sure the memory shown on the printout matches the installed memory.

39 Complex Page 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. 43 Font Card Not Supported Font card format not supported by printer. 44 Defective Font Card Defective font card installed in font slot. 47 Font Card Removed While

Printing 51 Defective Flash The printer detects a defective Flash

52 Flash Full Not enough ﬂash memory for data

53 Unformatted Flash Flash problem at POR or while

54 Serial Error Framing or parity error on serial. 57 Check Duplex Connection The duplex unit has been electrically

58 Duplex Not Attached Duplex is no longer connected, and

Printer needs data on removed card.

SIMM. If the error recurs replace the

Flash SIMM.

requested to be stored.

attempting to write.

disconnected from the printer but the

printer top cover is not open. Check the

auto-connect plugs on the duplex unit

and the printer.

printer top cover is closed. 59 Duplex Cover Open Top cover of duplex unit is sensed open. 62 Disk Full Not enough disk space for data that has

63 Unformatted Disk Format the disk.

6 Service Manual

been requested to be written to disk.

Error Code Explanation

64 Defective Disk The printer will ignore a disk it senses as

defective. Run the Quick Disk Test. If the test fails, the disk is defective or the data on track 1 is bad. If the Quick Disk Test passes but the disk does not work, run the Disk Test/Clean (2 hour test). Replace the disk if instructed by the operator panel.

7X Network Card Codes For example, 71:X

80 Scheduled Maintenance Printer has reached 200,000 prints

88 Toner Low Toner sensor detects low toner. 90X Software Error Unrecoverable software error. If one of

These user codes are documented in the

Network Printer Utility Guide

0822). page 25. Note: 7X codes are normal when an INA is installed but no LAN cable is attached. Press “Disable” to continue.

without maintenance count reset.

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.

See

“Network Wrap Tests” on

(SA40-

917 Transfer Roll Error Cannot start servo operation. 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.

Diagnostic Information 7

Error Code Explanation

918 Transfer Roll Error Servo Failure. Verify correct cable

connections from the Engine board to the

HVPS. Make sure there is continuity

between the transfer roller and its contact

on the HVPS; replace the transfer roll if

the continuity is correct. 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. 920 Fuser Error Fuser is below temperature while

printing.

Error” on page 20. 921 Fuser Error Fuser is below standby temperature

when idle.

Error” on page 20. 922 Fuser Error Fuser failed to reach standby

temperature.

922 Error” on page 20.

See

“Fuser: 920, 921, or 922

See

“Fuser: 920, 921, or 922

See

“Fuser: 920, 921, or

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.

“Fuser: 923 or 924 Error” on page 21. 927 Fan Stalled 928 Erase Lamps Erase lamp assembly missing or

931 Printhead Error No ﬁrst hsync.

932 Printhead Error Lost hsync. 934 Printhead Error Lost lock condition.

935 Printhead Error Mirror motor unable to reach operating

941 ROM SIMM ROM SIMM failed CRC; code data or font

See

“Fan (927 Error)” on page 19.

disconnected.

See

“Printhead” on page

29.

See

“Printhead” on page 29.

See

“Printhead” on

page 29.

speed.

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.

See

“Printhead” on page 29.

See

8 Service Manual

Error Code Explanation

944 RIP Board RIP processor failure. Replace the RIP

Board. 945 RIP Board ASIC 1 failure. Replace the RIP Board. 946 RIP Board ASIC 2 failure. Replace the RIP Board. 947 Engine Board Engine ASIC RAM failure. Replace the

engine board. 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 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 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

972 Network Card 1 Go to “Host Printing Problems” on

network card 2.

page 22.

Diagnostic Information 9

Error Code Explanation

972 Network Card 2 Network card 2 ROS/FLASH failure.

Replace network card 2.

973 Network Card 1 Go to “Host Printing Problems” on

page 22.

973 Network Card 2 Network card 2 EEPROM/NVRAM

failure. Replace network card 2.

974 Network Card 1 Go to “Host Printing Problems” on

page 22.

974 Network Card 2 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 a 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 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.

977 Network Card 1 Host card 1 is installed but is not

communicating with the RIP Board. “Network Card 977 Errors” on page 25.

977 Network Card 2 Network card 2 is installed but is not

communicating with the RIP Board. “Network Card 977 Errors” on page 25.

978 Network Card 1 General host 1 card hardware error. Go

to “Host Printing Problems” on page 22.

978 Network Card 2 General network 2 card hardware error.

Replace network card 2.

979 Network Card 1 General host 1 card software error. V erify

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.

See

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. 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.

on page 17.

See

“Duplex” on page 17.

See

“Duplex”

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. 1 1/2 rows of pels appear on the display and then clear.

2. Diamonds ﬁll the display and then clear.

3. The fuser lamp and the fan turn on. [Performing Self Test] 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 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 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 displayed, 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. 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

Host Printing Problems Go to “Host Printing Problems” on

Machine Hangs Displaying Diamonds Service Check

Operator Panel Service Check

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

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 Service Check Regularly Spaced Marks Regularly Spaced Marks Service Check Skew, all edges Skew Service Check Skew, top and bottom only Skew, top and bottom Service Check Light Print Light Print Service Check Blurred or Fuzzy Print Blurred Fuzzy Print Service Check Residual Image Residual Service Check Honeycomb Honeycomb Service Check Background 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

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, damage, 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 window.

V erify 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 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 voltage and the cable are good.

Inspect the contacts on the HVPS; make sure each spring-loaded contact 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:

Connector

Voltage while Printing

Voltage while Idling

J13-1 Less than 5VDC 0VDC J13-2 Less than 5VDC 0VDC J13-3 (Fluctuates

0VDC between pages) +1.5VDC

J13-8 Less than 1VDC +6VDC

If any voltages are not correct replace the engine board. If no problem is found, enter the diagnostics mode and change the

Charge Roll setting. 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 printing process, resulting in toner development on the entire photoconductor 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 voltage checks while printing and again while idling. If the voltages are not

Diagnostic Information 15

correct, replace the engine board.

Connector

Voltage while Printing

Voltage while Idling

J13-1 to J13-4 +4.5VDC 0VDC J13-2 to J13-4 +4VDC 0VDC

If no other trouble is found replace the HVPS.

Blank Page

Inspect the printhead shutter for proper operation and make sure the actuator on top of the cartridge is present and extends into the printhead 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 voltage checks:

Connector

Voltage while Printing

J13-1 to J13-4 Less than

Voltage while Idling

0VDC

5VDC

J13-2 to J13-4 Less than

0VDC

5VDC

J13-3 to J13-4 (Fluctuates

0VDC 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 damage, 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 reaching 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 connection 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 but homes after 5 or 6 seconds, the duplexer is receiving +34VDC from the printer but is not communicating 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 J52, and so on. With power on, you should have the following voltages:

Connector Voltage to Ground

Engine Board J3-3 +34VDC

J3-5 +5VDC J3-7 +5VDC

Duplex System

J5-2 +34VDC

Board

J5-4 +5VDC J5-6 +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 into 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 pressing 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 reinstall the duplexer on the printer. Measure the voltage on J5-12 of 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. 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 the cable connections to the fan are 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 replacing the fan. A bad fan can pull down the +24V line even if it runs; check that J2-8 has 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 thermistor 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 when 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 0VDC 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 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 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 damaged. 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 should 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 voltage are OK, check J4-16 to see if the engine board is sending the correct signal to the TRIAC. At POR this signal should go to +5VDC and then immediately drop to 0VDC until the fuser is warm; if it does not, replace the engine board. If 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 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 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 workings of the print cartridge and printhead shutter. If nothing is found “Blank Page” on page 16 and follow those instructions.

see

Diagnostic Information 21

Host Printing Problems

You are here for one of the following reasons:

1. Host (twinax or coax) printing problems.

2. 97x errors (if 977, go to “Network Card 977 Errors” on page 25)

3. An IPDS card error, such as “RAM Check”, printed out on a sheet of paper. 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.

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 replace an Engine Board or a RIP Board, you will need to reset the settings on this Printout 1.

4. 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 Setup menu.

b. Print out your host menu settings (1page with SCS-only,

2 pages with IPDS):

MENUS MORE

22 Service Manual

NETWORK MENU 1

TEST MENU

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.

c. Reseat the host card in the lower Network Menu 1 con-

nector J6. (See “RIP Board” on page 108.) Bad connection is a common cause of these problems.

d. 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.

• 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 attachment 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 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 for +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.

• 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 conﬁgurations 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. If the 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

Guide

ers that have LAN INAs pre-installed.

, SA40-0822, to ﬁnd the problem. This guide is shipped with print-

Network Printer Utility

• Make sure that the desired network protocol is enabled from the

printer operator panel.

• Verify proper print queue and printer driver conﬁguration

• Verify that the adapter port has been associated

• 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 a 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 are the same as for “Blank Page”.

Make sure Print Darkness on the customer Setup menu is set to Normal 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. V erify on the Print Test that the print is too light before performing service.

See

“Blank Page” on page 16.

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 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. If the +5VDC is OK, you have a problem with the card.

• 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 network card.

Diagnostic Information 25

Ethernet 10Base-2: Attach a 50 Ohm BNC terminator cap 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 are working correctly. If the customer 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 is an output bin sensor on the 31 16-002 and 3116-003. It is not on the 3112-001 or the 3116-001.

Make sure the plastic bails and guide are in good condition and that they guide the sensor ﬂag out of and into the sensor as paper passes into the bin. 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 displayed.

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 for +5VDC at pin 4 of the cable connector at the operator panel, and also at engine board J1-4. Replace the operator panel or the cable if they are the problem. 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 damage. 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 examine 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 Droll 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 Print 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.

• 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.

• 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. V ery 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 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. Examine 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 slippage in the paper path. Make sure the paper tray top cover is not damaged. 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 reinstalling the duplexer in the printer. Check for +5VDC at duplex system

28 Service Manual

board J15-10. The voltage will change from 0VDC to +5VDC as the selector lever is moved. Also

see

“23 Paper Jams” on page 18.

Paper Feed Problem, Envelope+ Feeder/ 100-Sheet Auxiliary Feeder

Check for the following: paper or envelope jammed in the feed path; missing hold-down weight; 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 damaged 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 magnet 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 J1 1-4, and +5VDC at engine board J12-8. If these voltages 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 voltage 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 size sensor.

Tray installed and set to:

A5 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 (legal tray)

Regularly Spaced Marks

This is caused by a defect on one of the rolls or gears in the print process. 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 photoconductor, 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 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 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.

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.

1. Enter Diagnostics mode.

2. Select [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 can be set from 1 to 60 seconds with a default of 1.

1. Enter Diagnostics mode.

2. Select [PRINTER SETUP].

3. Select [Auto Clean Delay].

4. Select [+] or [-] to display the delay desired.

5. Select [Save].

6. Press Return to return to Diagnostics mode main menu.

38 Service Manual

Button Test

To test the operator panel buttons:

1. Enter Diagnostics mode.

2. Select [HARDWARE TESTS].

3. Select [Button Test].

4. Press each button. [Closed] is displayed until the button is released. Then [Open] is displayed.

5. Press Return to return to the Diagnostics mode main menu.

Charge Roll

This setting varies the charge roll bias. 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].

4. Select [High], [Medium] or [Low].

5. 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.

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 a two hour test that should be performed only on a disk that contains bad data and is therefore unusable.

This test destroys all data on the disk by doing 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 Diagnostics mode main menu.

5. Select [CANCEL] to interrupt the test.

6. Press Return to return to Diagnostics mode main menu.

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. Enter Diagnostics mode.

2. Select [DUPLEX TESTS].

3. Select [Duplex Feed 1].

4. Select [Tray 1], or [Tray 2]. Note: Paper feeds all the way into the duplex unit and stop.

5. The message [Clear Paper] appears on the display.

6. Slide the tray extension all the way out until it stops.

7. 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.

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 as it feeds back over the top of the duplex paper tray.

1. Enter Diagnostics mode.

2. Select [DUPLEX TESTS].

3. Select [Duplex Feed 2].

4. 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.

5. The message [Clear Paper] appears on the display.

6. Open the printer top cover.

7. 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 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.

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 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.

1. Enter Diagnostics mode.

2. Select [PRINT TESTS].

3. Select [Envelope Print Test].

4. Select [Single] or [Continuous].

5. Select [CANCEL] to stop continuous print.

6. Press Return to return to the main diagnostic menu.

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 Diagnostics 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].

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 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].

Melting 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:

1. Enter Diagnostics mode.

2. Select [HARDWARE TESTS].

3. Select [LCD Test].

4. Select [Single] or [Continuous].

5. The display goes through a continuous sequence of turning pels on and off.

6. Press Return to stop continuous LCD test.

7. Press Return to return to the Diagnostics mode main menu.

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.

1. Enter Diagnostics mode.

2. Select [PAGE COUNTS].

3. Select [Maintenance Count].

4. Select [Reset] to set the count back to “0”.

5. Press Return to return to the Diagnostics mode main menu. See “Usage Kit Information” 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 [Page Count].

4. 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.

5. 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.

1. Enter Diagnostics mode.

2. Select [PAPER FEED TESTS].

3. Select [Tray 1], [Tray 2], [Feeder], or [Manual].

4. Select [Single] or [Continuous].

5. Select [CANCEL] to stop continuous.

6. Press Return to get back to 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 the customer menu does not allow the darkness to be set correctly, this setting can increase or decrease the entire darkness range.

1. Enter Diagnostics mode.

2. Select [PRINTER SETUP].

3. Select [Print Contrast].

4. Select [Low], [Medium], or [High].

5. Press Return to return to the Diagnostics mode main menu.

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. Enter Diagnostics mode.

2. Select [PRINT REGISTRATION].

3. Select one of the following: [Left Margin], [Top Margin], [Bottom Margin].

4. The value of the margin you selected is shown.

5. Margins:

• Left Margin can be 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 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. 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.

6. 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.

7. Select [Quick Test] to check your settings.

8. 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:

1. Enter Diagnostics mode.

2. Select [PRINT TESTS].

3. Select [Print Test 1].

4. Select [Single] or [Continuous].

5. Select [CANCEL] to stop continuous print.

6. 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:

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 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. Enter Diagnostics mode.

2. Select [PRINT TESTS].

3. 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.

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 prints faster than the other print tests.

Sensor Test

1. Enter Diagnostics mode.

2. Select [HARDWARE TESTS].

3. Select [Sensor Test].

4. Select one 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.

1. Enter Diagnostics mode.

2. Select [DUPLEX TESTS].

3. Select [Top Margin].

4. Select [+] or [-] to raise or lower the back image 0.01 inches per increment.

5. Press Return to return to the diagnostic menu.

The Duplex Quick Test is used to verify the Duplex Top Margin.

1. Enter 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 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.

1. Enter Diagnostics mode.

2. Select [PRINTER SETUP].

3. Select [Transfer].

4. Select [Low], [Medium], or [High].

5. Press Return to return to the Diagnostics mode main menu.

50 Service Manual

Wrap Tests

The Wrap Tests check the circuits used to communicate with the host computer.

To run the Wrap Test:

1. Turn the printer off.

2. Disconnect the interface cable.

3. Install the wrap plug in one of the interface cable connectors. Note: Install the parallel wrap plug part no. 1319128 for the par-

allel test or install the 25 pin serial wrap plug part no. 1329048 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 displayed after a failure is displayed.

10. Press Return to return to the Diagnostics mode main menu.

1 1. 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. Y ou 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 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 page also indicates to which type of LAN the printer is connected.

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:

1. Turn the printer on.

2. Select [MENUS].

3. Select [TESTS MENU].

4. Select [Print Test Page].

5. Select either [Single] for one page or [Continuous] for continuous test pages.

6. Select [Stop] when you want the continuous test to end.

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 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 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 Engine Board Removal” on page 91). The operator panel will have 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 precautions, 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.

• Put the ESD wrist strap on your wrist. Connect the 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.

• 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.

• 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.

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.

56 Service Manual

Envelope+ Feeder Magnet And 100-Sheet Auxiliary Feeder Magnet

1. Hold the armature [A] in the closed (coil active) position.

2. Loosen the mounting screw [B], and rotate the magnet assembly so the armature clears the clutch gear by 0.30 +/- 0.20 mm (0.012 +/- 0.008 in.).

3. Tighten the screw.

4. Check the adjustment on both sides of the gear.

Repair Information 57

Paper Feed Magnet

1. Remove the RIP board. (See “RIP Board, Inner EMC Shield, and Engine Board Removal” on page 91.)The magnet is accessed through the holes in the right frame.

2. With the armature latched on the cam step check for 0.60 mm +/- 0.07 mm (0.024 in +/- 0.003) between the foam pad and the magnet pole piece.

Note: Don’t let the sound deadening 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 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. Y ou 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.

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. 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.

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].

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.

Repair Information 61

Removals

Note: When there is artwork to support a procedure, it follows the

text.

Covers Right Cover Removal

1. Turn the printer off.

2. Remove all external trays.

3. Open the top cover.

4. Depress the latch and open the right cover.

5. Remove the E-clip from the rear 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 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.

2. Open the top cover and remove the print cartridge.

3. Remove the front cover.

4. Locate the latch [E] and lift the end to release it.

5. Push the top of the cover to the left.

6. 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.

64 Service Manual

14 in. 200-Sheet Paper Tray Top Cover

1. Push the tab where the left corner of the tray cover pivots.

2. Move the left tray cover pivot pin forward and then upward.

3. Remove the cover from the tray.

14 in. 500-Sheet Paper Tray Top Cover

1. 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 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 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. Lift the right bearing straight up and out of the machine.

Repair Information 65

D-roll Assembly Removal

1. Unplug the power cord.

2. Remove the paper tray.

3. Remove the print cartridge.

4. Remove the fuser input guide.

5. Remove the transfer roll housing assembly.

6. Pull the D-roll ﬁrmly to the left to remove it. Note: The D-roll is designed to be installed only once; 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

66 Service Manual

Drive Motor Removal

1. Unplug the power cord.

2. Remove the RIP board and inner EMC shield together.

3. Remove the engine board.

4. Remove the fuser input guide.

5. Remove the transfer housing assembly.

6. Remove the gear cover by releasing the rear latch and lifting up.

7. Remove the motor mounting nuts [B] and screws [D].

8. Work the motor out of the machine.

Repair Information 67

Fan/Redrive Removal

1. Open the top cover.

2. Remove the print cartridge.

3. Remove the top cover.

4. Remove the lower redrive shaft by disengaging the right end to the rear of the machine.

5. Disconnect the long redrive belt [A] and slip it off the lower shaft.

6. 31 16-002: 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.

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. 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 the four fuser mounting screws.

8. 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 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

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. 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.

72 Service Manual

Repair Information 73

HVPS Removal

1. Unplug the power cord.

2. Remove the left cover

3. Remove the fuser input guide.

4. Remove the transfer roll housing.

5. Remove the fuser cover.

6. Disconnect the cable from the HVPS connector.

7. Remove the power switch rod.

8. Remove the ground screw [B].

9. Remove the mounting screws [C].

10. Pull the ground strap through the 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 front of the power supply to the right (to clear the fuser power wires).

14. 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. Remove the fuser input guide.

2. Remove the transfer roll housing.

3. Remove the D-roll.

4. Disconnect the input sensor cable from the input sensor board. Note: Use care, the ﬂag can be damaged while removing the

board.

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.

76 Service Manual

Repair Information 77

Lower Frame Assembly Removal

1. Remove the right, front, and left covers

2. Remove the LVPS and the rod for the on/off switch.

3. Remove gear cover and the fuser input guide [A].

4. Remove the transfer roll housing.

5. Disconnect the cable from the HVPS.

6. 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 from the paper feed assembly.

78 Service Manual

Repair Information 79

LVPS Removal

1. Disconnect the power cord.

2. Remove all external feed trays.

3. Remove the left and right side covers.

4. Remove the RIP board and the inner EMC shield together.

5. Remove the left and right LVPS mounting screws and the screw for the cable tie.

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.

80 Service Manual

LVPS Cover Removal

1. Form tabs [D] away from the power supply to create clearance for tabs [A] to move downward.

2. Release the top latches [A].

3. Release the side latches [B].

4. Release the bottom latches [C].

Repair Information 81

Operator Panel Removal

1. Remove the top cover.

2. Disconnect the operator panel cable.

3. Remove the operator panel mounting screws from the inside of the top cover.

INA or Hard Disk Removal

1. Open the top cover.

2. Open the right cover.

3. Remove mounting screws as required.

4. 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

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 in the code level on the ﬁrst page of the Host print test. The IPDS card has a code patch if a “ * “ appears in the code level on the second page. (A higher level of code without a “ * “ probably incorporates the code patch.)

3. Disconnect the host attachment cable (T winax or Coax) from the Host Attachment Card. Remove all external trays.

82 Service Manual

4. Open the top cover. Then open the right side cover.

5. Remove the Host Attachment Card grounding screw.

6. With host attachment card, but no IPDS card, unplug the connector. With IPDS, pop the cards off the plastic standoffs as you unplug the connector. (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.

Repair Information 83

Host Attachment Card / IPDS Card Replacement

Note: The following directions also apply when you are installing a

new IPDS card.

1. With IPDS, attach the Host Attachment Card to the IPDS Card (2 screws).

2. Connect the Host Attachment Card onto the system board. With IPDS, snap the IPDS Card onto the standoffs. Ensure that the connector is seated.

3. Install the grounding 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.

2. Disconnect the fuser/sensor cable.

3. Disconnect the thermistor cable.

4. Disconnect the fuser solenoid cable.

5. Release the latches [A].

6. Pull the sensor board down to remove it.

84 Service Manual

IBM 3112, 3116 Service Manual

Specifications and Main Features

Frequently Asked Questions

User Manual