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IBM 4230 and 4232 Printers Maintenance Analysis Procedures
Document Number SA40-0571-04
IBML
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Note! Before using this information and the product it works with, ensure you read the general information under "Special Notices" on page v.
Fifth Edition (April 1994) This manual is for the use of IBM service personnel in the maintenance or repair of the IBM 4230 and 4232 Printers. IBM makes no representations that it is suitable for any other purpose. Publications are not stocked at the address given below; requests for IBM publications should be made to your IBM representative or to the IBM branch office serving your locality. 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 Pennant Systems Co., Serviceability Engineering, Department R64, 1701 North Street Endicott, NY 13760, USA. IBM/Pennant Systems may use or distribute any of the information you supply in any way it believes suitable without incurring any obligation to you. Copyright International Business Machines Corporation 1991, 1992. All rights reserved. Note to U.S. Government Users -- Documentation related to restricted rights -- Use, duplication or disclosure is subject to restrictions set forth in GSA ADP Schedule Contract with IBM Corp.
Contents
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Contents
Maintenance Analysis Procedures 1 MAP 1000: General Information 1 MAP 2010: Start/Verify 5 MAP 3100: Auto Sheet Feeder 29 MAP 3150: Automatic Forms Thickness Adjustment MAP 3200: Attachment 43 MAP 3320: Print Head Drive and Control 47 MAP 3400: Forms Motor Drive 53 MAP 3500: Print Wire 59 MAP 3600: Power Supply 65 MAP 3800: Ribbon Movement and Control 81 MAP 3900: Sensor 85 MAP 4000: Symptom 103
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IBM 4230 and 4232 Printers Maintenance Analysis Procedures
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Special Notices
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Special Notices
References in this publication to IBM products, programs, or services do not imply that IBM intends to make these available in all countries in which IBM operates. Any reference to an IBM product, program, or service is not intended to state or imply that only IBM's product, program, or service may be used. Any functionally similar product, program, or service that does not infringe any of IBM's intellectual property rights or other legally protectible rights may be used instead of the IBM product, program, or service. Evaluation and verification of operation with other products, programs, or services, except those expressly designated by IBM, are the user's responsibility. IBM may have patents or pending patent applications covering subject matter in this document. The supplying of this document does not give you any license to these patents. You can send license inquiries, in writing, to the IBM Director of Commercial Relations, IBM Corporation, Purchase, NY 10577. The following terms, denoted by an asterisk (*) in this publication, are trademarks of the IBM Corporation in the United States and/or other countries: AS/400 IBM.
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IBM 4230 and 4232 Printers Maintenance Analysis Procedures
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About This Book vii
About This Book
This Maintenance Analysis Procedures (MAPs) manual is a guide for servicing the IBM 4230 and 4232 Printers. It is the primary maintenance tool for problem analysis and repair of the 4230 and 4232 Printers. This manual is to be used with the IBM 4230 and 4232 Printers Maintenance Information Manual. You should use the Maintenance Information Manual (MIM) for supporting information such as service checks; part location; part removal, installation, or adjustment; diagnostic tests; and other helpful information.
Publications
The following publications provide information about the IBM 4230 and 4232 Printers.
IBM 4230 and 4232 Printers Library
For IBM 4230 Printer planning information, refer to:
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IBM 4230 Printer Planning and Site Preparation Guide, GC40-1700. This guide contains detailed information to help you plan for and prepare the site for a 4230 Printer installation.
For IBM 4232 Printer planning information, refer to:
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IBM 4232 Printer Model 302 Planning and Site Preparation Guide, GA24-4390. This guide contains detailed information to help you plan for and prepare the site for a 4232 Printer installation.
For information about the IBM 4230 Printer Auto Sheet Feeder, refer to:
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IBM 4230 Printer Auto Sheet Feeder General Information, SA40-0578. This manual describes the setup and use of the Auto Sheet Feeder with the 4230 Printer.
For information about the IBM 4232 Printer Auto Sheet Feeder, refer to:
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IBM 4232 Printer Model 302 Auto Sheet Feeder General Information, SA24-4391. This manual describes the setup and use of the Auto Sheet Feeder with the 4232 Printer.
For safety information about the IBM 4230 and 4232 Printers, refer to:
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IBM 4230 and 4232 Printers Safety Information, SA40-0575.
For service information, refer to:
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IBM 4230 and 4232 Printers Maintenance Analysis Procedures, SA40-0571. This manual is a guide for servicing the IBM 4230 and 4232 Printers. It is the primary maintenance tool for trouble analysis and repair of the 4230 and 4232 Printers. IBM 4230 and 4232 Printers Maintenance Information Manual, SA40-0572. This manual provides detailed maintenance procedures for the 4230 and 4232 Printers. IBM 4230 and 4232 Printers Illustrated Parts Catalog, SA40-0573. This parts catalog contains listings and illustrations of all replacement assemblies and detail parts for the 4230 and 4232 Printers. Binder for MAP, MIM, and Parts Catalog, SA40-0577. (One binder holds all 3 books)
IBM 4230 and 4232 Printers Maintenance Analysis Procedures
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About This Book ix
4230 Models 101, 1S2, 201, 2S2, 4S3, and 5S3 only
For setup and operating information, refer to:
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IBM 4230 Printer Models 101, 1S2, 201, 2S2, 4S3, and 5S3 User's Guide, SA40-0593. This guide describes the operating procedures for the IBM 4230 Printer (with special emphasis on using the forms devices). IBM 4230 Printer Models 101, 1S2, 201, 2S2, 4S3, and 5S3 Operator Panel Instructions, SA40-0594. This manual describes how to operate the 4230 Printer control panel. IBM 4230 Printer Models 101, 1S2, and 4S3 Quick Reference Guide, SA40-0591. This card shows the key functions and the available configuration values and the process for setting them. IBM 4230 Printer Models 201, 2S2, and 5S3 Quick Reference Guide, SA40-0592. This card shows the key functions and the available configuration values and the process for setting them. IBM 4230 Printer Models 101, 1S2, 201, 2S2, 4S3, and 5S3 Product and Programming Description, GC40-0595. This manual describes the printer and programming functions specific to 4230 Printers that attach to the IBM 3270 Information Display System, the IBM System/36, and AS/400*.
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4230 Models 102, 1I1, 202, 2I1, 4I3, and 5I3 only
For setup and operating information, refer to:
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IBM 4230 Printer Models 102, 1I1, 202, 2I1, 4I3, and 5I3 User's Guide, SA40-0564. This guide describes the operating procedures for the IBM 4230 Printer (with special emphasis on using the forms devices). IBM 4230 Printer Models 102, 1I1, 202, 2I1, 4I3, and 5I3 Operator Panel Instructions, SA40-0565. This manual describes how to operate the 4230 Printer control panel.
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IBM 4230 Printer Models 102, 1I1, and 4I3 Quick Reference Guide, SA40-0581. This card shows the key functions and the available configuration values and the process for setting them. IBM 4230 Printer Models 202, 2I1, and 5I3 Quick Reference Guide, SA40-0580. This card shows the key functions and the available configuration values and the process for setting them. IBM 4230 Printer Models 102, 1I1, 202, 2I2, 4I3, and 5I3 Product and Programming Description, GC40-1701. This manual describes the printer and programming functions specific to 4230 Printers that attach to the IBM 3270 Information Display System, the IBM System/36, and AS/400*.
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4232 Model 302 only
For setup and operating information, refer to:
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IBM 4232 Printer Model 302 User's Guide, SA24-4386. This guide describes the operating procedures for the IBM 4232 Printer (with special emphasis on using the forms devices). IBM 4232 Printer Model 302 Operator Panel Instructions, SA24-4387. This manual describes how to operate the 4232 Printer control panel. IBM 4232 Printer Model 302 Quick Reference Guide, SA24-4388. This card shows the key functions and the available configuration values and the process for setting them. IBM 4232 Printer Model 302 Product and Programming Description, GA24-4385. This manual describes the printer and programming functions specific to 4232 Printers that attach to the IBM 3270 Information Display System, the IBM System/36, and AS/400*.
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IBM 4230 and 4232 Printers Maintenance Analysis Procedures
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About This Book xi
Enterprise System/9000* Publications
For information about attaching the printer to Enterprise System/9000, refer to:
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Enterprise System/9000 Models 120, 130, 150, 170: Customizing Your Work Station Subsystem, SA24-4226 Enterprise System/9000 Models 120, 130, 150, 170: Planning Your Work Station Subsystem, GA24-4223 Enterprise System/9000 Models 120, 130, 150, 170: Work Station Subsystem Description and Reference, SA24-4236.
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Safety Information
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Safety Information
The construction of this machine provides extra protection against the risk of electric shock by grounding suitable metal parts. The extra protection may not function unless the power cord is connected to a properly grounded outlet. This machine has a grounding-type (3-wire) power cord because grounding is necessary. It is the responsibility of the customer or the person installing the machine to connect it to a properly grounded outlet. Seek professional assistance before using an adapter or extension cord; such a device could interrupt the grounding circuit. If this machine is connected to an outlet that has been incorrectly connected to the building wiring, serious electric shock could result. For continued protection against the risk of electric shock and personal injury:
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Connect the machine only to a properly grounded outlet of the correct voltage. The voltage your machine will accept is indicated on the machine. Ensure the machine is switched Off (O) before you connect or disconnect the power cord or other cables. If the machine has cables other than the power cord, you must connect them before you plug the power cord into an outlet. You must first unplug the power cord from the outlet when you remove the other cables. Do not use the machine in an area where it can become wet. Keep hair and personal articles away from moving parts in the machine to prevent them from getting caught. Refer service or repairs to qualified personnel.
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There may be some increased risks of electric shock and personal injury during disassembly and servicing of this machine. 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 same or equal characteristics as the original parts. The maintenance information for this machine has been written for the professional service person and is not intended to be used by others. This printer weighs approximately 20.4 kgs (45 lbs). Do not attempt to lift it by yourself.
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IBM 4230 and 4232 Printers Maintenance Analysis Procedures
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Maintenance Analysis Procedures 1
Maintenance Analysis Procedures
MAP 1000: General Information
These MAPs are designed to aid in diagnosing printer failures. The MAPs use a sequential plan for isolating the possible causes of machine failures and point you to the part needing adjustment, repair, or exchange. At some steps in the MAPs, you may see a reference similar to "(From step 018)" when you did not arrive at this step from Step 018. This reference means only that Step 018 also sends you to this step. At various steps in the MAPs, references are given to sections in the Maintenance Information Manual (MIM). These references instruct you to diagnostic tests; service checks; parts locations; and parts removal, installation, or adjustment. Review MIM "Section 000. General Information" on page 000-1 if you are unfamiliar with operator control of the printer. Take a moment to become familiar with the MAP format before you start diagnosing problems. This will prevent confusion later. Note: You will be instructed to continue at specific MAP or step numbers as you follow the flow of the MAPs. Ensure that you always go to the correct MAP or step numbers.
Suggested Steps for Using the MAPs
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Discuss the printer symptoms with the operator. Make a quick visual inspection for problems-- loose parts, broken parts, disconnected connectors, form jams. This check may quickly identify problem areas.
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The normal place to start a service call in these MAPs is at "MAP 2010: Start/Verify" on page 5. It sends you to a Field Replaceable Unit (FRU) or to another MAP that is determined by the symptoms. If you bypass "MAP 2010: Start/Verify" on page 5 and start the service call with another MAP, you may be using the wrong MAP. The questions in that MAP may not refer to your problem and may send you to a wrong solution. These MAPs are an aid in solving most problems. Sometimes, instructions or questions may be misunderstood. If a MAP leads you to the wrong solution, start again in the MAPs and read each step carefully. If, after going through the MAPs a second time, you still have no solution to the problem, the printer may have two interrelated problems. Use other diagnostic techniques or call your support structure for aid. Read carefully! The MAPs will aid you in finding the failure only if you follow every instruction and answer each question accurately. Follow the sequence! Always do one question at a time. When a procedure precedes the question, do all of the steps in the procedure before answering the question. Some steps have additional information that pertains to that step. This information is in the MAP flow and is an aid in describing why questions or actions are needed to find the correct failing FRU. At times the MAP instructions might not seem to point to the solution; however, they are important in determining the actual failing FRU. Follow instructions! Instructions must be followed exactly in the order given. Questions rely on the instructions immediately before the questions. Do not change the conditions prepared by the instructions before answering the question. Do not switch off power or disconnect any cable unless you are instructed to do so. Whenever possible, the MAPs are written so that No is the error path answer. Verify repair or exchange FRU! When a card or a cable is identified as the failing FRU, reseat it and verify that the same problem does not remain. If the printer is still failing for the same problem,
IBM 4230 and 4232 Printers Maintenance Analysis Procedures
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Maintenance Analysis Procedures 3
exchange the FRU. Start again at "MAP 2010: Start/Verify" on page 5 to ensure the correct operation of the printer before returning it to the customer.
Intermittent Strategy
Print the error log to identify the error/status code. "MAP 4000: Symptom" on page 103 has additional diagnostic information, error/status codes, error descriptions, suspect FRU lists, service checks, and symptom lists to aid in isolating the failing FRUs.
Voltage/Continuity Readings
When taking voltage or continuity readings, do exactly as the MAP instructs you to do. For example, If you are instructed to measure at driver card J8-4, then connect the meter lead to driver card J8 pin 4. If you are instructed to measure at cable J8-4, then connect the meter lead to cable J8 pin 4.
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Notes
IBM 4230 and 4232 Printers Maintenance Analysis Procedures
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Maintenance Analysis Procedures 5
MAP 2010: Start/Verify
001 Has the Customer done the Problem Solving Procedures in the User's Guide? Yes No 002 Attempt recovery using the Problem Solving Procedures in the User's Guide. Continue with Step 003 as needed. 003 Are you here because the forms are jamming? Yes No 004 Continue with Step 006. 005 Continue with the Forms Feed Service Check. (refer to MIM "Forms Feed Service Check" on page 000-93) 006 Does the printer display an error/status code? Yes No 007 (Step 007 continues)
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MAP 2010 (continued) 6
007 (continued) Continue with Step 009 on page 17. 008 - Locate the error/status code in the following table and go to the MAP indicated. Note: A "+" (plus) symbol below the second digit of the Error/Status code indicates that the printer has the extended memory feature. For example, 001 END OF FORMS + LOAD FORMS
Error Status Code 001 Error/Status Description MAP
End of Forms Ensure forms are installed correctly Forms Jam (Caused by forms jamming) Forms Jam (False message displayed)
"MAP 3900: Sensor" on page 85 MIM "Forms Feed Service Check" on page 000-93 "MAP 3400: Forms Motor Drive" on page 53 or "MAP 3900: Sensor" on page 85 "MAP 3900: Sensor" on page 85 "MAP 3400: Forms Motor Drive" on page 53 or "MAP 3900: Sensor" on page 85
002 002
003 004
Dual purpose forms device (F2) ejected Forms load error (F2 or F3)
IBM 4230 and 4232 Printers Maintenance Analysis Procedures
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Maintenance Analysis Procedures 7
Error Status Code 005
Error/Status Description
MAP
Margin error
"Printer Configuration" on page 000-49 or "MAP 3320: Print Head Drive and Control" on page 47 "MAP 4000: Symptom" on page 103 Error/Status Code 006 "MAP 4000: Symptom" on page 103 Error/Status Code 007 "MAP 4000: Symptom" on page 103 Error/Status Code 008 "MAP 3600: Power Supply" on page 65 or MAP 3600 step 044 on page 76 "MAP 3100: Auto Sheet Feeder" on page 29 "MAP 3100: Auto Sheet Feeder" on page 29 "MAP 3900: Sensor" on page 85 "MAP 4000: Symptom" on page 103 Error/Status Code 013 "MAP 4000: Symptom" on page 103 Error/Status Code 014
006
Host attention
007
Invalid Printer Control Information Area (PCIA) order Hold print timeout
008
009
Invalid operator key press
010 011 012 013
Load manual bin Check/load bin Check paper path Data to print load forms
014
Invalid forms select
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MAP 2010 (continued) 8
Error Status Code 015
Error/Status Description
MAP
Communications check
"MAP 4000: Symptom" on page 103 Error/Status Code 015 "MAP 3400: Forms Motor Drive" on page 53 or "MAP 3900: Sensor" on page 85 "MAP 4000: Symptom" on page 103 Error/Status Code 017 "MAP 3200: Attachment" on page 43 "MAP 4000: Symptom" on page 103 Error/Status Code 021 "MAP 4000: Symptom" on page 103 Error/Status Code 022 "MAP 4000: Symptom" on page 103 Error/Status Code 023 "MAP 4000: Symptom" on page 103 Error/Status Code 024 "MAP 4000: Symptom" on page 103 Error/Status Code 025 "MAP 4000: Symptom" on page 103 Error/Status Code 026
016
Forms load error (F2) or forms not at paper present sensor
017
Communications check
019 021
Printer logic board failure Receive buffer overrun
022
Unit address not received
023
Transmit buffer overrun
024
Parity error
025
Framing error
026
Hex print mode active
IBM 4230 and 4232 Printers Maintenance Analysis Procedures
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Maintenance Analysis Procedures 9
Error Status Code 027
Error/Status Description
MAP
Communications check
"MAP 4000: Symptom" on page 103 Error/Status Code 027 "MAP 4000: Symptom" on page 103 Error/Status Code 028 "MAP 4000: Symptom" on page 103 Error/Status Code 029 "MAP 3100: Auto Sheet Feeder" on page 29 Error/Status Code 030 "MAP 3900: Sensor" on page 85 Error/Status Code 031 MIM"Forms Feed Service Check" on page 000-93 "MAP 3400: Forms Motor Drive" on page 53 or "MAP 3900: Sensor" on page 85 "MAP 4000: Symptom" on page 103 Error/Status Code 034 MIM "Printer Configuration" on page 000-49 or "MAP 3320: Print Head Drive and Control" on page 47 "MAP 3400: Forms Motor Drive" on page 53
028
Communications check
029
DSR not active
030
Load manual bin - timeout
031
End of Forms - timeout
032 032
Forms Jam - time out (Caused by forms jamming) Forms Jam - time out (False message displayed)
034
Invalid forms selected timeout Margin error - timeout
035
042
Machine check
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MAP 2010 (continued) 10
Error Status Code 043 044 050
Error/Status Description
MAP
Machine check Machine check Machine check
"MAP 3400: Forms Motor Drive" on page 53 "MAP 3400: Forms Motor Drive" on page 53 "MAP 4000: Symptom" on page 103 Error/Status Code 050 "MAP 3320: Print Head Drive and Control" on page 47 "MAP 3320: Print Head Drive and Control" on page 47 "MAP 3320: Print Head Drive and Control" on page 47 "MAP 3320: Print Head Drive and Control" on page 47 "MAP 3320: Print Head Drive and Control" on page 47 "MAP 4000: Symptom" on page 103 Error/Status Code 058 "MAP 4000: Symptom" on page 103 Error/Status Code 059 "MAP 4000: Symptom" on page 103 Error/Status Code 060 "MAP 4000: Symptom" on page 103 Error/Status Code 061
051 052 053 055 056 058
Machine check Machine check Machine check Machine check Machine check Printer logic board failure
059
Cancel print active
060
Buffer reprint active
061
PA1 selected
IBM 4230 and 4232 Printers Maintenance Analysis Procedures
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Maintenance Analysis Procedures 11
Error Status Code 062
Error/Status Description
MAP
PA2 selected
"MAP 4000: Symptom" on page 103 Error/Status Code 062 "MAP 4000: Symptom" on page 103 Error/Status Code 063 "MAP 4000: Symptom" on page 103 Error/Status Code 064 "MAP 3200: Attachment" on page 43 "MAP 3200: Attachment" on page 43 "MAP 4000: Symptom" on page 103 Error/Status Code 068 "MAP 4000: Symptom" on page 103 Error/Status Code 069 "MAP 4000: Symptom" on page 103 Error/Status Code 072 "MAP 4000: Symptom" on page 103 Error/Status Code 075 "MAP 4000: Symptom" on page 103 Error/Status Code 076 "MAP 3800: Ribbon Movement and Control" on page 81
063
Printer in send state
064
Machine check
065 066 068
No attachment (bezel or card) Printer logic board failure Data cleared
069
Data lost
072
Printer logic board failure
075
Internal attachment microcode check Internal controller microcode check Ribbon jam
076
089
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MAP 2010 (continued) 12
Error Status Code 090 096 098
Error/Status Description
MAP
NOT READY Cover/door open Cover/door open Hold print timeout
"MAP 3900: Sensor" on page 85 "MAP 3900: Sensor" on page 85 "MAP 4000: Symptom" on page 103 Error/Status Code 008 "MAP 3150: Automatic Forms Thickness Adjustment" on page 35 "MAP 3150: Automatic Forms Thickness Adjustment" on page 35 "MAP 3150: Automatic Forms Thickness Adjustment" on page 35 "MAP 3150: Automatic Forms Thickness Adjustment" on page 35 "MAP 2010: Start/Verify" on page 5 Step 017 on page 19 "MAP 2010: Start/Verify" on page 5 Step 017 on page 19 "MAP 2010: Start/Verify" on page 5 Step 017 on page 19 "MAP 2010: Start/Verify" on page 5 Step 017 on page 19
0A1
Home sensor always active
0A2
Wrong number of steps back to home sensor Home sensor change not valid AFTA out of conversion range
0A3
0A4
300
Panel diagnostics failure
310
Panel communications failure
312
Panel communications failure
314
Panel communications failure
IBM 4230 and 4232 Printers Maintenance Analysis Procedures
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Maintenance Analysis Procedures 13
Error Status Code 316
Error/Status Description
MAP
Panel communications failure
"MAP 2010: Start/Verify" on page 5 Step 017 on page 19 "MAP 2010: Start/Verify" on page 5 Step 017 on page 19 "MAP 4000: Symptom" on page 103 Error/Status Code 7C0 "MAP 4000: Symptom" on page 103 Error/Status Code 7C1 "MAP 4000: Symptom" on page 103 Error/Status Code 7D0 "MAP 4000: Symptom" on page 103 Error/Status Code 7D1 "MAP 4000: Symptom" on page 103 Error/Status Code 7E0 "MAP 4000: Symptom" on page 103 Error/Status Code 7F0 "MAP 4000: Symptom" on page 103 Error/Status Code 7F1 "MAP 4000: Symptom" on page 103 Error/Status Code 997
320
Panel communications failure
7C0
Printer logic board failure
7C1
Printer logic board failure
7D0
Printer logic board failure
7D1
Printer logic board failure
7E0
Printer logic board failure
7F0
Printer logic board failure
7F1
Printer logic board failure
997
Printer logic board failure
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MAP 2010 (continued) 14
Error Status Code 998
Error/Status Description
MAP
Printer logic board failure
"MAP 4000: Symptom" on page 103 Error/Status Code 998 "MAP 4000: Symptom" on page 103 Error/Status Code 999 "MAP 4000: Symptom" on page 103 Error/Status Code AXX "MAP 4000: Symptom" on page 103 Error/Status Code AXX "MAP 4000: Symptom" on page 103 Error/Status Code AXX "MAP 4000: Symptom" on page 103 Error/Status Code AXX "MAP 4000: Symptom" on page 103 Error/Status Code AXX "MAP 4000: Symptom" on page 103 Error/Status Code AXX "MAP 4000: Symptom" on page 103 Error/Status Code AXX "MAP 4000: Symptom" on page 103 Error/Status Code AXX
999
Printer configuration invalid
AD3
Bin or media request not valid
AD4
Forms media task not on page boundary Too much font download data
A8A
A8B
Code point greater than hex
A8C
Page length not valid
A8D
Page width not valid
A81
Font does not exist
A85
CPI not valid
IBM 4230 and 4232 Printers Maintenance Analysis Procedures
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Maintenance Analysis Procedures 15
Error Status Code A86
Error/Status Description
MAP
Out of storage
"MAP 4000: Symptom" on page 103 Error/Status Code A86 "MAP 4000: Symptom" on page 103 Error/Status Code A87 "MAP 4000: Symptom" on page 103 Error/Status Code AXX "MAP 4000: Symptom" on page 103 Error/Status Code A89 "MAP 4000: Symptom" on page 103 Error/Status Code AXX "MAP 4000: Symptom" on page 103 Error/Status Code AXX "MAP 4000: Symptom" on page 103 Error/Status Code AXX "MAP 4000: Symptom" on page 103 Error/Status Code AXX "MAP 4000: Symptom" on page 103 Error/Status Code AXX "MAP 4000: Symptom" on page 103 Error/Status Code FE3
A87
Cell height not compatible
A88
Cell width not compatible
A89
00 code point (not valid)
A9E
Code page and font ID not compatible Attempt to move page backwards (not supported) Printing outside logical page
A91
A95
A96
Operation extends outside logical page Text graphic error
A97
FE3
Printer logic board failure
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MAP 2010 (continued) 16
Error Status Code FE4
Error/Status Description
MAP
Printer logic board failure
"MAP 4000: Symptom" on page 103 Error/Status Code FE4 "MAP 4000: Symptom" on page 103 Error/Status Code FE5 "MAP 4000: Symptom" on page 103 Error/Status Code FE6 "MAP 4000: Symptom" on page 103 Error/Status Code FE7 "MAP 4000: Symptom" on page 103 Error/Status Code FF8 "MAP 4000: Symptom" on page 103 Error/Status Code FF9 "MAP 4000: Symptom" on page 103 Error/Status Code FFA "MAP 4000: Symptom" on page 103 Error/Status Code FFB "MAP 4000: Symptom" on page 103 Error/Status Code FFD "MAP 4000: Symptom" on page 103 Error/Status Code FFE
FE5
Printer logic board failure
FE6
Printer logic board failure
FE7
Printer logic board failure
FF8
Printer logic board failure
FF9
Printer logic board failure
FFA
Extended memory failure
FFB
Extended memory failure
FFD
Printer logic board failure
FFE
Printer logic board failure
IBM 4230 and 4232 Printers Maintenance Analysis Procedures
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Maintenance Analysis Procedures 17
009 (From step 007) - Switch off power. - Ensure that a forms device, forms, and a ribbon cartridge are installed. - Switch on power and observe what happens during the power-on self test (POST). Note: Because of the many indicators occurring during POST, it may be necessary to perform more than one switch on power/switch off power procedure to answer the questions correctly. POST is started when the power is switched on and completes inside 20 seconds. Ensure that the paper is loaded and that the cover and door are tightly closed. Indicators during the first 20 seconds after the power is switched on are as follows: 1. 2. 3. 4. 5. For approximately 1 second, all indicators go on. The alarm sounds. The fan starts. The LCD test runs, all indicators go on. The printer displays
6. The printer displays "Diagnostics In Progress." 7. The printer displays "Calibrating Printer Please Wait." Note: This message does not appear if forms are in position at the platen. (Step 009 continues)
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MAP 2010 (continued) 18
009 (continued) 8. The print head moves and stops. 9. The ribbon motor turns the ribbon. 10. The Ready indicator goes on. 11. The Online indicator goes on (Model 102 and 202 only). 12. The carrier moves to the left side and stops. 13. The printer displays ready. - The fan will slow in 10 seconds if no printing occurs. - Switch on power and observe what happens during the POST. Note: If the printer completes the POST without an error and the ribbon does not move, continue with "MAP 3800: Ribbon Movement and Control" on page 81. Does the POST complete without failure? Yes No 010 Is the printer completely inactive (No indicators, no display, and no fan.) Yes No 011 Continue with Step 014 on page 19. 012 Continue with "MAP 3600: Power Supply" on page 65. 013 (Step 013 continues)
IBM 4230 and 4232 Printers Maintenance Analysis Procedures
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Maintenance Analysis Procedures 19
013 (continued) Continue with Step 022 on page 21. 014 (From step 011) Is the display completely blank or is there another problem with the operator panel; for example, indicators not working, constant beep, missing LCDs, bad keys, or unreadable characters? Yes No 015 Continue with Step 050 on page 26. 016 Continue with Step 017. 017 (From steps 008, 016, 026, and 050) - Switch off power. - Access the power-on operator panel test (refer to MIM "Power On Operator Panel Test" on page 000-64) by holding the Start and Test keys at the same time during power-on. The operator panel test runs. Does the test run successfully? Yes No 018 (Step 018 continues)
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MAP 2010 (continued) 20
018 (continued) Continue with Step 027 on page 21. 019 - Switch off power. - Remove covers. - Disconnect J1 at the operator panel cable. - Disconnect J4 at the printer logic board. - Set the CE meter on the RX1 scale. - Perform a pin to pin continuity check on the operator panel cable. Refer to MIM "757 - Operator Panel Cable" on page 750-6. Is there continuity on all lines? Yes No 020 - Install a new operator panel cable. 021 - Print, or obtain from the customer, the printer configuration and vital product data. Refer to MIM "052 - Operator Tests" on page 000-48. After installing a new printer logic board, use the configuration and vital product data to setup the printer. Refer to IBM 4230 Printer Quick Reference Guide. - Install a new printer logic board. Refer to MIM "211 - Printer Logic Board" on page 200-2. - Perform the AFTA setting procedure. Refer to MIM "AFTA Setting Procedure" on page 000-105. (Step 021 continues)
IBM 4230 and 4232 Printers Maintenance Analysis Procedures
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Maintenance Analysis Procedures 21
021 (continued) - Perform the Bidirectional adjustment. Refer to MIM "Bidirectional Adjustment" on page 000-67. 022 (From step 013) Does the operator report "bad keys"? Yes No 023 Does the operator report "slow printing"? Yes No 024 Continue with Step 030 on page 22. 025 Continue with MAP 3900 step 047 on page 96. 026 Continue with Step 017 on page 19. 027 (From step 018) - Access the offline CE tests. Refer to MIM "Performing Offline CE Tests" on page 000-61. (Step 027 continues)
21
MAP 2010 (continued) 22
027 (continued) - Scroll to the operator panel test. - Run the operator panel test. Refer to MIM "Operator Panel Test" on page 000-63. Note: If you are unable to run the operator panel test, answer No to the following question. Does the test run successfully? Yes No 028 Continue with MAP 3600 step 044 on page 76. 029 - Install a new operator panel. Refer to MIM "511 - Operator Panel" on page 500-1. 030 (From step 024) - Access the offline CE tests. Refer to MIM "Performing Offline CE Tests" on page 000-61. - Run the DP and NLQ Print Quality tests. Refer to MIM "DP Print Quality Test" on page 000-71 and "NLQ Print Quality Test" on page 000-69. Is the problem with poor print or was poor print reported? Yes No 031 (Step 031 continues)
IBM 4230 and 4232 Printers Maintenance Analysis Procedures
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Maintenance Analysis Procedures 23
031 (continued) Continue with Step 039 on page 24. 032 - Check the Lighter/Darker setting to verify that it is not wrong. - Perform the bidirectional adjustment. Refer to MIM"Bidirectional Adjustment" on page 000-67 . - Access the offline CE tests. Refer to MIM "Performing Offline CE Tests" on page 000-61. - Perform the AFTA setting procedure. Refer to MIM "AFTA Setting Procedure" on page 000-105. - Run the DP and NLQ Print Quality tests. Refer to MIM "DP Print Quality Test" on page 000-71 and "NLQ Print Quality Test" on page 000-69. Did running the above procedures correct the problem? Yes No 033 - Access the offline CE tests. Refer to MIM "Performing Offline CE Tests" on page 000-61. - Scroll to the print wire test. Refer to MIM "Print Wire Test" on page 000-66. - Press Enter. Do all nine wires print? Yes No 034 (Step 034 continues)
23
MAP 2010 (continued) 24
034 (continued) Continue with "MAP 3500: Print Wire" on page 59. 035 Does the ribbon move while the test is running? Yes No 036 Continue with "MAP 3800: Ribbon Movement and Control" on page 81. 037 Continue with Step 050 on page 26. 038 - Return the printer to the operator. 039 (From step 031) - Ensure the forms are loaded. - Press Stop to make the printer not ready. - Press Form Feed. Do the forms move each time the key is pressed? Yes No 040 (Step 040 continues)
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Maintenance Analysis Procedures 25
040 (continued) Continue with "MAP 3400: Forms Motor Drive" on page 53. 041 - Access the offline CE tests. Refer to MIM "Performing Offline CE Tests" on page 000-61. - Ensure all the covers are closed. - Scroll to the sensor test. Refer to MIM "Sensor Test" on page 000-65. - Insert a sheet of paper, with no holes, into the EOF sensor. - Slide the paper to the left until it stops. Do all sensors=1? Yes No 042 Continue with "MAP 3900: Sensor" on page 85. 043 - Remove the forms and the paper from the EOF sensor. Does EOF=0, HC=0, and PP=0? Yes No 044 Continue with "MAP 3900: Sensor" on page 85. 045 (Step 045 continues)
25
MAP 2010 (continued) 26
045 (continued) - Open the front paper door. Does DO=0? Yes No 046 Continue with "MAP 3900: Sensor" on page 85. 047 - Open the access cover. Does CO=0? Yes No 048 Continue with "MAP 3900: Sensor" on page 85. 049 No problem is found. - Verify operations. - Run an error log (refer to MIM "Print Error Log" on page 000-83) or continue with "MAP 4000: Symptom" on page 103. 050 (From steps 015 and 037) - Go to the MAP or perform an action contained in the following tables and verify the repair.
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Maintenance Analysis Procedures 27
Error/Status Description
Action Continue with Step 017 on page 19.
is displayed. Diagnostics In Progress is displayed. The print head does not move. Continue with Step 017 on page 19. Continue with "MAP 3320: Print Head Drive and Control" on page 47. Continue with "MAP 3200: Attachment" on page 43. Continue with "Forms Feed Service Check" on page 000-93. Continue with "MAP 3100: Auto Sheet Feeder" on page 29. Continue with "MAP 3600: Power Supply" Step 041 on page 74.
Ready and Online are not displayed. Forms jamming. Auto Sheet Feeder problems. Fan never runs.
Print Quality Failures and Solutions Description of Failure Refer to MIM "057 - Service Checks" on page 000-85 and perform the Service Checks indicated to solve the failure Perform "Print Density (Light/Dark) Service Check" on page 000-85. Perform "Vertical Alignment Service Check" on page 000-91, Perform "Smearing - Print Service Check" on page 000-86.
Differences in print density, light or dark across the page. Character or line spacing is not even or overprinting occurs. Smearing, or printing too light or constantly too dark.
27
MAP 2010 (continued) 28
Print Quality Failures and Solutions Description of Failure Refer to MIM "057 - Service Checks" on page 000-85 and perform the Service Checks indicated to solve the failure Perform "Missing Dots or Character Service Check" on page 000-88. Perform "Vertical Alignment Service Check" on page 000-91. Perform "Bidirectional Adjustment" on page 000-67. Perform "Bidirectional Adjustment" on page 000-67.
Missing dots or characters, not complete lines, or unreadable characters. Printing upward or downward from normal print location. NLQ characters, vertical lines not clear. Graphics not aligned well or not clear.
IBM 4230 and 4232 Printers Maintenance Analysis Procedures
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Maintenance Analysis Procedures 29
MAP 3100: Auto Sheet Feeder
The following are FRUs that can cause Auto Sheet Feeder (ASF) problems:
· · · ·
Printer logic board Forms feed motor F4 feeder assembly F4 forms device.
Before starting this map: 1. Fan the paper in the paper bins. 2. Ensure the feeder unit is installed correctly. Refer to MIM "840 Installing the F4 Forms Device" on page 800-40. 3. Ensure the printer configuration matches the forms device. Refer to MIM "Printer Configuration" on page 000-49. 4. Perform the Forms Feed Service Check. Refer to MIM "Forms Feed Service Check" on page 000-93. 5. Select offline CE tests (refer to MIM "Performing Offline CE Tests" on page 000-61) and scroll to the corresponding bin number test. 001 Are any gears, belts, or levers broken or binding? Yes No 002 Continue with Step 004 on page 30. 003 - Repair, or install a new, sheet feeder unit.
29
MAP 3100 (continued) 30
004 (From step 002) - Install the feeder unit and the forms device. - Load paper in bin 1. - Perform bin selection test 1. Does the paper feed from bin 1 to the forms device (no error/status code 10)? Yes No 005 Continue with Step 021 on page 33. 006 Does the paper feed to the platen, the print head print blanks, and the paper eject without jams? Yes No 007 Continue with Step 021 on page 33. 008 - Load the paper in bin 2. - Perform bin selection test 2 (Step 008 continues)
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Maintenance Analysis Procedures 31
008 (continued) Does the paper feed from bin 2 to the forms device (no error/status code 10)? Yes No 009 Continue with Step 021 on page 33. 010 Does the paper feed to the platen, the print head print blanks, and the paper eject without jams? Yes No 011 Continue with Step 021 on page 33. 012 - Load the paper in bin 3. - Perform bin selection test 3. Does the paper feed from bin 3 to the forms device (no error/status code 10)? Yes No 013 Continue with Step 021 on page 33. 014 (Step 014 continues)
31
MAP 3100 (continued) 32
014 (continued) Does the paper feed to the platen, the print head print blanks, and the paper eject without jams? Yes No 015 Continue with Step 021 on page 33. 016 - Load the paper in bin 4. - Perform bin selection test 4. Does the paper feed from bin 4 to the forms device (no error/status code 11)? Yes No 017 Continue with Step 021 on page 33. 018 Does the paper feed to the platen, the print head print blanks, and the paper eject without jams? Yes No 019 Continue with Step 021 on page 33. 020 (Step 020 continues)
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Maintenance Analysis Procedures 33
020 (continued) No problem is found. - Repeat "MAP 3100: Auto Sheet Feeder" on page 29. - If no problem is found again, run an error log to determine the problem. Refer to MIM "056 - Offline CE Tests Descriptions" on page 000-59. 021 (From steps 005, 007, 009, 011, 013, 015, 017, and 019) Do the feed rolls turn in the selected feeder assembly bin? Yes No 022 Continue with Step 024. 023 - Ensure that the paper is loaded correctly. - Ensure that the paper guides are not pressing too hard on the paper. - Ensure that the paper load lever is engaged. - Remove the right side cover and check the selection lever, selection spring, drive belt, and gears for wear or damage. - Exchange the broken or damaged parts. - If there are no damaged or broken parts, install a new feeder unit. 024 (From step 022) (Step 024 continues)
33
MAP 3100 (continued) 34
024 (continued) - Remove the feeder assembly and the forms device, and perform the forms motor test. Refer to MIM "Forms Motor Test" on page 000-81. Does the test complete without error? Yes No 025 Continue with "MAP 3400: Forms Motor Drive" on page 53. 026 - Install the forms device and run the forms motor test. Does the test run without error? Yes No 027 - Install a new forms device. 028 - Ensure that the paper is loaded correctly. - Ensure that the paper guides are not pressing too hard on the paper. - Ensure that the paper load lever is engaged. - Remove the right side cover and check the selection lever, selection spring, drive belt, and gears for wear or damage. - Exchange the broken or damaged parts. - If there are no damaged or broken parts, install a new feeder unit.
IBM 4230 and 4232 Printers Maintenance Analysis Procedures
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Maintenance Analysis Procedures 35
MAP 3150: Automatic Forms Thickness Adjustment
The following parts can cause Automatic Forms Thickness Adjustment (AFTA) problems:
· · · · ·
AFTA motor AFTA gear AFTA sensor Main sensor cable Printer logic board.
001 False 0A4 errors can be caused by the operator manually moving the AFTA gear (uses gear as a lever like on the 4224). - Ensure that the operator is not moving the gear. Is the error/status code 0A1, 0A2, 0A3, or 0A4? Yes No 002 Continue with Step 014 on page 38. 003 - Reseat the printhead (remove and install). - Verify the symptom. Does the printer fail with error/status code 0A1, 0A2, 0A3, or 0A4? Yes No 004 (Step 004 continues)
35
MAP 3150 (continued) 36
004 (continued) The printhead was not seated correctly. 005 - Check to see that the AFTA gear does not bind against the AFTA sensor dust shield or the acoustic foam inside the left cover. Does the gear move freely without binding? Yes No 006 Repair as needed. 007 - Remove the covers. - Check the AFTA gear for broken or damaged teeth. Are all the teeth present with no damage? Yes No 008 - Install a new AFTA gear. Refer to MIM "385 - AFTA Assembly" on page 300-26. 009 - Access the offline CE tests. 1. Press the Stop key. 2. Press and hold the Test key, then press the Quick Reference key. (Step 009 continues)
IBM 4230 and 4232 Printers Maintenance Analysis Procedures
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Maintenance Analysis Procedures 37
009 (continued) 3. Release both keys. 4. Press the Menu key. - Use the Scroll keys to scroll to the sensor test and press Enter. The display reads: PP=X EOF=X HC=X CO=X DO=X AF=X
(where X can be 1 or 0) - While observing AF on the display, slowly rotate the AFTA gear so that the AFTA gear flag moves into and out of the AFTA sensor. Note: Wait up to 3 seconds for the display to change. AF=1 when the flag is inside the sensor. AF=0 when the flag is outside the sensor. Does the AF value change while rotating the AFTA gear flag into and out of the AFTA sensor? Yes No 010 Continue with Step 017 on page 39. 011 - Switch off power. - Disconnect the AFTA motor cable (J11) from the printer logic board. Refer to MIM "753 - Printer Logic Board" on page 750-3. - At the connector, measure for 60 ohms or less between: (Step 011 continues)
37
MAP 3150 (continued) 38
011 (continued) · Pins 1 and 2 · Pins 3 and 4. Are both measurements 60 ohms or less? Yes No 012 - Install a new AFTA motor. Refer to MIM "385 - AFTA Assembly" on page 300-26. 013 - Print, or obtain from the customer, the printer configuration and vital product data. Refer to MIM "Printer Configuration" on page 000-49. After installing a new printer logic board, use the configuration and vital product data to setup the printer. Refer to IBM 4230 Printer Quick Reference Guide. - Install a new printer logic board. Refer to MIM "211 - Printer Logic Board" on page 200-2. - Perform the AFTA setting procedure. Refer to MIM "AFTA Setting Procedure" on page 000-105. - Perform the Bidirectional adjustment. Refer to MIM "Bidirectional Adjustment" on page 000-67. 014 (From step 002) (Step 014 continues)
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Maintenance Analysis Procedures 39
014 (continued) Is the problem with print quality? Yes No 015 - Verify the symptoms. Continue with "MAP 2010: Start/Verify" on page 5. 016 - Verify that the print head is seated correctly. - Verify that the print head stop screw is adjusted correctly ("Installation" on page 300-3). - Perform the AFTA setting procedure. Refer to MIM "AFTA Setting Procedure" on page 000-105. 017 (From step 010) Does AF=1 constantly? Yes No 018 Continue with Step 020 on page 40. 019 - Clean the AFTA sensor. If the problem continues, continue with Step 020 on page 40.
39
MAP 3150 (continued) 40
020 - Switch off power. - Disconnect connector GSM from the AFTA sensor. Refer to MIM "720 - Locations, Cable Connectors" on page 700-8. - Switch on power. - Measure for +5 V DC at pins 1 and 3 of the GSM connector and frame ground. Is +5 V DC present? Yes No 021 Continue with Step 023. 022 - Install a new AFTA sensor. Refer to MIM "385 - AFTA Assembly" on page 300-26. 023 - Switch off power. - Disconnect connector J3 from the printer logic board. - Refer to the wiring diagram section of MIM "759 - Main Sensor Cable" on page 750-7 and perform a continuity check of the GSM section of the main sensor cable. Return to this step when completed. (Step 023 continues)
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Maintenance Analysis Procedures 41
023 (continued) Is there continuity for all GSM cable references? Yes No 024 - Install a new main sensor cable. 025 - Print, or obtain from the customer, the printer configuration and vital product data. Refer to MIM "Printer Configuration" on page 000-49. After installing a new printer logic board, use the configuration and vital product data to setup the printer. Refer to IBM 4230 Printer Quick Reference Guide. - Install a new printer logic board. Refer to MIM "211 - Printer Logic Board" on page 200-2. - Perform the AFTA setting procedure. Refer to MIM "AFTA Setting Procedure" on page 000-105. - Perform the Bidirectional adjustment. Refer to MIM "Bidirectional Adjustment" on page 000-67.
41
42
Notes
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Maintenance Analysis Procedures 43
MAP 3200: Attachment
The following are FRUs that can cause attachment failures:
· · ·
Attachment bezel or card (4230 only) Attachment card/bezel (4232 only) Printer logic board.
001 - Switch off power. - Wait 20 seconds. - Switch on power. Does the display equal 19, 21, 23, 24, 25, 29, 64, 65, or 66? Yes No 002 Continue with "MAP 2010: Start/Verify" on page 5. 003 - If this is a 4230 printer answer the following question Yes. - If this is a 4232 printer answer the following question No. Is this a 4230 printer? Yes No 004 - Continue with Step 006 on page 44. 005 (Step 005 continues)
43
MAP 3200 (continued) 44
005 (continued) - Continue with Step 011 on page 45. 006 Note: For some hosts, Status 29 is normal and will be cleared when a print job starts. If you have a Status 29 that clears when a print job starts, end this MAP here. The following items are listed in sequence. The most probable failing item is first in the list. - Check the first list item and test the printer. If the printer still fails, continue with the next list item. 1. Communications cable and connector pins 2. Ensure that the following printer settings match the host settings: · Baud rate · Number of data bits · Number of stop bits · Pacing · Parity 3. Host program 4. Perform a serial/parallel attachment card/bezel service check. Refer to MIM "Serial/Parallel Attachment Card/Bezel Service Check" on page 000-113. Is the problem fixed? Yes No 007 - Install a new attachment card/bezel. Refer to MIM "413 Attachment Card/Bezel (4232 Model 302 Only)" on page 400-6. (Step 007 continues)
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Maintenance Analysis Procedures 45
007 (continued) Is the problem fixed? Yes No 008 - Put back the old card/bezel. Continue with Step 013 on page 46. 009 Return the printer to the operator. 010 Return the printer to the operator. 011 - Switch off power. - Remove the cover. - Perform the attachment bezel service check and return to this step. Refer to: MIM"Coaxial Attachment Bezel Service Check" on page 000-110 or · MIM"Twinaxial Attachment Bezel Service Check" on page 000-109 or · MIM"Twinaxial/Serial/Parallel Attachment Bezel Service Check" on page 000-111 or (Step 011 continues)
·
45
MAP 3200 (continued) 46
011 (continued) · MIM"Coaxial/Serial/Parallel Attachment Bezel Service Check" on page 000-112. Is the attachment bezel OK? Yes No 012 - Install a new attachment bezel or attachment card/bezel. Refer to:
·
·
MIM"411 - Attachment Bezel (4230 Models 101, 102, 1I1, 1S2, 201, 202, 2I1, 2S2 only)" on page 400-2 or MIM"412 - Attachment Cards/Bezel (4230 Models 4I3, 4S3, 5I3, and 5S3 Only)" on page 400-4.
013 - Print the printer configuration and vital product data. Refer to MIM "Printer Configuration" on page 000-49. After installing a new printer logic board, use the configuration and vital product data to setup the printer. Refer to IBM 4230 Printer Quick Reference Guide, or the IBM 4232 Printer Quick Reference Guide. - Install a new printer logic board. Refer to MIM "211 - Printer Logic Board" on page 200-2. - Perform the AFTA setting procedure. Refer to MIM "AFTA Setting Procedure" on page 000-105. - Perform the Bidirectional adjustment. Refer to MIM "Bidirectional Adjustment" on page 000-67.
IBM 4230 and 4232 Printers Maintenance Analysis Procedures
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Maintenance Analysis Procedures 47
MAP 3320: Print Head Drive and Control
The following are FRUs that can cause print head drive problems:
· · · · · · · · · ·
Carrier assembly Print head Carrier support guide Carrier motor Idler assembly Carrier shaft Belt Belt spring Printer logic board Main sensor.
You are entering this MAP because either the printer has displayed, or the operator has reported, an error/status code 51, 52, 53, 55, or 56. 001 - Check for correct operation of the ribbon, printhead and carrier mechanisms. See "Missing Dots or Character Service Check" on page 000-88. Are all indicators in the service check correct? Yes No 002 Repair as needed. 003 - Switch off power. - Remove the cover. - Switch on power. (Step 003 continues)
47
MAP 3320 (continued) 48
003 (continued) - Measure for +5 V DC between J2 test point 12 and frame ground. Refer to MIM "753 - Printer Logic Board" on page 750-3. Is +5 V DC present? Yes No 004 Continue with Step 016 on page 51. 005 - Measure for +5 V DC between J2 test point 1 and frame ground. Refer to MIM "753 - Printer Logic Board" on page 750-3. - Observe the meter as you slowly rotate the carrier motor gear. Note: Answer this question yes if the measurement is anywhere between 0 V DC and 5 V DC. For example, 1 V DC. Does the meter change between 0 V DC and +5 V DC? Yes No 006 Continue with Step 016 on page 51. 007 - Measure for +5 V DC between J2 test point 2 and frame ground. Refer to MIM "753 - Printer Logic Board" on page 750-3. - Observe the meter as you slowly rotate the carrier motor gear. Note: Answer this question yes if the measurement is anywhere between 0 V DC and 5 V DC. For example, 1 V DC. (Step 007 continues)
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Maintenance Analysis Procedures 49
007 (continued) Does the meter change between 0 V DC and +5 V DC? Yes No 008 Continue with Step 016 on page 51. 009 - Switch off power. - Disconnect both power leads from the carrier motor. - Set the CE meter on the RX1 scale, measure the resistance between the two carrier motor connectors at the motor. The resistance should be approximately 10 ohms for the 4230, or approximately 4 ohms for the 4232. Is the resistance OK? Yes No 010 - Continue with Step 013 on page 50. 011 - Disconnect J9 from the printer logic board. Refer to MIM "753 Printer Logic Board" on page 750-3. - Perform a continuity check on the carrier motor cable. (Step 011 continues)
49
MAP 3320 (continued) 50
011 (continued) Is there continuity? Yes No 012 Install a new carrier motor. Refer to "337 - Carrier Drive Motor" on page 300-12. 013 - Set the CE meter on the RX1 scale, measure the resistance between the carrier motor case and either of the motor leads. Is the resistance greater than 10 Ohms? Yes No 014 - Order a new carrier motor and perform the resistance check in Step 013 before installing the carrier motor. Refer to MIM "337 - Carrier Drive Motor" on page 300-12. 015 - Print, or obtain from the customer, the printer configuration and vital product data. Refer to MIM "Printer Configuration" on page 000-49. After installing a new printer logic board, use the configuration and vital product data to setup the printer. Refer to IBM 4230 Printer Quick Reference Guide. - Install a new printer logic board. Refer to MIM "211 - Printer Logic Board" on page 200-2. - Perform the AFTA setting procedure. Refer to MIM "AFTA Setting Procedure" on page 000-105. (Step 015 continues)
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Maintenance Analysis Procedures 51
015 (continued) - Perform the Bidirectional adjustment. Refer to MIM "Bidirectional Adjustment" on page 000-67. 016 (From steps 004, 006, and 008) - Switch off power. - Disconnect the HM connector and J3. Refer to MIM "720 - Locations, Cable Connectors" on page 700-8 and "753 - Printer Logic Board" on page 750-3. - Refer to the wiring diagram section of MIM "759 - Main Sensor Cable" on page 750-7 and perform a continuity check of the HM portion on the main sensor cable. Is there continuity? Yes No 017 - Install a new main sensor cable. 018 - Check for +38 V DC at J6 pins 1 and 2. Logic Board" on page 750-3. Is the voltage +38 V DC (±2 V DC)? ± Yes No 019 Continue with Step 021 on page 52. Refer to MIM "753 - Printer
51
MAP 3320 (continued) 52
020 - Print, or obtain from the customer, the printer configuration and vital product data. Refer to MIM "Printer Configuration" on page 000-49. After installing a new printer logic board, use the configuration and vital product data to setup the printer. Refer to IBM 4230 Printer Quick Reference Guide. - Install a new printer logic board. Refer to MIM "211 - Printer Logic Board" on page 200-2. - Perform the AFTA setting procedure. Refer to MIM "AFTA Setting Procedure" on page 000-105. - Perform the Bidirectional adjustment. Refer to MIM "Bidirectional Adjustment" on page 000-67. 021 (From step 019) - Verify the source voltage. Is the voltage correct? Yes No 022 - Have the customer repair the voltage source. 023 - Install a new power supply. Refer to MIM "611 - Power Supply" on page 600-2.
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Maintenance Analysis Procedures 53
MAP 3400: Forms Motor Drive
The following are FRUs that can cause forms drive problems:
· · · ·
Forms motor Printer logic board Forms device Frame assembly.
001 Note: Ensure that a forms device and forms are correctly installed before entering this MAP. - Switch off power. - Wait 20 seconds. - Switch on power. - Observe the display after approximately 20 seconds. Is error/status code 42, 43, or 44 displayed? Yes No 002 Continue with Step 004. 003 Continue with Step 009 on page 54. 004 (From step 002) - Switch off power. (Step 004 continues)
53
MAP 3400 (continued) 54
004 (continued) - Remove the forms and the forms device. - Switch on power. - Access the offline CE tests. Refer to MIM "Performing Offline CE Tests" on page 000-61. - Run the forms motor test. Refer to MIM "Forms Motor Test" on page 000-81. Did the test run without failure? Yes No 005 Continue with Step 009. 006 - Perform the Forms Feed Service Check. See "Forms Feed Service Check" on page 000-93. Is the Service Check good? Yes No 007 - Repair or exchange the failing part. 008 Continue with Step 014 on page 56. 009 (From steps 003, 005, and 016) (Step 009 continues)
IBM 4230 and 4232 Printers Maintenance Analysis Procedures
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Maintenance Analysis Procedures 55
009 (continued) - Switch off power. - Remove the rear electrostatic shield. - Put the printer logic board in the service location. Refer to MIM "707 Printer Logic Board Service Position" on page 700-1. - Disconnect J10. Refer to MIM "753 - Printer Logic Board" on page 750-3. - Perform a continuity check at the J10 cable connector as follows:
· ·
From pin 3 to frame ground - open From pin 4 to frame ground - open.
Do both pins measure open (no continuity)? Yes No 010 - Print, or obtain from the customer, the printer configuration and vital product data. Refer to MIM "Printer Configuration" on page 000-49. After installing a new printer logic board, use the configuration and vital product data to setup the printer. Refer to IBM 4230 Printer Quick Reference Guide. - Install a new forms motor. Refer to MIM "381 - Forms Motor" on page 300-22. - Install a new printer logic board. Refer to MIM "211 - Printer Logic Board" on page 200-2. - Perform the AFTA setting procedure. Refer to MIM "AFTA Setting Procedure" on page 000-105. - Perform the Bidirectional adjustment. Refer to MIM "Bidirectional Adjustment" on page 000-67.
55
MAP 3400 (continued) 56
011 - Perform a continuity check on the cable as follows:
· ·
From pins 1 to 3 - less than 5 Ohms From pins 2 to 4 - less than 5 Ohms.
Is the reading correct? Yes No 012 - Install a new forms motor. Refer to MIM "381 - Forms Motor" on page 300-22. 013 - Print, or obtain from the customer, the printer configuration and vital product data. Refer to MIM "Printer Configuration" on page 000-49. After installing a new printer logic board, use the configuration and vital product data to setup the printer. Refer to IBM 4230 Printer Quick Reference Guide. - Install a new printer logic board. Refer to MIM "211 - Printer Logic Board" on page 200-2. - Perform the AFTA setting procedure. Refer to MIM "AFTA Setting Procedure" on page 000-105. - Perform the Bidirectional adjustment. Refer to MIM "Bidirectional Adjustment" on page 000-67. 014 (From step 008) (Step 014 continues)
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Maintenance Analysis Procedures 57
014 (continued) - With the negative lead on J6-2 and the positive lead on J6-1, measure for +38 V DC ±2 V DC. Refer to MIM "753 - Printer Logic Board" on page 750-3. Is the voltage reading correct? Yes No 015 Continue with Step 017. 016 - Verify the operation and run an error log to isolate the problem. Refer to MIM "056 - Offline CE Tests Descriptions" on page 000-59. Continue with Step 009 on page 54. 017 (From step 015) - Verify the voltage source. Is the voltage source correct? Yes No 018 - Have the customer repair the voltage source. 019 - Install a new power supply. Refer to MIM "611 - Power Supply" on page 600-2.
57
58
Notes
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Maintenance Analysis Procedures 59
MAP 3500: Print Wire
The following are FRUs that can cause print wire problems:
· · ·
Print head Print head cable Printer logic board.
001 - Switch off power. - Remove the cover. - Verify that the print head cable is properly connected to the printer logic board at J7 and at the print head at CH1. Refer to MIM "753 Printer Logic Board" on page 750-3. - Reinstall the forms device and forms. - Switch on power. - Wait 20 seconds. - Select the offline CE tests and perform the AFTA setting procedure. Refer to MIM "AFTA Setting Procedure" on page 000-105. Note: The AFTA setting procedure ensures that the printhead to platen gap is not too wide. A gap that is too wide can appear as a missing print wire. - Perform the print wire test. Refer to MIM "Print Wire Test" on page 000-66. - Press Enter. Are any of the following lines missing? 1, 3, 4, 5, 6 Yes No 002 (Step 002 continues)
59
MAP 3500 (continued) 60
002 (continued) Continue with Step 010 on page 61. 003 Is line 6 missing? Yes No 004 - Disconnect the print head cable. - Reconnect to the test location. - Run print wire test 2. Refer to MIM "Print Wire Test 2" on page 000-66. Do five lines print? Yes No 005 Continue with Step 012 on page 61. 006 Continue with Step 015 on page 62. 007 - Disconnect the print head cable. - Reconnect to the test location. - Run print wire test 2. Refer to MIM "Print Wire Test 2" on page 000-66. (Step 007 continues)
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Maintenance Analysis Procedures 61
007 (continued) Is the second line missing? Yes No 008 Continue with Step 012. 009 Continue with Step 015 on page 62. 010 (From step 002) - Disconnect the print head cable from the print head. - Reconnect to the test location. - Run print wire test 2. Refer to MIM "Print Wire Test 2" on page 000-66. Do five lines print? Yes No 011 Continue with Step 015 on page 62. 012 (From steps 005 and 008) - Perform a continuity check on the print head cable. Refer to MIM "755 - Print Head Cable" on page 750-5. (Step 012 continues)
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MAP 3500 (continued) 62
012 (continued) Is there continuity for all cable wires? Yes No 013 - Install a new print head cable. Refer to MIM "325 - Print Head Cable" on page 300-4. - Return the connector to the run location. 014 - Print, or obtain from the customer, the printer configuration and vital product data. Refer to MIM "Printer Configuration" on page 000-49. After installing a new printer logic board, use the configuration and vital product data to setup the printer. Refer to IBM 4230 Printer Quick Reference Guide. - Install a new printer logic board. Refer to MIM "211 - Printer Logic Board" on page 200-2. - Return the connector to the run location. - Perform the AFTA setting procedure. Refer to MIM "AFTA Setting Procedure" on page 000-105. - Perform the Bidirectional adjustment. Refer to MIM "Bidirectional Adjustment" on page 000-67. 015 (From steps 006, 009, and 011) - Perform a continuity check on the print head cable. Refer to MIM "755 - Print Head Cable" on page 750-5. (Step 015 continues)
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015 (continued) Is there continuity for all cable wires? Yes No 016 - Install a new print head cable. Refer to MIM "325 - Print Head Cable" on page 300-4. - Return the connector to the run location. 017 - Install a new print head. Refer to MIM "321 - Print Head" on page 300-2. - Return the connector to the run location. - Perform the AFTA setting procedure. Refer to MIM "AFTA Setting Procedure" on page 000-105.
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Notes
IBM 4230 and 4232 Printers Maintenance Analysis Procedures
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MAP 3600: Power Supply
The following are FRUs that can cause power problems:
· · · · · ·
Printer logic board Power supply Sensors Motors Attachment bezel Power cable.
001 - Switch off power. - Ensure the power supply voltage switch is set to the source voltage. - Verify that the power cable is correctly connected between the voltage source and the printer. - Switch on power. Is the printer completely dead? (No indicators, no display, no fan) Yes No 002 Continue with Step 009 on page 67. 003 - Check the source. Is the voltage correct? Yes No 004 (Step 004 continues)
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004 (continued) Have the operator repair the voltage problem. 005 - Unplug the power cable from the voltage source. - Disconnect the power cable from the printer. - Check the power cable continuity. Is there continuity? Yes No 006 - Install a new power cable. 007 - Connect the power cable to the printer. - Plug the power cable to the voltage source. - Remove the cover. - Switch on power. Refer to MIM "721 - Locations, Rear (Cover Off)" on page 700-9. Is the green power supply indicator on? Yes No 008 Continue with Step 034 on page 73. 009 (Step 009 continues)
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Maintenance Analysis Procedures 67
009 (continued) (From step 002) - Switch off power. - Switch on power. Do the operator panel LEDs go on for at least one second? Yes No 010 Continue with Step 044 on page 76. 011 - Run the NLQ print quality test. Refer to MIM "NLQ Print Quality Test" on page 000-69. Does the printer power-off? Yes No 012 Continue with Step 028 on page 71. 013 - Switch off power. - Place the printer logic board in the service location. Refer to MIM "707 - Printer Logic Board Service Position" on page 700-1. - Remove the paper guide shield. - Disconnect:
· J9 (carrier motor), (Step 013 continues)
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MAP 3600 (continued) 68
013 (continued) · J10 (forms motor), · J8 (ribbon motor), · J11 (AFTA motor), · J1 (attachment con