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IBM 4230 Maintenance Analysis Procedures

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IBM 4230 and 4232 Printers
Maintenance Analysis Procedures
Document Number SA40-0571-04
IBML

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Summary of Contents for IBM 4230

  • Page 1 IBM 4230 and 4232 Printers Maintenance Analysis Procedures Document Number SA40-0571-04 IBML...
  • Page 2 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 representa- tions 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.

  • Page 3: Table Of Contents

    Contents Contents Maintenance Analysis Procedures MAP 1000: General Information MAP 2010: Start/Verify MAP 3100: Auto Sheet Feeder MAP 3150: Automatic Forms Thickness Adjustment MAP 3200: Attachment MAP 3320: Print Head Drive and Control MAP 3400: Forms Motor Drive MAP 3500: Print Wire MAP 3600: Power Supply MAP 3800: Ribbon Movement and Control MAP 3900: Sensor...
  • Page 4 IBM 4230 and 4232 Printers Maintenance Analysis Procedures...
  • Page 5 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.
  • Page 6 IBM 4230 and 4232 Printers Maintenance Analysis Procedures...
  • Page 7 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. IBM 4230 and 4232 Printers Mainte-...
  • Page 8 • 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: IBM 4230 and 4232 Printers Safety Information, SA40-0575. •...
  • Page 9 About This Book 4230 Models 101, 1S2, 201, 2S2, 4S3, and 5S3 only For setup and operating information, refer to: 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).
  • Page 10 • 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*.
  • Page 11 About This Book Enterprise System/9000* Publications For information about attaching the printer to Enterprise System/9000, refer to: 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 •...
  • Page 12 IBM 4230 and 4232 Printers Maintenance Analysis Procedures...
  • Page 13 xiii Safety Information Safety Information The construction of this machine provides extra protection against the risk of electric shock by grounding suitable metal parts. The extra pro- tection may not function unless the power cord is connected to a prop- erly grounded outlet.
  • Page 14 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. IBM 4230 and 4232 Printers Maintenance Analysis Procedures...

  • Page 15: Maintenance Analysis Procedures

    Maintenance Analysis Procedures 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.
  • Page 16 When a card or a cable is identi- • fied 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...
  • Page 17 Maintenance Analysis Procedures 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”...
  • Page 18 Notes IBM 4230 and 4232 Printers Maintenance Analysis Procedures...

  • Page 19: Map 2010: Start/Verify

    Maintenance Analysis Procedures MAP 2010: Start/Verify Has the Customer done the Problem Solving Procedures in the User's Guide? Attempt recovery using the Problem Solving Procedures in the User's Guide. Continue with Step 003 as needed. Are you here because the forms are jamming? Continue with Step 006.
  • Page 20 Dual purpose forms device “MAP 3900: Sensor” on (F2) ejected page 85 Forms load error (F2 or F3) “MAP 3400: Forms Motor Drive” on page 53 or “MAP 3900: Sensor” on page 85 IBM 4230 and 4232 Printers Maintenance Analysis Procedures...
  • Page 21 Maintenance Analysis Procedures Error Error/Status Description Status Code Margin error “Printer Configuration” on page 000-49 or “MAP 3320: Print Head Drive and Control” on page 47 Host attention “MAP 4000: Symptom” on page 103 Error/Status Code 006 Invalid Printer Control Infor- “MAP 4000: Symptom”...
  • Page 22 “MAP 4000: Symptom” on page 103 Error/Status Code 024 Framing error “MAP 4000: Symptom” on page 103 Error/Status Code 025 Hex print mode active “MAP 4000: Symptom” on page 103 Error/Status Code 026 IBM 4230 and 4232 Printers Maintenance Analysis Procedures...
  • Page 23 Maintenance Analysis Procedures Error Error/Status Description Status Code Communications check “MAP 4000: Symptom” on page 103 Error/Status Code 027 Communications check “MAP 4000: Symptom” on page 103 Error/Status Code 028 DSR not active “MAP 4000: Symptom” on page 103 Error/Status Code 029 Load manual bin - timeout “MAP 3100: Auto Sheet Feeder”...
  • Page 24 “MAP 4000: Symptom” on page 103 Error/Status Code 059 Buffer reprint active “MAP 4000: Symptom” on page 103 Error/Status Code 060 PA1 selected “MAP 4000: Symptom” on page 103 Error/Status Code 061 IBM 4230 and 4232 Printers Maintenance Analysis Procedures...
  • Page 25 Maintenance Analysis Procedures Error Error/Status Description Status Code PA2 selected “MAP 4000: Symptom” on page 103 Error/Status Code 062 Printer in send state “MAP 4000: Symptom” on page 103 Error/Status Code 063 Machine check “MAP 4000: Symptom” on page 103 Error/Status Code 064 No attachment (bezel or card) “MAP 3200: Attachment”...
  • Page 26 Step 017 on page 19 Panel communications failure “MAP 2010: Start/Verify” on page 5 Step 017 on page 19 Panel communications failure “MAP 2010: Start/Verify” on page 5 Step 017 on page 19 IBM 4230 and 4232 Printers Maintenance Analysis Procedures...
  • Page 27 Maintenance Analysis Procedures Error Error/Status Description Status Code Panel communications failure “MAP 2010: Start/Verify” on page 5 Step 017 on page 19 Panel communications failure “MAP 2010: Start/Verify” on page 5 Step 017 on page 19 Printer logic board failure “MAP 4000: Symptom”...
  • Page 28 “MAP 4000: Symptom” on page 103 Error/Status Code AXX Font does not exist “MAP 4000: Symptom” on page 103 Error/Status Code AXX CPI not valid “MAP 4000: Symptom” on page 103 Error/Status Code AXX IBM 4230 and 4232 Printers Maintenance Analysis Procedures...
  • Page 29 Maintenance Analysis Procedures Error Error/Status Description Status Code Out of storage “MAP 4000: Symptom” on page 103 Error/Status Code A86 Cell height not compatible “MAP 4000: Symptom” on page 103 Error/Status Code A87 Cell width not compatible “MAP 4000: Symptom” on page 103 Error/Status Code AXX 00 code point (not valid)
  • Page 30 “MAP 4000: Symptom” on page 103 Error/Status Code FFB Printer logic board failure “MAP 4000: Symptom” on page 103 Error/Status Code FFD Printer logic board failure “MAP 4000: Symptom” on page 103 Error/Status Code FFE IBM 4230 and 4232 Printers Maintenance Analysis Procedures...
  • Page 31 Maintenance Analysis Procedures (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.
  • Page 32 Does the POST complete without failure? Is the printer completely inactive (No indicators, no display, no fan.) Continue with Step 014 on page 19. Continue with “MAP 3600: Power Supply” on page 65. (Step 013 continues) IBM 4230 and 4232 Printers Maintenance Analysis Procedures...
  • Page 33 Maintenance Analysis Procedures 013 (continued) Continue with Step 022 on page 21. (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? Continue with Step 050 on page 26.
  • Page 34 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 Refer- ence Guide. - Install a new printer logic board. Refer to MIM “211 - Printer Logic Board”...
  • Page 35 Maintenance Analysis Procedures 021 (continued) - Perform the Bidirectional adjustment. Refer to MIM “Bidirectional Adjustment” on page 000-67. (From step 013) Does the operator report “bad keys”? Does the operator report “slow printing”? Continue with Step 030 on page 22. Continue with MAP 3900 step 047 on page 96.
  • Page 36 - 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? (Step 031 continues) IBM 4230 and 4232 Printers Maintenance Analysis Procedures...
  • Page 37 Maintenance Analysis Procedures 031 (continued) Continue with Step 039 on page 24. - 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”...
  • Page 38 (From step 031) - Ensure the forms are loaded. Stop ready. - Press to make the printer - Press Form Feed. Do the forms move each time the key is pressed? (Step 040 continues) IBM 4230 and 4232 Printers Maintenance Analysis Procedures...
  • Page 39 Maintenance Analysis Procedures 040 (continued) Continue with “MAP 3400: Forms Motor Drive” on page 53. - 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.
  • Page 40 - Run an error log (refer to MIM “Print Error Log” on page 000-83) or continue with “MAP 4000: Symptom” on page 103. (From steps 015 and 037) - Go to the MAP or perform an action contained in the following tables and verify the repair. IBM 4230 and 4232 Printers Maintenance Analysis Procedures...
  • Page 41 Maintenance Analysis Procedures Error/Status Description Action Continue with Step 017 on page 19. is displayed. Diagnostics In Progress is dis- Continue with Step 017 on played. page 19. The print head does not move. Continue with “MAP 3320: Print Head Drive and Control” on page 47.
  • Page 42 Check” on page 000-91. NLQ characters, vertical lines not Perform “Bidirectional Adjustment” clear. on page 000-67. Graphics not aligned well or not Perform “Bidirectional Adjustment” clear. on page 000-67. IBM 4230 and 4232 Printers Maintenance Analysis Procedures...

  • Page 43: Map 3100: Auto Sheet Feeder

    Maintenance Analysis Procedures MAP 3100: Auto Sheet Feeder The following are FRUs that can cause Auto Sheet Feeder (ASF) prob- lems: Printer logic board • Forms feed motor • F4 feeder assembly • F4 forms device. • Before starting this map: 1.
  • Page 44 Does the paper feed to the platen, the print head print blanks, and the paper eject without jams? Continue with Step 021 on page 33. - Load the paper in bin 2. - Perform bin selection test 2 (Step 008 continues) IBM 4230 and 4232 Printers Maintenance Analysis Procedures...
  • Page 45 Maintenance Analysis Procedures 008 (continued) Does the paper feed from bin 2 to the forms device (no error/status code 10)? Continue with Step 021 on page 33. Does the paper feed to the platen, the print head print blanks, and the paper eject without jams? Continue with Step 021 on page 33.
  • Page 46 Continue with Step 021 on page 33. Does the paper feed to the platen, the print head print blanks, and the paper eject without jams? Continue with Step 021 on page 33. (Step 020 continues) IBM 4230 and 4232 Printers Maintenance Analysis Procedures...
  • Page 47 Maintenance Analysis Procedures 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.
  • Page 48 - 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...

  • Page 49: Map 3150: Automatic Forms Thickness Adjustment

    Maintenance Analysis Procedures 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. • False 0A4 errors can be caused by the operator manually moving the AFTA gear (uses gear as a lever like on the 4224).
  • Page 50 - Install a new AFTA gear. Refer to MIM “385 - AFTA Assembly” on page 300-26. - 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...
  • Page 51 Maintenance Analysis Procedures 009 (continued) 3. Release both keys. 4. Press the Menu key. Scroll keys to scroll to the sensor test and press Enter. - Use the 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.
  • Page 52 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 Refer- ence Guide. - Install a new printer logic board. Refer to MIM “211 - Printer Logic Board”...
  • Page 53 Maintenance Analysis Procedures 014 (continued) Is the problem with print quality? - Verify the symptoms. Continue with “MAP 2010: Start/Verify” on page 5. - Verify that the print head is seated correctly. - Verify that the print head stop screw is adjusted correctly (“Installation”...
  • Page 54 - 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) IBM 4230 and 4232 Printers Maintenance Analysis Procedures...
  • Page 55 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 Refer- ence Guide. - Install a new printer logic board. Refer to MIM “211 - Printer Logic Board”...
  • Page 56 Notes IBM 4230 and 4232 Printers Maintenance Analysis Procedures...

  • Page 57: Map 3200: Attachment

    Does the display equal 19, 21, 23, 24, 25, 29, 64, 65, or 66? Continue with “MAP 2010: Start/Verify” on page 5. - If this is a 4230 printer answer the following question Yes. - If this is a 4232 printer answer the following question No.
  • Page 58 Refer to MIM “Serial/Parallel Attachment Card/Bezel Service Check” on page 000-113. Is the problem fixed? - Install a new attachment card/bezel. Refer to MIM “413 - Attachment Card/Bezel (4232 Model 302 Only)” on page 400-6. (Step 007 continues) IBM 4230 and 4232 Printers Maintenance Analysis Procedures...
  • Page 59 Maintenance Analysis Procedures 007 (continued) Is the problem fixed? Put back the old card/bezel. Continue with Step 013 on page 46. Return the printer to the operator. Return the printer to the operator. - Switch off power. - Remove the cover. - Perform the attachment bezel service check and return to this step.
  • Page 60 “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 Refer- ence Guide, or the IBM 4232 Printer Quick Reference Guide.

  • Page 61: Map 3320: Print Head Drive And Control

    Maintenance Analysis Procedures 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 •...
  • Page 62 - Observe the meter as you slowly rotate the carrier motor gear. Note: Answer this question if the measurement is anywhere between 0 V DC and 5 V DC. For example, 1 V DC. (Step 007 continues) IBM 4230 and 4232 Printers Maintenance Analysis Procedures...
  • Page 63 - 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? - Continue with Step 013 on page 50.
  • Page 64 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 Refer- ence Guide. - Install a new printer logic board. Refer to MIM “211 - Printer Logic Board”...
  • Page 65 Maintenance Analysis Procedures 015 (continued) - Perform the Bidirectional adjustment. Refer to MIM “Bidirectional Adjustment” on page 000-67. (From steps 004, 006, and 008) - Switch off power. - Disconnect the HM connector and J3. Refer to MIM “720 - Locations, Cable Connectors”...
  • Page 66 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 Refer- ence Guide. - Install a new printer logic board. Refer to MIM “211 - Printer Logic Board”...

  • Page 67: Map 3400: Forms Motor Drive

    Maintenance Analysis Procedures MAP 3400: Forms Motor Drive The following are FRUs that can cause forms drive problems: Forms motor • Printer logic board • Forms device • Frame assembly. • Note: Ensure that a forms device and forms are correctly installed before entering this MAP.
  • Page 68 Check” on page 000-93. Is the Service Check good? - Repair or exchange the failing part. Continue with Step 014 on page 56. (From steps 003, 005, and 016) (Step 009 continues) IBM 4230 and 4232 Printers Maintenance Analysis Procedures...
  • Page 69 000-49. 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”...
  • Page 70 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 Refer- ence Guide. - Install a new printer logic board. Refer to MIM “211 - Printer Logic Board”...
  • Page 71 Maintenance Analysis Procedures 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? Continue with Step 017.
  • Page 72 Notes IBM 4230 and 4232 Printers Maintenance Analysis Procedures...

  • Page 73: Map 3500: Print Wire

    Maintenance Analysis Procedures MAP 3500: Print Wire The following are FRUs that can cause print wire problems: Print head • Print head cable • Printer logic board. • - 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.
  • Page 74 Continue with Step 015 on page 62. - 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) IBM 4230 and 4232 Printers Maintenance Analysis Procedures...
  • Page 75 Maintenance Analysis Procedures 007 (continued) Is the second line missing? Continue with Step 012. Continue with Step 015 on page 62. (From step 002) - Disconnect the print head cable from the print head. - Reconnect to the test location. - Run print wire test 2.
  • Page 76 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 Refer- ence Guide. - Install a new printer logic board. Refer to MIM “211 - Printer Logic Board”...
  • Page 77 Maintenance Analysis Procedures 015 (continued) Is there continuity for all cable wires? - Install a new print head cable. Refer to MIM “325 - Print Head Cable” on page 300-4. - Return the connector to the run location. - Install a new print head. Refer to MIM “321 - Print Head” on page 300-2.
  • Page 78 Notes IBM 4230 and 4232 Printers Maintenance Analysis Procedures...

  • Page 79: Map 3600: Power Supply

    Maintenance Analysis Procedures MAP 3600: Power Supply The following are FRUs that can cause power problems: Printer logic board • Power supply • Sensors • Motors • Attachment bezel • Power cable. • - 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.
  • Page 80 - Switch on power. Refer to MIM “721 - Locations, Rear (Cover Off)” on page 700-9. Is the green power supply indicator on? Continue with Step 034 on page 73. (Step 009 continues) IBM 4230 and 4232 Printers Maintenance Analysis Procedures...
  • Page 81 Maintenance Analysis Procedures 009 (continued) (From step 002) - Switch off power. - Switch on power. Do the operator panel LEDs go on for at least one second? Continue with Step 044 on page 76. - Run the NLQ print quality test. Refer to MIM “NLQ Print Quality Test” on page 000-69.
  • Page 82 J1 (attachment connector for 4230 Models 101, 102, 1I1, 1S2, • 201, 202, 2I1, and 2S2 only) J5 (attachment connector for 4232 only) • J1 and J5 (attachment connectors for 4230 Models 4I3, 4S3, 5I3, • and 5S3 only), - Switch on power. (Step 015 continues)
  • Page 83 015 (continued) Does the printer remain on? - Install a new attachment bezel or card/bezel. Refer to: MIM“411 - Attachment Bezel (4230 Models 101, 102, 1I1, • 1S2, 201, 202, 2I1, 2S2 only)” on page 400-2 MIM“412 - Attachment Cards/Bezel (4230 Models 4I3, 4S3, •...
  • Page 84 - Install a new forms motor. Refer to MIM “381 - Forms Motor” on page 300-22. - Switch off power. - Connect J11 (AFTA motor). - Switch on power. (Step 023 continues) IBM 4230 and 4232 Printers Maintenance Analysis Procedures...
  • Page 85 Maintenance Analysis Procedures 023 (continued) Does the printer remain on? - Install a new AFTA motor. Refer to MIM “385 - AFTA Assembly” on page 300-26. - Switch off power. - Connect J8 (ribbon motor). - Switch on power. Does the printer remain on? - Install a new ribbon drive motor assembly.
  • Page 86 Cable” on page 300-4. - Install a new print head. Refer to MIM “321 - Print Head” on page 300-2. - Perform the AFTA setting procedure. Refer to MIM “AFTA Setting Procedure” on page 000-105. IBM 4230 and 4232 Printers Maintenance Analysis Procedures...
  • Page 87 Maintenance Analysis Procedures (From steps 008, 014, 045, and 049) - Disconnect J6 from the printer logic board. Refer to MIM “753 - Printer Logic Board” on page 750-3. Is the green LED inside the power supply on? - Install a new power supply. Refer to MIM “611 - Power Supply” on page 600-2.
  • Page 88 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 Refer- ence Guide. - Install a new printer logic board. Refer to MIM “211 - Printer Logic Board”...
  • Page 89 000-49. 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”...
  • Page 90 + + + + 5 V DC present at J1 pin 12? - Print, or obtain from the customer, the printer configuration and vital product data. Refer to MIM “Printer Configuration” on page 000-49. IBM 4230 and 4232 Printers Maintenance Analysis Procedures...
  • Page 91 Maintenance Analysis Procedures 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”...
  • Page 92 - Check the error log for intermittent problems. - Switch off power. - Unplug the sensors one at a time and switch on the power to deter- mine the failing sensor. (Step 055 continues) IBM 4230 and 4232 Printers Maintenance Analysis Procedures...
  • Page 93 Maintenance Analysis Procedures 055 (continued) - If the symptom does not change, install a new main sensor cable.
  • Page 94 Notes IBM 4230 and 4232 Printers Maintenance Analysis Procedures...

  • Page 95: Map 3800: Ribbon Movement And Control

    “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 Refer- ence Guide. - Install a new printer logic board. Refer to MIM “211 - Printer Logic Board”...
  • Page 96 - Access the offline CE tests. Refer to MIM “Performing Offline CE Tests” on page 000-61. - Run the ribbon test. Refer to MIM “Ribbon Motor Test” on page 000-82. (Step 006 continues) IBM 4230 and 4232 Printers Maintenance Analysis Procedures...
  • Page 97 Maintenance Analysis Procedures 006 (continued) Does the test run successfully? Continue with Step 009. No problem is found. - Verify the symptoms. (From step 007) - Remove the ribbon cartridge. - Run the ribbon test. Refer to MIM “Ribbon Motor Test” on page 000-82.
  • Page 98 000-49. 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”...

  • Page 99: Map 3900: Sensor

    Maintenance Analysis Procedures MAP 3900: Sensor The following are FRUs that can cause sensor failure: Paper present sensor • End of forms sensor • AFTA sensor • Front paper door • Access cover • Cover open sensor • Door open sensor •...
  • Page 100 Configure the printer to match the forms device. See “822 - Forms Device Configuration” on page 800-7. Note: If the paper moves above the paper present sensor when loading the paper, answer yes to the following question. (Step 005 continues) IBM 4230 and 4232 Printers Maintenance Analysis Procedures...
  • Page 101 Maintenance Analysis Procedures 005 (continued) Is error/status code 01, 02, 03, 031, or 032 displayed with paper in the printer? Continue with Step 044 on page 96. False forms jams occur when the printer stops and displays error codes 002 or 032 but there is no physical jam. Are you here because of false forms jams? Continue with Step 012 on page 88.
  • Page 102 - Perform the “False End Of Forms Service Check” on page 000-104 and return here. Were problems found during the service check? Continue with Step 017. Repair as needed. (From steps 013 and 015) (Step 017 continues) IBM 4230 and 4232 Printers Maintenance Analysis Procedures...
  • Page 103 Maintenance Analysis Procedures 017 (continued) - Check for obstructions on or around the paper present sensor. - Ensure that the paper present sensor is clean (free of paper dust). - Ensure that the paper is in the printer under the EOF sensor and in front of the paper present sensor.
  • Page 104 - Slide the paper to the left until it stops. Does HC=1? Continue with Step 032 on page 92. Does PP=1? (Step 024 continues) IBM 4230 and 4232 Printers Maintenance Analysis Procedures...
  • Page 105 Maintenance Analysis Procedures 024 (continued) Continue with Step 035 on page 93. - Remove the paper from the printer and the EOF sensor. Does EOF=0? Continue with Step 032 on page 92. Does HC=0? Continue with Step 032 on page 92. Does PP=0? Continue with Step 035 on page 93.
  • Page 106 - Measure for +5 V DC between frame ground (-lead) and the fol- lowing points (+lead): EOF-1 • EOF-3 • EOF-4 • + + + + 5 V DC present on all pins? Continue with Step 041 on page 95. (Step 034 continues) IBM 4230 and 4232 Printers Maintenance Analysis Procedures...
  • Page 107 Maintenance Analysis Procedures 034 (continued) - Clean or install a new EOF sensor. Refer to MIM “383 - End of Forms Sensor” on page 300-24. (From steps 024 and 030) - Switch off power. - Remove the printer cover. - Disconnect the PP connector at the paper present sensor. - Switch on power.
  • Page 108 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 Refer- ence Guide. - Install a new printer logic board. Refer to MIM “211 - Printer Logic Board”...
  • Page 109 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 Refer- ence Guide. - Install a new printer logic board. Refer to MIM “211 - Printer Logic Board”...
  • Page 110 - Select the offline CE tests. Refer to MIM “Performing Offline CE Tests” on page 000-61. - Scroll to the sensor test. - Press Enter. Does CO=1 and DO=1? Continue with Step 056 on page 98. IBM 4230 and 4232 Printers Maintenance Analysis Procedures...
  • Page 111 Maintenance Analysis Procedures - Open the cover. Does CO=0? - Refer to the wiring diagram section of MIM “757 - Operator Panel Cable” on page 750-6 and perform a continuity check of the sensor section of the operator panel cable. Is there continuity? - Install a new operator panel cable.
  • Page 112 - Remove the covers and disconnect connector DC. Refer to MIM “720 - Locations, Cable Connectors” on page 700-8. - Measure for +5 V DC between frame ground (-lead) and the fol- lowing points (+lead): (Step 060 continues) IBM 4230 and 4232 Printers Maintenance Analysis Procedures...
  • Page 113 000-49. 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”...
  • Page 114 - Open the access cover and check the access cover magnet. Is the access cover magnet installed? - Install a new cover assembly. Refer to MIM “113 - Access Cover” on page 100-4. IBM 4230 and 4232 Printers Maintenance Analysis Procedures...
  • Page 115 - 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.
  • Page 116 Setting Procedure” on page 000-105. - Perform the Bidirectional adjustment. Refer to MIM “Bidirectional Adjustment” on page 000-67. - Install a new operator panel. Refer to MIM “511 - Operator Panel” on page 500-1. IBM 4230 and 4232 Printers Maintenance Analysis Procedures...

  • Page 117: Map 4000: Symptom

    Maintenance Analysis Procedures MAP 4000: Symptom This MAP should be used when: Symptoms change • Other MAPs do not find the failure • An error indication is sensed and cannot be duplicated • A failure does not occur all the time. •...
  • Page 118 Static brush is installed and in good condition • Static brush ground spring to power supply • Static brush mounting screws are tight • Static brush ground wire to frame ground • IBM 4230 and 4232 Printers Maintenance Analysis Procedures...
  • Page 119 Maintenance Analysis Procedures Refer to MIM “751 - Ground Wire” on page 750-1 and “752 - ESD Grounds” on page 750-2. Check the connections to the extended memory feature (if present). Note: A “+” (plus) symbol below the second digit of the Error/Status code indicates that the printer has the extended memory feature.
  • Page 120 Press Load Paper present must be loaded sensor before printing loose/dirty can start Paper present sensor Printer logic board Print Head Cable Margin error Adjust margin or Printer logic line length board IBM 4230 and 4232 Printers Maintenance Analysis Procedures...
  • Page 121 Unit Checks or Suspect List Status Actions Code Host attention Press Stop Host print job clear the error (4230 Models Printer logic Start and press 201, 202, 2I1, board 2S2, 5I3, 5S3 and 4232 Model 302) Print order not Verify data...
  • Page 122 EOF sensor adjustment Data to print Forms device Printer logic load forms configuration board Printer has data EOF sensor EOF sensor to print and adjustment Paper present forms module is sensor IBM 4230 and 4232 Printers Maintenance Analysis Procedures...
  • Page 123 The host is no Attachment Attachment longer communi- Bezel Service bezel cating with the Check Printer logic printer board (4230 Models 101, 102, 1I1, 1S2, 4I3, and 4S3 only) Forms jam Forms device Paper present configuration sensor Forms device F2 or F3...
  • Page 124 Printer logic 4I3, 4S3, 5I3, match. board 5S3 and 4232 Model 302) Unit address not Check printer Printer logic received address board (4230 Models Host/cable 101, 102, 1I1, 1S2, 4I3, and 4S3 only) IBM 4230 and 4232 Printers Maintenance Analysis Procedures...
  • Page 125 Suspect List Status Actions Code Transmit buffer Press Stop. Host/cable overrun error Ensure host and Printer logic printer pacing (4230 Models board modes match. 4I3, 4S3, 5I3, Ensure proper 5S3 and 4232 host cabling. Model 302) Press Cancel Print. Restart job.
  • Page 126 Control unit not bezel ready Communications Check HI cable Control unit check Communications (4230 Models cable 201, 202, 2I1, Printer logic 2S2, 5I3, and board 5S3 only) Attachment Control unit not bezel ready IBM 4230 and 4232 Printers Maintenance Analysis Procedures...
  • Page 127 Description Unit Checks or Suspect List Status Actions Code DSR not active Press Stop. Host/cable Verify host and (4230 Models Host software printer system 4I3, 4S3, 5I3, interface set- Attachment card 5S3 and 4232 tings match. Model 302 Printer logic...
  • Page 128 2S2, 5I3, and configuration. cable 5S3 only) Printer logic EOF has been board detected and new forms have not been loaded in a set amount of time Host will be noti- fied IBM 4230 and 4232 Printers Maintenance Analysis Procedures...
  • Page 129 Suspect List Status Actions Code Forms jammed Clear jam and Forms device timeout load forms again Defective forms (4230 Models Check forms Forms feed 201, 202, 2I1, thickness setting drive/idler gear 2S2, 5I3, and EOF sensor 5S3 only) EOF sensor...
  • Page 130 Forms stepper Forms motor motor cannot be Printer logic stepped to the board next phase Machine Check Forms feed Printer logic service check board Not valid forms phases have been detected IBM 4230 and 4232 Printers Maintenance Analysis Procedures...
  • Page 131 Maintenance Analysis Procedures Error Description Unit Checks or Suspect List Status Actions Code Machine Check Switch off power Printer logic board Command Switch on power decode check, Wait 20 seconds error in proc- essing com- mands Machine Check Switch off power Carrier belt Switch on power No response...
  • Page 132 Print head out of Printer logic binds. place board See “Missing An obstruction Dots or Char- was present acter Service during the head Check” on calibration cycle page 000-88. Idler assembly adjustment Press Start IBM 4230 and 4232 Printers Maintenance Analysis Procedures...
  • Page 133 Maintenance Analysis Procedures Error Description Unit Checks or Suspect List Status Actions Code Machine check Check for carrier Carrier motor binds. Print head motor Printer logic See “Missing overcurrent board Dots or Char- acter Service Main sensor Check” on cable page 000-88.
  • Page 134 (4230 Models Printer logic 201, 202, 2I1, board 2S2, 5I3, and 5S3 only) Printer in send Press PA1 or Printer logic state board (4230 Models 201, 202, 2I1, 2S2, 5I3, and 5S3 only) IBM 4230 and 4232 Printers Maintenance Analysis Procedures...
  • Page 135 Unit Checks or Suspect List Status Actions Code Machine Check Host Attachment soft- Microcode ware check Printer logic (4230 Models board 101, 102, 1I1, 1S2, 4I3, and 4S3 only) No attachment Attachment bezel or card Printer logic board Attachment Attachment...
  • Page 136 Host ment microcode Printer logic check board (4230 Models Microcode 201, 202, 2I1, 2S2, 5I3, and 5S3 only) Internal con- Check cover Microcode troller microcode ground strap problem check Printer logic board IBM 4230 and 4232 Printers Maintenance Analysis Procedures...
  • Page 137 Cover/door open and paper door Operator panel installation Operator panel Printer logic board Hold print Place printer in Host program timeout ready status Operator panel (4230 Model Printer logic 201, 202, 2I1, board 2S2, 5I3, and 5S3 only)
  • Page 138 Printer logic sensor changes board Main sensor cable Machine check Check for AFTA assembly obstruction of Out of conver- the AFTA mech- sion range anism. Print head retaining spring installation Ribbon installa- tion IBM 4230 and 4232 Printers Maintenance Analysis Procedures...
  • Page 139 Maintenance Analysis Procedures Error Description Unit Checks or Suspect List Status Actions Code Panel diagnos- Operator panel tics failure Panel micro- processor fail Panel communi- Operator panel cation failure Operator panel No communi- cable cation with Printer logic printer board Panel communi- Printer logic cation failure...
  • Page 140 Micro processor failure Printer logic Printer logic board failure board Check SUM error Printer logic Printer logic board failure board Print PROC timeout Printer logic Printer logic board failure board BUS error IBM 4230 and 4232 Printers Maintenance Analysis Procedures...
  • Page 141 Maintenance Analysis Procedures Error Description Unit Checks or Suspect List Status Actions Code Printer logic Printer logic board check board NVRAM read/write error Printer logic Printer logic board check board NVRAM vital products data checksum error Printer config- Press Start Printer logic uration not valid set factory...
  • Page 142 5S3 and 4232 Model 302) Printer logic Printer logic board failure board 80188 Timer Possible micro- error code problem Printer logic Printer logic board failure board 80188 Interrupt Possible micro- error code problem IBM 4230 and 4232 Printers Maintenance Analysis Procedures...
  • Page 143 Maintenance Analysis Procedures Error Description Unit Checks or Suspect List Status Actions Code Printer logic Printer logic board failure board 80188 DMA Possible micro- error code problem Printer logic Printer logic board failure board 80188 CPU Possible micro- error code problem Printer logic Printer logic board failure...
  • Page 144 RAM data error Printer logic Printer logic board failure board Panel message Possible micro- ROS error code problem Printer logic Printer logic board failure board Code ROS error Possible micro- code problem IBM 4230 and 4232 Printers Maintenance Analysis Procedures...

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