Lexmark 4226 Parts Breakdown

Lexmark4226 Printer

• Table of Contents

• Start Diagnostics

• Safety and Notices

• Trademarks

4226-XXX

•Index

• Manuals Menu

Lexmark and Lexmark with diamond design are trademarks of Lexmark International, Inc., registered in the United States and/or other countries.

4226-001

First Edition (May, 1997)

The Following Paragraph Does Not Apply To The United Kingdom Or Any Country Where Such Provisions Are Inconsistent With Local Law: LEXMARK

INTERNATIONAL, INC.PROVIDESTHIS PUBLICATION“ASIS” WITHOUT WARRANTY OF ANY KIND, EITHER EXPRESS OR IMPLIED, INCLUDING, BUT NOT LIMITED TO, THE IMPLIED WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. Some states do not allow disclaimer of express or implied warranties in certain transactions, therefore, this statement may not apply to you.

This publication could include technical inaccuracies or typographical errors. Changes are periodically made to the information herein; these changes will be incorporated in later editions of the publication. Improvements or changes in the products or the programs described in this publication may be made at any time. Publications are not stocked at the address given below; requests for publications should be made to your point of purchase.

Comments may be addressed to Lexmark International, Inc., Department D22A/035-3, 740 New Circle Road NW, Lexington, Kentucky 40550, U.S.A. Lexmark may use or distribute any of the information you supply in any way it believes appropriate without incurring any obligation to you.

Lexmark is a trademark of Lexmark International, Inc., registered in the United States and/or other countries.

Other trademarks are the property of their respective owners

 Copyright Lexmark International, Inc. 1991, 1997

UNITED STATES GOVERNMENT RESTRICTED RIGHTS

This software and documentation are provided with RESTRICTED RIGHTS. Use, duplication or disclosure by the Government is subject to restrictions as set forth in subparagraph (c)(1)(ii) of the Rights in Technical Data and Computer Software clause at DFARS252.227-7013 and in applicable FAR provisions: Lexmark International, Inc., Lexington, KY 40550.

4226-001

Contents 1

Notices..............................................vii

SafetyInformation................................... vii

Preface..............................................xii

GeneralInformation...................................1-1

Description....................................... 1-1

Maintenance Approach.............................. 1-2

Power Supply Specifications ......................... 1-2

PrinterCables..................................... 1-3

Tools............................................ 1-3

Abbreviations..................................... 1-4

Using the Operator Panel . . .......................... 1-5

DisplayFormat................................. 1-5

Buttons....................................... 1-7

Indicators.................................... 1-10

Display...................................... 1-10

Alarm....................................... 1-11

DiagnosticInformation ................................2-1

Power-OnSelfTest(POST).......................... 2-1

Start............................................ 2-3

ErrorIndicationTable............................... 2-4

SensorTest1.................................. 2-7

SensorTest2.................................. 2-7

ButtonTest.................................... 2-7

SymptomTable.................................... 2-8

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4226-001

ServiceChecks.................................. 2-14

AbnormalNoiseServiceCheck................... 2-14

AbnormalPrintServiceCheck.................... 2-16

CamDriveFailureServiceCheck................. 2-17

CarrierDriveFailureServiceCheck............... 2-20

EOFServiceCheck............................ 2-22

IntermittentProblemServiceCheck............... 2-23

Operator Panel Service Check ................... 2-24

Paper Feed Service Check ...................... 2-25

POSTFailureServiceCheck..................... 2-28

PowerFailureServiceCheck.................... 2-30

PrintQualityServiceCheck...................... 2-32

PrintTest.................................... 2-32

PrintWireDriveFailureServiceCheck............. 2-36

ResistanceTable1............................ 2-37

ResistanceTable2............................ 2-37

Ribbon Drive Service Check ..................... 2-38

DiagnosticAids ......................................3-1

Offline Test (Resident Non-Automatic Tests) . . . ...... 3-1

SensorTest1................................. 3-2

SensorTest2................................. 3-2

ButtonTest................................... 3-2

LCDTest..................................... 3-2

BAT Loop Test................................. 3-3

FactorySetting ................................ 3-3

LogClear..................................... 3-3

PrintTest..................................... 3-4

PrintTestSample.............................. 3-6

Trace (Hexadecimal Print). . . ........................ 3-7

Hexadecimal Print Sample (Wide Width) ............ 3-8

RepairInformation....................................4-1

Handling ESD-Sensitive Parts........................ 4-1

Adjustments...................................... 4-2

CarrierAssemblyAdjustment..................... 4-2

CarrierBeltAdjustment.......................... 4-3

CharacterAlignmentAdjustment................... 4-5

EOFSwitchAdjustment.......................... 4-6

Printhead to Platen Adjustment.................... 4-6

Printhead Cable to Carrier Shaft Gap Adjustment...... 4-7

TractorAdjustment............................. 4-7

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RemovalProcedures............................... 4-8

AccessCoverRemoval.......................... 4-8

BottomPlateandGroundSheetRemoval............ 4-9

CamAssemblyRemoval........................ 4-11

CamMotorandCamSensorRemoval ............. 4-12

CarrierFrameAssemblyRemoval................. 4-13

CarrierMotorandBeltRemoval................... 4-16

EOFSwitchandJamSensorRemoval............. 4-18

FeedFrameAssemblyRemoval.................. 4-19

FeedGearsandFrictionBlocksRemoval........... 4-20

FeedUnitAssemblyRemoval.................... 4-21

FormsMotorRemoval.......................... 4-23

FormsThicknessLeverRemoval.................. 4-24

FrontCoverRemoval........................... 4-25

GapSensorAssemblyRemoval.................. 4-26

GearCoverRemoval........................... 4-27

Logic Board Removal. . ......................... 4-28

LowerPressureRollerAssemblyRemoval.......... 4-30

Operator Panel Removal ........................ 4-31

Pin Feeds Removal . . . ......................... 4-33

Power Supply Removal ......................... 4-35

Printhead Removal............................. 4-37

Printhead Cable Removal ....................... 4-39

PrintUnitAssemblyRemoval..................... 4-41

Ribbon Drive Assembly Removal. . ................ 4-44

Ribbon Drive Gears Removal..................... 4-45

Ribbon Drive Motor Assembly Removal............. 4-46

TensionPulleyAssemblyRemoval................ 4-47

TOFSensorRemoval........................... 4-49

TopCoverAssemblyRemoval.................... 4-51

TractorAssemblyRemoval...................... 4-53

Upper and Lower Feed Roller Shafts Removal ....... 4-55

Upper Pressure Roller Assembly Removal . . . ....... 4-57

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ConnectorLocations..................................5-1

Main Logic Board Connectors..................... 5-4

Carrier Motor Connector CP1 ..................... 5-5

FormsMotorConnectorCP2...................... 5-5

Cam Motor Connector CP3....................... 5-6

Printhead Connector CJ4 ........................ 5-7

Cam Initial Position Sensor Connector CP5 .......... 5-8

Ribbon Feed Motor Connector CP6 . ............... 5-9

Power Connector CP9. . . ....................... 5-10

Operator Panel Connector CP10.................. 5-11

TOFSensorConnectorCP11.................... 5-12

JamSensorConnectorCP12.................... 5-13

CM Encoder Connector CP13.................... 5-14

EOF Switch Connector CP14 .................... 5-14

GapPositionSensorConnectorCP15............. 5-15

Parallel/Serial Interface Signal Connector CJ17 . ..... 5-16

Printhead Connector CJ18 ...................... 5-17

Cover Open Connector CJ19 .................... 5-18

C/M Heat Sensor Connector CJ20 . . .............. 5-18

Carrier Motor Fan Connector CJ21 . . .............. 5-18

WiringDiagrams ................................. 5-19

4226 Printer Block Diagram...................... 5-19

Power Supply Wiring Diagram.................... 5-20

IBM 4226 Printer dc Grounding Diagram ........... 5-20

PreventiveMaintenance ...............................6-1

Lubrication....................................... 6-1

Lubrication Points .............................. 6-2

PartsCatalog ........................................7-1

HowtoUseThisPartsCatalog....................... 7-1

Assembly1:CoverandElectricalParts................. 7-2

Assembly2:PrintUnit.............................. 7-4

Assembly3:FeedUnit.............................. 7-6

Index...............................................X-1

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Notices

Safety Information

•

The maintenance information for this product has been prepared for use by a professional service person and is not intended to be used by others.

• There may be an increased risk of electric shock and

personal injur y during disassembly and servicing of this product. Professional service personnel should understand this and take necessary precautions.

• The safety features of some parts may not always be

obvious. Therefore, replacement parts must have the identical or equivalent characteristics as the original parts.

Sicherheitshinweise

•

Die Wartungsinformationen für dieses Produkt wurden zur Verwendung durch einen Wartungsfachmann entwickelt und sollten nicht von anderen benützt werden.

• Zusätzliches Risiko eines elektrischen Schlags und

körperlicher Verletzung existiert während des Auseinandernehmens und der Wartung des Geräts. Fachpersonal sollte im vollen Verständnis der Lage entsprechende Vorsichtsmaßnahmen ergreifen.

• Ersatzteile müssen gleiche oder gleichwertige Merkmale wie

die Or iginalteile aufweisen, da Sicherheitsvorkehrungen nicht immer offensichtlich sind.

Notices vii

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Consignes de Sécurité

•

Les consignes d'entretien et de réparation de ce produit s'adressent uniquement à un personnel de maintenance qualifié.

• Le démontage et l'entretien de ce produit pouvant présenter

certains risques électriques, le personnel d'entretien qualifié devra prendre toutes les précautions nécessaires.

• Les normes de sécurité de certaines pièces n'étant pas

toujours explicites, les pièces de rechange doivent être identiques ou conformes aux caractéristiques des pièces d'origine.

Norme di sicurezza

•

Le informazioni riguardanti la manutenzione di questo prodotto sono indirizzate soltanto al personale dell'assistenza autorizzato.

• Durante lo smontaggio e il manutenzionamento di questo

prodotto, è possibile il rischio accresciuto di scosse elettriche e danni personali. Il personale di assistenza autorizzato, consapevole di ciò, deve adottare le precauzioni necessarie.

viii

• È possibile che le funzioni di sicurezza di alcuni elementi non

siano così ovvie, quindi, i pezzi di ricambio devono avere caratteristiche identiche o equivalenti a quelle dei pezzi originali.

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Pautas de Seguridad

•

La información sobre el mantenimiento de este producto fue escrita para el personal de mantenimiento cualificado y no para cualquier otro usuario.

• Existen mayores riesgos de descargas eléctricas y daños

personales durante el desmontaje y la reparación de la máquina. El personal cualificado comprende esto y toma las precauciones necesarias.

• Los dispositivos de seguridad de algunas partes quizá no

siempre puedan ser reconocidas a simple vista. Por lo tanto, las partes de reemplazo deben poseer características idénticas o equivalentes a las partes originales.

Sikkerhedsoplysninger

•

Oplysningerne om vedligeholdelse af dette produkt er forberedt med henblik på professionelt servicepersonale, og bør derfor ikke benyttes af andre.

• Risikoen for elektrisk stød øges under demontering og

service af dette produkt, hvorfor der børtages de nødvendige forholdsregler.

• Sikkerhedsforanstaltningerne er ikke altid lige åpenbare for

alle reservedele. Der bør derfor kun anvendes originale reservedele eller reservedele med samme egenskaber som de oprindelige.

Notices ix

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Informações de Segurança

•

As informações de segurança relativas a este produto destinam-se a profissionais destes serviços e não devem ser utilizadas por outras pessoas.

• Risco de choques eléctricos e ferimentos graves durante a

desmontagem e manutenção deste produto. Os profissionais destes serviços devem estar avisados deste facto e tomar os cuidados necessários.

• Os dispositivos de segurança de algumas peças poderão

não ser sempre suficientemente evidentes. Assim, as peças sobressalentes devem possuir características idênticas ou equivalentes às peças originais.

Chinese Safety Information

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Korean Safety Information

Notices xi

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Preface

This manual is divided into the following chapters:

• General Information contains a general description of the

printer and the maintenance approach used to repair it. Special tools and test equipment are listed in this chapter, as well as general environmental and safety instructions.

• Diagnostic Information contains error code table, symptom

table,and service checks used to isolate failing field replaceable units (FRUs).

• Diagnostic Aids contains tests and checks used to locate or

repeat symptoms of printer problems.

• Repair Information provides instructions for making printer

adjustments and removing and installing FRUs.

• Connector Locations uses illustrations to identify the major

components and test points on the printer.

• Preventive Maintenance contains lubrication specifications,

and maintenance information to prevent problems and maintain optimum performance.

• Parts Catalog contains illustrations and part numbers for

individual FRUs.

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1. General Information

Description

The IBM 4226 Printer is a dot matrix impact printer that prints 1-byte code (alphanumeric, symbol) and attaches to the following as an output device:

• Personal System/2

• RISC System/6000

• AS/400

• 9370 System

General Information 1-1

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Maintenance Approach

The diagnostic information in this manual leads you to the correct field replaceable unit (FRU) or part. Use the error indication table, symptom/check table, service checks and diagnostic aids to determine the symptom and repair the failure.

Begin with “Start” on page 2-3.

Print Specifications

Character Size 1-byte code character

(Alphanumeric, symbol)

Character Spacing 1-byte code character

(Alphanumeric, symbol)

Print Speed 1-byte code character

(10 CPI)

Maximum Print Width

Line Spacing Variable in multiples of 1/144 in.

1-byte code character (10 CPI)

9(H)X12(V)dots 9(H)X 9(V)dots

10, 12, 15, 17.1, 20 CPI, Proportional Spacing

Draft Print...........400 cps

FastDraft Print....533 cps

80/136 characters 8 inch/13.6

Power Supply Specifications

Input Voltage Single phase: 90 to 132 V ac (LV), 50/60Hz

180 to 265 V ac (HV), 50/60Hz

Power Consumption Operating:.276 VA (all character print)

Idling:.......... 70 VA

1-2

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Printer Cables

When connecting the printer to a host personal computer, use the following cables:

• Parallel Cable P/N 1525612 or its equivalent.

• Serial Interface Cable RS-232 P/N 6486685.

• Serial Adapter Plug P/N 1319143 - when using a non-IBM serial

printer cable.

Note: The RS-422 serial interface cable may also be used.

Tools

The jumper wire is used to put the cover sensor in a closed condition (jumper CJ19-1 to CJ19-2 on the operator panel card) and is contained in the parts packet.

The Push-Pull gauge is used for weight ranges between 400g (0.88 lb) and 500g (1.1 lb).

General Information 1-3

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Abbreviations

ASIC Application-Specific Integrated Circuit CSU Customer Setup DRAM Dynamic Random Access Memory EPROM Erasable Programmable Read-Only Memory ESD Electrostatic Discharge FRU Field Replaceable Unit HVPS High Voltage Power Supply LCD Liquid Crystal Display LED Light-Emitting Diode LVPS Low Voltage Power Supply NVRAM Nonvolatile Random Access Memory OEM Original Equipment Manufacturer POR Power-On Reset POST Power-On Self Test ROS Read-Only Storage UPR Used Parts Replacement V ac Volts alternating current V dc Volts direct current

1-4

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Using the Operator Panel

This section provides a brief description of the operator panel buttons, lights and settings. Refer to the User’s Guide for additional information.

The operator panel has three LED indicator lights (Power, Ready and Check) and an LCD message display. The display presents the printer status, instructions and messages. When an error occurs, a code and a message are automatically displayed and an alarm sounds. Pressing Start/Stop will stop the alarm.

Display Format

There are two kinds of status codes:

1. Intervention Request Code (IRC) - IRC “00X” is displayed in three digit hexadecimal with five additional codes as follows:

Code Meaning

001 Paper Out 002 Paper Jam 005 Cover Open 007 Data error in serial interface 00D I/F error (Check interface mode)

General Information 1-5

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2. Error code “6xx” is displayed in three digit hexadecimal.

• 6 - Classification Code - 6 for all printers

• x - Function Code - Error function code

• x - Detailed Code - Error part code

The following table shows error codes and their associated meaning.

Code Meaning

631 Display RAM Read/Write Error 632 System RAM Read/Write Error 633 Timer Interrupt Controller Error 634 + 40 V dc Power Failure 635 Cam Position Error 636 Non-Volatile Memory (NVM) Read/Write Error 637 - 639 Carrier Drive Error 63A Font ROM Error 63B Button Scanning Error

1-6

4226-001

Buttons

Button Description

Start/Stop • Used to return to Ready and to Start/Stop.

• Thisisthe only active button when the printer is printing. Printing continues until the current line is completed.

•WhenStart/Stop is pressed at the tear-off position in manual tear-off mode, the forms are retracted to the line 1 position.

• Loads the forms to line 1 position with the Ready indicator on.

• Turns off the printer alarm.

Load/Unload • Loads forms to line position 1.

• Retractsthe forms to the tractor position. When the printer detects an end-of-form condition, pressing this button ejects the forms from the printer.

• Opens the pinch rollers when held for more than two seconds.

FormFeed • Advances the forms to line 1 position of the

next page.

• Loads the forms to the line 1 position.

General Information 1-7

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Button Description

LineFeed • Advances the forms one line.

• When this button is held for more than one second in the offline (not ready state), the forms move continuously until the button is released.

↑ Micro ↓ • Advance the forms down 0.35 mm (1/72 in.)

Micro

in either direction.

• When this button is held for more than one second, the forms move continuously until the button is released.

Tear Off • Advance the forms to the tear-off position.

• Retractstheformstoline1positionwhenthe forms are at the tear-off position.

Pitch • Advances the pitch to the next setting when

pressed.

• The following pitches can be selected: 10, 12, 15, 17.1, 20, PS

Each pitch can be locked which prevents your software from changing pitch settings at the operator panel. When pressing Pitch, the printer goes offline and displays the current pitch and font. When a font conflicts with a selected pitch, the

Invalid Pitch message appears on the display.

Font • Advances the font to the next setting when

pressed.

• The following fonts can be selected: FastDraft, Draft, Gothic, Courier

• The following Epson Emulation Modes can be selected: Draft (Fast & Normal), Gothic, Courier)

Each font can be locked which prevents your software from changing font settings at the operator panel. When pressing Font, the printer goes offline and displays the current pitch and font. When a font conflicts with a selected pitch, the

Invalid Pitch message appears on the display.

1-8

4226-001

Button Description

Menu/Quit • Enters the function mode and the printer

goes offline.

• Exits the function mode and the printer performs the Power-On Self Test (POST).

↑ / Item ↓ Scrolls up or down to display the desired

Item

function.

↑ / Scroll ↓ Scrolls up or down to display the desired value

Scroll

intheselectedfunctionmenu.

Store Saves the values selected in the menus.

General Information 1-9

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Indicators

Indicator

Power (Green) Indicates the printer power is on. Ready (Green) The printer is on-line and ready to print.

Check (Yellow) Any of the following conditions may have

Description

The following conditions cause the Ready light to turn off:

•PressingStart/Stop

•End-of-form(EOF)

• Paper jam

• Cover open

• Hardware error

• Power-On Self Test failure

occurred:

•End-of-form(EOF)

• Paper jam

• Cover open

• Hardware error

• Data transmission error

• Interface mode error

• Power-On Self Test (POST) failure

Display

The display shows error status codes, function menus and optional values when the printer is in the printer function setting mode.

1-10

4226-001

Alarm

The alarm sounds to indicate the printer status or an error condition when:

• A cover is opened.

• An end-of-form (EOF) condition is detected.

• A paper jam.

• A data transmission error.

• An interface mode error.

• A hardware error.

To stop the alarm, press Start/Stop.

General Information 1-11

4226-001

2. Diagnostic Information

Power-On Self Test (POST)

The Power-On Self Tests diagnose the basic hardware printer functions and initialize the default value settings. POST starts automatically when power to the printer is turned on, or when the printer receives an INIT signal from the controller.

• Display and Indicator Function Test - Checks LCD functions and

LED indicators.

• RAM Test - Checks that the CPU can write/read the RAM.

• Font ROS Test - Calculates the check-sum value.

• Drive Voltage (+40 V dc) Test - Checks the voltage of the motors

and printhead.

• Button Scan Test - Scans all operator panel buttons.

• NVRAM Test - Checks that the NVRAM data is correct.

• Button Scan Test - Checks all buttons on the operator panel.

• Cover Open Check - Checks if any covers are open.

• Carrier Drive Check and Initialization - Checks the carrier

positioning.

• Cam Drive Check and Initialization - Checks the cam motor and

cam sensor.

If the POST completes successfully, the Power and Ready indicators are on associated with a blank display. If any errors occur during POST, an error indicator shows which test failed. See “Start” on page 2-3.

2-1

4226-001

Diagnostic Information 2-2

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Start

Make a quick visual check for defects (loose or broken parts, unplugged connectors, or paper jams).

If there is no power after turning the printer on, go to the “Power

Failure Service Check” on page 2-30.

To prevent the printer from starting while service is performed, disconnect the interface cables.

Unload paper from the tractor. The cover open interlock can be bypassed by placing a jumper on

the rear of the operator panel. If the printer displays an error indication code go to the “Error

Indication Table” on page 2-4.

Run the “Print Test” on page 3-4 and refer to the Error Log for details of error indication information. If no error indication appears, refer to the “Symptom Table” on page 2-8.

2-3

4226-001

Error Indication Table

The following table describes the service check entries for the printer error indication codes.

When an error indication changes after you have entered a service check, you have an intermittent problem. If this occurs, leave the service c heck and go to “Intermittent Problem Service Check” on

page 2-23.

Display

Indication

Blank LCD busy condition.

Replace the following in the order listed:

1. Operator panel assembly

2.Logic board. Go to the “Operator Panel Ser vice Check”

on page 2-24.

001 EOF state is detected, or the EOF switch

fails to operate. Go to the “EOF Service Check” on page

2-22.

002 Frequent jams occur, or the jam sensor fails

to make contact. Go to the “Paper Feed Service Check” on

page 2-25.

005 Cover open condition is not detected, or is

not reset. Go to the “POST Failure Service Check” on

page 2-28.

Description / Action

007 Data error.

Go to the “Abnormal Print Service Check” on

page 2-16.

Diagnostic Information 2-4

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Display

Indication

Description / Action

00D Statusof the interface mode switches do not

match the setting in the NVM. Go to the “Abnormal Print Service Check” on

page 2-16.

631 Display RAM Read/Write Error. This error is

detected only in the Display Test. Replace the following in the order listed:

1. Operator panel assembly

2.Logic board. Go to the “Operator Panel Service Check”

on page 2-24.

632 System RAM Read/Write Error.

Replace the logic board.

633 Timer and Interrupt Controller Error.

Replace the logic board.

634 / 638 + 40 V dc power failed to drop.

Go to the “Power Failure Service Check” on

page 2-30.

2-5

635 Cam Positioning Error.

Go to the “Cam Drive Failure Service Check”

on page 2-17.

636 Non-Volatile Memory (NVM) Read/Write

Error. Replace the logic board.

637 Carrier Drive Timeout Error.

Go to the “Carrier Drive Failure Service

Check” on page 2-20.

638 No Emitter Pulse Error.

Go to the “Carrier Drive Failure Service

Check” on page 2-20.

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Display

Indication

Description / Action

639 Carrier Positioning Error.

Go to the “Carrier Drive Failure Service

Check” on page 2-20.

63A Font ROM Error. Replace the logic board. 63B Button Scanning Error.

Replace the following in the order listed:

1. Operator panel assembly

2.Logic board.

Go to the “Operator Panel Ser vice Check”

on page 2-24.

Diagnostic Information 2-6

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Sensor Test 1

For the offline test procedure, do the following:

1. POR the printer.

2. Press and hold Menu/Quit during POST until the message “Sensor Test 1” is displayed.

3. Press Item↑until “Print Test” is displayed.

4. Press Start/Stop to start printing. The message changes to “Printing”.

5. Press and hold Start/Stop to stop printing.

6. Turn the power off to exit this test mode.

Sensor Test 2

1. POR the printer.

2. Press and hold Menu/Quit during POST until the message “Sensor Test 2” is displayed.

3. Press Item↑until “Print Test” is displayed.

4. Press Start/Stop to start printing. The message changes to “Printing”.

5. Press and hold Start/Stop to stop printing.

6. Turn the power off to exit this test mode.

Button Test

1. POR the printer.

2. Press and hold Menu/Quit during POST until the message “Button Test” is displayed.

3. Press Item↑until “Print Test” is displayed.

4. Press Start/Stop to start printing. The message changes to “Printing”.

5. Press and hold Start/Stop to stop printing.

6. Turn the power off to exit this test mode.

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