Lexmark 4226 Parts Breakdown

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Lexmark4226 Printer

• Table of Contents

• Start Diagnostics

• Safety and Notices

• Trademarks

4226-XXX

•Index

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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

4226-001

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

4226-001

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

4226-001

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

4226-001

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.

xii

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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

4226-001

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

4226-001

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

4226-001

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

4226-001

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

4226-001

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

4226-001

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

4226-001

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.

4226-001

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

4226-001

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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Symptom Table

1. Select the symptom that best describes the problem.

2. Perform the appropriate action before you go to the indicated service check.

Abnormal Indications

Symptom Action

All indicators turn on, but do not turn off.

Machine model “IBM 4226” is displayed on the message display, the printer stops and an alarm sounds.

Abnormal Print Operation Problems

Symptom Action

Printer will not print, or become Ready. Abnormal operation, incorrect

characters, or incorrect line width. Printer is ready but will not print from

the computer correctly. Undefined or incorrect characters.

Intermittent Problems

Symptom Action

Go to the “POST Failure

Service Check” on page 2-28.

Be sure the interface cable is connected properly.

Go to the “Abnormal

Print Service Check” on page 2-16.

Problem appears to be intermittent. Go to the “Intermittent

Problem Service Check” on page 2-23.

Diagnostic Information 2-8

4226-001

6XX Error Indications

Symptom Action

6XX Machine Check is displayed. Turn the printer off and

then on. Go to “Error Indication

Table” on page 2-4.

Paper Feed Problems

Symptom Action

Pressing any feed function does not feed paper.

Go to the “Paper Feed

Service Check” on page

2-25.

Pressing Load/Unload does not move paper down to park.

Paper stops at the tractor and does not feed.

Frequent jams, paper skews or creases.

Forms do not travel to TOF or travel past TOF.

Line spacing problems. Error “001 paper Out” cannot be

cleared.

Go to the “EOF Service

Check” on page 2-22.

EOF condition occurs with paper on the tractor.

No EOF condition occurs with the end of paper.

Paper did not move. Check the configuration

data for an incorrect paper

length setting.

2-9

4226-001

Operator Panel Problems

Symptom Action

Missing dotted characters, or unreadable characters displayed.

Ready does not turn off when Start/Stop is pressed.

Turn the printer off and then on.

Go to the “Operator

PanelService Check” on page 2-24.

Only the Power light turns on. One or more buttons do not function. Power light does not come on but

carrier moves. One or more lights do not function. Blank display. Cover open displayed.

Power Problems

Symptom Action

No Power indicator on and no carrier movement.

Check the continuity of the power cord and the voltage of the electrical outlet.

Carrier does not move during POST.

Go to the “Power Failure

Service Check” on page 2-30.

Diagnostic Information 2-10

4226-001

Print Quality Problems

Symptom Action

No print, but carrier moves as if printing.

Be sure the printhead

cables are not loose or

damaged. Carrier moves slowly or stops at every line.

Be sure the interface cable

is connected properly.

Check the ribbon cartridge

for binds or damage.

Go to the “Print Wire Drive

Failure Service Check” on

page 2-36.

Print density is light. If the ribbon has reached

its end of life or is worn,

the ribbon cartridge needs

to be replaced. Check the

“Printhead to Platen

Adjustment” on page 4-6.

Go to the “Ribbon Drive

Service Check” on page

2-38.

2-11

4226-001

Symptom Action

Uneven print density across the print line.

Specific dots missing.

Scattered ink smearing, blurred characters.

Fuzzy print.

Be sure the printhead cables are connected correctly to the printhead.

Clean the printhead. Run the Print Test, see

“Test Execution” on page 3-1.Iftheprintislightat

one edge and uniformly gets darker across the page to the other edge, perform the “Printhead to

Platen Adjustment” on page 4-6.

Go to the “Print Wire Drive

Failure Service Check” on page 2-36.

Clean the printhead. Clean the ribbon guide. If the ribbon has reached

its end of life or is worn, the ribbon cartridge needs to be replaced.

Wavy vertical lines, uneven left margin or character width is reduced.

Go to the “Print Quality

Service Check” on page 2-32.

Clean and lubricate the carrier shaft.

Check the“Character

Alignment Adjustment” on page 4-5.

Go to the “Carrier Drive

Failure Service Check” on page 2-20.

Diagnostic Information 2-12

4226-001

Ribbon Feed Problems

Symptom Action

Ribbon comes off, becomes loose or folded, or jams.

Ribbon feeds correctly but is noisy.

Check the ribbon cartridge

for binds or damage.

Go to the “Ribbon Drive

Service Check” on page

2-38.

Noise

Symptom Action

Printer is noisy during idle.

Go to the “Abnormal Noise

Service Check” on page

Abnormal sounds when feeding

2-14.

paper, printing or during POST.

2-13

4226-001

Service Checks

Abnormal Noise Service Check

FRU Action

1Covers

Ribbon Cartridge

2PrintUnit

Assembly

Be sure that all covers are correctly mounted with no loose screws or latches.

Be sure the ribbon cartridge is installed correctly.

If the pri nter makes noise during POST or idling, perform a POR and wait a few minutes to complete POST.

If the printer continues to make noise during POST, but not idling, turn the printer off and disconnect CP6 from the logic board.

If the printer continues to make noise during POST, turn the power off, reconnect CP6 to the logic board, disconnect CP3 from the logic board and turn the power on.

If the printer continues to make noise, turn the power off, reconnect CP3 to the logic board, disconnect CP1 from the logic board and turn power on.

If the printer continues to make noise, replace the print unit assembly.

3 Ribbon

Cartridge

Feed Unit Assembly

If the ribbon cartridge is installed correctly, load paper on the tractor and press Form Feed.

If the printer makes noise during paper loading, replace the feed unit assembly.

Diagnostic Information 2-14

4226-001

FRU Action

4 Printhead

Ribbon Cartridge

Disconnect CP4 (Printhead) from the logic board and perform the “Print Test” on

page 2-32. If the printer makes noise while

performing the print test, check for broken print wires or a dirty printhead nose. If there are broken print wires or if the printhead nose is dirty, replace the printhead.

If the printer did not make noise during the print test, replace the ribbon cartridge.

5 Form Feed

Mechanism

Turn power off and measure the resistance of the following pins using the lowest ohm range:

CP2-1 & CP2-5 CP2-2 & CP2-5 CP2-3 & CP2-6 CP2-4 & CP2-6

If the above resistances are not correct, replace the forms motor assembly.

6 Logic Board Turn power off and remove the feed idler

gear. Check the following by rotating the line feed motor gear by hand and observing the parts; replace the appropriate FRU as required:

2-15

• Broken gear teeth on the feed gears.

• Incorrect gear alignment.

• Foreign objects in the gears.

• No lubricants on the gear teeth.

• Lubrication, or excess wear of metal bushing.

• Bent or worn feed roller shafts.

If the failure remains, replace the logic board.

4226-001

Abnormal Print Service Check

FRU Action

1 Printer Interface

Cable

2 Logic Board Be sure the interface switch on the logic

If the printer interface cable is connected correctly, check the continuity of all connector signals. Replace the printer interface cable if necessary.

board is correctly set and that the printer emulation is consistent with the host computer. If the problem remains, replace the logic board.

Diagnostic Information 2-16

4226-001

Cam Drive Failure Service Check

Note: FRUs in this service check may be worn, broken, binding or

corroded.

FRU Action

1 Logic Board

Cam Assembly Upper Pressure

Roller Assembly Lower Pressure

Roller Assembly

If error code 635 is displayed, POR and observe the upper and lower pressure rollers.

If both pressure rollers move up and down smoothly, POR again and observe the cam motion.

If the cam motor moves smoothly, replace the logic board.

If the cam motor does not move up and down smoothly, check the following mechanical connections:

• Linkage between the bracket of the upper pressure roller and cam.

• Linkage between the bracket of the lower pressure roller and cam.

If both linkage connections are good, POR again and observe the cam motion. If the cam motor moves smoothly, replace the logic board. If the linkage connections are incorrect, replace the appropriate FRU (cam assembly, upper pressure roller assembly, lower pressure roller assembly).

2MetalBushing

Upper Pressure Roller Assembly

Lower Pressure Roller Assembly

2-17

The upper or lower feed roller shafts may be binding or worn. Replace the appropriate FRU.

4226-001

FRU Action

3 Cam Sensor Perform the “Sensor Test 2” on page 2-7.

Check that the cam position sensor status changes correctly by using the blade of a screw driver.

If the cam sensor status did not change correctly, measure the voltage between TP4 and GND,performingthe same check as the previous step. If the cam sensor is good, the voltage changes from + 5 V dc to 0 V dc alternately.

• If the voltage changed correctly, replace the cam sensor.

• If the voltage did not change correctly, replace the logic board.

If the cam sensor status changed correctly, POR and observe the cam motion. If the cam motor moves smoothly, replace the logic board.

If the cam motor does not move smoothly, turn power off, disconnect CP3 and remove the cam motor from the bracket. Manually turn the cam drive gear to move the cam one full revolution. If the cam does not move smoothly, replace the cam assembly.

Diagnostic Information 2-18

4226-001

FRU Action

4CamMotor

Assembly

Manually turn the cam drive gear to move the cam one full revolution. If the cam does move smoothly, measure the resistance of the following pins using the lowest ohm range of the meter:

CP3-1 & CP3-5 CP3-2 & CP3-5 CP3-3 & CP3-6 CP3-4 & CP3-6

The correct resistance of all measurements is approximately 40 ohms. If the above resistances are not correct, replace the cam motor assembly.

• If the above resistances are correct, turn the cam motor shaft by hand. It the motor shaft turns smoothly, replace the logic board.

• If the motor shaft does not turn smoothly, replace the cam motor assembly.

2-19

4226-001

Carrier Drive Failure Service Check

Note: When the printer detects an Error Code of 637 or 639, verify

the same error exists after removing the jammed paper.

FRU Action

1 Carrier Belt

Carrier Motor

Logic Board

If the error code is 637 or 639, or if there is incorrect vertical print registration, check for breakage, wear or loose tension of the carrier belt.

If the belt is good, turn power off and manually move the carrier to check for smooth operation.

If the carrier moves smoothly, replace the carrier motor assembly. If the problem remains, replace the logic board.

If the carrier does not move smoothly, adjust and lubricate the following parts:

• Gap between the printhead and the platen. See “Printhead to Platen Adjustment” on

page 4-6. If the printhead gap is incorrect or

unevenright to left, reinstall the printhead or replace the upper pressure roller assembly.

• Dirt or no oil on the carrier shaft or support.

• Binding or broken idler pulley.

If the above items are good, remove the carrier belt from the carrier motor pulley and move the carrier manually to check for smooth carrier motion. If the carrier moves smoothly, replace the carrier motor assembly. If the carrier does not move smoothly, replace the carrier frame assembly.

Diagnostic Information 2-20

4226-001

FRU Action

2 Logic Board

Carrier Motor

3 Carrier Motor

Logic Board

If the error code is not 637 or 639, or if the vertical print registration is ok, POR and verify the carrier motor rotates. If the carrier motor rotates slightly, POR and observe the status of the following TPs, using an ILP during carrier movement:

• TP9 and GND

•TP10andGND

Movecarrier slowly in both directionsIf the status changes alternately on both positions, replace the logic board.

If the failure re-occurs, reinstall the old logic board and replace the carrier motor assembly.

If the carrier motor does not rotate slightly, measure the voltage between TP1 (+40 V dc Motor) and GND.

• If the voltage is between +36 V dc and +42 V dc, disconnect CP1 and measure the resistance between pins 1 and 2 of CP1. If the resistance is infinity, replace the carrier motor assembly. If not, replace the logic board.

• If the voltage is not between +36 V dc and +42 V dc, go to the “Power

Failure Service Check” on page 2-30.

2-21

4226-001

EOF Service Check

FRU Action

1EOFSwitch

Assembly

2Tractor

Assembly Logic Board

If the left tractor is loose or operating incorrectly, replace the left pin feed.

If the left tractor is operating correctly, perform “Sensor Test 1” on page 2-7.

If the status did not change correctly, check the switching status using an ILP between TP5 and GND. If the status did change correctly, perform the Sensor Test 1 again and check the EOF switch on/off operation when loading and removing continuous forms. If it does not operate correctly, adjust the locating position of the EOF switch. If the problem remains after adjusting, replace the EOF switch assembly.

If the status did not change correctly, replace the EOF switch assembly.

Check that the TOF sensor status changes correctly by using a piece of paper.

If the TOF sensor status does not change correctly, measure the voltage between TP3 and GND,performingthe same check as in the previous step.

If the TOF sensor is good, the voltage changes from + 5 V dc to 0 V dc alternately.

• If the voltages change correctly, replace the TOF sensor arm.

• If the voltage changes incorrectly, replace the logic board.

Diagnostic Information 2-22

4226-001

Intermittent Problem Service Check

FRU Action

1 Logic Board Reconnect all connectors to the logic

board. Check the following:

• Power supply ground

• Machine frame ground

• Static eliminator brush ground

• Printer interfacecable ground

If the voltages are low, check all dc voltages at the logic board.

If the voltages are not correct, replace the power supply.

If the failure remains, replace the logic board.

2 Power Supply

Printhead Cable

Logic Board

3 Thermal Control

Failure

2-23

Check the customer’s outlet voltage and ensure that it is within tolerance.

Check the continuity of the power cord. Check all dc output voltages at the

connector CN9 pins and ensure they are within tolerance while printing.

Check the electric leakage of the ac wiring.

If the problem remains, replace the power supply, printhead cable and logic board.

Go to the “Print Wire Drive FailureService

Check” on page 2-36.

4226-001

Operator Panel Service Check

Note: When the display is blank with no indications, go to the

“Power Failure Service Check” on page 2-30.

FRU Action

1 Operator Panel

Assembly

2 Logic Board If the buttons do not function, replace the

If the error code 63B, or 631 is displayed, replace the operator panel assembly.

If there are undefined or no characters displayed (except missing or extra dots), replace the operator panel assembly.

Perform the “Button Test” on page 2-7.If the switches did not operate correctly, replace the operator panel assembly.

Note: If the problem is not fixed after replacing the operator panel assembly, replace the logic board.

logic board. Go to the “Paper Feed

Service Check” on page 2-25.

If the printer displays “IBM 4226” during POST, replace the logic board.

If the message is not correct, but the display is blank and if the carrier moves during POST, go to the “POST Failure

Service Check” on page 2-28.

If the carrier did not move during POST, replace the operator panel assembly.

Diagnostic Information 2-24

4226-001

Paper Feed Service Check

Remove the paper jam if it exists, load paper and press Form Feed.

FRU Action

1 Logic Board

Forms Motor Assembly

If the paper does not move, go to the following step (2), “Feed Gears” on page

2-26.

If the paper moves slightly, remove all paper from the printer. Perform “Sensor

Test 1” on page 2-7. Check that the jam

sensor status changes correctly by using a piece of paper.

If the jam sensor status does not change, measure the voltage between TP6 and GND, while performing “SensorTest1”on

page 2-7. If the jam sensor is good, the

voltage changes from + 5 V dc to 0 V dc alternately. If the voltage does not change, replace the jam sensor assembly. If the voltagedoes change correctly, replace the logic board.

If the jam sensor status changes, check that the TOF sensor status changes correctly by using a piece of paper.

If the TOF sensor status does not change correctly, measure the voltage between TP3 and GND, while performing “Sensor

Test 1” on page 2-7. If the TOF sensor is

good, the voltage changes from + 5 V dc to 0 V dc alternately. If the voltage changes correctly,replacethe TOFsensor assembly. If not, replace the logic board.

2-25

4226-001

FRU Action

2CamAssembly

Feed Gears Tractor Pins Tractor Pads

If the TOF sensor status changes correctly, remove the paper jam, load forms and POR. Press Form Feed and carefully observe the feed motion.

• If the printer detects an error code 002, and ifbothpressurerollersmovedupordown, perform the print test for about ten pages.

• If the pressure rollers did not move, check the connection between the upper and lower pressure roller assemblies and cam. If both linkages are good, replace the cam assembly.

If a paper jam still occurs, remove the paper jam, perform the print test again and observe if the feed roller shafts rotate.

• If the shafts do not rotate, check the feed gears (large feed gear, feed idler gear, feed gear,idlergear) replacing the defectivegear.

• If the shafts do rotate, and if the paper travels to or past the TOF sensor, verify that the top edge of the paper is correct.

If so, turn power off, and turn the feedidler gear clockwise by hand.

• If the paper did not move up smoothly, remove the tractor drive idler gear and manually turn the tractor shaft gear clockwise.

• If the paper does not move up smoothly, Check if the tractor pins and both tractor pads are broken or loose and replace as required.

If the paper does move up smoothly, remove the feed idler gear while manually turning the large gear counterclockwise by hand.

• If the large gear does not turn smoothly, check and replace the following parts as required: (metal bushing, feed idler gear, largegearrollershafts).

• If the large gear does turn smoothly, continue.

Diagnostic Information 2-26

4226-001

FRU Action

3 Logic Board

If the paper does move smoothly, remove

connector CP2 and measure the Forms Motor Assembly

resistance of the following pins using the

lowest ohm range. The correct resistance

should be approximately 7 ohms.

CP2-1 & CP2-5 CP2-2 & CP2-5 CP2-3 & CP2-6 CP2-4 & CP2-6

• If all the above resistances are correct, replace the logic board.

• If they are not correct, replace the forms motor assembly.

4 Feed Gears Ensure that the feed gears engage

correctly.

• Turn the forms drive motor while observing the gears.

• If the gears do not engage correctly,reinstall the suspected gear.

• If the stopper lugs of the suspected gear are loose, broken or worn, replace the defected gear.

2-27

4226-001

POST Failure Service Check

FRU Action

1 Logic Board POR the printer.

If the alarm sounds during POST, and the error code displayed is 005, by-pass the cover open sensor CJ19 on the operator panel board by using the jumper wire in the parts packet.

• If the alarm still sounds, replace the logic board. If the alarm still sounds, check the following:

• Cover magnet of the access cover.

• Operator panel position.

• Connector terminal surface of the operator panel cable.

• If the aboveitems are all correct, replace the logic board. If not, repair or replace the suspected item.

2 Operator Panel

Assembly

If the alarm does not sound and “IBM 4226” is not displayed, check if the power indicator turns on. If it does, replace the logic board. If it does not, go to the “Power

Failure Service Check” on page 2-30.

If the error code displayed is not 005 and the display is blank, verify the check indicator turns on.

• If it does, replace the operator panel assembly.

• If it does not, replace the logic board.

Diagnostic Information 2-28

4226-001

FRU Action

3 Printer Interface

Cable

If the alarm does not sound and “IBM 4226” is displayed, check the following:

• Turn the power off.

• Remove the printer interface cable from the printer.

• Turn the power on.

Observe the display and Check indicator and if the failure re-occurs, replace the logic board. If the failure does not reoccur,the problem may exist in the printer interface cable or the host. Replace the printer interface cable.

2-29

4226-001

Power Failure Service Check

FRU Action

1 Operator Panel If the operator panel or cable is damaged

or disconnected, the machine is completely inoperable.

If the power LED is not on steady, check the cable continuity and replace the cable or the operator panel.

POR the printer. If the Power indicator turns on, go to the “POST Failure Service

Check” on page 2-28.

2 Power Supply If the printer is completely inoperable,

disconnect the power supply cable from the Logic Board. Measure the following voltages.

CP 9-1 & CP 9-4 (+ 40 V dc) CP 9-2 & CP 9-5 (+ 40 V dc) CP 9-3 & CP 9-6 (+ 40 V dc) CP 9-9 & CP 9-7 (+ 5 V dc)

CP 9-10 & CP 9-8 (+ 5 V dc)

If one or more of the voltages are not present, replace the power supply.

3 Logic Board Measure the voltage between TP2

(printhead drive + 40 V dc) and GND on the logic board.

If the voltage at TP2 is between +36 and +42 V dc, measure the voltage between TP1 (motor drive + 40 V dc) and GND on the logic board.

If the voltage is between +36 and +42 V dc, replace the logic board.

Diagnostic Information 2-30

4226-001

FRU Action

4 Printhead

Cables Printhead

5 Forms Motor

Ribbon Motor

Cam Motor

Carrier Motor

If the voltage at TP1 is not between +36 and +42 V dc, disconnect the printhead cables(CP4) from the logic board and turn the printer on. If the Power LED lights, there is a short in the printhead cables or printhead.

Disconnect the forms motor, the ribbon motor, the cam motor and the carrier motor from the logic board. Turn the power on. If the power problem remains, replace the logic board.

If the machine POSTs, one of the motors is holding down the +40 V dc line. Reconnect them one at a time, turning the printer on between each connection. Replace the part that causes the power failure.

2-31

4226-001

Print Quality Service Check

This procedure should be used only when you have print quality problems without any other visible machine problem. That is, the machine runs, feeds the correct number of pages without an error indication and stops normally.

The Symptom Description Table provides the details of the problem with defect samples.

Print Test

Two types of print tests are provided for the verification of print quality. One test prints the built-in character image, while the other prints several specific test patterns. The following methods describe the print quality checking procedures.

To run the Print Demo in the utility function:

1. Make sure the "Ready" indicator is on.

2. Press Start/Stop; the "Ready" indicator turns off.

3. Press Menu/Quit; then press Item − or Item ↓ to select "Print Demo".

4. Press Start/Stop;thePrintDemowillstart.

5. Press hold Start/Stop to stop this test.

If you need correct print samples, s ee the IBM 4226 Printer User's Reference.

To run the print test procedure:

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.

If you need the correct print samples, see Chapter 3, Diagnostic Test in the IBM 4226 printer Maintenance Information Manual.

Diagnostic Information 2-32

4226-001

Print Test Patterns

Test Patterns Function

Pattern 101 (Special Box Pattern)

Pattern 102 (Draft Font Pattern)

Pattern 103 (Print Wire Pattern)

Pattern 104 (Unidirectional Grid Pattern)

Pattern 105 (Bidirectional Grid Pattern)

Pattern 106 (Non-Volatile Memory (NVM) Dump)

This test pattern is used to check the TOF position, print registration, print density,or to find dirty or void spots.

This test pattern is used to verify the style of the selected font and to check the draft print quality.

this test pattern is used to check the impression of each wire or to find the missing dots.

This test pattern is used to check the alignment of vertical and horizontal line spacing in the unidirectional printing mode.

This test pattern is used to check the alignment of vertical and horizontal line spacing in bidirectional printing mode.

This pattern prints the contents of the Non-Volatile Memory (NVM). it consists of two parts, including 32 bytes of customer configuration data, and 16 bytes of error logs with 16 bytes of counters.

2-33

4226-001

Quick Check Table

Symptom Action

No Print

Light print Light zone Light spots Scratches Voids

Missing dots Extra dots Horizontal streaks

• Set the lever to position 1 and adjust the gap between the printhead and platen.

• If the printhead cable is loose, folded or broken, reconnect or replace it.

• If the printer interface mode mismatches the physical connection, change the configuration data or switch the I/F mode selection switch on the rear of the logic board.

• If the ribbon is worn, replace the ribbon cartridge.

• Be sure the ribbon cartridge is installed correctly.

• Check for loose ribbon motor and ribbon drive mounting screws.

• Be sure the printhead to platen gap is adjusted correctly.

Be sure the printhead cable connector is seated properly to the printhead and the and the logic board.

Be sure the printhead nose is clean. Check the position of the forms thickness

lever and be sure it is set to “1”. If the ribbon shield is dirty, replace the

ribbon cartridge.

Poor resolution Blurred density Uneven density Fuzzy text Smeared text

Be sure the printhead nose is clean. If the ribbon shield is dirty, replace the

ribbon cartridge. If the ribbon is worn, replace the ribbon

cartridge. Be sure the printhead to platen gap is

equal at left and right ends. If adjusting the gap does not fix the problem, replace the carrier frame assembly.

Diagnostic Information 2-34

4226-001

Symptom Action

Incorrect registration Incorrect margins Distortion Wavy text

Incorrect vertical registration Incorrect line spacing

If the carrier drive belt is worn, adjust or replace it.

Be sure the carrier motor turns smoothly and silently (no noise), while printing. Clean and lubricate the carrier shaft.

Check the tension pulley and bracket for wear or looseness. Tighten the bracket mounting screws or replace the tension pulley assembly.

Adjust the character alignment. If you cannot adjust it correctly, readjust the carrier drive belt tension and perform the

“Character Alignment Adjustment” on page 4-5 again.

Replace or lubricate the feed gears or metal bushing.

Be sure the feed motor turns smoothly and silently (no noise) while feeding paper. Replace the forms motor assembly.

Replace or tighten any broken tractor pads or pins.

2-35

Clean or replace the roller shafts.

4226-001

Print Wire Drive Failure Service Check

FRU Action

1 Printhead

Logic Board Printhead Cable

If the problem appears as a missing or extra dot, or no print wire, perform the

“Print Test” on page 2-32 to determine the

failing print wire(s). If the same wires still fail, turn power off,

remove the connector CP-4 from the logic board and check the cable continuity with the coil resistance of the specified magnet wire signal in “Resistance Table 1” on

page 2-37, using the lowest ohm range.

If the resistances are correct, the problem may be the printhead or the logic board. Replace the printhead and if the problem remains, replace the old printhead and replace the logic board. Note: it is a good practice to inspect the printhead nose carefully. If all wires are not aligned to the head surface, the case may break or strain print wires in the printhead.

If resistances are not correct, remove connector CP18 from the printhead. Check the cable continuity of the specified magnet wire signal and its common signal in “Resistance Table 2” on page 2-37, using the lowest ohm range. If the continuity is good, replace the printhead cable.If the continuity is not good, replace the printhead.

Diagnostic Information 2-36

4226-001

Resistance Table 1

Pin Number Pin Description

CP4-1 & CP4-2 No. 1 Print Wire Magnet CP4-20 & CP4-19 No. 2 Print Wire Magnet P4-4 & CP4-3 No. 3 Print Wire Magnet CP4-17 & CP4-18 No. 4 Print Wire Magnet CP4-5 & CP4-6 No. 5 Print Wire Magnet CP4-15 & CP4-16 No. 6 Print Wire Magnet CP4-8 & CP4-7 No. 7 Print Wire Magnet CP4-13 & CP4-14 No. 8 Print Wire Magnet CP4-10 & CP4-11 No. 9 Print Wire Magnet

Resistance Table 2

Pin Number Pin Description

CP4-1 & CP18-1 No. 1 Print Wire Magnet CP4-2 & CP18-2 No. 1 Print Wire Common CP4-20 & CP18-20 No. 2 Print Wire Magnet CP4-19 & CP18-19 No. 2 Print Wire Common CP4-4 & CP18-4 No. 3 Print Wire Magnet CP4-3 & CP18-3 No. 3 Print Wire Common CP4-17 & CP18-17 No. 4 Print Wire Magnet CP4-18 & CP18-18 No. 4 Print Wire Common CP4-5 & CP18-5 No. 5 Print Wire Magnet CP4-6 & CP18-6 No. 5 Print Wire Common CP4-15 & CP18-15 No. 6 Print Wire Magnet CP4-16 & CP18-16 No. 6 Print Wire Common CP4-8 & CP18-8 No. 7 Print Wire Magnet CP4-7 & CP18-7 No. 7 Print Wire Common CP4-13 & CP18-13 No. 8 Print Wire Magnet CP4-14 & CP18-14 No. 8 Print Wire Common CP4-10 & CP18-10 No. 9 Print Wire Magnet CP4-11 & CP18-11 No. 9 Print Wire Common

2-37

4226-001

Ribbon Drive Service Check

Note: Turn the power off, remove the ribbon cartridge and turn

power on.

FRU Action

1 Ribbon

Cartridge

If the ribbon drive shaft rotates during POST, install the ribbon cartridge and perform the “Print Test” on page 2-32.If the feed knob rotates continuously while printing, rotate the drive knob on the ribbon cartridge manually.

If the ribbon does not feed smoothly, replace the ribbon cartr idge.

If the ribbon feeds smoothly, check the following items and adjust, clean or replace defective parts as necessary:

• Dirt on the printhead nose.

• Printhead mounting position and loosened screws.

• Incorrect gap between the printhead and platen.

• Dirty or damaged ribbon shield.

If all items are good, go to the “Print Wire

Drive Failure Service Check” on page 2-36.

Diagnostic Information 2-38

4226-001

FRU Action

2 Ribbon Drive

Double Gear Planet Gear

Spring Ribbon Drive

Assembly

3 Logic Board

Ribbon Drive Motor Assembly

If the ribbon drive shaft does not rotate during POST, turn the power off, remove the ribbon drive assembly and turn power on while observing the ribbon drive motor shaft.

If the ribbon drive motor turns normally, check the r ibbon planet gear spring for damage.

If the spring is mounted incorrectly, install or replace the planet gear spring.

If the gear is mounted correctly, check all gears of the ribbon feed.

If the gears are not engaged correctly, replace the ribbon drive double gear.

If the gears are engaged correctly, replace the ribbon drive assembly.

If the ribbon drive motor does not turn normally, turn the printer off, disconnect the ribbon motor connector CP6 from the logic board and measure the resistance of the following pins:

2-39

CP6-1 & CP6-5 CP6-2 & CP6-5 CP6-3 & CP6-6 CP6-4 & CP6-6

The correct resistance of all measurements is approximately 150 ohm. If all the resistances are correct, replace the logic board. If the resistances are not correct, replace the ribbon drive motor assembly.

4226-001

3. Diagnostic Aids

Offline Test (Resident Non-Automatic Tests)

Test Execution

Offline test aid in detecting intermittent problems or to observe the NVM contents. To run the test, do the following:

• POR.

• Press and hold Menu/Quit during POST until the "Sensor Test

1" message is displayed.

• Press Item

or Item↑to select a test item.

↓

• Press Start/Stop to start selected test.

• Press Menu/Quit to stop all tests except BAT Loop and the

Button tests.

• Turn the power off to exit test mode.

The test menu includes a sensor test which displays the status of the sensors in the following manner:

• Underline - sensor is inactive.

• Box pattern - sensor is active.

If the EOF switch is on, the printer is in the EOF state. If the TOF sensor is on, the paper is under the TOF sensor.

Diagnostic Aids 3-1

4226-001

Sensor Test 1

Device Display Type On State

TOF Sensor TOF Photointerrupter Form in printer EOF Switch EOF Micro-switch No paper on the

tractor

Jam Sensor JAM Photointerrupter Paper under the

sensor

GapLeverPosition Sensor

GAP Photointerrupter The forms thickness

lever position is set between 1 and 2.5

Note: The gap lever position is in the off state when the forms thickness lever position is set between 3 and 6.

Sensor Test 2

Device Display Type On State

Cover Open Sensor

Cam Sensor CAM Photointerrupter Shut off (cam is at

Head or Carrier Motor Thermal Sensor

Cover Hole device Cover open

home)

HEAT Posistor High temperature

Button Test

This test verifies the button operation on the operator panel. When anybutton is pressed, the alarm sounds continuously until the button is released. If two or more buttons are pressed simultaneously, the alarm does not sound. To end the test, perform a POR.

LCD Test

This test verifies the LCD Ram Read/Write functions. All dots on the LCD flash on and off at one-second intervals. If an error is detected, Error Code 631 is displayed and the test stops.

3-2

4226-001

BATLoopTest

This test is helpful in determining intermittent problems. The test repeats each test item of the BAT. To end the test, perform a POR.

Factory Setting

This test sets the printer to the factory settings. To run this test:

• Press the Scroll

or Scroll ↓to select the setting.

↑

• Press Store

The following settings are selectable at shipment:

Setting U.S. Non-U.S.

Page length 11 inches 12 inches Character set 1 2 Codepage 437 850 Download Codepage 437 850

Log Clear

This test clears the NVM log when Start/Stop is pressed.

Diagnostic Aids 3-3

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Print Test

This test detects print quality problems and stores the results in the NVM dump area.

WARNING: Do not run this test for more than 10 pages or printhead damage may occur.

Pattern 101

(Special Box Pattern) - Checks the print registration, print density or dirty / voided spots.

Pattern 102

(Draft Font Pattern) - Verifies the draft font style and print quality.

Pattern 103

(Print Wire Pattern) - Checks the impression of each print wire.

Pattern 104

(Unidirectional Grid Pattern) - Checks alignment of vertical and horizontal line spacing in unidirectional mode.

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Pattern 105

(Bidirectional Grid Pattern) - Checks alignment of vertical and horizontal line spacing in bidirectional mode.

Pattern 106

(NVM Dump) - Prints the contents of NVM. This consists of two parts (including 80 bytes of data), address X’00’ through X’2F’ (which is the configuration or the customer setup data), and address X’50’ through X’6F’ data (which is the sequential error logs with counter).

Diagnostic Aids 3-5

4226-001

Note: Error Log in the Pattern 106.

• Error codes are printed on the top line of the Error Log and their

corresponding counters are printed below. (An error code X’00’ indicates no errors are registered in the counter.)

• Each new error appears on the left-most position and the

previous error code shifts to the right, one position.

• If the new error code is the same as the previous error code, the

counter is increased by 1. The maximum count number for the same error is 256 and the counter remains at this value (X’FF’). No more than the 16 most recent error codes can be printed in the error log area.

PrintTestSample

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Trace (Hexadecimal Print)

The hex trace mode can help the user test and troubleshoot programs. You can use the hex trace procedure to get a hexadecimal printout of the data stream sent to the printer. All data, including control and character data, print in hexadecimal instead of ASCII.

To activate trace print:

1. Press Menu/Quit. The "Set Line 1" message is displayed.

2. Press Item↑once.

3. The "Trace Mode" is shown on the operator panel.

4. Press Start/Stop to start the trace printing.

5. Press Start/Stop again to stop the trace printing.

6. When the trace printing ends, do a POR.

When printing with this function, print width is automatically defined by setting default values in NVM. Printing format is as follows:

Narrow Width Pattern

Diagnostic Aids 3-7

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Wide Width Pattern

Hexadecimal Print Sample (Wide Width)

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4226-001

4. Repair Information

This chapter contains adjustments and removal procedures. Before analyzing or repairing the printer, you must by-pass the cover open circuit using the jumper wire in the parts packet. When replacing parts, be sure to use the appropriate diagnostic procedure and adjustment.

Handling ESD-Sensitive Parts

Many electronic products use parts that are known to be sensitive to electrostatic discharge (ESD). To prevent damage to ESD-sensitive parts, follow the instructions below in addition to all the usual precautions, such as turning off power before removing logic boards:

• Keep the ESD-sensitive part in its original shipping container

(a special “ESD bag”) until you are ready to install the part into the machine.

• Make the least-possible movements with your body to prevent

an increase of static electricity from clothing fibers, carpets, and furniture.

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

the system ground point. This discharges any static electricity in your body to the machine.

• Hold the ESD-sensitive part by its edge connector shroud

(cover); do not touch its pins. If you are removing a plugable module, use the correct tool.

• Do not place the ESD-sensitive part on the machine cover or on

a metal table; if you need to put down the ESD-sensitive part for any reason, first put it into its special bag.

• Machine covers and metal tables are electrical grounds. They

increase the risk of damage because they make a discharge path from your body through the ESD-sensitive part. (Large metal objects can be discharge paths without being grounded.)

• Prevent ESD-sensitive parts from touching other personnel.

Install machine covers when not working on the machine, and do not put unprotected ESD-sensitive parts on a table.

• Keep all ESD-sensitive parts in a grounded metal cabinet

(case).

• Low humidity increases static electricity during cold weather.

Repair Information 4-1

4226-001

Adjustments

CAUTION: Be sure to unplug the power cord whenever you are

working on the printer with any of the covers removed. Note: Before returning the printer to the customer, reset all

customer setup values. Refer to the IBM 4226 Printer User’s Reference for instructions.

Carrier Assembly Adjustment

Note: After power is turned off and the ribbon cassette is removed,

the moving load of the carrier assembly should be equal in all positions when it is moved left ore right by hand. Whenever you replace or adjust carrier related parts, perform the character alignment adjustment, see “EOF Switch Adjustment” on page 4-6.

Symptoms Actions

Dry oil pad The carrier drags when you move it left and right by hand.

Broken bearings When moving the carrier by hand, it drags intermittently or makes abnormal noise. To check for broken bearings, remove the carrier drive belt.

Broken ribbon drive assembly When turning the ribbon feed knob by hand, the ink ribbon intermittently drags, sticks or does not turn.

4-2

Remove the printhead and lubricate the two oil pads with an appropriate amount of IBM # 6 oil.

Replace the carrier motor if the motor bearings are bad or replace the tension pulley assembly if the tension pulley bearing is bad.

Replace the ribbon cartridge. If the problem still occurs, replace the ribbon drive assembly.

4226-001

Symptoms Actions

Broken carrier shaft bushing or support shaft bushing. When moving the carrier by hand, the carrier intermittently drags or does not move.

Broken ribbon shield When feeding the form in the printer, the form feeding drags or breaks at the ribbon shield.

REplace the carrier frame assembly.

Replace the ribbon cartridge.

Carrier Belt Adjustment

Note: Whenever you replace or adjust carrier related parts, perform

the character alignment adjustment, see “EOF Switch Adjustment”

on page 4-6.

1. Remove the top cover.

2. Remove the front cover.

3. Move the carrier to the left end.

4. Insert the Push-Pull gauge [7] through the hole of the plate. Push up the bottom side of the carrier belt [6] by the Push-Pull gauge in the direction shown.

5. Be sure that the push gauge value is between 400g (0.88 lb) and 500g (1.10 lb) when both tops of the beet teeth touch.

6. Remove the retainer [1] and the spring [2].

7. When the belt tension value is higher than the standard value, remove the appropriate number of washers [8]. When the belt tension value is lower than the standard value, install the appropriate number of washers [8]. Then install the spring [2] and retainer [1].

8. Move the carrier to the left and loosen the two screws [3] that hold the tension pulley bracket [5]. This will set the left spring tension.

9. Tighten the two screws [3].

10. Perform the check items as described again. If the belt tension value is not the standard value, install or remove the washers until the standard tension value is achieved.

Adjust the ruled line. See “EOF Switch Adjustment” on page 4-6.

Repair Information 4-3

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Character Alignment Adjustment

Note: This function is used to adjust the bidirectional ruled line

printing so that the deviation of the ruled lines printing from left and right will be minimal.

1. Be sure the forms are set to the line 1 position.

2. Press Menu/Quit to enter the function menu.

3. Press Item↑until the Print Adjust message appears on the display.

4. Press Start/Stop to print the alignment pattern similar to the following:

5. Press Scroll↑or Scroll↓to display the best character alignment value.In the above example, alignment pattern, +3 would be selected as the best character alignment value.

6. Press Store to save the selected value.

7. Press Start/Stop to print the alignment pattern and check that the best character alignment position is 0. If it is not 0, repeat steps 4 through 7 until the position is 0.

Repair Information 4-5

4226-001

8. After printing, press Menu/Quit to return to the not-ready state.

Alignment Pattern

Menu Menu Meaning Selection Selection Meaning

Print Adjust

Ruled line registration adjustment

+ 6 to - 6 1/720 inch space

between selected numbers

EOF Switch Adjustment

Note: Switching point when the actuator of the EOF switch is

pressed should be 0.5 to 1.0 mm (0.02 - 0.04 inch) between the bottom of the tractor gate and the top of the actuator.

• Loosen the two screws holding the EOF switch and adjust it as

described above, then tight the two screws. See “EOF Switch

and Jam Sensor Removal” on page 4-18.

PrintheadtoPlatenAdjustment

Insert the feeler gauge between the printhead and platen at both ends of the printer. The printhead to platen gap should be

0.35 mm ± 0.03 mm (0.014 inch) ± 0.0001 inch with the ribbon removed and the forms thickness lever set to position 1. Do not make adjustments at the cut-away areas of the platen.

Note: Inspect the left and right printhead to platen adjustment screws for the presence of a silver colored star washer located between the adjustment screw flat washer and the carr ier frame. If the star washer is present, remove the adjusting screw, discard the star washer and reinstall the adjusting screw.

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4226-001

To set the gap:

• When adjusting the left side, position the center of the printhead

below and between the first and second left-most upper pressure rollers. Insert the 0.014 inch gauge into the gap from the right side of the printhead with the gauge holder toward the center of the printer and parallel to the platen. A slight drag will be felt when the gap is correct.

• When making the adjustment at the right side, position the

center of the printhead below and between the fifth and sixth right-most upper pressure rollers. Insert the gauge into the gap from the left side of the printhead with the gauge holder toward the center of the printer and parallel to the platen. A slight drag will be felt when the gap is correct.

• Re-check the adjustment at the left and right side and repeat if

necessary until the proper gap is obtained. Using the .013 inch gauge, there should be very little drag. Using the .015 inch gauge, there should be noticeable drag when the gap is set correctly.

Printhead Cable to Carrier Shaft Gap Adjustment

Be sure the printhead cable is parallel to the carrier shaft.

Tractor Adjustment

Note: The sprocket pins on both left and right pin feeds must be

parallel with each other.

• Insert the square tractor shaft into both pin feeds after matching

the mark on the pin feeds shaft bearing with the mark on the pin feed base. These marks are located on the paper path side of the pin feeds.

Repair Information 4-7

4226-001

Removal Procedures

Use the following procedures to remove and replace individual FRUs.

CAUTION: Be sure to unplug the power cord whenever you are working on the printer with one of the covers removed.

Access Cover Removal

1. Switch off power, disconnect the power cord plug from the wall outlet and disconnect the interface cable.

2. Open the access cover [1] slightly (about 30 degrees) and lift the left side of the cover and remove it by sliding it to the left.

Replacement

Reverse the removal procedure.

4-8

30°

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Bottom Plate and Ground Sheet Removal

Observe all ESD procedures when handling logic FRUs and cables.

1. Switch off power, disconnect the power cord plug from the wall outlet and disconnect the interface cable.

2. Remove the cover assembly.

3. Remove the front cover assembly.

4. Remove the gear cover.

5. Remove the power supply.

6. Remove the C-clip [1] and pull out the feed idler gear [2].

7. Press the two latches [6] on both sides of the bottom plate [3] and remove the bottom plate from the printer.

8. Remove the ground plate [4] which is adhered to the bottom plate with the double sided tape from the bottom plate.

Repair Information 4-9

4226-001

Replacement

Reverse the removal procedure.

Notes:

• When installing the feed idler gear [2], insert the hub of the gear

completely into the hole of the friction block [ 5].

• Be sure the ground plate [4] that goes between the bottom plate

[3] is in place.

• Be sure the cables are not trapped between the printer and the

bottom plate.

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4226-001

Cam Assembly Removal

1. Switch off power, disconnect the power cord plug from the wall outlet and disconnect the interface cable.

2. Remove the top cover assembly.

3. Remove the front cover.

4. Remove the gear cover.

5. Remove the print unit.

6. Disconnect connectors CP3 and CP5 from the logic board.

7. Remove studs [1] from each link of the upper and lower pressure roller assembly [7].

8. Remove the C-clip [2] then pull out the feed idler gear [3] and the large gear [4] with the friction block [8].

9. Remove the two screws [5] on the cam assembly [6].

10. Remove the cam motor from the cam assembly [6].

3 2

Replacement

• Reverse the removal procedure.

• Lubricate the cam assembly with IBM # 23 grease.

• When installing the gears, insert the hub completely into the

holes of the friction block.

Repair Information 4-11

4226-001

Cam Motor and Cam Sensor Removal

1. Switch off power, disconnect the power cord plug from the wall outlet and disconnect the interface cable.

2. Remove the top cover assembly.

3. Disconnect the connector CP3 from the logic board.

4. Remove the two screws [2] with a wrench and then remove the cam motor [1].

5. Disconnect the connector CP5 from the logic board.

6. Remove the two screws [4] with a wrench and then remove the cam sensor [3].

Replacement

Reverse the removal procedure. Note: When installing the cam motor [1], lightly press the cam

motor gear to the cam drive gear [5], and then tighten the two screws [2].

4-12

4226-001

Carrier Frame Assembly Removal

Note: Whenever you replace or adjust carrier related parts, perform

the character alignment adjustment, see “EOF Switch Adjustment”

on page 4-6.

1. Switch off power, disconnect the power cord plug from the wall outlet and disconnect the interface cable.

2. Remove the top cover assembly.

3. Remove the ribbon cartridge.

4. Remove the front cover.

5. Remove the gear cover.

6. Remove the operator panel [1].

7. Remove the print unit assembly.

8. Remove the printhead [2].

9. Remove the ribbon drive motor assembly [3].

10. Remove the ribbon drive assembly [4].

11. Remove the ribbon drive gears [5].

12. Remove the gap sensor assembly [6].

13. Remove the tension pulley assembly, bracket and tension spring [7].

14. Remove the carrier [8] and belt [10] from the carrier frame [9].

Repair Information 4-13

4226-001

4-14

4226-001

Replacement

Reverse the removal procedure.

Repair Information 4-15

4226-001

Carrier Motor and Belt Removal

Note: Whenever you replace or adjust carrier related parts, perform

the character alignment adjustment, see “EOF Switch Adjustment”

on page 4-6.

1. Switch off power, disconnect the power cord plug from the wall outlet and disconnect the interface cable.

2. Remove the top cover assembly.

3. Remove the operator panel.

4. Remove the print unit.

5. Loosen the tension pulley assembly enough to remove.

6. Remove the two screws [1] and remove the carrier motor [2].

7. Pull out and remove the carrier belt [3]fromthecarrier[4].

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4226-001

Replacement

Reverse the removal procedure.

Notes:

• The shaft and bearings of the tension pulley assembly [5]may

come apart.

• When installing the carrier motor [2], install it so that the

protrusion on the end of the motor emitter faces toward the outside of the printer.

• Be sure the carrier belt [3] and carrier teeth are engaged and

the belt is taut.

• After installation is complete, perform the ruled line adjustment.

Repair Information 4-17

4226-001

EOF Switch and Jam Sensor Removal

1. Switch off power, disconnect the power cord plug from the wall outlet and disconnect the interface cable.

2. Remove the top cover assembly.

3. Remove the front cover.

4. Remove the power supply.

5. Disconnect the connectors CP12 and CP14 from the logic board.

6. Unlock the core latch.

7. Release the latch [5] and remove the jam sensor [1].

8. Remove the two screws [3] and washers [4], then remove the EOF switch [2].

Replacement

Reverse the removal procedure. Note: When installing the EOF switch, the switching point where the

actuator is pressed should be 0.5 to 1.0 mm (0.020 - 0.040 inches) between the bottom of the tractor guide and the top of the actuator.

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4226-001

Feed Frame Assembly Removal

1. Switch off power, disconnect the power cord plug from the wall outlet and disconnect the interface cable.

2. Remove the two screws [1] from the rear side of the printer and remove the top cover assembly [2]. To remove the cover, lift the rear side of the cover approximately 10 mm (0.40 inch), then release the front latches [3] by gently spreading the cover at the front corners with a screwdriver.

Replacement

Reverse the removal procedure. When installing the top cover assembly, be sure not to damage the paint on the operator panel.

Repair Information 4-19

4226-001

Feed Gears and Friction Blocks Removal

1. Switch off power, disconnect the power cord plug from the wall outlet and disconnect the interface cable.

2. Remove the top cover assembly.

3. Remove the gear cover.

4. Remove the C-clip [1], pull out the feedidler gear [3], large gear [2] along with the long friction block [6].

5. Remove the four idler gears [5] and the two feed roller gears [4] with the two short friction blocks [7].

6. Remove the friction blocks [6] and [7] from the studs.

4-20

6 2

4226-001

Replacement

Reverse the removal procedure.

Notes:

• When installing the large gear [2] and the feed idler gear [3],

install them in the direction shown.

• Insert the hub of gears completely into the hole of the friction

blocks.

Feed Unit Assembly Removal

1. Switch off power, disconnect the power cord plug from the wall outlet and disconnect the interface cable.

2. Remove the top cover assembly.

3. Remove the front cover.

4. Remove the power supply.

5. Remove the gear cover.

6. Remove the print unit assembly [2].

7. Remove the C-clip [4] and pull out the feed idler gear [5].

8. Press the two latches [7] on both sides of the bottom cover and remove the feed unit [1] from the bottom plate [3].

Repair Information 4-21

4226-001

Replacement

Reverse the removal procedure. Note: When installing the feed idler gear [5], insert the hub [8]

completely into the hole in the friction block [6].

4-22

4226-001

Forms Motor Removal

1. Switch off power, disconnect the power cord plug from the wall outlet and disconnect the interface cable.

2. Remove the top cover assembly.

3. Remove the gear cover.

4. Disconnect connector CP2 [6] from the logic board [1].

5. Remove the C-clip [3] and the feed idler gear [2].

6. Remove the two screws [5].

7. Remove the forms motor [4] by turning it so that the cable [8] dies not interfere with the side plate.

Replacement

Reverse the removal procedure. Note: When installing the feed idler gear [2], insert the hub [9]

completely into the hole of the friction block [7].

Repair Information 4-23

4226-001

Forms Thickness Lever Removal

1. Switch off power, disconnect the power cord plug from the wall outlet and disconnect the interface cable.

2. Remove the top cover assembly.

3. Remove the front cover.

4. Remove the screw [1] and the forms thickness lever [2].

Replacement

Reverse the removal procedure.

Note: Check the gap sensor position in the sensor test.

4-24

4226-001

Front Cover Removal

1. Switch off power, disconnect the power cord plug from the wall outlet and disconnect the interface cable.

2. Remove the top cover.

3. Pull out and remove the forms thickness lever knob [1].

4. Release the two studs [2] of the front cover [3] by pulling the cover up.

5. Press the front latch [4] down on both sides of the cover, removing the cover by pulling it toward the front.

Replacement

Insert the two studs [2] into the holes of the bottom plate [5], pressing the front cover [3] to the rear until it latches.

Repair Information 4-25

4226-001

Gap Sensor Assembly Removal

Observe all ESD procedures when handling logic FRUs and cables.

1. Switch off power, disconnect the power cord plug from the wall outlet and disconnect the interface cable.

2. Remove the top cover assembly.

3. Disconnect connector CP15 [1] from the logic board.

4. Unlock the core latch.

5. Remove the screw [2], then remove the gap sensor assembly [3] together with the bracket [4].

Replacement

Reverse the removal procedure.

Note: Check the gap sensor position in the sensor test.

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4226-001

Gear Cover Removal

1. Switch off power, disconnect the power cord plug from the wall outlet and disconnect the interface cable.

2. Remove the cover assembly.

3. Release the three latches [2] and remove the gear cover [1].

Replacement

Reverse the removal procedure.

Repair Information 4-27

4226-001

Logic Board Removal

Observe all ESD procedures when handling logic FRUs and cables. Set the customer configuration values to the same values as were

present prior to replacing the logic board. See “Factory Setting” on

page 3-3.

1. Switch off power, disconnect the power cord plug from the wall outlet and disconnect the interface cable.

2. Remove the top cover assembly.

3. Loosen the one screw [5].

4. Remove the one screw [4] and remove the cover [2].

5. Disconnect all connectors from the logic board [1].

6. Remove the two screws [3] and slide the logic board [1]inthe direction shown in the following illustration.

7. Disconnect the fan connector [6].

Replacement

Reverse the removal procedure.

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4226-001

Notes:

• Connect the fan connector [6] before installing the logic board

[1].

• When installing the logic board, insert both sides of the board

intotheslitofthebracket[7] on the power supply, then tighten the two screws [3].

• Be sure the bare wire side of the head cable is to the rear of the

printer.

• Be sure the bare wire side of the operator panel cable is facing

to the left when viewed from the rear of the printer.

• Be sure to pass the printhead cable through the core [4] and

pass the other cable from the logic board through the core [6]as shown.

Repair Information 4-29

4226-001

Lower Pressure Roller Assembly Removal

1. Switch off power, disconnect the power cord plug from the wall outlet and disconnect the interface cable.

2. Remove the top cover assembly.

3. Remove the gear cover.

4. Remove the print unit.

5. Remove the two C-clips [1] and release the linkage stud [2]from the shaft bracket.

6. Slide the lower pressure roller assembly [3] to the right and pull out. Replace in reverse order.

4-30

Lexmark 4226 Parts Breakdown

Specifications and Main Features

Frequently Asked Questions

User Manual

1. General Information

Description

Maintenance Approach

Power Supply Specifications

Printer Cables

Tools

Abbreviations

Using the Operator Panel

Display Format

Buttons

Indicators

Display

Alarm

2. Diagnostic Information

Power-On Self Test (POST)

Start

Error Indication Table

Sensor Test 1

Sensor Test 2

Button Test

Symptom Table

Service Checks

Abnormal Noise Service Check

Abnormal Print Service Check

Cam Drive Failure Service Check

Carrier Drive Failure Service Check

EOF Service Check

Intermittent Problem Service Check

Operator Panel Service Check

Paper Feed Service Check

POST Failure Service Check

Power Failure Service Check

Print Quality Service Check

Print Test

Print Wire Drive Failure Service Check

Resistance Table 1

Resistance Table 2

Ribbon Drive Service Check

3. Diagnostic Aids

Offline Test (Resident Non-Automatic Tests)

Sensor Test 1

Sensor Test 2

Button Test

LCD Test

BATLoopTest

Factory Setting

Log Clear

Print Test

PrintTestSample

Trace (Hexadecimal Print)

Hexadecimal Print Sample (Wide Width)

4. Repair Information

Handling ESD-Sensitive Parts

Adjustments

Carrier Assembly Adjustment

Carrier Belt Adjustment

Character Alignment Adjustment

EOF Switch Adjustment

PrintheadtoPlatenAdjustment

Printhead Cable to Carrier Shaft Gap Adjustment

Tractor Adjustment

Removal Procedures

Access Cover Removal

Bottom Plate and Ground Sheet Removal

Cam Assembly Removal

Cam Motor and Cam Sensor Removal

Carrier Frame Assembly Removal

Carrier Motor and Belt Removal

EOF Switch and Jam Sensor Removal

Feed Frame Assembly Removal

Feed Gears and Friction Blocks Removal

Feed Unit Assembly Removal

Forms Motor Removal

Forms Thickness Lever Removal

Front Cover Removal

Gap Sensor Assembly Removal