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IBM 4230 and 4232 Printers

Maintenance Information Manual

Document Number SA40-0572-04

IBML
ii

Note!
Before using this information and the product it works with, ensure
that you read the general information under “Special Notices” on
page xiii.

Fifth Edition (April 1994)

This manual is for the use of IBM service personnel in the maintenance
or repair of the IBM 4230 and 4232 Printers. IBM makes no
representations that it is suitable for any other purpose.

Publications are not stocked at the address given below; requests for
IBM publications should be made to your IBM representative or to the
IBM branch office serving your locality.

A form for reader’s comments is provided at the back of this publication.


If the form has been removed, address comments to Pennant Systems
Inc., Serviceability Engineering, Department R64, 1701 North Street
Endicott, NY 13760, USA. IBM/Pennant Systems may use or distribute
any of the information you supply in any way it believes suitable without
incurring any obligation to you.

 Copyright International Business Machines Corporation 1991,


1992. All rights reserved.
Note to U.S. Government Users — Documentation related to restricted
rights — Use, duplication or disclosure is subject to restrictions set forth
in GSA ADP Schedule Contract with IBM Corp.
Contents iii

Contents
Section 000. General Information 000-1
001 - Printer Summary 000-1
Types of Printing 000-1
Character Spacing 000-2
Line Spacing 000-3
Text Highlighting 000-4
Advanced Printing Functions 000-6
Printer Service 000-9
Forms Devices 000-10
Printer Electronics 000-10
Model Identification 000-11
003 - Control and Data Flow Description 000-11
005 - Power-On Self Test (POST) 000-13
010 - Operator Panel 000-14
011 - Indicators 000-17
Power Indicator 000-17
Ready Indicator 000-17
Format Indicator (4230 Models 201,202, 2I1, 2S2, 5I3, and
5S3) 000-18
Online Indicator (4230 Models 101, 102, 1I1, 1S2, 4I3, 4S3, and
4232 Model 302) 000-18
Processing Indicator 000-19
Attention Indicator 000-19
Unit Check Indicator 000-19
012 - The Display 000-20
013 - The Keys 000-23
Start Key 000-24
Stop Key 000-24
Line Feed Key 000-25
Load/Eject Key 000-26
Form Feed Key 000-28
Set Top of Form Key 000-28
Micro /Scroll Key 000-29

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Micro /Scroll Key 000-29


Darker/Enter Key 000-30
Lighter/Return Key 000-31
Menu Key 000-33
Quick Reference Key 000-33
Cancel Print Key 000-34
Test Key 000-34
Hex Print Key (4230 Models 101, 102, 1I1, 1S2, 4I3, 4S3, and 5I3,
5S3 when Serial/Parallel Active and 4232 Model 302) 000-35
Display Address Key (4230 Models 101, 102, 1I1, 2S2) 000-36
Display Interface Key (4230 Models 4I3, 4S3, 5I3, 5S3, and 4232
Model 302) 000-36
PA1 Key (4230 Models 201, 202, 2I1, 2S2, 5I3, and
5S3) 000-37
PA2 Key (4230 Models 201, 202, 2I1, 2S2, 5I3, and
5S3) 000-38
020 - Controls 000-38
021 - Power Switch 000-39
023 - Alarm 000-39
030 - Printer Functional Units 000-40
031 - Print Mechanism 000-40
Print Head Drive 000-40
Print Head 000-41
032 - Forms Drive 000-41
033 - Forms Devices 000-41
Continuous Forms Device (F1) 000-41
Dual Purpose Forms Device (F2) 000-42
Document Insertion Device (F3) 000-42
Auto Sheet Feeder Device (F4) 000-43
034 - Ribbon Drive 000-43
Ribbons 000-43
035 - Cooling Fan 000-44
036 - Sensors 000-44
End of Forms Sensor 000-44
Paper Present Sensor 000-45
Door Open and Cover Open Sensors 000-45

IBM 4230 and 4232 Printers Maintenance Information Manual iv


Contents v

Automatic Forms Thickness Sensor 000-45


037 - Power Supply 000-45
038 - Printer Logic Board 000-46
040 - Attachment Bezel (4230 Only) 000-46
041 - Attachment Card/Bezel (4230 Models 4I3, 4S3, 5I3, 5S3, and
4232 Model 302) 000-46
050 - Diagnostics 000-47
051 - Replaceable Units 000-47
Customer-Replaceable Unit (CRU) 000-47
Field-Replaceable Unit (FRU) 000-48
052 - Operator Tests 000-48
Operator Test Descriptions 000-48
Selecting Operator Tests 000-48
Printer Configuration 000-49
Bidirectional Adjustment 000-61
Left Margin Alignment 000-61
Printer Demonstration 000-62
Printer Verification 000-62
Top of Form Alignment 000-62
056 - Offline CE Tests Descriptions 000-63
Performing Offline CE Tests 000-65
Error Log 000-66
Error Log Utilization 000-66
Operator Panel Test 000-67
Power On Operator Panel Test 000-68
Sensor Test 000-68
AFTA Setting 000-69
Print Wire Test 000-70
Print Wire Test 2 000-70
Bidirectional Adjustment 000-71
NLQ Print Quality Test 000-72
NLQ 80 Ripple Pattern 000-73
DP Print Quality Test 000-74
DPT Print Quality Test 000-75
Fast Draft Quality Test 000-76
20 CPI Test 000-77

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17.1 CPI Test 000-78


16.7 CPI Test 000-79
15 CPI Test 000-80
12 CPI Test 000-81
10 CPI Test 000-82
Slow Head Test 000-83
Fast Head Test 000-84
Attachment Storage Dump (4230 Only) 000-84
Print ROS Part Numbers Test 000-84
Forms Motor Test 000-85
Bin 1 Selection Test (F4 - AFS Forms Drive) 000-85
Bin 2 Selection Test (F4 - AFS Forms Drive) 000-85
Bin 3 Selection Test (F4 - AFS Forms Drive) 000-85
Bin 4 Selection Test (F4 - AFS Forms Drive) 000-86
Ribbon Motor Test 000-86
Display Memory Locations 000-86
Enable/Disable Cover Sensors 000-86
Perpetual AFTA 000-87
AFTA Run In 000-87
Print Usage Metrics 000-87
Print Error Log 000-87
Set Factory Defaults 000-88
Clear Error Log 000-88
057 - Service Checks 000-89
Print Density (Light/Dark) Service Check 000-89
Smearing - Print Service Check 000-90
Missing Dots or Character Service Check 000-92
Vertical Alignment Service Check 000-94
Forms Feed Service Check 000-97
False Forms Jam Service Check 000-108
False End Of Forms Service Check 000-108
AFTA Setting Procedure 000-109
Twinaxial Attachment Bezel Service Check 000-112
Coaxial Attachment Bezel Service Check 000-113
Twinaxial/Serial/Parallel Attachment Bezel Service
Check 000-114

IBM 4230 and 4232 Printers Maintenance Information Manual vi


Contents vii

Coaxial/Serial/Parallel Attachment Bezel Service


Check 000-115
Serial/Parallel Attachment Card/Bezel Service Check 000-117

Section 100. Covers, Shields, and Frame 100-1


111 - Acoustic Cover 100-2
Removal 100-2
Installation 100-2
113 - Access Cover 100-4
Removal 100-4
Installation 100-4
115 - Front Paper Door 100-5
Removal 100-5
Installation 100-5
117 - Printer Cover Assembly 100-6
Removal 100-6
Installation 100-6
119 - Static Brush 100-8
Removal 100-8
Installation 100-9
121 - Rear Shield 100-10
Removal 100-10
Installation 100-10
123 - Entry Paper Chute 100-12
Removal 100-12
Installation 100-13
125 - Frame Assembly 100-14
Removal 100-14
Installation 100-15
127 - Air Deflectors 100-16
Removal 100-16
Installation 100-16

Section 200. Logic Boards 200-1


211 - Printer Logic Board 200-2
Removal 200-2

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Installation 200-3
217 - Extended Memory Card (4230 Models 102, 1I1, 202, and 2I1
only) 200-4
Removal 200-4
Installation 200-4

Section 300. Print Units 300-1


320 - Print Head and Carrier 300-1
321 - Print Head 300-2
Removal 300-2
Installation 300-3
325 - Print Head Cable 300-4
Removal 300-4
Installation 300-4
329 - Print Head Carrier and Shaft 300-6
Removal 300-6
Installation 300-6
331 - Paper Present Sensor 300-8
Removal 300-8
Installation 300-8
333 - Carrier Upper Bearing, Lower Bearing, and Spring 300-10
Removal 300-10
Installation 300-10
337 - Carrier Drive Motor 300-12
Removal 300-12
Installation 300-12
339 - Carrier Drive Belt 300-14
Removal 300-14
Installation 300-14
343 - Idler Assembly 300-16
Removal 300-16
Installation 300-16
Adjustment 300-16
345 - Door Open Sensor 300-18
Removal 300-18
Installation 300-18

IBM 4230 and 4232 Printers Maintenance Information Manual viii


Contents ix

360 - Ribbon Units 300-20


361 - Ribbon Drive Crossbar 300-20
Removal 300-20
Installation 300-20
380 - Forms Feed Units 300-22
381 - Forms Motor 300-22
Removal 300-22
Installation 300-22
383 - End of Forms Sensor 300-24
Removal 300-24
Installation 300-24
Adjustment 300-24
385 - AFTA Assembly 300-26
Removal 300-26
Installation 300-26

Section 400. Communications 400-1


411 - Attachment Bezel (4230 Models 101, 102, 1I1, 1S2, 201, 202,
2I1, 2S2 only) 400-2
Removal 400-2
Installation 400-2
412 - Attachment Cards/Bezel (4230 Models 4I3, 4S3, 5I3, and 5S3
Only) 400-4
Removal 400-4
Installation 400-5
413 - Attachment Card/Bezel (4232 Model 302 Only) 400-7
Removal 400-7
Installation 400-7

Section 500. Operator Panel 500-1


511 - Operator Panel 500-1
Removal 500-1
Installation 500-1
515 - Operator Panel Overlay 500-2
Removal 500-2
Installation 500-2

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Section 600. Power and Fan 600-1


611 - Power Supply 600-2
Removal 600-2
Installation 600-3
613 - Cooling Fan and Bracket 600-4
Removal 600-4
Installation 600-4

Section 650. Auto Sheet Feeder 650-1


667 - Auto Sheet Feeder Belt and Drive Gear 650-1
Removal 650-1
Installation 650-1
670 - Auto Sheet Feeder Lever and Lever Spring 650-3
Removal 650-3
Installation 650-3

Section 700. Reference Information 700-1


705 - Service Positions 700-1
707 - Printer Logic Board Service Position 700-1
708 - Operator Panel Service Position 700-3
710 - Locations 700-4
711 - Locations, Front (Cover On) 700-4
713 - Locations, Rear (Cover On) 700-5
717 - Locations, Right Side (Cover On) 700-6
719 - Locations, Front (Cover Off) 700-7
720 - Locations, Cable Connectors 700-8
721 - Locations, Rear (Cover Off) 700-9
723 - Locations, Left Side (Cover Off) 700-11
725 - Locations, Right Side (Cover Off) 700-12
740 - Tools and Test Equipment 700-13
743 - Digital CE Voltmeter (P/N 8496278) 700-13
745 - Miniprobe (P/N 453718) 700-13
746 - Connector Probe (P/N 2548300) 700-13
747 - Metric Tool Supplement (P/N 1749235) 700-13
748 - Feeler Gauge (P/N 450745) 700-13
749 - Feeler Gauge Metric (P/N 1749245) 700-13

IBM 4230 and 4232 Printers Maintenance Information Manual x


Contents xi

Section 750. Wiring Diagrams 750-1


751 - Ground Wire 750-1
752 - ESD Grounds 750-2
753 - Printer Logic Board 750-3
CE Test Points 750-3
755 - Print Head Cable 750-5
757 - Operator Panel Cable 750-7
759 - Main Sensor Cable 750-8
760 4232 Model 302 Attactment Cable Connector Pin
Assignments 750-9
The 4232 Printer Model 302 Serial Cable Connector Pin
Assignment 750-9
4232 Model 302 Parallel Cable Connector Pin
Assignments 750-11

Section 800. Changing Ribbons, Forms, and Forms


Devices 800-1
810 - Ribbon Cartridge 800-1
811 - Ribbon Cartridge Removal 800-1
812 - Ribbon Cartridge Installation 800-2
820 - Forms Devices 800-7
821 - Forms Device Removal 800-7
822 - Forms Device Configuration 800-7
823 - Forms Device Installation 800-8
824 - Installing the F1 Forms Device 800-9
825 - Loading Forms (F1) 800-13
827 - Removing the F1 Forms Device 800-17
829 - Installing the F2 Forms Device 800-18
831 - Loading Forms (F2) 800-23
833 - Removing the F2 Forms Device 800-29
835 - Installing the F3 Forms Device 800-31
836 - Loading Forms (F3) 800-37
837 - Removing the F3 Forms Device 800-39
840 - Installing the F4 Forms Device 800-40
842 - Loading Forms (F4) 800-45
844 - Removing the F4 Forms Device 800-50

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Section 900. Vital Product Data 900-1


Serial Number 900-1
Displaying Device Specific Information 900-2

Index X-1

IBM 4230 and 4232 Printers Maintenance Information Manual xii


Special Notices xiii

Special Notices
References in this publication to IBM products, programs, or services do
not imply that IBM intends to make these available in all countries in
which IBM operates. Any reference to an IBM licensed program in this
publication is not intended to state or imply that only IBM’s licensed
program may be used. Any functionally equal program that does not
infringe any of IBM’s intellectual property rights or other legally
protectible rights may be used instead of the IBM product, program, or
service. Evaluation and verification of operation with other products,
programs, or services, except those expressly designated by IBM, are
the user’s responsibility.

IBM may have patents or patent applications covering subject matter in


this document. The supplying of this document does not give you any
license to these patents. You can send license inquiries, in writing, to
the IBM Director or Commercial Relations, IBM Corporation, Purchase,
NY 10577.

The following terms, denoted by an asterisk (*) in this publication, are


trademarks of the IBM Corporation in the United States and/or other
countries:
Application System/400
AS/400
Enterprise System/9000
IBM.

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IBM 4230 and 4232 Printers Maintenance Information Manual xiv


About This Book xv

About This Book


The purpose of this book is to provide you, the service representative,
with the information necessary to repair the IBM* 4230 and 4232
Printers.

You use this book after you follow the IBM 4230 and 4232 Printers
Maintenance Analysis Procedures (MAPs). Once you identify the failing
unit, the MAPs refer you to pages in this book so that you can exchange
the unit.

How This Book is Organized


“Section 000. General Information” on page 000-1 introduces you to the
4230 Models 101, 102, 201, 202, 1S2, 2S2, 1I1, 2I1, 4I3, 5I3, 4S3, and
5S3, and the 4232 Model 302. the various functional units, operator
controls, and diagnostic procedures.

“Section 100. Covers, Shields, and Frame” on page 100-1 through


“Section 650. Auto Sheet Feeder” on page 650-1 describe the removal
and installation procedures.

“Section 700. Reference Information” on page 700-1 provides reference


information such as locations, tools, and test equipment.

“Section 750. Wiring Diagrams” on page 750-1 Section 750 provides


information about the printer’s wiring.

“Section 800. Changing Ribbons, Forms, and Forms Devices” on


page 800-1 through “Section 900. Vital Product Data” on page 900-1
provide you with operator information that aid you in repairs.

In addition, an index helps you find the material presented in this book.

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Publications
The following publications provide information about the IBM 4230 and
4232 Printers.

IBM 4230 and 4232 Printers Library


For IBM 4230 Printer planning information, refer to:
• IBM 4230 Printer Planning and Site Preparation Guide, GC40-1700.
This guide contains detailed information to help you plan for and
prepare the site for a 4230 Printer installation.

For IBM 4232 Printer planning information, refer to:


• IBM 4232 Printer Model 302 Planning and Site Preparation Guide,
GA24-4390. This guide contains detailed information to help you
plan for and prepare the site for a 4232 Printer installation.

For information about the IBM 4230 Printer Auto Sheet Feeder, refer to:
• IBM 4230 Printer Auto Sheet Feeder General Information,
SA40-0578. This manual describes the setup and use of the Auto
Sheet Feeder with the 4230 Printer.

For information about the IBM 4232 Printer Auto Sheet Feeder, refer to:
• IBM 4232 Printer Model 302 Auto Sheet Feeder General
Information, SA24-4391. This manual describes the setup and use
of the Auto Sheet Feeder with the 4232 Printer.

For safety information about the IBM 4230 and 4232 Printers, refer to:
• IBM 4230 and 4232 Printers Safety Information, SA40-0575.

For service information, refer to:

IBM 4230 and 4232 Printers Maintenance Information Manual xvi


About This Book xvii

• IBM 4230 and 4232 Printers Maintenance Analysis Procedures,


SA40-0571. This manual is a guide for servicing the IBM 4230 and
4232 Printers. It is the primary maintenance tool for trouble analysis
and repair of the 4230 and 4232 Printers.
• IBM 4230 and 4232 Printers Maintenance Information Manual,
SA40-0572. This manual provides detailed maintenance
procedures for the 4230 and 4232 Printers.
• IBM 4230 and 4232 Printers Illustrated Parts Catalog, SA40-0573.
This parts catalog contains listings and illustrations of all
replacement assemblies and detail parts for the 4230 and 4232
Printers.
• Binder for MAP, MIM, and Parts Catalog, SA40-0577.
(One binder holds all 3 books)

4230 Models 101, 1S2, 201, 2S2, 4S3, and 5S3 only
For setup and operating information, refer to:
• IBM 4230 Printer Models 101, 1S2, 201, 2S2, 4S3, and 5S3 User’s
Guide, SA40-0593. This guide describes the operating procedures
for the IBM 4230 Printer (with special emphasis on using the forms
devices).
• IBM 4230 Printer Models 101, 1S2, 201, 2S2, 4S3, and 5S3
Operator Panel Instructions, SA40-0594. This manual describes
how to operate the 4230 Printer control panel.
• IBM 4230 Printer Models 101, 1S2, and 4S3 Quick Reference
Guide, SA40-0591. This card shows the key functions and the
available configuration values and the process for setting them.
• IBM 4230 Printer Models 201, 2S2, and 5S3 Quick Reference
Guide, SA40-0592. This card shows the key functions and the
available configuration values and the process for setting them.
• IBM 4230 Printer Models 101, 1S2, 201, 2S2, 4S3, and 5S3 Product
and Programming Description, GC40-0595. This manual describes
the printer and programming functions specific to 4230 Printers that

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attach to the IBM 3270 Information Display System, the IBM


System/36, and AS/400*.

4230 Models 102, 1I1, 202, 2I1, 4I3, and 5I3 only

For setup and operating information, refer to:


• IBM 4230 Printer Models 102, 1I1, 202, 2I1, 4I3, and 5I3 User’s
Guide, SA40-0564. This guide describes the operating procedures
for the IBM 4230 Printer (with special emphasis on using the forms
devices).
• IBM 4230 Printer Models 102, 1I1, 202, 2I1, 4I3, and 5I3 Operator
Panel Instructions, SA40-0565. This manual describes how to
operate the 4230 Printer control panel.
• IBM 4230 Printer Models 102, 1I1, and 4I3 Quick Reference Guide,
SA40-0581. This card shows the key functions and the available
configuration values and the process for setting them.
• IBM 4230 Printer Models 202, 2I1, and 5I3 Quick Reference Guide,
SA40-0580. This card shows the key functions and the available
configuration values and the process for setting them.
• IBM 4230 Printer Models 102, 1I1, 202, 2I2, 4I3, and 5I3 Product
and Programming Description, GC40-1701. This manual describes
the printer and programming functions specific to 4230 Printers that
attach to the IBM 3270 Information Display System, the IBM
System/36, and AS/400*.

4232 Model 302 only

For setup and operating information, refer to:


• IBM 4232 Printer Model 302 User’s Guide, SA24-4386. This guide
describes the operating procedures for the IBM 4232 Printer (with
special emphasis on using the forms devices).

IBM 4230 and 4232 Printers Maintenance Information Manual xviii


About This Book xix

• IBM 4232 Printer Model 302 Operator Panel Instructions,


SA24-4387. This manual describes how to operate the 4232 Printer
control panel.
• IBM 4232 Printer Model 302 Quick Reference Guide, SA24-4388.
This card shows the key functions and the available configuration
values and the process for setting them.
• IBM 4232 Printer Model 302 Product and Programming Description,
GA24-4385. This manual describes the printer and programming
functions specific to 4232 Printers that attach to the IBM 3270
Information Display System, the IBM System/36, and AS/400*.

Enterprise System/9000* Publications


For information about attaching the printer to Enterprise System/9000,
refer to:
• Enterprise System/9000 Models 120, 130, 150, 170: Customizing
Your Work Station Subsystem, SA24-4226
• Enterprise System/9000 Models 120, 130, 150, 170: Planning Your
Work Station Subsystem, GA24-4223
• Enterprise System/9000 Models 120, 130, 150, 170: Work Station
Subsystem Description and Reference, SA24-4236.

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IBM 4230 and 4232 Printers Maintenance Information Manual xx


Safety Information xxi

Safety Information
The construction of this machine provides extra protection against the
risk of electric shock by grounding suitable metal parts. The extra
protection may not function unless the power cord is connected to a
properly grounded outlet. This machine has a grounding-type (3-wire)
power cord because grounding is necessary. It is the responsibility of
the customer or the person installing the machine to connect it to a
properly grounded outlet. Seek professional assistance before using an
adapter or extension cord; such a device could interrupt the grounding
circuit.

If this machine is connected to an outlet that has been incorrectly


connected to the building wiring, serious electric shock could
result.

For continued protection against the risk of electric shock and personal
injury:
• Connect the machine only to a properly grounded outlet of the
correct voltage. The voltage your machine will accept is indicated
on the machine.
• Ensure the machine is switched Off (O) before you connect or
disconnect the power cord or other cables.
• If the machine has cables other than the power cord, you must
connect them before you plug the power cord into an outlet. You
must first unplug the power cord from the outlet when you remove
the other cables.
• Do not use the machine in an area where it can become wet.
• Keep hair and personal articles away from moving parts in the
machine to prevent them from getting caught.
• Refer service or repairs to qualified personnel.

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• There may be some increased risks of electric shock and personal


injury during disassembly and servicing of this machine.
Professional service personnel should understand this and take
necessary precautions.
• The safety features of some parts may not always be obvious.
Therefore, replacement parts must have the same or equal
characteristics as the original parts.
• The maintenance information for this machine has been written for
the professional service person and is not intended to be used by
others.
• This printer weighs approximately 20.4 kgs (45 lbs). Do not attempt
to lift it by yourself.

IBM 4230 and 4232 Printers Maintenance Information Manual xxii


Safety Inspection Procedure xxiii

Safety Inspection Procedure


Perform the following safety inspection when there is any reason to
question the safety of a 4230 or 4232 Printer that is being decided on for
an IBM maintenance agreement. If the inspection indicates that the
safety level is unacceptable, it must be increased to an acceptable level
before IBM service can be provided.

Getting Ready
Before doing the inspection procedures, ensure that the present
conditions are safe, the printer is powered off, and all electrical power is
removed at the power cord.

Safety Conditions
If present conditions are not safe, you must not continue with the
inspection until you have corrected the problem.

For example, the following conditions are not safe:


• Electrical: Missing ground strap from the power supply to the frame
assembly (see “611 - Power Supply” on page 600-2).
• Mechanical: Any of the power supply installing screws missing (see
“611 - Power Supply” on page 600-2).
• Rear shield not fastened (see “121 - Rear Shield” on page 100-10).

You must correct any problem found in these areas before you continue
with this inspection.

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Safety Education
Before doing the inspection procedures, you must have completed the
Electrical Safety Training Course for IBM Service Representatives.

Performing the Inspection


IBM machines are designed and assembled with safety items installed
to protect owners, operators, and service personnel from injury. This
inspection identifies areas of the machine that may not be safe. Use
good judgment to identify other safety conditions not covered by this
guide.
1. Check the power cord for visible cracks, wear, or damage.
2. Ensure that the power cord has the correct power plug.
3. Check for 0.1 ohm (or less) of resistance between the power
cord ground and the power supply frame.
4. Ensure that the safety ground screw and wire are connected as
shown in “751 - Ground Wire” on page 750-1.
5. Check the inside of the printer for foreign materials.
6. Check all printer covers for loose or broken hinges and sharp
edges.
7. Ensure that the power supply rivets have not been tampered
with.
8. With the power switch Off (O), verify that the printer does not
switch on power.
9. With the power switch On (|), verify that the printer powers on.
10. With the power switch On (|), verify that the printer powers off
when the switch is switched Off (O).

IBM 4230 and 4232 Printers Maintenance Information Manual xxiv


Safety Inspection Procedure xxv

11. Return the printer to the customer and inform the local branch
office of the inspection results.

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IBM 4230 and 4232 Printers Maintenance Information Manual xxvi


General Information 000-1

Section 000. General Information

001 - Printer Summary


The IBM 4230 and 4232 Printers are serial, impact wire-matrix, table-top
printers with an integrated controller/processor. The IBM 4230 Printer
prints bidirectionally at speeds of 75 to 600 characters per second
(CPS), depending on the model and print quality setting. The IBM 4232
Printer prints bidirectionally at speeds of 100 to 600 characters per
second (CPS), depending on the print quality setting.

Types of Printing
The IBM 4230 and 4232 Printers are for business or general purpose
printing. They have four print qualities:
Fast draft (FD) Fast draft print quality has a 9-high by
8-wide character box, with a maximum
character height of 3.2 mm (0.126 in.).
Data processing (DP) Data processing print quality has a 9-high
by 10-wide character box, with a maximum
character height of 3.2 mm (0.126 in.).
Data processing text (DPT) Data processing text print quality has a
9-high by 20-wide character box, with a
maximum character height of 3.2 mm
(0.126 in.). It multiplies by two the dot
density horizontally as compared to the
DP quality.
Near letter quality (NLQ) Near letter quality print has an 18-high by
20-wide character box, with a maximum
character height of 3.8 mm (0.133 in.). It
multiplies by two the dot density both

000-1
000-2

horizontally and vertically as compared to


DP quality.

The IBM 4230 Printer models 102, 202, 1I1, 2I1, 4I3, 5I3, (Models 4S3
and 5S3 when using the Serial/Parallel attachment) and IBM 4232
Printer Model 302 can print:
• OCR A
• OCR B
• Bar codes
• Oversized characters
• Rotated characters
• Graphics for business applications
• Forms
• User defined symbols
• Images
• Retained segments
• Overlays
• Word processing applications.

Character Spacing
The IBM 4230 and 4232 Printers provide character spacing at 10, 12,
and 15 characters per inch (CPI) at all print quality levels. The printer
also provides 16.7 CPI in FD and DP modes. 4230 Models 4I3, 4S3,
5I3, and 5S3 (when using the serial/parallel attachment) also provide
17.1 and 20 CPI in FD and DP modes. A 12 CPI proportionally spaced
mode (PSM) approximates 11.5 CPI for DP Text and NLQ modes for
4230 Models 102, 202, 1I1, 2I1, 4I3, 5I3, (Models 4S3 and 5S3 when
using the Serial/Parallel attachment), and 4232 Model 302.

All character spacing is selectable.

For 4230 Models 101, 102, 1I1, 1S2, 201, 202, 2I1, 2S2, and 4232
Model 302, the maximum print position (MPP) is for a 335.3 mm (13.2
in.) print line. The maximum values are:

IBM 4230 and 4232 Printers Maintenance Information Manual 000-2


General Information 000-3

• 132 at 10 CPI
• 158 at 12 CPI
• 198 at 15 CPI
• 220 at 16.7 CPI
• 151 with PSM, for 11.5 CPI average.
For 4230 Models 4I3 and 5I3, the maximum print position (MPP) is for a
345.44 mm (13.6 in.) print line. The maximum values are:
• 136 at 10 CPI
• 163 at 12 CPI
• 204 at 15 CPI
• 227 at 16.7 CPI
• 232 at 17.1 CPI
• 272 at 20.0 CPI
• 156 with PSM, for 11.5 CPI average.

Line Spacing
The maximum page length (MPL) is the maximum length of the logical
page in units of lines. All line spacing is selectable, as is the MPL.

4230 Models 102, 202, 1I1, 2I1, 4I3, 5I3, (Models 4S3 and 5S3
when using the Serial/Parallel attactment), and 4232 Model
302: These printers provide line spacing of 3, 4, 6, and 8 lines per inch
(LPI) or increments of 0.18 mm (1/144 in.) under program control. The
operator panel provides a selection of 6 LPI or 8 LPI.

4230 Models 101, 201, 1S2, 2S2, and (Models 4S3 and 5S3
when using the Coaxial or Twinaxial attactment):These printers
provide line spacing of 3, 4, 6, and 8 LPI under program control (plus 9
LPI for Models 101 and 1S2). The operator panel provides a selection
of 6 LPI or 8 LPI.

000-3
000-4

Text Highlighting
The IBM 4230 Printer Models 102, 202,1I1, 2I1, 4I3, 5I3, and (Models
4S3 and 5S3 when using the Serial/Parallel attachment), and the IBM
4232 Printer Model 302 provide several modes of text highlighting. The
modes are available in combination and for all print qualities and pitch,
including PSM. 4230 Models 101, 201, 1S2, 2S2, and (Models 4S3 and
5S3 when using the Coaxial or Twinaxial attachment) provide
underscore only.

The following are the text highlighting modes:


Bold Bold highlighting repeats each dot in a character
without affecting the number of CPI.
Double Strike Double strike highlighting prints the same character
dot image on two passes. It does not change the dot
image, but causes the ink density to be increased.
Double High Double high highlighting makes each character twice
normal height by duplicating each dot option vertically
and above the base line. The second dot is printed in
the second dot options position above the original dot.
For 4230 Models 102, 1I1, 201, 2I1, and (Models 4I3
and 5I3 when using the Coaxial or Twinaxial
attachment), double high is available only in Intelligent
Printer Data Stream (IPDS) with deferred (unordered)
text. For 4230 Models 4I3, 5I3, 4S3, and 5S3 when
using the Serial/Parallel attachment and for 4232
Model 302, double high printing is emulated by
printing normal height characters at double high
spacing.
Double Wide Double wide highlighting makes each character twice
normal width by duplicating each dot option in the
second dot option position after the original dot.

IBM 4230 and 4232 Printers Maintenance Information Manual 000-4


General Information 000-5

Overstrike Overstrike highlighting lets any character be logically


ORed into the dot image of other characters before
the characters are printed. This function can generate
adjacent dots.
Underscore Underscore highlighting specifies that the bottom
most alternate dots are to be logically ORed into the
dot image of other characters before the characters
are printed. This function generates adjacent dots for
NLQ and may generate adjacent dots for FD, DP, or
DPT.
Overscore For 4230 Models 4I3, 5I3, 4S3, and 5S3 when using
the Serial/Parallel attachment and for 4232 Model
302, overscore highlighting specifies characters to be
overscored with a straight line above the characters.
Italicize Italicize highlighting specifies that the character dot
image is to be selectively shifted to the right on given
rows of the dot image, without affecting the number of
CPI. This function changes the dot image, but does
not generate adjacent dots.

000-5
000-6

Advanced Printing Functions


The IBM 4230 Printer Models 102, 202, 1I1, 2I1, 4I3, 5I3, (Models 4S3
and 5S3 when using the Serial/Parallel attachment) and the IBM 4232
Printer Model 302 provide the following advanced data processing, word
processing, and graphics functions:
Overlays
Overlays let you store an already defined page or part of a
page in the printer memory to be merged with incoming host
page data at a later time. For 4230 Models 4I3, 5I3, 4S3,
and 5S3 when using the Serial/Parallel attachment and for
4232 Model 302, overlays are available in 4224 emulation
mode.
Page segments
This function lets you store data streams in the printer
memory to be invoked from the incoming host data. For
4230 Models 4I3, 5I3, 4S3, and 5S3 when using the
Serial/Parallel attachment and for 4232 Model 302, page
segments are available in 4224 emulation mode.
Superscripting
Superscripting uses NLQ vertical dot spacing in the upper
area of the character box.
Subscripting
Subscripting uses NLQ vertical dot spacing in the lower area
of the character box.
Graphics
Graphics ability includes a resolution of 144 x 144 dot
positions per inch. High density graphics allows printing in
every mode. High speed (low density) graphics reduces
printing of adjacent dots horizontally. The 4230 Models 101,
201, 1S2, 2S2, and (Models 4S3 and 5S3 when using the
coaxial or twinaxial attachment) can print graphics generated
on the host computer at 100 x 72 dot positions per inch. For
4230 Models 4I3, 5I3, 4S3, and 5S3 when using the

IBM 4230 and 4232 Printers Maintenance Information Manual 000-6


General Information 000-7

Serial/Parallel attachment and for 4232 Model 302, vector


graphics are available in 4224 emulation mode. Graphics
generated on the host computer can be printed at 60, 120,
and 240x72 dot positions per inch.
Stored images
Non-coded information can be printed immediately or stored
at the printer for later printing under data stream control.
Host loadable symbols
Host loadable symbols are applied against all available fonts.
This function is available on 4230 Models 101, 201, 1S2,
2S2, (Models 4I3, 5I3, 4S3, and 5S3 when using the
Serial/Parallel attachment), (Models 4S3 and 5S3 when
using the Coaxial or the Twinaxial attachment) and on 4232
Model 302 in 4224 emulation mode.
Bar codes (4230 Models 102, 202, 1I1, 2I1, 4I3, 5I3, and 4232 Model
302)
The bar codes printed on the IBM 4230 and 4232 Printers
are intended to be read with visible light and infrared readers
(633 to 900 nanometer light sources). The printer cannot
print bar codes with X dimensions less than 0.356 mm (0.014
in.) or with a dot to dot tolerance of less than ±0.076 mm
(0.003 in.). All printing of bar codes should be tested for
acceptability.
The IBM 4230 and 4232 printers can print the following bar
codes:
• POSTNET
• Code 3 of 9
• UPC A and E
• EAN 8 and 13
• UPC/EAN Supplemental encoding (2 and 5 characters)
• Interleaved 2 of 5
• Matrix 2 of 5, Industrial 2 of 5
• MSI

000-7
000-8

• Code 128
• Codabar.
The printer can generate the bar codes using the following
options:
Mode High contrast mode, high
speed mode
X dimension (narrow bar) 0.014, 0.017, 0.021, 0.028 in.
Wide to narrow ratio 2, 2.5, 3.
Notes:
1. The following bar code options are not available in high
speed mode with horizontal bar codes:
• Unit module width of 0.533 mm (0.021 in.), all ratios
• Unit module width of 0.432 mm (0.017 in). with a
ratio of 2.5:1.
• Unit module width of 0.356 mm (0.014 in.), with a
ratio of 2.5:1.
2. Unit module width of 0.432 mm (0.017 in.) is not
available with vertical bar codes.
3. Because of physical restrictions of the printer, the 2.5
wide to narrow ratio is 2.66 for a unit module width of
0.533 mm (0.021 in.).
4. All UPC and EAN bar codes are generated only with a
unit module width of 0.356 mm (0.014 in.).
5. Postnet bar codes print only at a fixed width and height.
Unit module width and wide-to-narrow ratio do not apply
for Postnet bar codes.
Large characters
Character strings can generate large characters with the
following capabilities:
• NLQ font

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General Information 000-9

• Rotated 0, 90, 180, 270 degrees


• Four directions: left to right, top to bottom, right to left,
bottom to top
• Number magnification.
The large character generation algorithms for high speed
graphics generate characters that are of lower density in the
horizontal direction. For 4230 Models 4I3, 5I3, 4S3, and 5S3
when using the serial/parallel attachment and 4232 Model
302, large characters are available in 4224 emulation mode.
OCR A and B
The IBM 4230 Printer Models 101, 1I1, 102, 1S2, 201, 2I1,
202, 2S2, and (Models 4I3, 5I3, 4S3, and 5S3 when using
the coaxial or the twinaxial attachment) can print the
following OCR fonts:
• OCR A code page 340 (EBCDIC), character set 968
• OCR A code page 892 (EBCDIC), character set 968
• OCR B code page 340 (EBCDIC), character set 969
• OCR B code page 893 (EBCDIC), character set 969.
4230 Models 4I3, 5I3, 4S3, and 5S3 when using the
serial/parallel attachment and the 4232 Model 302 Printers
can print the following OCR fonts:
• OCR A code page 876 (ASCII), character set 968
• OCR B code page 877 (ASCII), character set 969.

Printer Service
The ribbon cartridge is the only customer-replaceable unit (CRU).
Service for this assembly is not covered by the IBM Maintenance
Agreement. See “810 - Ribbon Cartridge” on page 800-1 for more
information about the ribbon cartridge.

000-9
000-10

Forms Devices
The printer can use one of four forms-handling devices. They are:
Continuous Forms Device (F1) For high performance continuous
forms feeding
Dual Purpose Forms Device (F2) For continuous forms and document
on demand feeding
Document Insertion Device (F3) For manual cut forms feeding
Auto Sheet Feeder Device (F4) For automatic cut forms feeding.

The customer can remove and install each device (“821 - Forms Device
Removal” on page 800-7) and (“822 - Forms Device Configuration” on
page 800-7). The IBM Maintenance Agreement covers all
forms-handling devices as part of the base machine.

Printer Electronics
The electronics are contained in the power supply, operator panel, and
printer logic board. For the IBM 4230 (Models 102, 1I1, 202, 2I1, 101,
1S2, 201, 2S2, 4I3, 4S3, 5I3, and 5S3), the logic board connects to the
coaxial or twinaxial attachment bezel by a cable. For 4230 Models 4I3,
5I3, 4S3, 5S3, and 4232 Model 302, a separate serial/parallel
attachment card connects to the extended memory connector on the
logic board. 4230 Models 4I3, 4S3, 5I3, and 5S3 have both attachment
connections.

IBM 4230 and 4232 Printers Maintenance Information Manual 000-10


General Information 000-11

Model Identification
The model name defines the system attachment and maximum burst
speed:
4230 Model Definition
102 480 CPS, IPDS, Twinaxial
1I1 375 CPS, IPDS, Twinaxial
202 480 CPS, IPDS, Coaxial
2I1 375 CPS, IPDS, Coaxial
101 375 CPS, Non-IPDS, Twinaxial
1S2 480 CPS, Non-IPDS, Twinaxial
201 375 CPS, Non-IPDS, Coaxial
2S2 480 CPS, Non-IPDS, Coaxial
4I3 600 CPS, PPDS, Serial/Parallel, IPDS, Twinaxial
5I3 600 CPS, PPDS, Serial/Parallel, IPDS, Coaxial
4S3 600 CPS, PPDS, Serial/Parallel, Non-IPDS, Twinaxial
5S3 600 CPS, PPDS, Serial/Parallel, Non-IPDS, Coaxial
4232 Model Definition
302 600 CPS, PPDS, Serial/Parallel

003 - Control and Data Flow Description


Figure 1 on page 000-12 shows the basic data flow paths for the
IBM 4230 and 4232 Printers.

000-11
000-12

Figure 1. Basic Data Flow Paths for the 4230 and 4232 Printers

IBM 4230 and 4232 Printers Maintenance Information Manual 000-12


General Information 000-13

005 - Power-On Self Test (POST)


When power is supplied to the control card, the power-on self test
(POST) starts. The panel displays the message

until initial communications between the panel processor and the printer
are complete. If any errors are found during this phase of diagnostics,
the printer displays an error code. Once these are complete, the printer
displays the following to indicate that the next level of diagnostics is to
be run:

DIAGNOSTICS IN PROGRESS < A >

The mechanism tests are run while the printer displays the diagnostics
message. The print head moves to the right approximately 25.4 mm (1
in.), then moves to the left side frame. The print head then moves to the
right side frame to verify that there are no physical obstructions. One
line of blank characters prints from position 55 to 60 at the highest
speed. The print head then returns to the home position.

Once all internal printer diagnostic tests have been completed, and
before control passes to the attachment, the printer displays the
following for two seconds:

DIAGNOSTICS COMPLETE < A >

000-13
000-14

If there are no forms at the platen the printer displays the following for
two seconds:

CALIBRATING PRINTER < A >


PLEASE WAIT

If all tests are successful, the controller card becomes online ready, the
Ready indicator goes on and displays the following:

READY < A >

If the Auto Sheet Feeder operation is enabled, the printer performs an


automatic forms eject.
Note: The printer can display an error message if no forms are loaded
or if the host cable is not connected.

010 - Operator Panel


The operator panel consists of:
• Six light emitting diode (LED) indicators, known as the Operator
Panel Indicators
• 16 keys
• A two-line by 40-character alphanumeric liquid crystal display (LCD),
known as the Operator Panel Display. Figure 2 on page 000-15
shows the operator panel for 4230 Models 101, 102, 1I1, 1S2, 4I3,
and 4S3. Figure 3 on page 000-15 shows the operator panel for
4230 Models 201, 202, 2I1, and 2S2. Figure 4 on page 000-16
shows the operator panel for 4230 Models 5I3 and 5S3. Figure 5
on page 000-16 shows the operator panel for the 4232 Model 302.

IBM 4230 and 4232 Printers Maintenance Information Manual 000-14


General Information 000-15

Figure 2. Operator Panel: 4230 Models 101, 102, 1I1, and 1S2 (Twinax)

Figure 3. Operator Panel: 4230 Models 201, 202, 2I1, and 2S2 (Coax)

000-15
000-16

Figure 4. Operator Panel: 4230 Models 5I3 and 5S3 (Coax)

Figure 5. Operator Panel: 4230 Models 4I3, 4S3, and 4232 Model 302
(Serial/Parallel)

IBM 4230 and 4232 Printers Maintenance Information Manual 000-16


General Information 000-17

011 - Indicators
This section describes the following indicators on the operator panel:
• Power
• Ready
• Format (4230 Models 201, 202, 2I1, 2S2, 5I3, and 5S3)
• Online (4230 Models 101, 102, 1I1, 1S2 4I3, 4S3, and 4232 Model
302)
• Processing
• Attention
• Unit Check.

Power Indicator

The green Power indicator has two operating conditions:


On The printer has power.
Off The printer has no power.

The Power indicator goes on when the power switch is On (|).

Ready Indicator

The green Ready indicator has two operating conditions:


On The printer is ready (can print).
Off The printer is not ready (cannot print).

The Ready indicator goes on for any of the following conditions:


• A successful power-on sequence
• Pressing the Start key after the indicator was switched off
depending on one of the following:
- An error condition (if the error is corrected)
- An intervention-required condition
- Pressing the Stop key.

000-17
000-18

The Ready indicator is switched off for any of the following conditions:
• Pressing the Stop key
• Detection of an intervention-required condition
• Detection of a printer error.

When the Ready indicator is off, the printer can receive data but not
process it.

Format Indicator (4230 Models 201,202, 2I1, 2S2, 5I3, and


5S3)
Note: For 4230 Models 5I3 and 5S3, the Format indicator is used when
the Coaxial attachment is active. The Format indicator serves as the
Online indicator when the Serial/Parallel attachment is active.

The green Format indicator has two operating conditions:


On The Cancel Print, PA1, and PA2 keys are active (for the
SCS data stream), or the Cancel Print key is active (for the
IPDS stream).
Off The PA1 and PA2 keys are not active, and the Cancel Print
key is active only in Test mode.

Online Indicator (4230 Models 101, 102, 1I1, 1S2, 4I3, 4S3,
and 4232 Model 302)
Note: For 4230 Models 5I3 and 5S3, the Online indicator serves as the
Format indicator when the Coaxial attachment is active.

The green Online indicator has two operating conditions:


On The printer is in communication with the host.
Off The printer is not in communication with the host.

IBM 4230 and 4232 Printers Maintenance Information Manual 000-18


General Information 000-19

Processing Indicator

The green Processing indicator has three operating conditions:


On The printer is receiving, processing, or printing data.
Off There is no data to be processed and no data in the printer
buffer.
Blinking The printer buffer contains data but cannot immediately print
it.

Attention Indicator
The yellow Attention indicator has two operating conditions:
Off The printer has detected no condition that requires operator
intervention.
Blinking The printer requires immediate operator intervention.

Conditions that require operator intervention cause the printer to be not


ready (the Ready indicator is off) and require the operator to perform a
task such as adding paper to a supply or clearing a jam.

The Attention indicator is always joined by a short description of the


condition on the Operator Panel Display. If the alarm is not disabled, it
beeps when the Attention indicator blinks.

Pressing the Stop will switch off the Attention indicator. The indicated
condition, however, may still exist and will be detected when the Start
key is pressed.

Unit Check Indicator

The yellow Unit Check indicator has two operating conditions:


Off The printer has no printer errors.
Blinking A printer error has occurred.

000-19
000-20

Printer errors usually require that the printer be reset, or switched off and
then back on.

The printer records each printer error in an error log that you can access
for help in isolating printer failures (“Error Log” on page 000-66).

The Unit Check indicator is always joined by a short description of the


error condition on the Operator Panel Display. If the alarm is not
disabled, it beeps when the Unit Check indicator blinks.

Pressing the Stop key will switch off the Unit Check indicator. The
indicated condition may remain and will be detected when the error is
found again.

012 - The Display


The Operator Panel Display contains two lines of 40 characters each.
The display does the following:
• Displays warning conditions
• Identifies specific conditions requiring operator intervention
• Identifies specific error conditions detected by the printer
• Identifies printer status
• Displays Configuration Menu parameters for review, selection, and
change
• Displays a selection of diagnostic tests.
• Displays the currently selected custom set.

Multiple printer conditions may try to use of the display at the same time.
The printer prioritizes its display usage by the severity of the condition
and whether the printer is ready or not ready, or online or offline. The
following are the general rules for the usage priorities:

IBM 4230 and 4232 Printers Maintenance Information Manual 000-20


General Information 000-21

• The highest priority condition for the existing ready/not ready status
takes control of the display and writes over what, if anything, is
displayed.
• If the printer changes between ready and not ready, or online and
offline, the highest priority condition for the new status takes control
of the display.
• If the Menu or Test key is pressed, those menus write over any
existing messages but do not affect the status of the indicators.

The following list shows the priority order for printer conditions that use
the display when the Ready indicator is off (highest priority first):
1. Configuration options (when in Configuration mode) or Test options
(when in Test mode)
2. Printer error (Unit Check indicator is blinking)
3. Supplies intervention required (Attention indicator is blinking)
4. Communication checks (Attention indicator is blinking)
a. 4230 Models 201, 2I1, 202, 2S2, 5I3, and 5S3
b. 4230 Models 4I3 and 4S3 when the Serial/Parallel attachment is
active
c. 4232 Model 302
5. Host requests attention (Attention indicator is blinking)
a. 4230 Models 201, 2I1, 202, 2S2, 5I3, and 5S3
b. 4230 Models 4I3 and 4S3 when the Serial/Parallel attachment is
active
c. 4232 Model 302
6. Test options (when in a Test mode)
7. Cancel or PA function active, buffer reprint or hex print active, and
printer in send status
a. 4230 Models 201, 2I1, 202, 2S2, 5I3, and 5S3
b. 4230 Models 4I3 and 4S3 when the Serial/Parallel attachment is
active
8. Printer Address during power-on reset (POR) warm-up cycle - 4230
Models 101, 102, 1I1, 1S2, 4I3, and 4S3

000-21
000-22

9. Normal (not ready)


10. POR messages (displayed during power-on reset warm-up cycle).

The following list shows the priority order for printer conditions that use
the display when the Ready indicator is on (highest priority first):
1. Configuration options (when in Configuration mode) or Test options
(when in Test mode)
2. Communication checks (Attention indicator is blinking)
a. 4230 Models 201, 2I1, 202, 2S2, 5I3, and 5S3
b. 4230 Models 4I3 and 4S3 when the serial/parallel attachment is
active
c. 4232 Model 302.
3. Host requests attention (Attention indicator is blinking)
a. 4230 Models 201, 2I1, 202, 2S2, 5I3, and 5S3
b. 4230 Models 4I3 and 4S3 when the serial/parallel attachment is
active
c. 4232 Model 302.
4. Cancel or PA function active, buffer reprint or hex print active, and
printer in send status
a. 4230 Models 201, 2I1, 202, 2S2, 5I3, and 5S3
b. 4230 Models 4I3 and 4S3 when the serial/parallel attachment is
active.
5. Normal operating messages (READY or information messages).

IBM 4230 and 4232 Printers Maintenance Information Manual 000-22


General Information 000-23

013 - The Keys


The operator panel has the following keys:
• Start
• Stop
• Line Feed
• Load/Eject
• Form Feed
• Set Top of Form
• Micro /Scroll
• Micro /Scroll
• Darker/Enter
• Lighter/Return
• Menu
• Quick Reference
• Cancel Print
• Test
• Hex Print
1. 4230 Models 101, 102, 1I2, 1S2, 4I3, 4S3
2. 4230 Models 5I3 and 5S3 when the serial/parallel attachment is
active
3. 4232 Model 302.
• Display Address (4230 Models 101, 102, 1I1, 1S2, 4I3, and 4S3)
• Display Interface
1. 4232 Model 302
2. 4230 Models 4I3, 4S3, 5I3, and 5S3.
• PA1 (4230 Models 201, 202, 2I1, 2S2, 5I3, and 5S3)
• PA2 (4230 Models 201, 202, 2I1, 2S2, 5I3, and 5S3).

000-23
000-24

Start Key

Pressing the green Start key:


• Makes the printer ready. The Ready indicator goes on or blinks if
data is ready to print. The printer displays a ready message.
• Starts the printer printing if no error conditions appear in the display
and if the computer is sending data to be printed.
• Starts a test when the printer is in Test mode.
• If in Configuration mode, exits that mode with changes saved and
makes the printer ready.

Stop Key

Pressing the yellow Stop key:


• Stops printing when possible without losing print data.
• Stops the printer from printing a test if the printer is in Test mode.
• Stops the printer alarm (if beeping).
• Clears error codes and status codes from the display, switches off
the alarm if it is set to beep, and makes the printer not ready.
• Switches off the Ready indicator unless data is in the printer, in
which case the Ready indicator blinks.

IBM 4230 and 4232 Printers Maintenance Information Manual 000-24


General Information 000-25

• 4230 Models 201, 202, 2I1, 2S2, and Models 5I3 and 5S3 when the
Coaxial attachment is active - Starts a 10 minute timer. If the printer
is still not ready after 10 minutes has elapsed, the Unit Check
indicator goes on, the alarm starts to beep (if not disabled), and the
printer displays

008 HOLD PRINT TIMEOUT


PRESS START

This timeout feature can be disabled in the Configuration Menu.


• (F3 or F4 forms device) Starts a forms thickness adjustment.

The Stop key has no function while in Configuration mode and is read
as a not valid key press. The Stop key also has no function while in
Operator or CE Test modes before running a test (unless an error
condition exists). The Offline CE Test Menu, however, can be left by
pressing Test and Quick Reference at the same time, and then
pressing Stop.

Line Feed Key


Pressing the blue Line Feed key:
• Advances the print forms 4.23 mm (1/6 in.) without regarding the
LPI setting
• Advances the print forms continuously by 4.23 mm (1/6 in.) if the
key is held down.

The Line Feed key is active only when the printer is not ready. The key
provides a coarse adjustment for aligning the paper vertically (use the
Micro key for fine adjustment). The printer remembers the adjustment
until a new top of form position is set.

000-25
000-26

Load/Eject Key

The blue Load/Eject key is active for each paper feed source:

F1 Forms Device

For Loading: This key is not suitable.

For Ejecting: Pressing the Load/Eject key ejects remaining forms


from the printer when at the end of forms. Pressing Stop to clear an
error and then pressing Load/Eject ejects all remaining forms.

F2 Forms Device

For Loading: The Auto Top of Form/Autoload Assist function is active.


Once the forms are loaded under the forms sensor and on the tractors
at the bottom of the forms device, pressing the Load/Eject key
automatically loads the forms to a standard top of form position. Use the
Micro and Micro keys to align the top of form position as needed.
This new position is stored by the printer.

For Ejecting: The eject function is controlled by your selection (either


Immediate or Delayed) for F2 Eject Mode in the Configuration Menu:
• In the Immediate mode, pressing Load/Eject causes the form to
immediately advance a fixed distance to a tear-off bar and causes
the printer to be not ready.
• In the Delayed mode, pressing Load/Eject causes the form to
advance a fixed distance to a tear off bar when a page boundary is
reached during printing and causes the printer to be not ready.

Pressing Load/Eject while the printer is ready causes one of the


previous actions to occur, depending on your selection for F2 Eject
Mode. The form may then be removed or inspected for registration.

IBM 4230 and 4232 Printers Maintenance Information Manual 000-26


General Information 000-27

Use the Micro and Micro keys to align the tear-off position, when
ejected, as needed. This new position is stored by the printer.

The printer ignores all Start key presses until Load/Eject is pressed a
second time. Pressing Load/Eject a second time causes the paper
motion to reverse and the forms to move back to the previous position.
The printer returns to ready, unless an error condition is detected.

The Load/Eject key can also be used to eject the remaining forms from
the printer when at the end of forms.

F3 Forms Device

For Loading: When a form is inserted in the printer, pressing the


Load/Eject key causes the form to advance to the top of form position.
The printer becomes ready, unless an error is detected.

For Ejecting: Pressing the Load/Eject key causes the printer to eject
the form from the printer and causes the printer to be not ready.

F4 Forms Device

For Loading: The Load/Eject key will not work with the F4 device.

For Ejecting: The Load/Eject key is active only when the printer is
ready. If a form is loaded, pressing Load/Eject causes the printer to
perform the eject function. If no paper is present, pressing the key
causes the printer to attempt a paper eject.

000-27
000-28

Form Feed Key

Pressing the blue Form Feed key moves the forms forward so that the
next form is located at the top of form position, providing that the form’s
length has been set.

The Form Feed key is active only when the F1 or F2 forms devices are
selected. The key is inactive when the F3 forms device is selected.
With the Configuration Menu, you can set the Form Feed function to be
active only in the online not ready status, or in both the online not ready
and online ready statuses.

If the F4 forms device is selected, pressing Form Feed displays the


source bin for the next sheet to be loaded if data is in the printer. If no
data is in the printer (the Processing indicator is off), the display reflects
the last active bin selected.

Set Top of Form Key

Pressing the blue Set Top of Form key sets the existing position of the
print head as the top of form position. This key is active only when the
printer is not ready.

The alarm beeps once when the top of form position is set, even if the
alarm has been disabled in the Configuration Menu setting.

A form feed causes the paper to move to the top of form position,
providing that the form length has been set.

IBM 4230 and 4232 Printers Maintenance Information Manual 000-28


General Information 000-29

Micro /Scroll Key

The blue Micro /Scroll key has two functions, depending on whether
the printer is not ready, or in Configuration or Test mode:

Printer Not Ready: When the printer is not ready, the Micro key
advances the forms one increment (0.35 mm, 1/72 in.). Holding the key
down advances the forms continuously by 0.35 mm (1/72 in.)
increments.

The Micro key performs the same function as the Line Feed key. The
printer remembers the adjustment set by the Micro key until a new top
of form position is set.

Configuration or Test Mode: When the printer is in Configuration or


Test mode, the Scroll key scrolls through options in a selected
parameter or Test menu. Scroll cycles up through the option list (from
the last to the first item in the list). If you reach the first item in the list,
pressing the Scroll key will scroll to the last item in the list.

Pressing Scroll once displays the previous item in the list. Holding the
key down causes the display to cycle up through the option list until the
key is released.

Micro /Scroll Key

The blue Micro /Scroll key has two functions, depending on whether
the printer is not ready, or in Configuration or Test mode:

Printer Not Ready: When the printer is not ready, the Micro key
moves the forms down into the printer one increment (0.35 mm, 1/72
in.). If the F2 device is selected, holding the key down moves the forms
down continuously by 0.35 mm (1/72 in.) increments. The key is not
typematic for the other forms devices.

000-29
000-30

The printer remembers the adjustment set by the Micro key until a
new top of form position is set.

Configuration or Test Mode: When the printer is in Configuration or


Test mode, the Scroll key scrolls through options in a selected
parameter or Test menu. Scroll cycles down through the option list
(from the first to the last item in the list). If you reach the last item in the
list, pressing the Scroll will scroll to the first item in the list.

Pressing Scroll once displays the next item in the list. Holding the key
down causes the display to cycle down through the option list until the
key is released.

Darker/Enter Key

The blue Darker/Enter key has two functions, depending on whether


the printer is ready, or in Configuration or Test mode:

Printer Ready: When the printer is ready, the Darker key moves the
print head closer to the platen, decreasing the Forms Thickness Setting.
The print becomes darker because there is more force on the ribbon
when it is pressed against the paper.
Note: The print may not get darker if the ribbon is worn or if there is a
problem with the print head. The Darker and Lighter keys are not
functional until the first line is printed.

Pressing the key makes the print darker and displays the new setting in
the Operator Panel Display. The gap between the print head and the
platen is decreased by 0.0127 mm (0.0005 inch) for forms less than
0.254 mm (0.010 inch) thickness or by 0.025 mm (0.001 inch) for forms
greater than or equal to 0.25 mm (0.010 inch) thick for each press of the
Darker key. The adjustment value is indicated by a bar graph on the
display.

IBM 4230 and 4232 Printers Maintenance Information Manual 000-30


General Information 000-31

The range of adjustment to the forms thickness setting is 0.1143 mm


(0.0045 inch.) in either the lighter or darker direction for forms less than
0.254 mm (0.010 inch) thickness. For forms greater than or equal to
0.254 mm (0.010 inch) the range is 0.229 mm (0.009 inch) in either
direction. If you reach either limit, the printer displays a message
informing you the limit is reached.

The printer stores the adjustments made with this key. If the gap is
adjusted to anything other than the default density the automatically
calculated value is saved and becomes the Reference Forms
Thickness. If the Forms Thickness Setting is changed again, the
automatically calculated value for the forms in the printer at that time
becomes the new Reference Forms Thickness.

Configuration or Test Mode: When the printer is in Configuration


mode, the Enter key selects menu options. When the operator has
scrolled through the display so that the desired menu setting, parameter,
or value is displayed on the second line of the Operator Panel Display,
pressing Enter causes the selection to be accepted and the display to
be updated.

When the printer is in Test mode, the Enter key runs a selected test.
When the operator has selected a test to be run, pressing Enter causes
the test to run and the printer to return to the test selection menu. (The
Start key also runs tests.)

Lighter/Return Key

The blue Lighter/Return key has two functions, depending on whether


the printer is ready, or in Configuration or Test mode:

Printer Ready: When the printer is ready, the Lighter key moves the
print head farther from the platen, increasing the Forms Thickness
Setting. The print becomes lighter because there is less force on the
ribbon when it is pressed against the paper.

000-31
000-32

Pressing the key makes the print lighter and displays the new setting in
the Operator Panel Display. The gap between the print head and the
platen is increased by 0.0127 mm (0.0005 inch) for forms less than
0.254 mm (0.010 inch) thickness or by 0.025 mm (0.001 inch) for forms
greater than or equal to 0.25 mm (0.010 inch) thick for each press of the
Lighter key. The adjustment value is indicated by a bar graph on the
display.

The range of adjustment to the forms thickness setting is 0.1143 mm


(0.0045 inch.) in either the lighter or darker direction for forms less than
0.254 mm (0.010 inch) thickness. For forms greater than or equal to
0.254 mm (0.010 inch) the range is 0.229 mm (0.009 inch) in either
direction. If you reach either limit, the printer displays a message
informing you the limit is reached.

The printer stores the adjustments made with this key. If the gap is
adjusted to anything other than the default density, the automatically
calculated value is saved and becomes the Reference Forms
Thickness. If the Forms Thickness Setting is changed again, the
automatically calculated value for the forms in the printer at that time
becomes the new Reference Forms Thickness.

Configuration or Test Mode: When the printer is in Configuration


mode, the Return key moves to the previous level of the Configuration
Menu. At any point in the parameter update sequence, pressing Return
causes the printer to return to the previous level of the sequence without
updating any value that was not saved with the Enter key. Pressing
Return at the highest level of the Configuration Menu returns the printer
to not ready with the entered changes saved.

When the printer is in Test mode before performing a test, pressing the
Return key returns the printer to the not ready status that existed before
the Test key was pressed. Return is not active while any test is
running.

IBM 4230 and 4232 Printers Maintenance Information Manual 000-32


General Information 000-33

Menu Key

Pressing the black Menu key displays the Configuration Menu for
selecting or changing the parameter values. The printer becomes offline
not ready, enters Configuration mode, and displays the menu heading
on the first line and the first Configuration Menu on the second line.

Entering Configuration mode activates the following keys:


• Enter
• Return
• Scroll
• Scroll
The Start and Quick Reference keys also remain active.

Quick Reference Key

Pressing the blue Quick Reference key lets you print help information.
The Quick Reference function is available when the printer is:
• Online and no print job is in process
• In Configuration mode
• In Operator Test mode with no test occurring.

The Quick Reference function is not available from the Offline CE Test
Menu.

After the first key press, the printer displays a message asking for
verification of the Quick Reference request. The second key press
prints information about the operator panel keys and lists the
Configuration Menu on the forms in the printer. When the printer
completes printing the help information, it becomes not ready. You can
stop printing by pressing Stop or Cancel Print.

000-33
000-34

Cancel Print Key

Pressing the blue Cancel Print key has two functions, depending on
whether the printer is online or in Test mode:

Online: If the printer is online, pressing the Cancel Print key cancels
the existing print request. The printer asks for verification before
sending the command to the host. The host usually responds with a
command to clear all print data.

For 4230 Models 101, 102, 1I1, 1S2, and Models 4I3 and 4S3 when the
Twinaxial attachment is active the Cancel Print key is active when the
printer is ready or not ready.

For 4230 Models 201, 202, 2I1, 2S2, and Models 5I3 and 5S3 when the
Coaxial attachment is active the Cancel Print key is active only when
the printer is not ready. After pressing Cancel Print, press Start to
process the request. Pressing Cancel Print instead of Start makes the
printer not ready, canceling the cancel request.

For 4230 Models 4I3, 4S3, 5I3, and 5S3 when the Serial/Parallel
attachment is active and for 4232 Model 302, the Cancel Print key
clears buffered data without host intervention.

Test Mode: If the printer is in Test mode (offline), pressing Cancel


Print causes the printer to leave the Test mode, perform a partial reset,
and become online ready.

Test Key

Pressing the blue Test key when the printer is online not ready causes
the printer to become offline not ready and to enter the Test mode. The
printer displays a menu heading on the first line of the display and the
name of the first test on the second line.

Entering Test mode activates the following keys:

IBM 4230 and 4232 Printers Maintenance Information Manual 000-34


General Information 000-35

• Return
• Stop
• Scroll
• Scroll

The Start key also remains active to start executing the tests. Enter
remains active to make the selections in some of the Operator Print and
Offline CE tests.

The operator may scroll up and down to look at the test names and
press Start to run a test. Pressing Stop or Cancel Print stops the test.
Pressing Return while a test is not running leaves the test menus and
makes the printer ready.

Hex Print Key (4230 Models 101, 102, 1I1, 1S2, 4I3, 4S3,
and 5I3, 5S3 when Serial/Parallel Active and 4232 Model
302)
Pressing the blue Hex Print key causes the printer to enter Hex Print
mode. This key is active only when the printer is online not ready. (For
4230 Models 5I3 and 5S3, it is active only when the serial/parallel
attachment is active.)

Press Start while in Hex Print mode to print all data (including
commands) in hexadecimal codes as they reside in the buffer. This
function applies only to data formatted for printing after Hex Print mode
has been enabled. The Hex Print mode function is an aid to service
personnel and application programmers for host program debug.

Press Stop or power-off the printer to leave Hex Print mode.

000-35
000-36

Display Address Key (4230 Models 101, 102, 1I1, 2S2)

Pressing the blue Display Address key displays the existing value of
the Printer Address Setting on the Operator Panel Display for as long as
the key is held. This key is active only when the printer is online not
ready.

Display Interface Key (4230 Models 4I3, 4S3, 5I3, 5S3,


and 4232 Model 302)

Pressing the blue Display Interface key displays the currently active
interface as long as the key is held.

Note: For 4230 Models 4I3, 4S3, 5I3, and 5S3 when the coaxial
interface is active, the Display Interface key acts as the PA2 key.

For 4230 Models 4I3, 4S3, 5I3, and 5S3 the active interface could be:
• Parallel
• RS232
• RS422
• Twinax (includes printer address).

For 4232 Model 302 the active interface could be:


• Parallel
• RS232
• RS422
This key is active only when the printer is online not ready.

IBM 4230 and 4232 Printers Maintenance Information Manual 000-36


General Information 000-37

PA1 Key (4230 Models 201, 202, 2I1, 2S2, 5I3, and 5S3)

Pressing the blue PA1 key sends a PA1 request to the host. The PA1
request is defined by the host program as a special operator request.
This key is active only when the data stream active in the printer is SCS
(the Format indicator is lighted) and the printer is not ready. (For
Models 5I3 and 5S3, it is active only when the Coaxial attachment is
active.)

The printer displays the message

061 PA1 SELECTED

until the host accepts the PA1 request. When the printer displays

063 PRINTER IN SEND STATE

press Start to activate the PA1 response to the host.

Pressing PA1 or PA2 before the send status message appears resets
the PA1 function, returning the printer to the receive status.

000-37
000-38

PA2 Key (4230 Models 201, 202, 2I1, 2S2, 5I3, and 5S3)

Pressing the blue PA2 key sends a PA2 request to the host. The PA2
request is defined by the host program as a special operator request.
This key is active only when the data stream active in the printer is SCS
(the Format indicator is lighted) and the printer is not ready. (For
Models 5I3 and 5S3, it is active only when the coaxial attachment is
active.)

The printer displays the message

062 PA2 SELECTED

until the host accepts the PA2 request. When the printer displays

063 PRINTER IN SEND STATE

press Start to activate the PA2 response to the host.

Pressing PA2 or PA1 before the send status message appears resets
the PA2 function, returning the printer to the receive status.

020 - Controls
The 4230 and 4232 Printer controls include the power switch and the
alarm. This section describes both.

IBM 4230 and 4232 Printers Maintenance Information Manual 000-38


General Information 000-39

021 - Power Switch


The power switch, located toward the rear on the lower left side of the
printer, has two positions:
• On (|)
• Off (O).

This switch should remain On (|) during printing operations unless you
are having printer problems. If you switch the power Off (O), you must
wait at least 5 seconds before you switch the power On (|) again.

If printing must be stopped to align or change forms, or to adjust or


change the print ribbon, press the Stop key.

Important
Do not switch the printer power Off (O) or you may lose data in
the printer buffer and data coming from the system to your
printer.

023 - Alarm
The printer alarm, located in the lower left corner of the operator panel,
“beeps” (if it is enabled) to show a printer error or status condition. The
alarm also beeps briefly as part of the display and indicator tests.

When the alarm beeps, it emits a tone nearly every second for
approximately one third of a second. Press the Stop or Start key to
switch off the alarm beep.

Use the Configuration Menu to enable or disable the alarm, or to adjust


its volume.
Note: The alarm sounds a short beep (whether it is enabled or
disabled) when you press the Set Top of Form key. Some printer error
(unit check) conditions may also override the alarm setting.

000-39
000-40

030 - Printer Functional Units


This section describes each of the printer functional units.

031 - Print Mechanism


The print mechanism is the mechanical base of the printer. It consists of
two side frames, a permanently installed platen, the print head carrier,
shafts, forms motor, print head motor, drive belt, ribbon motor, sensors,
and cable assemblies.

Print Head Drive

The print head drive is a DC motor with an encoder attached at the end
of the motor. The printer logic board tracks and controls print head
movement. A belt attaches the motor to the print head carrier. The
tension spring on the idler assembly adjusts the belt tension
automatically.

The printer logic board sets the encoder to zero when the print head is in
the left-most (home) position. The printer references all print head
movement from the home position and automatically returns the print
head to the home position when the printer is inactive for more than
three seconds.

Error codes display for overcurrent conditions, open-motor or driver


circuits, and internal driver failures on the printer logic board.

IBM 4230 and 4232 Printers Maintenance Information Manual 000-40


General Information 000-41

Print Head

The print head consists of nine ballistic print wires. Electromagnets


activate the wires through mechanical rocker-arm hammers. The print
head will last for approximately 750 million DP print characters for all
4230 and 4232 printers, depending on the ribbons being used. The
ribbons must be IBM or equal ribbons. For more information about
ribbons, see “Ribbons” on page 000-43.

032 - Forms Drive


The forms drive is a DC stepper motor controlled by a printer logic
board.

Error codes display for open-motor or logic-board circuits and internal


logic-board failures.

033 - Forms Devices


The 4230 Printer uses one of four forms devices to transport forms
through the printer:
• Continuous Forms Device (F1)
• Dual Purpose Forms Device (F2)
• Document Insertion Device (F3)
• Auto Sheet Feeder Device (F4).

Continuous Forms Device (F1)

The F1 forms device is optional on all models. It consists of two pin feed
tractors, a drive train, an adjustable paper tension device, and a frame.
The F1 forms device installs inside the printer and vertically positions
continuous forms (paper sheets separated by perforations).

The F1 forms device is normally used when printing large volume work
or work that requires minimal operator intervention. The F1 forms

000-41
000-42

device feeds forms having from one to a maximum of six parts. Forms
with more than four parts should be tested for acceptable operation.

Dual Purpose Forms Device (F2)

The F2 forms device is the default device on all models. It consists of


two pin feed tractors, feed rollers, a drive train, forms separation device,
and a frame. When positioned inside the printer, the tractors are located
below the platen and the two sets of feed rolls (four total) are above the
platen. The right hand rolls and tractor assembly can be adjusted to the
left or right as a unit.

The F2 forms device lets a form be easily torn off using a forms
separation device after the form has been printed and positioned. The
F2 forms device feeds forms having from one to a maximum of six parts.
Forms with more than four parts should be tested for acceptable
operation.

Document Insertion Device (F3)

The F3 forms device is optional on all models. It consists of a set of feed


rolls, drive gears, and a frame. Each roll set consists of two sets of
rollers (four total), one set above the platen and one below. Included
with the device is a left edge guide that connects to the paper insertion
sensor, and a special paper door.

The F3 forms device installs inside the printer to vertically position


single-part cut forms (single paper sheets). Multiple-part forms can be
used, but should be tested for acceptable operation.

IBM 4230 and 4232 Printers Maintenance Information Manual 000-42


General Information 000-43

Auto Sheet Feeder Device (F4)

The F4 forms device is available on all models. It is a mechanical sheet


feeder with four input bins. Three bins are fully automatic; the fourth bin
provides manual insertion ability. You select a bin from the
Configuration Menu; selecting a bin starts a series of reverse, forward,
and reverse forms motor movements.

The Auto Sheet Feeder consists of a paper separator (the ASF


mechanism) that is placed on the printer table in front of the printer, the
F4 forms device that attaches to the platen, and the output
stacker/printer access cover (output hopper). The F4 forms device
consists of four sets of feed rollers, two below and two above the platen.

The F4 forms device can automatically feed single, multiple-part, and


preprinted forms. The F4 forms device attaches directly to the forms
drive system. No electrical connection is required.

034 - Ribbon Drive


The ribbon drive motor is a DC motor controlled by the printer logic
board. There is an overcurrent detection circuit for the ribbon drive. All
other failures are observed as print or ribbon failures.

Ribbons

Note: The IBM ribbons for the IBM 4230 and 4232 Printers are
specially formulated with a lubricating ink that ensures suitable print
head performance. The use of ribbons that do not meet IBM
specifications could result in binding print wires or missing dots.

Each ribbon is packed in a disposable cartridge that installs on the print


mechanism. For information about ribbon cartridge part numbers, see
“051 - Replaceable Units” on page 000-47.

000-43
000-44

035 - Cooling Fan


The cooling fan is driven by a DC motor and runs at full speed during
printing and slow speed when the printer is idle.

036 - Sensors
The following are the printer sensors:
• Hole count sensor (Paper Jam)
• End of forms sensor
• Paper present sensor
• Door open sensor
• Cover open sensor
• Automatic Forms thickness sensor.
Note: The cover open sensor is part of the operator panel.

End of Forms Sensor

F1 or F2 Forms Devices: The forms sensor detects the last form


feeding into the printer. When the trailing edge of the form passes this
sensor, the printer will continue normal printing for 6.3 inches (160 mm).
The printer will then post the END OF FORMS message.

If the hole count sensor (Paper Jam Sensor), located in the end of forms
assembly, does not detect a hole within 2 inches (50.8 mm) of forms
movement a PAPER JAM message is displayed on the operator panel.

F3 Forms Device: The forms sensor shows when paper is inserted


and signals the device to move the paper to the first print line.

F4 Forms Device: The forms sensor signals the printer to load


another form from the same bin as the previous form.

IBM 4230 and 4232 Printers Maintenance Information Manual 000-44


General Information 000-45

Paper Present Sensor

F3 Forms Devices: If the paper present sensor does not detect


paper when the Load/Eject key is pressed, the printer displays an error
condition at the operator panel.

F4 Forms Device: If the paper present sensor does not detect a form
when it loads, the printer displays an error condition at the operator
panel.

Door Open and Cover Open Sensors

These sensors cause the printer to print at a slower speed (211.7 mm,
8 1/3 inches per second) when you open the access cover or the front
paper door.

Automatic Forms Thickness Sensor

For the printer to perform correctly, the print head must have a usable
range of head to platen gap over which it can operate. The automatic
forms thickness sensor senses the AFTA gear flag as the flag passes
through the sensor.

037 - Power Supply


There is one power supply provided to operate in the AC input voltage
range. The power supply has a factory or CE selectable voltage switch
to select input voltage 115 V or 230 V The voltage selection switch is not
accessible to the customer.

The power supply (a high frequency switching design) accepts a single


phase, 50/60 Hertz AC input, and generates a single regulated +38 Volt
DC output. Input power protection is provided. The power supply output
has under voltage, over voltage, over current, and short circuit

000-45
000-46

protection circuits, which will switch off the power supply under fault
conditions.

038 - Printer Logic Board


The printer logic board contains the logic for all electro-mechanical
functions and basic operations as instructed by the host program or the
operator through the operator panel. The board also contains driving
circuits for all electro-mechanical functions, and the microprocessor that
performs the power-on self test (POST).

4230 Only
The attachment logic resides on the printer logic board and connects
to the attachment bezel by a cable.

040 - Attachment Bezel (4230 Only)


The IBM 4230 Printer attaches to twinaxial or coaxial or combinations of
twinaxial/serisl/parallel or coaxial/serial/parallel cable systems,
depending on the model of printer. The bezel connects the printer and
the using system. The attachment bezel connects by a cable to J1 on
the printer logic board. The attachment logic resides on the printer logic
board.

041 - Attachment Card/Bezel (4230 Models 4I3,


4S3, 5I3, 5S3, and 4232 Model 302)
The IBM 4232 Printer attaches to serial and parallel cable systems. The
attachment card/bezel connects the printer and the using system. The
card/bezel connects to the printer logic board at connector J5. The
attachment logic resides on the attachment card.

IBM 4230 and 4232 Printers Maintenance Information Manual 000-46


General Information 000-47

050 - Diagnostics
This section describes methods used to determine what is causing the
printer to fail. It contains instructions for selecting repair tests and the
customer tests necessary for successful diagnosis to isolate the failing
unit.

Printouts are provided to help you check the output of the printer against
the expected results for the tests.

051 - Replaceable Units


The IBM 4230 and 4232 Printers are designed so that service work can
be done simply. The repair procedures make it not necessary to find
failing parts down to the smallest part. Rather, the printer is divided into
convenient replaceable units.

Customer-Replaceable Unit (CRU)

The CRUs are units that customer personnel exchange to repair a


printer. The only CRU is the ribbon cartridge.

Two ribbon cartridges are available for use on the 4230 and 4232
Printers. IBM part number 1040580 has a black multipurpose ink with
an average ribbon life of 15 million DP characters. IBM part number
1040440 has a black general purpose ink with an average ribbon life of
6 million DP characters. The customer can remove and reinstall the
ribbon cartridge with the printer cover still on the printer. Internal parts
are not accessible.

Order replacement ribbon cartridges from IBM Supplies (Direct) at


1-800-IBM-2468.

000-47
000-48

Field-Replaceable Unit (FRU)

The FRUs are units that service personnel exchange to repair a printer.
Internal parts are fully accessible. A maintenance procedure for each
FRU is in Sections 100 through 670.

052 - Operator Tests


Operator tests let the operator perform tests and functions from the
operator panel.

Operator Test Descriptions

The following offline operator tests are available:


• Printer configuration (See “Printer Configuration” on page 000-49.)
• Bidirectional adjustment (See “Bidirectional Adjustment” on
page 000-71.)
• Left margin alignment (See “Left Margin Alignment” on
page 000-61.)
• Printer demonstration (See “Printer Demonstration” on
page 000-62.)
• Printer verification (See “Printer Verification” on page 000-62.)
• Top of form alignment. (See “Top of Form Alignment” on
page 000-62.)

Selecting Operator Tests

To select operator tests, follow these steps:


1. Press the Stop key to make the printer not ready.
2. Press the Test key. The option list of tests is displayed.
3. Use the Scroll or Scroll keys to display the desired test.
4. Press Start to start the test.
5. Press Stop when the test is complete.

IBM 4230 and 4232 Printers Maintenance Information Manual 000-48


General Information 000-49

6. Press the Cancel Print key to make the printer READY and online.

Printer Configuration

The printer configuration test prints the existing values for the printer
configuration parameters.

Important Notes:
1. There are four possible configuration sets (A, B, C, and D) that can
be stored in this printer. Ask the customer if they use these
configuration sets. If configuration sets are used:
• Recall and print each configuration set
• If the configuration identification character (A, B, C, or D) does
not print at the top of the printout, write the correct character on
each printout.
• Retain the printouts to use when entering the configuration data.
2. If you are replacing a printer logic board:
• Print the all 4 configuration sets (A, B, C, and D) before
removing the old board
• Install the new board
• Enter the configuration data
• Perform the AFTA setting procedure on 000-109.
• Perform the Bidirectional adjustment on “Bidirectional
Adjustment” on page 000-71.
3. Store the printer configuration printouts with the printer for future
use.
4. For 4230 Models 4I3, 4S3, 5I3, and 5S3 printers, the active
configuration selection must match the attachment selected. See
the User's Guide.

Each parameter is shown with its corresponding value printed to the


right. The category and parameter names are printed in the existing

000-49
000-50

Display Language used on the operator panel. See Figure 6 on


page 000-52 through Figure 10 on page 000-60 for sample printouts.

Note: Sample Printer Configuration Printouts for 4230 Models 4I3, 5I3,
4S3, and 5S3 are not available.

To print the printer configuration


1. Press the Stop key to make the printer NOT READY.
2. Press the Test key.
The printer displays

OPERATOR PRINT TESTS


Printer Demonstration

3. Press Scroll or Scroll until the printer displays

OPERATOR PRINT TESTS


Printer Configuration

4. Press Enter or Start.


The Ready indicator goes on and printing starts. If the configuration
identification character (A, B, C, or D) does not print at the top of the
printout, write the correct character on each printout. The
configuration printout is complete when the Ready indicator goes
off.
5. Press the Return key until NOT READY is displayed.
6. If other configuration sets need to be printed, go to the next step.
If printing is completed, stop here.
7. To access other configuration sets, press Menu.
8. Press Scroll or Scroll until the printer displays

IBM 4230 and 4232 Printers Maintenance Information Manual 000-50


General Information 000-51

CONFIGURATION MENU
Configuration Storage

9. Press Enter.
10. Press Scroll or Scroll until the printer displays

Configuration Storage
Recall Custom Set Values

11. Press Enter.


12. Press Scroll or Scroll until the desired Custom Set value is
displayed (X is A, B, C, or D).

Recall Custom Set Values


Custom Set X

13. Press Enter.


14. Press the Return key until NOT READY is displayed.
15. Go to Step 2 on page 000-50.

000-51
000-52

IBM 4230 and 4232 Printers Maintenance Information Manual 000-52


General Information 000-53

Figure 6. Sample Printer Configuration Printout (4230 Models 102 and 1I1)

000-53
000-54

IBM 4230 and 4232 Printers Maintenance Information Manual 000-54


General Information 000-55

Figure 7. Sample Printer Configuration Printout (4230 Models 202 and 2I1)

000-55
000-56

IBM 4230 and 4232 Printers Maintenance Information Manual 000-56


General Information 000-57

Figure 8. Sample Printer Configuration Printout (4230 Models 101 and 1S2)

000-57
000-58

IBM 4230 and 4232 Printers Maintenance Information Manual 000-58


General Information 000-59

Figure 9. Sample Printer Configuration Printout (4230 Models 201 and 2S2)

000-59
000-60

Figure 10. Sample Printer Configuration Printout (4232 Model 302)

IBM 4230 and 4232 Printers Maintenance Information Manual 000-60


General Information 000-61

Bidirectional Adjustment

This procedure is the same as the CE procedure. Go to “Bidirectional


Adjustment” on page 000-71.

Left Margin Alignment


The left margin alignment test prints a single line of text to help in setting
the left margin position. You can also change the existing left margin
position with this test.

You can set the left margin position from 1 to 66 units (each unit is
0.686 mm [0.027 in.]). The default is 10. The margin starts at 3.81 mm
(0.15 in.) from the center of the tractor pins for continuous forms and
from the left edge of a cut form.

To align the left margin position:


1. Enter the Operator Print Tests (see “Selecting Operator Tests” on
page 000-48).
The printer displays

OPERATOR PRINT TESTS


Printer Demonstration

2. Press Scroll or Scroll until the printer displays

OPERATOR PRINT TESTS


Left Margin Alignment

3. Press Enter or Start to start the test.


The printer displays

000-61
000-62

Left Margin Position


* xxx

where xxx is the existing value of the left margin position. The
printer also prints a single line of H’s.
4. If the H’s do not start where you want the left margin, press Scroll
or Scroll until the printer displays the desired value.
5. Press Enter.
An asterisk ( ) appears in front of the selected value. The forms
*
advance one line and the row of H’s prints again.
6. Repeat steps 4 and 5 until the left margin is correctly aligned.

Printer Demonstration

The printer demonstration test prints samples of what the printer can do.
The samples include text of all possible print qualities. 4230 Models
102, 202, 1I1, 2I1, 4I3, 5I3, and 4232 Model 302 also print
representative charts, graphs, and bar codes. This test may be
performed without the printer being connected to a host.

Printer Verification

The printer verification test verifies general print quality. The test prints
nine horizontal lines (using each wire in the print head), two lines of DP
characters, and two lines of NLQ characters.

Top of Form Alignment

The top of form alignment test prints a single line of text to help in setting
the top of form position. The test prints rows of H’s until the top of form
position is adjusted.

To perform the top of form alignment, follow these steps:

IBM 4230 and 4232 Printers Maintenance Information Manual 000-62


General Information 000-63

1. Select the test from the test menu (see “Selecting Operator Tests”
on page 000-48).
2. Press Enter. The printer performs a form feed to move to the
existing top of form position and prints a single line of H’s.
3. If the H’s do not print at the correct top of form position, adjust the
setting with the following keys:
Line Feed Advance form one line.
Micro Move form forward 0.35 mm (1/72 in.)
Micro Move form backward 0.35 mm (1/72 in.)
When the adjustment is correct, press Enter (to print the H’s on the
same page) or Form Feed and then Enter (to print the H’s at the top
of form position on the next page).
4. Press Set Top of Form to set the new position.

056 - Offline CE Tests Descriptions


This section describes the error log and error log utilization. It also
describes how to perform offline CE tests and describes the following
tests:
• Operator Panel Test (See “Operator Panel Test” on page 000-67.)
• Power On Operator Panel Test (See “Power On Operator Panel
Test” on page 000-68.)
• Sensor Test (See “Sensor Test” on page 000-68.)
• AFTA Setting (See “AFTA Setting” on page 000-69.)
• Print Wire Test (See “Print Wire Test” on page 000-70.)
• Print Wire Test 2 (See “Print Wire Test 2” on page 000-70.)
• Bidirectional Adjustment (See “Bidirectional Adjustment” on
page 000-71.)
• NLQ Print Quality Test (See “NLQ Print Quality Test” on
page 000-72.)
• NLQ 80 Ripple Pattern (See “NLQ 80 Ripple Pattern” on
page 000-73.)
• DP Print Quality Test (See “DP Print Quality Test” on page 000-74.)

000-63
000-64

• DPT Print Quality Test (See “DPT Print Quality Test” on


page 000-75.)
• Fast Draft Quality Test (See “Fast Draft Quality Test” on
page 000-76.)
• 20 CPI Test (See “20 CPI Test” on page 000-77.)
• 17.1 CPI Test (See “17.1 CPI Test” on page 000-78.)
• 16.7 CPI Test (See “16.7 CPI Test” on page 000-79.)
• 15 CPI Test (See “15 CPI Test” on page 000-80.)
• 12 CPI Test (See “12 CPI Test” on page 000-81.)
• 10 CPI Test (See “10 CPI Test” on page 000-82.)
• Slow Head Test (See “Slow Head Test” on page 000-83.)
• Fast Head Test (See “Fast Head Test” on page 000-84.)
• Attachment Storage Dump (4230 only) (See “Attachment Storage
Dump (4230 Only)” on page 000-84.)
• Print ROS Part Numbers (See “Print ROS Part Numbers Test” on
page 000-84.)
• Forms Motor Test (See “Forms Motor Test” on page 000-85.)
• Bin 1 Selection Test (See “Bin 1 Selection Test (F4 - AFS Forms
Drive)” on page 000-85.)
• Bin 2 Selection Test (See “Bin 2 Selection Test (F4 - AFS Forms
Drive)” on page 000-85.)
• Bin 3 Selection Test (See “Bin 3 Selection Test (F4 - AFS Forms
Drive)” on page 000-85.)
• Bin 4 Selection Test (See “Bin 4 Selection Test (F4 - AFS Forms
Drive)” on page 000-86.)
• Ribbon Motor Test (See “Ribbon Motor Test” on page 000-86.)
• Display Memory Locations (See “Display Memory Locations” on
page 000-86.)
• Enable/Disable Cover Sensors (See “Enable/Disable Cover
Sensors” on page 000-86.)
• Print Usage Metrics (See “Print Usage Metrics” on page 000-87.)
• Print Error Log (See “Print Error Log” on page 000-87.)
• Set Factory Defaults (See “Set Factory Defaults” on page 000-88.)
• Clear Error Log. (See “Clear Error Log” on page 000-88.)

IBM 4230 and 4232 Printers Maintenance Information Manual 000-64


General Information 000-65

Performing Offline CE Tests

To perform an offline CE test, follow these steps:


1. To access the offline CE tests, press Stop to make the printer not
ready.
2. Press and hold the Test key, and then press Quick Reference.
Release both keys.
3. Press Menu.
Note: There can be a delay of up to 5 seconds after the Menu key
is depressed before the display changes.
4. Use the Scroll or Scroll keys to display the desired test.
5. Press Enter to start the test.
6. Press Stop to stop the test.
7. Press Return to leave the Offline CE Test Menu, perform a partial
reset, and return the printer to not ready.
Note: Pressing Cancel Print at any time while in Test mode will cause
the printer to stop the test in process, leave Test mode, perform a partial
reset, and return the printer to ready.

000-65
000-66

Error Log

Seventeen bytes in Non-Volatile Random Access Memory (NVRAM) are


reserved for the printer internal error log, which consists of eight error
code bytes, eight corresponding number bytes, and one control byte.

When an error is found during printer operation, the error is placed into
the error log and the number byte is increased accordingly. If the error
code is not in the error log, a new entry in the log is used to represent
the new error. When the error log has been filled with eight codes, the
last entry in the log is moved out and a new log entry and number is
rotated in. If the error number reaches 255, the number value for that
error is no longer increased.

When the error code differs from the last recorded error code, the new
error is indicated by an asterisk (*).

Example
Error Count Description
000A1 001 MACHINE CHECK
* 00052 020 MACHINE CHECK
00002 025 FORMS JAM

In this example, 52 is the most recent error and it occurred 20 times.

Error Log Utilization

Use the offline CE tests to get the error log. The CE option Print Error
Log prints the existing error log. On the printed error log, the most
recent error entry is displayed with an asterisk next to it. The error
codes are displayed followed by a number value. Each code/number
set of two is printed on a single line.

The error log is intended to be used by service personnel to recognize


any intermittent or possible future problems with the printer. The CE

IBM 4230 and 4232 Printers Maintenance Information Manual 000-66


General Information 000-67

may clear the error log by selecting the Clear Error Log test in the
Offline CE Tests Menu.

Operator Panel Test

This test performs the following tests:


LED and Audio Alarm Test
The printer displays

LED and AUDIO ALARM test

Each LED (except the power LED) goes on for one second. After
the illumination sequence repeats three times, all LEDs blink three
times. The audio alarm sounds and then changes tone from low to
high volume. Finally, all LEDs (except the power LED) blink, and
the alarm sounds.
LCD Test
The printer displays

LCD test

Each pixel in the LCD displays for three seconds. A horizontal bar
separated by a blank line displays for three seconds, then the
display alternates between the blank line and the bar. A vertical
bar separated by a blank line displays for three seconds, then the
display alternates between the blank line and the bar. (If the
vertical or horizontal bar is not separated by a blank line, the LCD
is faulty.) The printer then displays 80 random characters starting
with 0,1,2,..., followed by special characters and the alphabet.
Key Test
If you entered the test using the “Power On Operator Panel Test”
on page 000-68, the printer displays

000-67
000-68

Press each key to test


To exit, power down the printer

If you entered the test while the printer was running and in the
offline CE test mode, the printer displays

Press each key to test


To exit, hold STOP.

Press each key to test. If a key is performing correctly, the number


on the display that corresponds to the key disappears when the
key is pressed and reappears when it is released. Do not press
the keys multiple times. To exit, hold STOP.

Power On Operator Panel Test

While powering on, press and hold the Start and Test keys until the
printer displays

Operator Panel Unit CE Test

To leave the test, switch off power and then switch on power.

Sensor Test
This test verifies the operation of the following sensors:
• Paper present sensor (PP)
• End of forms/top of form sensor (EOF)
• Hole count sensor (HC) (Paper Jam Sensor)
• Cover open sensor (CO)
• Door open sensor (DO)
• AFTA home sensor (AF).

IBM 4230 and 4232 Printers Maintenance Information Manual 000-68


General Information 000-69

The panel displays the following information:

PP=X EOF=X HC=X CO=X DO=X AF=X

The displayed sensor values are either 0 or 1, and change as paper


passes over the sensor, the door is opened or closed, or the AFTA flag
passes over sensor.

The sensors are located as follows:


Sensor Location
Paper present On the head carrier
End of forms On the outer edge of the entry chute
Hole count (Paper Jam) On the inside part (far left) of the end of forms
sensor
Cover open On the left side of the operator panel
Door open On the left side of the entry chute.
AFTA home On the left end of the head carrier shaft.

AFTA Setting

AFTA setting must be done after exchanging the following FRUs:


• AFTA Assembly (“385 - AFTA Assembly” on page 300-26)
• Carrier shaft (“385 - AFTA Assembly” on page 300-26)
• Carrier assembly (“329 - Print Head Carrier and Shaft” on
page 300-6)
• Printer logic board (“211 - Printer Logic Board” on page 200-2)
• Print head (“321 - Print Head” on page 300-2).

This test calibrates the gap between the print head and the platen. An
optimum gap ensures suitable print quality and print head life. “AFTA
Setting Procedure” on page 000-109 describes how to perform the
AFTA Setting test. The test requires a feeler gauge.

000-69
000-70

Print Wire Test

The AFTA setting procedure on “AFTA Setting Procedure” on


page 000-109 should be performed before performing this test. If the
throat gap is too big, it can appear as though a print wire is missing.

This test verifies that all print wires are working. In the Offline CE Test
Menu, scroll to Print Wire Test and press Enter. Nine horizontal lines
with their associated wire numbers should print. Missing lines can be
diagnosed by putting the print head cable into the test position, running
print wire test 2, and following MAP procedures (see Figure 11).

Print Wire Test 2

The AFTA setting procedure on “AFTA Setting Procedure” on


page 000-109 should be performed before performing this test. If the
throat gap is too big, it can appear as though a print wire is missing.

This test isolates a problem in the print drivers or the print head.

Figure 11. Print Head Cable Connector in Test Position (Print Wire Test 2)

IBM 4230 and 4232 Printers Maintenance Information Manual 000-70


General Information 000-71

Bidirectional Adjustment
This test allows horizontal adjustment to be made from the operator
panel. It adjusts dot registration, and print quality, for characters that are
made with two passes of the print head in opposite directions
(bidirectional printing).

To perform the bidirectional adjustment, follow these steps:


1. Select the test from the test menu (see “Performing Offline CE
Tests” on page 000-65).
2. Press Enter. The printer prints 11 lines and ejects the paper.
3. Use the Scroll and Scroll keys to indicate the line with the best
appearance.
4. Press Enter to save the new value. A line of NLQ characters prints
to show the new value. If no new selection is made, no line prints.
5. If the new value does not correct your print quality problem, repeat
the bidirectional adjustment.
Note: If a problem still exists check the carrier drive belt tension, and
the clamp on the bottom of the carrier to ensure that the mounting
screws are tight.

000-71
000-72

NLQ Print Quality Test

This print test verifies print quality in near letter quality (NLQ) mode. A
ripple pattern prints until you press the Stop key. Figure 12 shows a
sample printout of this test.

Note: This test requires the installation of 14 inch wide paper.

Figure 12. NLQ Print Quality Test Sample

IBM 4230 and 4232 Printers Maintenance Information Manual 000-72


General Information 000-73

NLQ 80 Ripple Pattern

This test verifies print quality in NLQ 80 column mode. This routine
prints a ripple pattern and is for testing in F3 or F4 mode on 8 inch
paper, or in F1 or F2 with 9 inch paper. The ripple pattern prints until
you press the Stop key. Figure 13 shows a sample printout of this test.

Note: This test requires the installation of 8 or 9 inch wide paper.

Figure 13. NLQ 80 Print Quality Test Sample

000-73
000-74

DP Print Quality Test

This print test verifies print quality in data processing (DP) mode. A
ripple pattern prints until you press the Stop key. Figure 14 shows a
sample printout of this test.

Note: This test requires the installation of 14 inch wide paper.

Figure 14. DP Print Quality Test Sample

IBM 4230 and 4232 Printers Maintenance Information Manual 000-74


General Information 000-75

DPT Print Quality Test

This print test verifies the print quality in data processing text (DPT)
mode. A ripple-pattern prints until you press the Stop key. Figure 15
shows a sample printout of this test.

Note: This test requires the installation of 14 inch wide paper.

Figure 15. DPT Print Quality Test

000-75
000-76

Fast Draft Quality Test

This print test verifies the print quality in fast draft (FD) mode. Figure 16
shows a sample printout of this test.

Note: This test requires the installation of 14 inch wide paper.

Figure 16. Fast Draft Print Quality Test

IBM 4230 and 4232 Printers Maintenance Information Manual 000-76


General Information 000-77

20 CPI Test
This test prints 264 characters at 20 CPI. It verifies full line print
registration.

Verify that the print density is the same at the left edge and the right
edge. The test pattern prints until you press the Stop key. Figure 17
shows a sample printout of this test.

Note: This test requires the installation of 14 inch wide paper.

Figure 17. 20 CPI Test Sample

000-77
000-78

17.1 CPI Test


This test prints 225 characters at 17.1 CPI. It verifies full line print
registration.

Verify that the print density is the same at the left edge and the right
edge. The test pattern prints until you press the Stop key. Figure 18
shows a sample printout of this test.

Note: This test requires the installation of 14 inch wide paper.

Figure 18. 17.1 CPI Test Sample

IBM 4230 and 4232 Printers Maintenance Information Manual 000-78


General Information 000-79

16.7 CPI Test


This test prints 220 characters at 16.7 CPI. It verifies full line print
registration.

Verify that the print density is the same at the left edge and the right
edge. The test pattern prints until you press the Stop key. Figure 19
shows a sample printout of this test.

Note: This test requires the installation of 14 inch wide paper.

Figure 19. 16.7 CPI Test Sample

000-79
000-80

15 CPI Test
This test prints 198 characters at 15 CPI. It verifies full line print
registration.

Verify that the print density is the same at the left edge and the right
edge. The test pattern prints until you press the Stop key. Figure 20
shows a sample printout of this test.

Note: This test requires the installation of 14 inch wide paper.

Figure 20. 15 CPI Test Sample

IBM 4230 and 4232 Printers Maintenance Information Manual 000-80


General Information 000-81

12 CPI Test
This test prints 158 characters at 12 CPI. It verifies full line print
registration.

Verify that the print density is the same at the left edge and the right
edge. The test pattern prints until you press the Stop key. Figure 21
shows a sample printout of this test.

Note: This test requires the installation of 14 inch wide paper.

Figure 21. 12 CPI Test Sample

000-81
000-82

10 CPI Test

This test prints 132 characters at 10 CPI. It verifies full line print
registration.

Verify that the print density is the same at the left edge and the right
edge. The test pattern prints until you press the Stop key. Figure 22
on page 000-83 shows a sample printout of this test.
Note: This test requires the installation of 14 inch wide paper.

IBM 4230 and 4232 Printers Maintenance Information Manual 000-82


General Information 000-83

Figure 22. 10 CPI Test Sample

Slow Head Test


This test verifies that the print head runs correctly by printing blanks at
10 CPI in NLQ mode.

000-83
000-84

Fast Head Test

This test verifies that the print head runs correctly by printing blanks at
10 CPI in DP mode.

Attachment Storage Dump (4230 Only)


This procedure prints the data that is in the attachment storage buffer.
This data includes the following:
• Attachment Error Log
• Attachment Control Blocks
• Attachment ROS Number
• One or more attachment buffers.

Print ROS Part Numbers Test

This test prints the controller card EPROM numbers.

Example
ROS0 ROS1 ROS2
6351193 6351194 6351195
where ROSn = the controller card EPROM or ROS part numbers.
Note: The number of ROS part numbers printed is model dependent.

IBM 4230 and 4232 Printers Maintenance Information Manual 000-84


General Information 000-85

Forms Motor Test

This test verifies that the forms motor runs correctly. The forms motor
runs continuously with or without the ribbon or a forms device (all
sensors are ignored). This test runs until an error is detected or the
Stop key is pressed. For F3 forms devices, remove all paper from the
printer before starting the test. This test does not load and eject forms
from the Auto Sheet Feeder mechanism.

Bin 1 Selection Test (F4 - AFS Forms Drive)

This test selects a form from bin 1 and loads it into the print position.
Pressing Enter with the form already loaded causes a line of 75 blanks
to print. Pressing Load/Eject ejects the form. No operation results for
non-F4 printers or an F4 printer with the forms device F1, F2, or F3
selected.

Bin 2 Selection Test (F4 - AFS Forms Drive)

This test selects a form from bin 2 and loads it into the print position.
Pressing Enter with the form already loaded causes a line of 75 blanks
to print. Pressing Load/Eject ejects the form. No operation results for
non-F4 printers or an F4 printer with the forms device F1, F2, or F3
selected.

Bin 3 Selection Test (F4 - AFS Forms Drive)

This test selects a form from bin 3 and loads it into the print position.
Pressing Enter with the form already loaded causes a line of 75 blanks
to print. Pressing Load/Eject ejects the form. No operation results for
non-F4 printers or an F4 printer with the forms device F1, F2, or F3
selected.

000-85
000-86

Bin 4 Selection Test (F4 - AFS Forms Drive)

This test selects a form from bin 4, the manual bin. When Start is
pressed without a form loaded in the printer, the printer displays

010 LOAD MANUAL BIN


PRESS STOP, THEN ENTER

Insert a form in the manual bin. Press Stop to clear the message, and
then press Enter to run the test. Pressing Enter with a form already
loaded in the printer causes a line of 75 blanks to print. Pressing
Load/Eject ejects the form. No operation results for non-F4 printers or
an F4 printer with the forms device F1, F2, or F3 selected.

Ribbon Motor Test

This test verifies that the ribbon drive motor runs correctly. The motor
runs continuously with or without a ribbon or forms device installed. All
sensors are ignored during the test. Press the Stop key to leave the
test. When testing a printer with the F3 forms device installed, remove
all paper from the printer before starting the test.

Display Memory Locations

This test allows the CE to inspect memory locations in RAM and ROM.
Leave the test by pressing Cancel Print or Stop.

Enable/Disable Cover Sensors

This test allows the printer to ignore the cover and door sensors while
testing. It allows the printer to run at full speed with cover or door, or
both, removed. The CE must enable the sensors or power-off the
printer, or the sensors will remain ignored during normal operations.

IBM 4230 and 4232 Printers Maintenance Information Manual 000-86


General Information 000-87

Perpetual AFTA

This test helps isolate AFTA problems. To leave the test, press Stop.

Note: This test is for engineering use only, the service representative
should not use this test.

AFTA Run In

This test helps isolate AFTA problems. To leave the test, press Stop.

Note: This test is for engineering use only, the service representative
should not use this test.

Print Usage Metrics

This test prints numbers, in decimal value, for the following data:
• Power-on Hours
• Power-on Cycles
• Fast Draft, DP, DPT, NLQ characters
• Number of barcodes (4230 Models 102, 202, 1I1, 2I1, 4I3, 4S3, 5I3,
5S3, and 4232 Model 302 only)
• Number of pages with graphics (4230 Models 102, 202, 1I1, 2I1,
4I3, 4S3, 5I3, 5S3, and 4232 Model 302 only).

Print Error Log


This test prints the Error Log. The most recent error is displayed with an
asterisk (*) next to the error code.

000-87
000-88

Set Factory Defaults

This test resets the printer factory defaults. Select the test with the
Enter key. The printer displays

Enter to reset defaults and custom sets

Press Enter to set the factory defaults.


Note: You can press Stop to return to the offline CE Test menu, or
Cancel to return to the ready status.

After the test completes, the printer displays

FACTORY DEFAULTS SET

for two seconds, and then the display clears.

Notes:
1. The Set Factory Defaults test resets the customer configuration to
the factory default.
2. Unless factory defaults are stored to a custom set, the custom set
indicator will display a blank. This display indicates a static
configuration which will be lost when the printer is powered off.

Clear Error Log

This test clears the error log and number bytes. After pressing the Enter
key, the printer displays a message stating that the error log is cleared.

IBM 4230 and 4232 Printers Maintenance Information Manual 000-88


General Information 000-89

057 - Service Checks


Perform the service checks specified in the MAPs.

Print Density (Light/Dark) Service Check


1. Ensure that the power supply voltage switch is set for the correct
voltage.
2. Check the Lighter/Darker setting. While the printer is printing, press
and hold the darker or lighter key. A grid will display on the operator
panel showing where print density is set. Each time the lighter or
darker key is pressed, an adjustment is made in that direction.
3. Observe while printing to verify that the ribbon moves while printing.
4. Remove the ribbon.
Check the condition of the ribbon. The ribbon should be exchanged
if it is:
a. Dry (no ink)
b. Folding
c. Worn or torn
d. The ribbon shield is damaged or worn
e. Ensure the ribbon is installed correctly (800-2).
5. Inspect the forms device.
• Ensure that the forms device is installed correctly and the
tractors are adjusted correctly (800-7).
• If F1 is being used, ensure that the forms tension knob is
adjusted correctly (800-13).
6. Ensure that the print head latch (Figure A) is secure and correctly
latched (300-2).
7. Ensure that the print head stop screw, at the right side of the carrier
(Figure B), is adjusted correctly (300-3).

000-89
000-90

8. Manually move the print head carrier from one side frame to the
other to check for binds. Exchange the failing print head carrier and
shaft if necessary (300-6).
9. Perform the AFTA setting test on page 000-109 to ensure the platen
gap is correct.
10. Perform the bidirectional adjustment procedure on page 000-71.

Smearing - Print Service Check


1. Ensure that the power supply voltage switch is set for the correct
voltage.
2. Check the Lighter/Darker setting. If the setting is too dark, smearing
could occur. While the printer is printing, press and hold the darker
or lighter key. A grid will display on the operator panel showing
where print density is set. Each time the lighter or darker key is
pressed, an adjustment is made in that direction.
3. Remove the ribbon.
Check the condition of the ribbon. The ribbon should be exchanged
if it is:

IBM 4230 and 4232 Printers Maintenance Information Manual 000-90


General Information 000-91

a. Dry (no ink)


b. Folding
c. Worn or torn
d. The ribbon shield is damaged
e. Ribbon does not move while printing.
f. Ensure the ribbon is installed correctly (800-2).
4. Inspect the forms device:
• Ensure that the forms device is installed correctly and the
tractors are adjusted correctly (800-7).
• If F1 is being used, ensure that the forms tension knob is
adjusted correctly (800-13).
5. Inspect the print head, carrier, and drive assembly as follows:
a. Ensure that the print head latch (Figure A) is secure and
correctly latched (300-2).
b. Ensure that the print head stop screw, at the right side of the
carrier (Figure B), is adjusted correctly (300-3).

c. Ensure that the print head (300-2) and print head cables (300-4)
are installed correctly.

000-91
000-92

d. Inspect the carrier drive belt for worn or missing teeth (300-14)
and the idler assembly (300-16) for loose, defective, or missing
parts. If any problems are found, exchange the failing part.
e. Adjust the carrier drive belt idler assembly (300-16). Ensure that
the belt clamp is tightly connected to the carrier assembly.

f. Inspect the carrier upper bearing, support guide, pad, and


spring (300-10) for damaged, loose, or missing parts. Repair or
exchange as necessary.
6. Perform the AFTA setting test on page 000-109, to ensure the
platen gap is correct.
7. Perform the bidirectional adjustment procedure on page 000-71.

Missing Dots or Character Service Check


1. Ensure that the power supply voltage switch is set for the correct
voltage.
2. Observe while printing to verify that the ribbon moves while printing.
Note: If the print density is set too dark while printing on multi-part
forms, the print head can be too close to the platen. This can cause
the ribbon to bind against the forms and stop moving.
3. Remove the ribbon.
Check the condition of the ribbon. Turn the ribbon knob and
advance the ribbon. The ribbon should be exchanged if it is:

IBM 4230 and 4232 Printers Maintenance Information Manual 000-92


General Information 000-93

a. Dry (no ink)


b. Does not advance smoothly.
c. Folding
d. Worn or torn
e. The ribbon shield is damaged
f. Ensure the ribbon is installed correctly (800-2).
4. Inspect the forms device:
• Ensure that the forms device is installed correctly and the
tractors are adjusted correctly (800-7).
• If F1 is being used, ensure that the forms tension knob is
adjusted correctly (800-13).
5. Inspect the print head, carrier, and drive assembly as follows:
a. Ensure that the print head latch (Figure A) is secure and
correctly latched (300-2).
b. Ensure that the print head stop screw, at the right side of the
carrier (Figure B), is adjusted correctly (300-3).

c. Ensure that the print head (300-2) and print head cables (300-4)
are installed correctly.

000-93
000-94

d. Inspect the carrier drive belt for worn or missing teeth (300-14)
and the idler assembly (300-16) for loose, defective, or missing
parts. If any problems are found, exchange the failing part.
e. Adjust the carrier drive belt idler assembly (300-16). Ensure that
the belt clamp is tightly connected to the carrier assembly.

f. Inspect the carrier upper bearing, support guide, pad, and


spring (300-10) for damaged, loose, or missing parts. Repair or
exchange as necessary.
g. Manually move the print head carrier from one side frame to the
other to check for binds. Exchange the failing print head carrier
and shaft if necessary (300-6).
6. Perform the AFTA setting test on page 000-109, to ensure the
platen gap is correct.
7. Perform the bidirectional adjustment procedure (000-71).
8. Perform the print wire test (000-70).

Vertical Alignment Service Check


1. Ensure that the power supply voltage switch is set for the correct
voltage.
2. Inspect the forms device:
a. Ensure that the forms device is installed correctly and the
tractors are adjusted correctly (“820 - Forms Devices” on
page 800-7)

IBM 4230 and 4232 Printers Maintenance Information Manual 000-94


General Information 000-95

b. Remove the forms device, and look for torn pieces of paper,
foam, or other obstructions that could be causing a jam (800-7).
c. Inspect the forms feed device for broken or missing parts.
d. Rotate the drive gear on the forms feed device and check for
binds.
e. For the F1 and F2 devices, ensure that the tractor pins and the
shafts turn as you turn the drive gear.
f. For the F2 and F3 devices, ensure that the feed rolls also turn
correctly.
If any problems are found, exchange the device (800-7).
g. Verify that the forms feed drive gear (on the drive motor) and the
forms idler gear are not damaged and that they install together
correctly with the forms feed device gear (700-7). Ensure that
the gears are not packed with any foreign materials. Repair or
exchange parts as necessary.
h. If F1 is being used, ensure that the forms tension knob is
adjusted correctly (800-13).
3. Inspect the print head, carrier and drive assembly as follows:
a. Ensure that the print head latch (Figure A) is secure and
correctly latched (300-2).
b. Ensure that the print head stop screw, at the right side of the
carrier (Figure B), is adjusted correctly (300-3).

000-95
000-96

c. Inspect the carrier drive belt for worn or missing teeth (300-14)
and the idler assembly (300-16) for loose, defective, or missing
parts. If any problems are found, exchange the failing part.
d. Adjust the carrier drive belt idler assembly (300-16). Ensure that
the belt clamp is tightly connected to the carrier assembly.

e. Manually move the print head carrier from one side frame to the
other to check for binds. Exchange the failing print head carrier
and shaft if necessary (300-6).
f. Inspect the carrier upper bearing, support guide, pad, and
spring (300-10) for damaged, loose, or missing parts. Repair or
exchange as necessary.

IBM 4230 and 4232 Printers Maintenance Information Manual 000-96


General Information 000-97

4. Perform the AFTA setting procedure on page 000-109.


5. Perform the bidirectional adjustment procedure on page. 000-71.

Forms Feed Service Check


Note: Check RETAIN, if available, for the latest service and parts
information about forms feeding.
1. If the ribbon shield binds on the horizontal perforation and the top of
form position is not set at the top of the platen as described in step
18 on page 000-103, the customer software should be changed as
described in step 19 on page 000-104. If this is not done, the
following steps in this service check may partially fix the problem.
2. In cases where the F2 forms device is not needed, install the F1
forms device for best paper feed reliability. Remember to change
the Printer Configuration setting if the forms device is exchanged.
Note: Because the F1 device pulls paper through the printer, the
forms perforations are less likely to bind on the ribbon shield.
3. Remove the forms device. See “821 - Forms Device Removal” on
page 800-7.
• Look for torn pieces of paper, foam, or other obstructions can
cause paper jams. Repair as needed.
• Inspect the forms device for broken or missing parts. If you find
any broken or missing parts, or if it does not operate correctly,
install a new device. See “823 - Forms Device Installation” on
page 800-8.
• For F2 forms devices, check the 3 small gears on the right side
frame for damage. The side frame or gear shafts can wear
severely causing the gears to wobble.
• Rotate the drive gear on the forms device and check for binds.
- For the F1 and F2 devices, ensure that the tractor pins and
the shafts turn as you turn the drive gear.
- For the F2 and F3 devices, ensure that the feed rolls also
turn correctly.

000-97
000-98

• If any problems are found, install a new device. See “823 -


Forms Device Installation” on page 800-8.
• Ensure that the forms feed drive gear and the forms idler gear
are not damaged and that they engage correctly with the forms
device gear. See “719 - Locations, Front (Cover Off)” on
page 700-7. Ensure that all the gear teeth are clean and not
packed with foreign materials. Repair or install new parts as
needed.
4. Perform the AFTA setting procedure. See “AFTA Setting Procedure”
on page 000-109.
Note: Do not enter a larger number than you actually measured.
That will decrease the stored platen gap setting and cause jams.
5. Ensure that the customer has set the top of form position if they use
the document on demand function. Refer to "Adjusting the Top of
Form Position" in the User's Guide.
6. With the F2 forms devices, forms can jam if the first sheet through
the upper rollers has a poorly torn leading edge. To obtain a
smooth leading edge of the forms the tear-off position can be set as
follows:
a. With the top of form set, press the Load/Eject key to advance
the form to the tear-off position
b. Use the Micro and Micro keys to align the horizontal page
perforation at the top of the F2 forms device (tear-off position)
c. Press the Load/Eject key to move the forms back down to the
Top-of-Forms position.
The printer saves this setting but a new setting must be saved if a
different length form is installed. See "Adjusting the Tear-off
Position" section in the User's Guide for more information.
7. Inspect the ribbon shield for damage.
Ribbon (PN 1040580) has 2 different level shields.

IBM 4230 and 4232 Printers Maintenance Information Manual 000-98


General Information 000-99

• The latest level has 1 tab facing downward in the middle of the
shield and a larger window. The box that it comes in specifies
4224/4230/4232 printers.
• The earlier level has 2 tabs facing downward at the sides of the
shield and has a smaller window. This style sometimes catches
on the forms horizontal perforations and causes jams. This style
is no longer available.
• Try P/N 1040440. It is NOT a long life ribbon, has a plastic
ribbon shield that is more flexible, and depending on the
customer's application, may perform better.
Ensure that the ribbon is installed correctly. See “811 - Ribbon
Cartridge Removal” on page 800-1.
8. Install the forms device. See “823 - Forms Device Installation” on
page 800-8.

F1 Device

• Ensure that the forms device is fully latched. Severe forms jams
can unlatch the forms device.
• Install the forms.
• Adjust the right tractor so there is no blouse or slack in the forms
• Use the Line Feed key to space up one complete form. Then
use the Form Feed key to feed 2 forms. Check the forms feed
holes for for damage. If damaged, the tractors are adjusted too
tight. Adjust the right tractor and repeat this step.
• Ensure that the forms tension knob is set correctly for forms
being used.

End of F1 Device

F2 Device

000-99
000-100

• Ensure that the forms device is fully latched. Severe forms jams
can unlatch the forms device.
• Align the 5 blue forms guides evenly across the width of the
forms.
• Install 3 forms feed holes into the tractors and lock the right
tractor in position.
• Use the Load/Eject key to load the form. Use the Micro and
Micro keys to align the top edge of the paper with the platen. If
the form does not lay flat across the width of the platen, the
tractors need to be adjusted slightly wider. Unlock the right
tractor and adjust it slightly, and lock it in position.
• Use the Line Feed key to space up one complete form. Then
use the Form Feed key to feed 2 forms. Check the forms feed
holes for for damage. If damaged, the tractors are adjusted too
tight. Repeat this step until the adjustment is correct.
• P/N 1059300 is the old style F2 device, P/N 56G8910 is the new
style F2 device. The new F2 has a longer tractor door and an
improved upper wire form guide. The new tractor doors help
keep the forms flat against the platen to help prevent the forms
from binding on the ribbon shield. The old style F2 device can
be upgraded by installing P/N 56G8913.
• Chect eject position by pressing Load/Eject after a form feed.
Adjust as needed with the Micro and Micro keys so that the
top edge aligns with the tear-off bar.

End of F2 Device

9. Check the forms. Excessive moisture in the paper can cause form
feed and stacking problems. Forms should be stored in the printer
environment for 24 hours prior to use.
10. Check the Lighter/Darker setting. The forms can jam if the setting is
too dark. While the printer is printing, press and hold the darker or
lighter key. A grid will display on the operator panel showing where
print density is set. If the density is set on the darker side, press the

IBM 4230 and 4232 Printers Maintenance Information Manual 000-100


General Information 000-101

lighter key. This moves the print head further away from the platen.
This will reduce jams and increase ribbon life.
11. Ensure that the End Of Forms sensor is working and correctly
adjusted. See “Sensor Test” on page 000-68 and “Adjustment” on
page 300-24.
AFTA should adjust for forms thickness each time a new form is
installed. If the print head does not adjust (move right then left)
suspect a bad EOF sensor. A throat gap that is too tight will cause
paper jams.
12. Inspect the carrier drive belt (“339 - Carrier Drive Belt” on
page 300-14) and idler assembly (“343 - Idler Assembly” on
page 300-16) for loose, defective, or missing parts. If any problems
are found, exchange the failing part.
Manually move the print head carrier from one side frame to the
other to check for binds or excessive loosening. Exchange the
failing print head carrier and shaft if necessary (“329 - Print Head
Carrier and Shaft” on page 300-6).
Inspect the carrier upper bearing, support guide, pad, and spring
(“333 - Carrier Upper Bearing, Lower Bearing, and Spring” on
page 300-10) for damaged, loose, or missing parts. Repair or
exchange as necessary. See “AFTA Setting Procedure” on
page 000-109.
13. If paper jams occur when the Load/Eject key is pressed the second
time (paper is moving down) or when the Micro Down key is used,
check for outfolds catching the latches for the rollers on the front
door. Carefully file down the latches if needed.
14. Perform the Forms Motor Test. Press Stop, Test, and scroll forward
or backward until FORMS MOTOR TEST is displayed. Press Start
to begin the test and Stop to end the test.
15. Ensure that the printer is at the front edge of the table to reduce any
restriction from the forms supply.

000-101
000-102

Ensure that the forms supply is correctly aligned with the printer and
that there is no obstruction from the paper supply container. Poor
paper supply to printer alignment can also cause false forms jam
(002, 032) errors.
16. Ensure that the metal wire forms guide inside the acoustic cover is
installed and not damaged.
17. The following Printer Configuration settings can cause the top of
form setting to vary if not set correctly:
• Maximum Page Length (MPL) must match forms being used
• Lines-per-Inch (LPI)
• Correct forms device installed.
To print the Printer Configuration see “Printer Configuration” on
page 000-49. To change the configuration, see “822 - Forms
Device Configuration” on page 800-7.
Notes:
a. The data stream or application software can be set to override
the Printer Configuration. If jams continue to occur, verify these
settings.
b. Ensure that the controller is set to form feed after a local print.
c. If it appears that the printer occasionally loses the top of form
setting, suspect an operator intervention such as a print screen
or local copy operation. Compatibility option 07 or 08 may need
changing in the printer configuration. Refer to the operator
panel instructions (customer documentation).
d. Ensure that the installed forms device matches the forms device
configuration. Check the printer configuration under printer
setup options.
e. Ensure that the correct forms eject mode is selected. Check the
printer configuration under performance options.
f. Ensure that the top of form is set correctly.

IBM 4230 and 4232 Printers Maintenance Information Manual 000-102


General Information 000-103

If all settings are correct, the print head will move to the left off the
form each time the top of the form (perforation) passes over the
platen.
18. Forms jams can occur if the ribbon shield binds on the top of the
form (horizontal perforation). Figure 23 shows how the print head
remains over the form as the form passes over the platen. This
occurs because the Set Top of Form key was pressed with the
physical top of form above the top of the platen. As shown, the
logical and physical top of form are not aligned. Figure 24 on
page 000-106 shows the correct print head path when the logical
and physical top of form are aligned.

Figure 23. Example Problem Application

000-103
000-104

19. The following information explains how the printer should work, and
the problems if the top of form is not set correctly, or the software
commands are not used correctly.
(Refer to RETAIN service tips H096874 and H20263 for the newest
information.) The print head should move left off the form each time
a page perforation passes. (Printing on the page is complete and
the form advances to the top of the next page.) If all the steps in this
service check have been performed and the ribbon shield still
catches on the page perforations, observe the following:
Note: The following fix requires an application software change
and may require customer, programmer, or IBM SE help.
If the print head passes vertically in a straight line down the page
and continues through the forms perforation (as shown in Figure 23
on page 000-103), suspect a problem with the application software
driving the printer. This problem typically occurs in older
applications (especially on Coax/NDS attached 4230 Models 201,
202, 2I1, 5S3, and 5I3 where the following conditions exist:
• Logical and physical top of form locations are not aligned
• Software uses multiple new line commands after the printed text
to move the paper to the top of the next page.
The recommended top of form position is set when the horizontal
page perforation is aligned with the top of the flat area on the platen
as shown in Figure 24 on page 000-106. This tells the printer
where the forms perforation is located. If the customer sets the top
of forms position in another location, the logical and physical pages
do not match. The data for line 1 is not printed on line 1 on the form,
and may be printed several lines down the page.
Observe the motion of the print head. See if the print head remains
over the forms as the forms advance to the next page immediately
following the last data printed on the page. This indicates that the
software application uses multiple new line commands (SCS control
code 15 or 03 in DSE or DSC mode, both are single space carriage
moves) to advance the form to the top of the next page. Using

IBM 4230 and 4232 Printers Maintenance Information Manual 000-104


General Information 000-105

multiple new lines causes the print head to remain over the form as
the form is advanced.
The recommended method to advance the form to the top of the
next page is to use a carriage return (SCS control code OD) and
form feed (SCS control code OC) command, as shown in Figure 25.
(For more information, see "Section 4" in the 4230 or 4232 Product
and Programming Description Manual).
To correct these conditions, the Customer software application
should be changed to:
• Align the logic and physical page as shown in Figure 24 on
page 000-106.

000-105
000-106

Figure 24. Example Application with Logical and Physical Pages Aligned

- or -
• Remove the multiple new line commands and replace them with
a carriage return and form feed command as shown in
Figure 25 on page 000-107. (Even with the logical and
physical pages not aligned, this will typically correct the
problem.)

IBM 4230 and 4232 Printers Maintenance Information Manual 000-106


General Information 000-107

Figure 25. Example Application with New Lines Removed

000-107
000-108

False Forms Jam Service Check


Note: Check RETAIN, if available, for the latest service and parts
information about false forms jams.

False forms jams occur when the printer stops and displays error codes
002 or 032 but there is no physical jam. False forms jams occur when 2
inches of forms pass the EOF sensor without a pin feed hole being
detected.

Perform the following steps to isolate the causes of false forms jams:
1. Check the EOF sensor (see "End of Forms Sensor Adjustment" on
page 300-24).
2. Ensure that the forms supply is aligned with the printer paper path
and tractors. Poor forms alignment can cause the paper feed holes
to move left or right out of the sensor. This alignment and the
sensor adjustment are more critical with the F1 device because the
tractors are located farther from the sensor.
3. Check the ESD grounds (“752 - ESD Grounds” on page 750-2).
Especially check the ground strap on the forms device to ensure
that it makes good contact with the printer frame.

False End Of Forms Service Check


Note: Check RETAIN, if available, for the latest service and parts
information about false end of forms problems.

False end of forms occur when the printer stops and displays error
codes 001 or 031 without getting to the physical end of forms.

Perform the following steps to isolate the causes of false end of forms:
1. Check the EOF sensor (see "End of Forms Sensor Adjustment" on
page 300-24).
2. Check the forms for holes. These holes may be for putting the form
in a binder, or there may be defects in the forms.

IBM 4230 and 4232 Printers Maintenance Information Manual 000-108


General Information 000-109

3. Check the perforations. Forms perforations that are too large can
be detected by the sensor as an end of forms.
4. Check for forms that the sensor can see through, such as a clear
form that holds labels.

AFTA Setting Procedure

The AFTA setting test measures the following values needed to maintain
the correct gap between the print head and the platen, ensuring suitable
print quality and print head life:
• The platen flex value
• The absolute distance from the AFTA home sensor to the bare
platen without flex at the center, and right and left sides of the
platen. (Early level microcode checks only the left side of the
platen).

Perform the AFTA setting procedure as follows:


1. Ensure that the print head is properly latched and that the stop
screw is properly adjusted (“321 - Print Head” on page 300-2).
2. Enter the AFTA setting test in the Offline CE Test Menu. The print
head moves to the center of the platen and the printer displays a
message to install the ribbon and remove the forms.
3. Remove the forms device (“821 - Forms Device Removal” on
page 800-7).
4. Install the ribbon (“812 - Ribbon Cartridge Installation” on
page 800-2).
Note: If the test runs without the ribbon installed, a wrong value is
stored and the printer sets the platen gap wrong.
5. Press Enter. The print head moves to the left side of the platen and
the AFTA mechanism moves the print head in to perform a platen
flex calibration. When the calibration completes, the printer saves
the platen flex value in memory so it can be saved in NVRAM at

000-109
000-110

power-off. The print head moves to the center of the print line. The
printer displays a message to remove the ribbon and press Enter.
6. Remove the ribbon (“811 - Ribbon Cartridge Removal” on
page 800-1).
7. Press Enter. The AFTA mechanism moves the print head toward
the bare platen to a pre-defined measuring position. The printer
displays a message to measure the gap.
Note: The measurement must be made at the right side of the print
head where the print wires are located. The individual gauges can
be removed from the handle to make this measurement easier. An
incorrect measurement may affect print quality or cause paper jams.
8. Measure the platen gap with a feeler gauge without moving the print
head from the measuring position.
9. Press Enter. The printer displays:

Adjust Gap, Press Enter when Ready


Head-Platen Gap = X.XXXX inch (x.xxxx mm)

where X.XXXX is the existing Head to Platen Gap stored in NVRAM.


10. Use the Scroll and Scroll keys to adjust the displayed Head to
Platen Gap.
11. When the measured value is displayed on the panel, press Enter.
The printer stores the value.
Notes:
a. It is extremely important that you do not force the feeler gauge
between the print head and platen (it should pass freely).
b. It is recommended that you use a feeler gauge set equipped
with a 0.001 in. (0.025 mm) gauge to get an accurate reading.
An error of 0.002 in (0.050 mm) can have a noticeable print
quality effect.

IBM 4230 and 4232 Printers Maintenance Information Manual 000-110


General Information 000-111

c. The print head to platen gap should be 0.015 to 0.025 in. (0.38
to 0.635 mm). If the gap is not correct, there is another problem.
d. If you are performing this procedure because of a forms
jamming problem, do not enter a larger number that actually
measured. This will decrease the stored platen gap setting,
causing forms/ribbon jams.
12. If the display is:

Install Ribbon
Press Enter when Ready

the printer has early level microcode and only makes one
measurement. The procedure is finished.
Install the ribbon and press Enter.
If the display is:

Measure the Head to Platen Gap


Press Enter when Ready

three measurements will be taken. Press Enter and continue with


the next step.
13. The print head moves to the left side of the platen.
Important: This measurement is the most important because at
End-of-Forms, AFTA recalibration occurs at the left side. Also, often
more printing occurs at the left side of the platen.
14. Repeat steps 8 on page 000-110 through 11 on page 000-110.
15. The print head moves to the right side of the platen.
16. Repeat steps 8 on page 000-110, through 10 on page 000-110.
17. When the measured value is displayed, press Enter. The printer
calculates an average of the three measurements and stores this

000-111
000-112

value (representing the absolute distance from the AFTA home


sensor to the bare platen without flex) in the NVRAM. The print
head moves to the center.
18. Install the ribbon (“812 - Ribbon Cartridge Installation” on
page 800-2).
19. Press Cancel or Return to leave the procedure.

Twinaxial Attachment Bezel Service Check

Notes:
1. Ensure that the printer is switched Off (O) before you connect or
disconnect the power cable or other cables.
2. If the printer has cables other than the power cable, connect them
before you plug the power cable into an outlet. Always unplug the
power cable from the outlet before you remove the other cables.

Perform the twinaxial attachment bezel service check as follows:

IBM 4230 and 4232 Printers Maintenance Information Manual 000-112


General Information 000-113

1. Switch Off (O) the printer power.


2. Disconnect the printer power cable from the printer.
3. Disconnect the twinaxial cable from the printer.
4. Disconnect J1 from the logic board.
5. Check for continuity between J1 pin 6 and the upper female
connector on the attachment bezel; it should be 0 ohms.
6. Check for continuity between J1 pin 4 and the lower female
connector of the attachment bezel; it should be 0 ohms.
7. Check for continuity between J1 pin 5 and the attachment bezel
housing; it should be 0 ohms.
8. Check for any damage, such as bent pins.

Coaxial Attachment Bezel Service Check

000-113
000-114

Notes:
1. Ensure that the printer is switched Off (O) before you connect or
disconnect the power cable or other cables.
2. If the printer has cables other than the power cable, connect them
before you plug the power cable into an outlet. Always unplug the
power cable from the outlet before you remove the other cables.

Perform the coaxial attachment bezel service check as follows:


1. Switch Off (O) the printer power.
2. Disconnect the printer power cable from the printer.
3. Disconnect the coaxial cable from the printer.
4. Disconnect J1 from the logic board.
5. Measure the resistance between pins 1 and 6; it should be less than
100 ohms.
6. Measure the resistance between pins 1 and 4; it should be less than
100 ohms.
7. Measure the resistance between pins 4 and 6; it should be less than
100 ohms.
8. Measure the resistance between pins 2 and 5; it should be less than
100 ohms.
9. Check for continuity between the center pin and the attachment
shroud; it should be 0 ohms.
10. Check for any damage, such as bent pins.

Twinaxial/Serial/Parallel Attachment Bezel Service Check

IBM 4230 and 4232 Printers Maintenance Information Manual 000-114


General Information 000-115

Notes:
1. Ensure that the printer is switched Off (O) before you connect or
disconnect the power cable or other cables.
2. If the printer has cables other than the power cable, connect them
before you plug the power cable into an outlet. Always unplug the
power cable from the outlet before you remove the other cables.

Perform the twinaxial/serial/parallel attachment bezel service check as


follows:
1. Switch Off (O) the printer power.
2. Disconnect the printer power cable from the printer.
3. Disconnect the attachment cables from the printer.
Note: Some model 4I3 and 4S3 printers have a sliding latch that
holds the twinax connector installed. The sliding latch is located on
the printer connector. Move the sliding latch up to remove the cable
connector. To install, connect the connector and move the sliding
latch down.

4. Disconnect J1 from the logic board.


5. Check for continuity between J1 pin 6 and pin 7 of the 15 pin
twinaxial connector on the attachment bezel; it should be 0 ohms.
6. Check for continuity between J1 pin 4 and pin 14 of the twinaxial
connector; it should be 0 ohms.
7. Check for continuity between J1 pin 5 and pin 5 of the twinaxial
connector; it should be 0 ohms.
8. Check for any damage, such as bent pins.

Coaxial/Serial/Parallel Attachment Bezel Service Check

000-115
000-116

Notes:
1. Ensure that the printer is switched Off (O) before you connect or
disconnect the power cable or other cables.
2. If the printer has cables other than the power cable, connect them
before you plug the power cable into an outlet. Always unplug the
power cable from the outlet before you remove the other cables.

Perform the coaxial/serial/parallel attachment bezel service check as


follows:
1. Switch Off (O) the printer power.
2. Disconnect the printer power cable from the printer.
3. Disconnect the attachment cables from the printer.
4. Disconnect J1 from the logic board.
5. Measure the resistance between pins 1 and 6; it should be less than
100 ohms.
6. Measure the resistance between pins 1 and 4; it should be less than
100 ohms.
7. Measure the resistance between pins 4 and 6; it should be less than
100 ohms.
8. Measure the resistance between pins 2 and 5; it should be less than
100 ohms.
9. Check for continuity between the coaxial connector center pin and
the attachment shroud; it should be 0 ohms.
10. Check for any damage, such as bent pins.

IBM 4230 and 4232 Printers Maintenance Information Manual 000-116


General Information 000-117

Serial/Parallel Attachment Card/Bezel Service Check

Notes:
1. Ensure that the printer is switched Off (O) before you connect or
disconnect the power cable or other cables.
2. If the printer has cables other than the power cable, connect them
before you plug the power cable into an outlet. Always unplug the
power cable from the outlet before you remove the other cables.

Perform the serial/parallel attachment card/bezel service check as


follows:
1. Switch Off (O) the printer power.
2. Disconnect the printer power cable from the printer.
3. Disconnect the serial or parallel cable from the printer.
4. Remove attachment card/bezel. Refer to “413 - Attachment
Card/Bezel (4232 Model 302 Only)” on page 400-7.
5. Check for any damage, such as bent pins.

000-117
000-118

IBM 4230 and 4232 Printers Maintenance Information Manual 000-118


Covers, Shields, and Frame 100-1

Section 100. Covers, Shields, and


Frame

100-1
100-2

111 - Acoustic Cover


Removal
1. Pivot the acoustic cover open until it is vertical.
2. Locate the latch release tabs A on both brackets.
3. Press the latch tabs while lifting the acoustic cover.
4. Ensure that the wire forms guide (as shown below) is installed and
properly latched.

Installation
Note: Do not install a new acoustic cover if only the hinge is
broken. The hinge is a FRU and has been redesigned to increase
its strength.
1. Locate the slots B near the paper exit area of the access cover.
2. Hold the brackets of the acoustic cover and insert them into the slots
until they latch tightly.
3. Pivot the acoustic cover until it is closed over the paper exit area.

IBM 4230 and 4232 Printers Maintenance Information Manual 100-2


Covers, Shields, and Frame 100-3

100-3
100-4

113 - Access Cover


Removal
1. Remove the acoustic cover (“111 - Acoustic Cover” on page 100-2).
2. Open the access cover A to 90 degrees.
3. Remove the access cover by pulling it straight up.

Installation

Use reverse procedures for installation.

IBM 4230 and 4232 Printers Maintenance Information Manual 100-4


Covers, Shields, and Frame 100-5

115 - Front Paper Door


Removal
1. Open the front paper door A to a fully opened position as shown.
2. Press in on the tabs B as you slowly pull the door toward you.

Installation
1. Align the slots C on the door with the pins D on each side of the
printer, at the angle shown.
2. Slowly push the door into place.

100-5
100-6

117 - Printer Cover Assembly


Removal
1. Remove the forms from the printer.
2. Switch the power Off (O).
3. Disconnect the power cord at both ends.
4. Remove the front paper door A (“115 - Front Paper Door” on
page 100-5).
5. Remove the operator panel B (“511 - Operator Panel” on
page 500-1).
6. Remove the two screws C at the rear of the cover.
7. Move the print head to the center of the printer.
8. Disconnect the static wire from the right side frame D .
9. Reach under the left side of the cover and pull the molded latch.
10. Repeat step 9 for the right side of the printer cover.
11. Lift the cover straight up to remove it from the printer.

Installation
1. Ensure that the print head is in the center of the printer.
2. Place the cover on the printer.
3. Connect the static wire to the right side frame D .
4. Push down on the top side frame of the cover until it latches on both
sides.
5. Install the operator panel (“511 - Operator Panel” on page 500-1).
6. Install the front paper door (“115 - Front Paper Door” on
page 100-5).
7. Install the two screws C at the rear of the cover.

IBM 4230 and 4232 Printers Maintenance Information Manual 100-6


Covers, Shields, and Frame 100-7

8. Connect the power cord to the printer and plug it into the electrical
outlet.

100-7
100-8

119 - Static Brush


Removal
1. Remove the operator panel (“511 - Operator Panel” on
page 500-1).
2. Remove the cover assembly (“117 - Printer Cover Assembly” on
page 100-6) .
3. Turn the cover over and remove the four screws holding the parts in
place.
4. Remove the grounding spring A by inserting a flat-blade
screwdriver between the spring and the cover.
5. Remove the static brush B and static wire C .

IBM 4230 and 4232 Printers Maintenance Information Manual 100-8


Covers, Shields, and Frame 100-9

Installation

Perform reverse procedure for installation.

100-9
100-10

121 - Rear Shield


Removal
1. Switch the power Off (O).
2. Remove the operator panel (“511 - Operator Panel” on
page 500-1).
3. Remove the printer cover (“117 - Printer Cover Assembly” on
page 100-6).
4. Remove the air deflectors (“127 - Air Deflectors” on page 100-16).
5. Remove the forms device (“821 - Forms Device Removal” on
page 800-7).
6. Remove the two installing screws A .
7. Back out the locating screw C on the right side of the frame until it
is just even with the side frame. Do not remove the screw from the
side frame.
8. Remove the rear shield B .

Installation
Perform reverse procedures for installation.

IBM 4230 and 4232 Printers Maintenance Information Manual 100-10


Covers, Shields, and Frame 100-11

100-11
100-12

123 - Entry Paper Chute


Removal
1. Switch the power Off (O).
2. Remove the operator panel (“511 - Operator Panel” on
page 500-1).
3. Remove the printer cover (“117 - Printer Cover Assembly” on
page 100-6).
4. Remove the forms device (“821 - Forms Device Removal” on
page 800-7).
5. Disconnect the end of forms sensor A from the main sensor cable.
6. Carefully remove the cable ties holding the cables.
7. Disconnect the print head cable clamps from the top of the entry
paper chute.
8. Remove the attachment bezel, “411 - Attachment Bezel (4230
Models 101, 102, 1I1, 1S2, 201, 202, 2I1, 2S2 only)” on page 400-2
or “412 - Attachment Cards/Bezel (4230 Models 4I3, 4S3, 5I3, and
5S3 Only)” on page 400-4 or “413 - Attachment Card/Bezel (4232
Model 302 Only)” on page 400-7.
9. Carefully place the printer on its back.
10. Release the two locking tabs.
11. Lift the left side of the entry paper chute until the locator stud clears
the base.
12. Lift the entry paper chute B from the printer.
13. Place the printer on its base.
14. If necessary, remove the door open sensor (“345 - Door Open
Sensor” on page 300-18) and the end of forms sensor (“383 - End
of Forms Sensor” on page 300-24) from the entry paper chute.

IBM 4230 and 4232 Printers Maintenance Information Manual 100-12


Covers, Shields, and Frame 100-13

Installation

Perform reverse procedures for installation.

100-13
100-14

125 - Frame Assembly


Removal
1. Switch the power Off (O).
2. Remove the operator panel (“511 - Operator Panel” on
page 500-1).
3. Remove the printer cover (“117 - Printer Cover Assembly” on
page 100-6).
4. Remove the forms device (“821 - Forms Device Removal” on
page 800-7).
5. Remove the ribbon cartridge (“811 - Ribbon Cartridge Removal” on
page 800-1).
6. Remove the rear shield (“121 - Rear Shield” on page 100-10).
7. Remove the screw that attaches the power supply ground strap A
to the left side frame.
Installation Note: Use a meter set to the lowest resistance scale to
verify that the resistance from the power supply frame to the printer
frame is 0.1 ohm or less.
8. Put the printer logic board in the service position (“707 - Printer
Logic Board Service Position” on page 700-1).
9. Remove the ribbon drive crossbar (“361 - Ribbon Drive Crossbar”
on page 300-20).
10. Remove the carrier drive motor and idler assembly (“337 - Carrier
Drive Motor” on page 300-12).
11. Remove the forms motor (“381 - Forms Motor” on page 300-22).
12. Remove the AFTA assembly (“385 - AFTA Assembly” on
page 300-26).
13. Remove the printhead carrier and shaft (“329 - Print Head Carrier
and Shaft” on page 300-6).

IBM 4230 and 4232 Printers Maintenance Information Manual 100-14


Covers, Shields, and Frame 100-15

14. Remove the four cable clamps B .


15. Remove the four frame assembly installing nuts C.
16. Lift out the frame assembly.

Installation

Perform reverse procedures for installation.

100-15
100-16

127 - Air Deflectors


Removal
1. Switch the power Off (O).
2. Remove the operator panel (“511 - Operator Panel” on
page 500-1).
3. Remove the printer cover (“117 - Printer Cover Assembly” on
page 100-6).
4. Slide the left air deflector A up to remove it from the left side frame.
5. Remove the screw C from the right side air deflector.
6. Disconnect J3 and J4 (“753 - Printer Logic Board” on page 750-3).
7. Remove the cables and slide the right air deflector B up to remove
it from the right side frame.

Installation

Perform reverse procedures for installation.

IBM 4230 and 4232 Printers Maintenance Information Manual 100-16


Covers, Shields, and Frame 100-17

100-17
100-18

IBM 4230 and 4232 Printers Maintenance Information Manual 100-18


Logic Boards 200-1

Section 200. Logic Boards

200-1
200-2

211 - Printer Logic Board


Removal
Note: Before exchanging the printer logic board, print the configuration
and vital product data, or obtain the printer configuration printout from
the customer. Also, obtain the configuration set data from the printer or
customer. For more information, refer to “Printer Configuration” on
page 000-49.
1. Switch the power Off (O).
2. Remove the operator panel (“511 - Operator Panel” on
page 500-1).
3. Remove the printer cover (“117 - Printer Cover Assembly” on
page 100-6).
4. Remove the forms device (“821 - Forms Device Removal” on
page 800-7).
5. Disconnect the logic board ground wire.
6. Remove the rear shield (“121 - Rear Shield” on page 100-10).
7. Remove the attachment bezel or card/bezel, use:
“411 - Attachment Bezel (4230 Models 101, 102, 1I1, 1S2, 201,
202, 2I1, 2S2 only)” on page 400-2
or
“412 - Attachment Cards/Bezel (4230 Models 4I3, 4S3, 5I3, and
5S3 Only)” on page 400-4
or
“413 - Attachment Card/Bezel (4232 Model 302 Only)” on
page 400-7.
8. Disconnect all cables from the printer logic board.
9. Loosen the two screws A that attach the printer logic board holder
to the base.
10. Slide the printer logic board holder slots past the screws and lift the
printer logic board out of the printer.
11. Remove the logic board from the logic board holder.
12. Read the installation notes.

IBM 4230 and 4232 Printers Maintenance Information Manual 200-2


Logic Boards 200-3

Installation

Perform reverse procedures for installation.


Note: If the printer logic board is being exchanged:
1. Use the configuration and vital product data to set up the printer
(see IBM 4230 Printer Quick Reference Guide)
2. Perform the AFTA setting (“AFTA Setting Procedure” on
page 000-109)
3. Perform the Bidirectional adjustment (“Bidirectional Adjustment” on
page 000-71).

200-3
200-4

217 - Extended Memory Card (4230 Models 102,


1I1, 202, and 2I1 only)
Removal
1. Put the printer logic board in the service position (“707 - Printer
Logic Board Service Position” on page 700-1).
2. Remove the extended memory card from the standoffs.
3. Carefully disconnect the extended memory card from the printer
logic board.

Installation

Use reverse procedures for installation.

IBM 4230 and 4232 Printers Maintenance Information Manual 200-4


Print Units 300-1

Section 300. Print Units

320 - Print Head and Carrier


This section has removal and installation procedures for the print head
and carrier.

300-1
300-2

321 - Print Head


Removal
1. Switch the power Off (O).
2. Remove the operator panel (“511 - Operator Panel” on
page 500-1).
3. Remove the forms device (“821 - Forms Device Removal” on
page 800-7).
4. Move the print head to the center of the printer.
5. Remove the ribbon (“811 - Ribbon Cartridge Removal” on
page 800-1).
6. Remove the retaining clip from the print head cable.
7. Disconnect the the print head cable (PH) F from the print head.
8. Release the print head latch B by rotating the latch handles toward
the platen.
9. Remove the retaining clip A from the print head and carrier.
10. Lift the print head up and out of the printer.
11. Loosen the lock nut C on the stop screw D , and back the screw
out several turns.

IBM 4230 and 4232 Printers Maintenance Information Manual 300-2


Print Units 300-3

Installation

Perform reverse procedures for installation.

Notes:
1. Ensure that the printhead connector is connected to Run. Refer to
“Print Wire Test 2” on page 000-70.
2. Adjust the stop screw so that it just touches the side of the print
head, and then tighten the lock nut.
3. Perform the AFTA setting procedure (“AFTA Setting Procedure” on
page 000-109).
4. Perform the Bidirectional adjustment (“Bidirectional Adjustment” on
page 000-71).

300-3
300-4

325 - Print Head Cable


Removal
1. Switch the power Off (O).
2. Remove the operator panel (“511 - Operator Panel” on
page 500-1).
3. Remove the printer cover (“117 - Printer Cover Assembly” on
page 100-6).
4. Remove the ribbon cartridge (“811 - Ribbon Cartridge Removal” on
page 800-1).
5. Remove the forms device (“821 - Forms Device Removal” on
page 800-7).
6. Remove the rear shield (“121 - Rear Shield” on page 100-10).
7. Remove the print head cable clamps A .
8. Place the printer logic board in the service position (“707 - Printer
Logic Board Service Position” on page 700-1).
9. Disconnect the print head cable J7 from the printer logic board (“753
- Printer Logic Board” on page 750-3).
10. Remove the print head cable.

Installation

Perform reverse procedures for installation.


Note: Check the cable to verify that:
1. The 4 sensor wires are not clamped to the carrier with the printhead
driver wires.
2. The 4 sensor wires should be under the printhead cable, not over
the top of the cable.

IBM 4230 and 4232 Printers Maintenance Information Manual 300-4


Print Units 300-5

300-5
300-6

329 - Print Head Carrier and Shaft


Removal
1. Switch the power Off (O).
2. Remove the operator panel (“511 - Operator Panel” on
page 500-1).
3. Remove the printer cover (“117 - Printer Cover Assembly” on
page 100-6).
4. Remove the print head (“321 - Print Head” on page 300-2).
5. Remove the automatic forms thickness gear E .
6. Remove the idler assembly (“343 - Idler Assembly” on
page 300-16).
7. Remove the print head cable clamp A from the carrier.
8. Remove the paper present sensor from the carrier (“331 - Paper
Present Sensor” on page 300-8).
9. Remove the carrier belt from the carrier drive motor pulley (“339 -
Carrier Drive Belt” on page 300-14).
10. Slide the shaft C , carrier assembly B , and belt D to the right
and lift them out of the printer.
11. Slide the shaft out of the carrier assembly.
12. Remove the carrier belt D .
13. Read the installation notes.

Installation

Perform reverse procedures for installation.

IBM 4230 and 4232 Printers Maintenance Information Manual 300-6


Print Units 300-7

Notes:
1. Adjust the stop screw so it touches the side of the print head, then
tighten the lock nut (“321 - Print Head” on page 300-2).
2. After installation, perform the AFTA setting procedure (“AFTA Setting
Procedure” on page 000-109).

300-7
300-8

331 - Paper Present Sensor


Removal
1. Switch the power Off (O).
2. Remove the ribbon (“811 - Ribbon Cartridge Removal” on
page 800-1).
3. Disconnect the paper present (PP) connector A from the paper
present sensor
4. Remove the paper present sensor by carefully releasing it from its
bracket.

Installation

Perform reverse procedures for installation.

IBM 4230 and 4232 Printers Maintenance Information Manual 300-8


Print Units 300-9

300-9
300-10

333 - Carrier Upper Bearing, Lower Bearing, and


Spring
Removal
1. Switch the power Off (O).
2. Remove the operator panel (“511 - Operator Panel” on
page 500-1).
3. Remove the printer cover (“117 - Printer Cover Assembly” on
page 100-6).
4. Remove the print head (“321 - Print Head” on page 300-2).
5. Remove the carrier (“329 - Print Head Carrier and Shaft” on
page 300-6).
6. Remove the retainer clip A and the upper bearing B .
7. Disconnect the spring C from the lower bearing and carrier
assembly.
8. Remove the retainer clip A .
9. Remove the lower bearing D .

Installation

Perform reverse procedures for installation.


Note: After installation, perform the AFTA setting procedure (“AFTA
Setting Procedure” on page 000-109).

IBM 4230 and 4232 Printers Maintenance Information Manual 300-10


Print Units 300-11

300-11
300-12

337 - Carrier Drive Motor


Removal
1. Switch the power Off (O).
2. Remove the operator panel (“511 - Operator Panel” on
page 500-1).
3. Remove the printer cover (“117 - Printer Cover Assembly” on
page 100-6).
4. Remove the forms device (“821 - Forms Device Removal” on
page 800-7) and the rear shield (“121 - Rear Shield” on
page 100-10).
5. Disconnect J9 from the printer logic board, and disconnect the
emitter cable from the main sensor cable at connector HM (“Section
700. Reference Information” on page 700-1).
6. Remove the idler pulley assembly (“343 - Idler Assembly” on
page 300-16).
7. Remove the drive belt from the motor pulley.
8. Remove the three screws A that attach the carrier motor to the
right side frame.
9. Remove the carrier motor.

Installation

Perform reverse procedures for installation.


Note: Adjust the drive belt tension (“Adjustment” on page 300-16).

IBM 4230 and 4232 Printers Maintenance Information Manual 300-12


Print Units 300-13

300-13
300-14

339 - Carrier Drive Belt


Removal
1. Switch the power Off (O).
2. Remove the operator panel (“511 - Operator Panel” on
page 500-1).
3. Remove the printer cover (“117 - Printer Cover Assembly” on
page 100-6).
4. Remove the entry paper chute (“123 - Entry Paper Chute” on
page 100-12); do not disconnect any cables from the chute.
5. Loosen the adjusting screw on the idler assembly and disconnect
the idler assembly spring (“343 - Idler Assembly” on page 300-16).
6. Remove the carrier belt A from the carrier drive motor pulley B .
7. Pivot out the idler assembly and remove the carrier belt (the idler
pulley is loose).
8. Remove the belt clamp C from the bottom of the carrier.
9. Remove the carrier drive belt from the carrier.

Installation

Perform reverse procedures for installation.


Note: Adjust the belt tension (“Adjustment” on page 300-16).

IBM 4230 and 4232 Printers Maintenance Information Manual 300-14


Print Units 300-15

300-15
300-16

343 - Idler Assembly


Removal
1. Switch the power Off (O).
2. Remove the operator panel (“511 - Operator Panel” on
page 500-1).
3. Remove the printer cover (“117 - Printer Cover Assembly” on
page 100-6).
4. Loosen the adjusting screw A on the idler assembly.
5. Remove the tension spring B .
6. Pivot the idler assembly C away from the adjusting screw A .
7. Remove the carrier belt D from the carrier drive motor pulley.
8. Remove the idler assembly (pulley and idler bracket).

Installation

Perform reverse procedures for installation.

Adjustment
1. Loosen the adjusting screw A on the idler assembly.
2. Allow the tension spring to self-adjust the idler assembly.
3. Move the carrier to the left and right several times to seat the parts.
4. Tighten the adjusting screw.

IBM 4230 and 4232 Printers Maintenance Information Manual 300-16


Print Units 300-17

300-17
300-18

345 - Door Open Sensor


Removal
1. Switch the power Off (O).
2. Remove the operator panel (“511 - Operator Panel” on
page 500-1).
3. Remove the printer cover (“117 - Printer Cover Assembly” on
page 100-6).
4. Disconnect the connector DC from the door open sensor.
5. Press down on the top tabs while pulling out on the sensor.
6. Remove the sensor.

Installation
Use reverse procedures for installation.

IBM 4230 and 4232 Printers Maintenance Information Manual 300-18


Print Units 300-19

300-19
300-20

360 - Ribbon Units

361 - Ribbon Drive Crossbar


Removal
1. Switch the power Off (O).
2. Remove the operator panel (“511 - Operator Panel” on
page 500-1).
3. Remove the printer cover (“117 - Printer Cover Assembly” on
page 100-6).
4. Remove the ribbon cartridge (“811 - Ribbon Cartridge Removal” on
page 800-1).
5. Remove the two screws A .
6. Lift the cross bar up and slide it to the left from the right side frame.
7. Remove the forms device (“821 - Forms Device Removal” on
page 800-7).
8. Remove the rear shield (“121 - Rear Shield” on page 100-10).
9. Disconnect J8 (“753 - Printer Logic Board” on page 750-3).

Installation

Perform reverse procedures for installation.

IBM 4230 and 4232 Printers Maintenance Information Manual 300-20


Print Units 300-21

300-21
300-22

380 - Forms Feed Units

381 - Forms Motor


Removal
1. Switch the power Off (O).
2. Remove the operator panel (“511 - Operator Panel” on
page 500-1).
3. Remove the printer cover (“117 - Printer Cover Assembly” on
page 100-6).
4. Remove the forms device (“821 - Forms Device Removal” on
page 800-7).
5. Remove the rear shield (“121 - Rear Shield” on page 100-10).
6. Disconnect the forms motor cable J10 from the printer logic board
(“753 - Printer Logic Board” on page 750-3).
7. Remove the two screws A .
8. Remove the motor.

Installation

Perform reverse procedures for installation.

IBM 4230 and 4232 Printers Maintenance Information Manual 300-22


Print Units 300-23

300-23
300-24

383 - End of Forms Sensor


Removal
1. Switch the power Off (O).
2. Remove the forms, if present.
3. Remove the two screws A that attach the end of forms sensor B
to the entry paper chute.
4. Disconnect the end of forms sensor connector (EOF) from the end
of forms sensor C .
5. Remove the end of forms sensor from the printer.

Installation

Perform reverse procedures for installation.

Adjustment
1. Loosen the mounting screws A .
2. Align the lug at the top of the sensor with the center of the forms
feed holes (as shown).
3. Ensure that the right side of the sensor assembly is parallel to the
ribs in the paper entry chute.
4. Tighten the mounting screws A .
Note: EOF/Jam sensor alignment is critical to prevent false 002 and
032 errors. Also ensure that the forms supply is aligned with the
tractors. Poorly aligned forms may move left or right out of the sensor,
causing false jams, especially when using the F1 forms device.

IBM 4230 and 4232 Printers Maintenance Information Manual 300-24


Print Units 300-25

300-25
300-26

385 - AFTA Assembly


Removal
1. Switch the power Off (O).
2. Remove the operator panel (“511 - Operator Panel” on
page 500-1).
3. Remove the printer cover (“117 - Printer Cover Assembly” on
page 100-6).
4. Disconnect the GSM connector C from the AFTA assembly.
5. Remove the rear shield.
6. Disconnect the motor connector J11 on the logic board (“753 -
Printer Logic Board” on page 750-3).
7. Remove the AFTA assembly A by removing the two screws B.
8. Read the installation notes.

Installation

Perform reverse procedures for installation.


Note: When installing the AFTA assembly, ensure that the AFTA gear
turns freely with minimum backlash. Verify this with the covers installed.
Ensure that the acoustic foam on the left side panel, or the dust shield
covering the AFTA home sensor do not interfere with the AFTA gear.

Perform the AFTA setting procedure (“AFTA Setting Procedure” on


page 000-109) after installation.

IBM 4230 and 4232 Printers Maintenance Information Manual 300-26


Print Units 300-27

300-27
300-28

IBM 4230 and 4232 Printers Maintenance Information Manual 300-28


Communications 400-1

Section 400. Communications

400-1
400-2

411 - Attachment Bezel (4230 Models 101, 102,


1I1, 1S2, 201, 202, 2I1, 2S2 only)
Removal
1. Switch the power Off (O).
2. Remove the operator panel (“511 - Operator Panel” on
page 500-1).
3. Remove the printer cover (“117 - Printer Cover Assembly” on
page 100-6).
4. Loosen the screw A that attaches the bezel to the base.
5. Disconnect J1 B from the printer board.
6. Remove the bezel.

Installation

Perform reverse procedures for installation.

IBM 4230 and 4232 Printers Maintenance Information Manual 400-2


Communications 400-3

400-3
400-4

412 - Attachment Cards/Bezel (4230 Models 4I3,


4S3, 5I3, and 5S3 Only)
Removal
1. Switch the power Off (O).
2. Disconnect the attachment cables from the printer.
Note: Some model 4I3 and 4S3 printers have a sliding latch that
holds the twinax connector installed. The sliding latch is located on
the printer connector. Move the sliding latch up to remove the cable
connector. To install, connect the connector and move the sliding
latch down.

3. Remove the operator panel (“511 - Operator Panel” on


page 500-1).
4. Remove the printer cover (“117 - Printer Cover Assembly” on
page 100-6).
5. Loosen the screw B that attaches the bezel to the base.
6. Remove the three screws A that secure the card/bezel to the
printer logic board.
7. Disconnect connector J1 D from the logic board.
8. Disconnect the the ground strap F from the logic board mounting
bracket.
9. Remove the smaller (coax or twinax) attachment card E from the
standoffs.
10. Carefully pull apart the serial/parallel attachment card from the
printer logic board to disconnect J5 C .
11. Remove the cards/bezel.
12. Remove the 4 screws H that mount the bezel and small
attachment card J to the serial/parallel attachment card G .

IBM 4230 and 4232 Printers Maintenance Information Manual 400-4


Communications 400-5

Installation

Perform reverse procedures for installation.

400-5
400-6

IBM 4230 and 4232 Printers Maintenance Information Manual 400-6


Communications 400-7

413 - Attachment Card/Bezel (4232 Model 302


Only)
Removal
1. Switch the power Off (O).
2. Remove the operator panel (“511 - Operator Panel” on
page 500-1).
3. Remove the printer cover (“117 - Printer Cover Assembly” on
page 100-6).
4. Loosen the screw A that attaches the bezel to the base.
5. Remove the three screws C that secure the card/bezel to the
printer logic board.
6. Carefully pull apart the serial/parallel attachment card from the
printer logic board to disconnect J1 B .
7. Remove the card/bezel.

Installation

Perform reverse procedures for installation.

400-7
400-8

IBM 4230 and 4232 Printers Maintenance Information Manual 400-8


Operator Panel 500-1

Section 500. Operator Panel


511 - Operator Panel
Removal
1. Open the top cover.
2. Press in on the latch A at the top center of the operator panel
while pushing down; lift the panel up and away.
3. Disconnect J1 from the operator panel.

Installation
Note: A new operator panel overlay is required when installing a new
operator panel. See the Parts Catalog for the national language
dependent part number.

Perform reverse procedures for installation. Run the operator panel test
(“Operator Panel Test” on page 000-67).

500-1
500-2

515 - Operator Panel Overlay


Removal
1. Switch the power Off (O).
2. Remove the operator panel (“511 - Operator Panel” on
page 500-1).
3. Carefully remove the adhesive-backed overlay from the operator
panel.

Installation

Perform reverse procedures for installation.

IBM 4230 and 4232 Printers Maintenance Information Manual 500-2


Power and Fan 600-1

Section 600. Power and Fan

600-1
600-2

611 - Power Supply


Removal
1. Switch the power Off (O).
2. Unplug the printer power cable.
3. Remove the operator panel (“511 - Operator Panel” on
page 500-1).
4. Remove the printer cover (“117 - Printer Cover Assembly” on
page 100-6).
5. Remove the forms device (“821 - Forms Device Removal” on
page 800-7).
6. Remove the rear shield (“121 - Rear Shield” on page 100-10).
7. Remove the screw that attaches the power supply ground strap A
to the left side frame.
Installation Note: Use a meter set to the lowest resistance scale to
verify that the resistance from the power supply frame to the printer
frame is 0.1 ohm or less.
8. Disconnect power supply ground strap from the printer logic board.
(A ground strap comes with a new power supply.)
9. Disconnect J6 from the printer logic board (“753 - Printer Logic
Board” on page 750-3).
10. Loosen the three screws B that attach the power supply to the
base.
11. Slide the power supply slots past the screws and lift the power
supply out of the printer.

IBM 4230 and 4232 Printers Maintenance Information Manual 600-2


Power and Fan 600-3

Installation

Perform reverse procedures for installation.


Installation Note: Verify that the voltage switch on the power
supply is set the same as the outlet voltage.

600-3
600-4

613 - Cooling Fan and Bracket


Removal
1. Switch the power Off (O).
2. Remove the operator panel (“511 - Operator Panel” on
page 500-1).
3. Remove the printer cover (“117 - Printer Cover Assembly” on
page 100-6).
4. Place the printer logic board in the service position (“707 - Printer
Logic Board Service Position” on page 700-1).
5. Remove the front and back of the fan cover by inserting a
screwdriver in the two slots A .
6. Remove the fan and disconnect J12 from the printer logic board
(“753 - Printer Logic Board” on page 750-3).

Installation

Perform reverse procedures for installation.

IBM 4230 and 4232 Printers Maintenance Information Manual 600-4


Power and Fan 600-5

600-5
600-6

IBM 4230 and 4232 Printers Maintenance Information Manual 600-6


Auto Sheet Feeder 650-1

Section 650. Auto Sheet Feeder


667 - Auto Sheet Feeder Belt and Drive Gear
Removal
1. Remove the right side cover by pushing down on the bottom center
A of the cover and pulling the cover out from the frame.
2. Remove the two screws C .
3. Remove the gear housing B while holding the shafts in place.
4. Remove the two gears D .
5. Remove two screws E and the belt cover F .
6. Remove the belt.

Installation

Perform reverse procedures for installation.

650-1
650-2

IBM 4230 and 4232 Printers Maintenance Information Manual 650-2


Auto Sheet Feeder 650-3

670 - Auto Sheet Feeder Lever and Lever Spring


Removal
1. Remove the right side cover by pushing down on the bottom center
A of the cover and pulling the cover out from the frame.
2. Remove the spring D .
3. Remove the lever C by compressing the installing post B and
pulling the lever off the post.

Installation

Perform reverse procedures for installation.

650-3
650-4

IBM 4230 and 4232 Printers Maintenance Information Manual 650-4


Reference Information 700-1

Section 700. Reference Information

705 - Service Positions

707 - Printer Logic Board Service Position


1. Switch the power Off (O).
2. Unplug the printer power cable.
3. Remove the operator panel (“511 - Operator Panel” on
page 500-1).
4. Remove the printer cover (“117 - Printer Cover Assembly” on
page 100-6).
5. Loosen the printer logic board bracket screws.
6. Disconnect power supply ground strap from the printer logic board.
(A ground strap comes with a new power supply.)
7. Remove the attachment bezel, “411 - Attachment Bezel (4230
Models 101, 102, 1I1, 1S2, 201, 202, 2I1, 2S2 only)” on page 400-2
or “412 - Attachment Cards/Bezel (4230 Models 4I3, 4S3, 5I3, and
5S3 Only)” on page 400-4 or “413 - Attachment Card/Bezel (4232
Model 302 Only)” on page 400-7.
8. Disconnect connectors J3 and J4.
9. Lift the printer logic board up and align the notches on the printer
logic board bracket with the tabs on the printer base. Attach the
printer logic board to the base at an angle of approximately 60
degrees.

700-1
700-2

IBM 4230 and 4232 Printers Maintenance Information Manual 700-2


Reference Information 700-3

708 - Operator Panel Service Position


Connect the J1 connector to the operator panel and place the lugs in the
mounting bracket as shown.

700-3
700-4

710 - Locations
This section shows the location of various parts of the printer both with
the covers on and with the covers off.

711 - Locations, Front (Cover On)


1. Acoustic cover
2. Operator panel
3. Serial number and model type
4. Entry paper chute
5. Forms sensor
6. Front paper door
7. Access cover.

IBM 4230 and 4232 Printers Maintenance Information Manual 700-4


Reference Information 700-5

713 - Locations, Rear (Cover On)


1. Acoustic cover
2. Power cord connector
3. Power requirements label
4. Attachment bezel.

700-5
700-6

717 - Locations, Right Side (Cover On)


1. Exit paper chute
2. Operator panel
3. Printer cover
4. Serial number and model type
5. Entry paper chute
6. End of forms sensor
7. Front paper door
8. Access cover
9. Acoustic cover bracket.

IBM 4230 and 4232 Printers Maintenance Information Manual 700-6


Reference Information 700-7

719 - Locations, Front (Cover Off)


1. Air deflectors (left and right)
2. Drive and idler gears.
3. Ribbon crossbar
4. Carrier drive belt
5. Print head
6. Ribbon drive motor
7. Paper entry chute
8. Forms sensor
9. AFTA gear
10. Power supply

700-7
700-8

720 - Locations, Cable Connectors


1. PP (Paper Present)
2. HM (Head Motor)
3. EOF (End Of Forms) Sensor
4. DC (Door Closed)
5. GSM (Gap Setting Motor) Sensor
6. PH. (Print Head)

IBM 4230 and 4232 Printers Maintenance Information Manual 700-8


Reference Information 700-9

721 - Locations, Rear (Cover Off)


1. AFTA gear 8. Attachment bezel (4230
2. Power supply Models 101, 102, 1I1, 1S2,
3. Base 201, 202, 2I1, and 2S2 only)
4. Power connector 9. Fan assembly
5. Ground wire 10. Printer logic board
6. Power supply LED. 11. Attachment bezel cable (4230
7. Electrostatic shield Models 101, 102, 1I1, 1S2,
201, 202, 2I1, and 2S2 only)
12. Print head

700-9
700-10

721 - Locations, Rear (Continued)

13. Attachment card (4230 Models 4I3, 4S3, 5I3, 5S3, and 4232 Model
302 only)
14. Attachment bezel and card (4230 Models 4I3, 4S3, 5I3, and 5S3
only).

IBM 4230 and 4232 Printers Maintenance Information Manual 700-10


Reference Information 700-11

723 - Locations, Left Side (Cover Off)


1. Ribbon crossbar 6. On/Off switch
2. Paper entry chute 7. Power supply
3. Idler assembly 8. Frame assembly
4. AFTA assembly 9. Rear shield
5. Ground wire 10. Printer logic board.
11. Ribbon motor

700-11
700-12

725 - Locations, Right Side (Cover Off)


1. Main sensor cable 6. Ribbon drive motor
2. Cooling fan 7. Ribbon cross bar
3. Forms drive motor 8. Print head
4. Carrier drive motor 9. Power supply
5. Ribbon drive gears 10. Printer logic board.

IBM 4230 and 4232 Printers Maintenance Information Manual 700-12


Reference Information 700-13

740 - Tools and Test Equipment


This section describes the tools and test equipment needed to isolate
and solve problems.

743 - Digital CE Voltmeter (P/N 8496278)


The digital CE voltmeter is used for measuring the AC and DC voltage
and for doing continuity checks.

745 - Miniprobe (P/N 453718)


The miniprobe attaches to the test leads of the CE voltmeter and is used
to probe connectors.

746 - Connector Probe (P/N 2548300)


The connector probe is used as an aid in probing connectors.

747 - Metric Tool Supplement (P/N 1749235)


The metric tool supplement (not shown) contains the tools needed to
repair metric machines.

748 - Feeler Gauge (P/N 450745)

749 - Feeler Gauge Metric (P/N 1749245)

700-13
700-14

IBM 4230 and 4232 Printers Maintenance Information Manual 700-14


Wiring Diagrams 750-1

Section 750. Wiring Diagrams

751 - Ground Wire

750-1
750-2

752 - ESD Grounds

IBM 4230 and 4232 Printers Maintenance Information Manual 750-2


Wiring Diagrams 750-3

753 - Printer Logic Board


1. J1 Attachment (4230 only) 8. J8 Ribbon Motor
2. J2 CE Test Points 9. J9 Carrier Motor
3. J3 Sensors 10. J10 Forms Motors
4. J4 Operator Panel 11. J11 AFTA Motor
5. J5 Extended Memory (4230 12. J12 Fan
only) 13. − 5 V DC Test Point
J5 Attachment (4232 only) 14. + 5 V DC Test Point
6. J6 Power +38 V DC 15. GND Test Point
7. J7 Print Head Cable

CE Test Points
J2-1 Carrier Motor Phase B
J2-2 Carrier Motor Phase A
J2-3 Cover Closed Sensor
J2-4 Ground
J2-5 Door Closed Sensor
J2-6 Hole Count Sensor (Forms Jam)
J2-7 AFTA Sensor
J2-8 Not Used
J2-9 Reset
J2-10 Not Used
J2-11 Not Used
J2-12 + 5 V DC

750-3
750-4

Note: J5 is located on the front side for 4230 Models 101, 102, 1I1,
1S2, 201, 202, 2I1, and 2S2.

J5 is located on the back side for 4230 Models 4I3, 4S3, 5I3, 5S3, and
4232 Model 302.

IBM 4230 and 4232 Printers Maintenance Information Manual 750-4


Wiring Diagrams 750-5

755 - Print Head Cable

Table 1 (Page 1 of 2). Pin Table 1 (Page 1 of 2). Pin


to Pin Reference Chart to Pin Reference Chart
PH-26 J7-16 PH-15 J7-9
PH-24 J7-17 PH-17 J7-8
PH-22 J7-18 PH-19 J7-7
PH-20 J7-19 PH-21 J7-6
PH-18 J7-20 PH-23 J7-5
PH-16 J7-21 PH-25 J7-4
PH-14 J7-22 PP-1 J7-3
(sensor)
PH-12 J7-23
PP-2 J7-15
PH-10 J7-24
(sensor)
PH-9 J7-12
PP-3 J7-2
PH-11 J7-11 (sensor)
PH-13 J7-10

750-5
750-6

Table 1 (Page 2 of 2). Pin


to Pin Reference Chart
PP-4 J7-14
(sensor)

IBM 4230 and 4232 Printers Maintenance Information Manual 750-6


Wiring Diagrams 750-7

757 - Operator Panel Cable

Table 2. Pin to Pin Table 2. Pin to Pin


Reference Chart Reference Chart
J1-12 J4-1 J1-1 J4-12
(Sensor)
J1-11 J4-2
Note: These lines are cover
J1-10 J4-3
open sensor lines.
J1-9 J4-4
J1-8 J4-5
J1-7 J4-6
J1-6 J4-7
J1-5 J4-8
J1-4 J4-9
J1-3 J4-10
(Sensor)
J1-2 J4-11
(Sensor)

750-7
750-8

759 - Main Sensor Cable

Table 3 (Page 1 of 2). Pin Table 3 (Page 1 of 2). Pin


to Pin Reference Chart to Pin Reference Chart
J3-1 HM-1 J3-13 EOF-2
J3-2 HM-2 J3-14 EOF-3
J3-3 HM-3 J3-15 EOF-4
J3-4 HM-4 J3-16 GSM-1
J3-5 DC-1 J3-17 GSM-2
J3-6 DC-2 J3-18 GSM-3
J3-7 DC-3 J3-19 Open
J3-12 EOF-1

IBM 4230 and 4232 Printers Maintenance Information Manual 750-8


Wiring Diagrams 750-9

Table 3 (Page 2 of 2). Pin


to Pin Reference Chart
J3-20 Open
Note: EOF Pin 1 is identified
by a black mark on the
connector.

760 4232 Model 302 Attactment Cable


Connector Pin Assignments

The 4232 Printer Model 302 Serial Cable


Connector Pin Assignment
The 4232 Printer Model 302 attaches to a host or controller by one of
two serial interfaces, RS-232C or RS-422A. A single 25-pin D connector
mounts directly to the adapter card.

The RS-232C interface uses a standard serial cable up to 15.2 m (50 ft)
in length with transmission rates up to 19.2 Kbps.

The RS-422A interface uses a serial cable up to 1219 m (4,000 ft) in


length with transmission rates up to 38.4 Kbps.

RS-232C Connector Pin Assignments

Pin Signal Description


Number Name
2 TXD Transmit Data
3 RXD Receive Data
4 RTS Request to Send
5 CTS Clear to Send

750-9
750-10

Pin Signal Description


Number Name
6 DSR Data Set Ready
7 SG Signal Ground
20 DTR Data Terminal Ready

Continued...

IBM 4230 and 4232 Printers Maintenance Information Manual 750-10


Wiring Diagrams 750-11

RS-422A Connector Pin Assignments

Pin Signal Description


Number Name
15 - RXD Receive Data
17 + RXD Receive Data
19 - TXD Transmit Data
25 + TXD Transmit Data

4232 Model 302 Parallel Cable Connector Pin


Assignments
The 4232 Printer Model 302 supports the IBM Parallel Printer Interface.
A single 36-pin connector is mounted on the adapter card.

The PC-parallel interface attaches to the host with a standard PC


Parallel Printer cable up to 1.8 m (6 ft) in length.

Continued...

750-11
750-12

IBM Parallel Connector Pin Assignments

Pin Signal Name Description


Number
1 -STROBE Strobe
2-9 DATA Eight Data Lines
10 -ACKNLG Acknowledge
11 BUSY Busy
12 PE Out of Paper
13 SLCT Printer Selected
14 -AUTO FEED XT Automatic Line Feed on
EOL
15 Unused
16 LOGIC GND Logic Ground
17 CHASSIS GROUND Chassis Ground
18 Unused
19 - 30 GROUND Ground
31 -INIT Initialize Printer
32 -ERROR Printer Error
33 GROUND Ground
34, 35 Unused
36 -SLCT IN Make printer selected

IBM 4230 and 4232 Printers Maintenance Information Manual 750-12


Ribbons, Forms, and Forms Devices 800-1

Section 800. Changing Ribbons,


Forms, and Forms Devices

810 - Ribbon Cartridge


Not using ribbons specifically designed for the 4230 and 4232 Printers
(such as IBM's) can:

Notes:
1. Damage the printer
2. Cause poor print quality because of ribbon shield thickness
differences which effect AFTA calibration at end of forms.
3. Cause early printhead failures. (IBM ribbons have lubrication for the
printhead.)
For information about ribbon cartridge part numbers, see “051 -
Replaceable Units” on page 000-47.

811 - Ribbon Cartridge Removal


1. Press the Stop key.
2. Press Stop again to switch off the alarm.
3. Open the access cover.
4. Slide the print head to the center of the printer.
5. Remove the ribbon guide from the guide post by pushing it toward
the back of the printer, then up.
6. Pull the cartridge upward to remove the ribbon cartridge from the
printer housing.

800-1
800-2

812 - Ribbon Cartridge Installation


1. Press the Stop key.
2. Open the access cover.
3. Slide the print head to the center of the printer.
4. Remove the ribbon cartridge from the package.
5. Remove the yellow clip from the ribbon.
6. Turn the ribbon advance knob clockwise to remove looseness in the
ribbon.

IBM 4230 and 4232 Printers Maintenance Information Manual 800-2


Ribbons, Forms, and Forms Devices 800-3

7. Align the blue slotted opening on the bottom of the ribbon cartridge
with the metal post. You may have to turn the ribbon advance knob
to align the slots.
Lower the ribbon cartridge on the metal post. Ensure that the plastic
tab on the bottom of the ribbon cartridge aligns with the hole in the
printer housing.

800-3
800-4

8. Press down firmly on the ribbon cartridge to lock it in place.

IBM 4230 and 4232 Printers Maintenance Information Manual 800-4


Ribbons, Forms, and Forms Devices 800-5

9. Align the holes in the ribbon guide with the ribbon guide pins on the
print head. Press the guide all the way down on the pins until the
tops of the pins are even with the top of the ribbon guide.
The left side of the ribbon cartridge should latch tightly on the printer.
The right side installs over the ribbon drive post but does not latch
down.
Ensure that the ribbon does not twist, fold, or get stuck on the print
head.

800-5
800-6

10. Rotate the ribbon advance knob clockwise to remove any looseness
in the ribbon.

IBM 4230 and 4232 Printers Maintenance Information Manual 800-6


Ribbons, Forms, and Forms Devices 800-7

820 - Forms Devices

821 - Forms Device Removal


To remove the forms device:
• If you have the F1 forms device, go to “827 - Removing the F1
Forms Device” on page 800-17.
• If you have the F2 forms device, go to “833 - Removing the F2
Forms Device” on page 800-29.
• If you have the F3 forms device, go to “837 - Removing the F3
Forms Device” on page 800-39.
• If you have the F4 forms device, go to “844 - Removing the F4
Forms Device” on page 800-50.

822 - Forms Device Configuration


1. Switch the power On (|).
2. To set the forms device in the Configuration Menu, follow these
steps:
a. Press Menu, and then press Scroll or Scroll until the printer
displays the Printer Setup category.
b. Press Enter, and then press Scroll or Scroll until the printer
displays the Forms Device parameter.
c. Press Enter, and then press Scroll or Scroll until the printer
displays the desired forms device.

800-7
800-8

d. Press Enter to set the device.


e. Save the setting to the power-on custom set (Custom Set A):
1) Press Return twice to return to the category level of the
Configuration Menu.
2) Press Scroll or Scroll until the printer displays the
Configuration Storage category.
3) Press Enter, and then press Enter again. The printer
displays the Custom Set A value.
4) Press Enter to save the changes.
5) Switch the power Off (O).
6) Slide the print head to the center of the printer.
Note: The printer performs a partial reset to put any change to this
parameter value into effect when you leave the Configuration Menu with
Start or Return. Buffered data will be lost.

823 - Forms Device Installation


To install the forms device:
• If you have the F1 forms device, go to “824 - Installing the F1 Forms
Device” on page 800-9.
• If you have the F2 forms device, go to “829 - Installing the F2 Forms
Device” on page 800-18.
• If you have the F3 forms device, go to “835 - Installing the F3 Forms
Device” on page 800-31.
• If you have the F4 forms device, go to “840 - Installing the F4 Forms
Device” on page 800-40.

IBM 4230 and 4232 Printers Maintenance Information Manual 800-8


Ribbons, Forms, and Forms Devices 800-9

824 - Installing the F1 Forms Device


Note: The F1 forms device has a circle around the F1 symbol on
the forms device. Ensure you have the correct forms device before
you install it. If you use the wrong forms device, the forms device
could be damaged. Ensure the correct forms device is configured
(“822 - Forms Device Configuration” on page 800-7).
1. Press the Stop key.
2. Open the printer access cover.
3. Open the front paper door as follows:
a. Pull the door up until it will not go any higher.
b. Push the door back slightly to lock it in the open position.
4. Hold the forms device so that the device code (F1) is in the upper
left corner facing you. Note the bottom metal bar and the clips.

800-9
800-10

5. Remove the orange shipping clip, if present, from the bottom of the
metal bar and discard the clip.
6. Lower the forms device into the printer behind the platen rod so that
the bottom metal bar enters the printer first. Align the ends of the
forms device with the slots in the frame. Continue to lower the forms
device until the device stops in the frame.

7. Look through the front bottom opening in the printer and find the
metal bar at the bottom of the forms device.

IBM 4230 and 4232 Printers Maintenance Information Manual 800-10


Ribbons, Forms, and Forms Devices 800-11

8. Hold the metal bar at the bottom of the device with BOTH hands and
pull the device strongly toward you and then upward until both ends
lock into place on the platen rod.

800-11
800-12

9. Check both the left and right sides of the forms device to ensure that
the clips are around the platen rod as shown.

IBM 4230 and 4232 Printers Maintenance Information Manual 800-12


Ribbons, Forms, and Forms Devices 800-13

825 - Loading Forms (F1)


1. Press the Stop key.
2. Open the access cover.
3. Slide the print head to the far left side of the printer.
4. Rotate the forms tension knob clockwise as shown to loosen the
tension on the forms.

5. Move the forms tension knob counterclockwise until you see the
below the number 1. *

800-13
800-14

6. Unlock the blue locking lever on the right tractor. Slide the tractor to
the extreme right.

7. Open both of the blue tractor doors.

IBM 4230 and 4232 Printers Maintenance Information Manual 800-14


Ribbons, Forms, and Forms Devices 800-15

8. Feed the form into the bottom front of the printer. Ensure that the
form goes under the blue forms guide/forms sensor and between
the tensioner plates (see the figure on page 800-9 for the location of
the tensioner plates).

9. Align and put the left paper holes of the form over the left tractor
pins. Close the left blue tractor door.
10. Move the right tractor until the right paper holes of the form install on
the right tractor pins. Ensure that the forms are straight.

800-15
800-16

11. Close the right blue tractor door. Hold the tractor in place and lock
the blue locking lever.
Note: If necessary, unlock the tractor and adjust it so that the forms
are not buckled or stretched. Lock the locking lever after any
adjustment.

12. Close the access cover. Close the front paper door by pulling it out
and pushing it down until it latches.

IBM 4230 and 4232 Printers Maintenance Information Manual 800-16


Ribbons, Forms, and Forms Devices 800-17

827 - Removing the F1 Forms Device


Note: If you are removing this forms device to install a different forms
device, ensure you change the selected forms device in the
Configuration Menu (“822 - Forms Device Configuration” on
page 800-7).
1. Remove the forms from the printer.
2. Switch the power Off (O).
3. Open the access cover. Then open the front paper door as follows:
a. Pull the door up until it will not go up.
b. Push the door back slightly to lock it in the open position.
4. Push the metal bar at the bottom of the forms device toward the rear
of the printer until the forms device unlocks.

5. Hold the top of the forms device and lift it out of the printer.

800-17
800-18

829 - Installing the F2 Forms Device


Note: The F2 forms device has a square around the F2 name on
the forms device. Ensure you have the correct forms device before
you install it. If you use the wrong forms device, the forms device
could be damaged. Ensure the correct forms device is configured
(“822 - Forms Device Configuration” on page 800-7).
1. Press the Stop key.
2. Open the printer access cover and move the print head to the center
of the printer.
3. Open the front paper door as follows:
a. Pull the door up until it will not go any higher.
b. Push the door back slightly to lock it in the open position.
4. Hold the forms device so that the device code (F2) is in the upper
left corner facing you. Note the bottom metal bar.

IBM 4230 and 4232 Printers Maintenance Information Manual 800-18


Ribbons, Forms, and Forms Devices 800-19

5. Unlock the right blue locking lever and move the right tractor
assembly to the extreme right. Ensure that the tractor doors are
closed.

800-19
800-20

6. Lower the forms device into the printer behind the platen rod.
Ensure that F2 is in the upper left corner facing you, and the blue
tractor doors at the bottom of the device enter the printer first. Align
the ends of the device with the slots in the frame. Continue to lower
the device until the ends of the device stop in the slots of the frame.

7. Look through the front bottom opening in the printer and find the
metal bar at the bottom of the forms device.

IBM 4230 and 4232 Printers Maintenance Information Manual 800-20


Ribbons, Forms, and Forms Devices 800-21

8. Hold the metal bar at the bottom of the device with BOTH hands and
pull the device strongly toward you and then upward until both ends
lock into place.

800-21
800-22

9. Check both the left and right sides of the forms device to ensure that
the clips are around the platen rod as shown.

IBM 4230 and 4232 Printers Maintenance Information Manual 800-22


Ribbons, Forms, and Forms Devices 800-23

831 - Loading Forms (F2)


1. Press the Stop key.
2. Slide the print head to the far left side of the printer.
3. Open both of the blue tractor doors.

800-23
800-24

4. Feed the form into the printer until the paper is on at least two tractor
pins on each side. Ensure that the form goes under the blue forms
guide/forms sensor.

IBM 4230 and 4232 Printers Maintenance Information Manual 800-24


Ribbons, Forms, and Forms Devices 800-25

5. Put the left paper holes of the form over the left tractor pins. Close
the left blue tractor door.

6. Unlock the right tractor door.


7. Move the right tractor assembly and the blue sliding guides until the
right paper holes of the form install on the right tractor pins. Ensure
that the forms are straight.

800-25
800-26

8. Close the right tractor door.

IBM 4230 and 4232 Printers Maintenance Information Manual 800-26


Ribbons, Forms, and Forms Devices 800-27

9. Hold the right tractor in place and lock the blue locking lever.

Note: If necessary, unlock the tractor and adjust it so that the forms
are not buckled or stretched. Lock the locking lever after any
adjustment.

800-27
800-28

10. Space the blue sliding guides evenly between the tractors.

11. Close the access cover. Close the paper door by pulling it out and
pushing it down until it latches.

IBM 4230 and 4232 Printers Maintenance Information Manual 800-28


Ribbons, Forms, and Forms Devices 800-29

833 - Removing the F2 Forms Device


Note: If you are removing this forms device to install a different forms
device, ensure you change the selected forms device in the
Configuration Menu (“822 - Forms Device Configuration” on
page 800-7).
1. Remove the forms from the printer.
2. Switch the power Off (O).
3. Open the access cover. Then open the front paper door as follows:
a. Pull the door up until it will not go up.
b. Push the door back slightly to lock it in the open position.
4. Close the blue tractor doors.

800-29
800-30

5. Push the metal bar at the bottom of the forms device toward the rear
of the printer until the forms device unlocks.

6. Hold the top of the forms device and lift it out of the printer.

IBM 4230 and 4232 Printers Maintenance Information Manual 800-30


Ribbons, Forms, and Forms Devices 800-31

835 - Installing the F3 Forms Device


Note: The F3 forms device has an F3 symbol on the forms device.
Ensure you have the correct forms device before you install it. If you
use the wrong forms device, the forms device could be damaged.
Ensure the correct forms device is configured (“822 - Forms Device
Configuration” on page 800-7).
1. Press the Stop key.
2. Open the printer access cover and move the print head to the center
of the printer.
3. Open the front paper door as follows:
a. Pull the door up until it will not go any higher.
b. Push the door back slightly to lock it in the open position.
4. Hold the forms device so that the device code (F3) is in the upper
left corner facing you. Note the bottom of the device, the finger
grips, and the clips.

800-31
800-32

5. Unlock the blue locking lever and move the right roller assembly to
the extreme right.

IBM 4230 and 4232 Printers Maintenance Information Manual 800-32


Ribbons, Forms, and Forms Devices 800-33

6. Hold the forms device at the top with the F3 in the upper left corner
facing you. The finger grips should be at the bottom and should
enter the printer first.
Lower the device into the printer behind the platen rod and align the
ends of the device with the slots in the frame. Continue to lower the
device until the ends of the device stop in the slots of the frame.

7. Look through the front bottom opening in the printer and find the
finger grips at the bottom of the forms device.

800-33
800-34

8. Hold the finger grips with BOTH hands and pull the device strongly
toward you and then upward until both ends lock into place.

IBM 4230 and 4232 Printers Maintenance Information Manual 800-34


Ribbons, Forms, and Forms Devices 800-35

9. Check both the left and right sides of the forms device to ensure that
the clips are around the platen rod as shown.

10. The printer must have a different paper door installed to be used
with the F3 forms device. Refer to the User’s Guide for instructions
on changing the paper door.

800-35
800-36

11. Place the lower forms guide in front of the forms chute so that the
tab is under the chute.

12. Align the lower forms guide next to the blue forms guide/forms
sensor. Then slide the lower forms guide to the left until it locks on.

IBM 4230 and 4232 Printers Maintenance Information Manual 800-36


Ribbons, Forms, and Forms Devices 800-37

836 - Loading Forms (F3)


1. Slide the print head to the far left side.
2. Get three or four sheets of 8 1/2 in. x 11 in. single-part cut forms.
3. Hold a form in front of the upper forms guide and against the left
stop.
Unlock the blue locking lever and move the right roller assembly so
that the pointer aligns with the right edge of the form.

If needed, use the white writing surface near the blue sliding guides
to make pencil marks to help you align the form.

800-37
800-38

4. Lock the blue locking lever.

5. Center the blue sliding guide between the roller assemblies.

6. Close the access cover. Then close the paper door by pulling it out
and pushing it down until it latches.
7. Feed the form under the forms guide/forms sensor until the top edge
of the form touches both the left and right feed rollers.

IBM 4230 and 4232 Printers Maintenance Information Manual 800-38


Ribbons, Forms, and Forms Devices 800-39

8. Press the Load/Eject key. The printer automatically advances the


form to the top of form position.

837 - Removing the F3 Forms Device


Note: If you are removing this forms device to install a different forms
device, ensure you change the selected forms device in the
Configuration Menu (“822 - Forms Device Configuration” on
page 800-7).
1. Remove the forms from the printer.
2. Switch the power Off (O).
3. Open the access cover. Then open the front paper door as follows:
a. Pull the door up until it will not go up.
b. Push the door back slightly to lock it in the open position.
4. Push the bottom of the forms device toward the rear of the printer
until it unlocks.
5. Hold the top of the forms device and lift it out of the printer.
6. If you are removing the F3 forms device to install a different forms
device, you must remove the lower forms guide.
With a strong hold, slide the lower forms guide to the right off the
blue forms guide/forms sensor. Ensure that the tab clears the
bottom of the chute before pulling the lower forms guide away from
the printer.
7. If you are removing the F3 forms device to install a different forms
device, you may have to reinstall the standard front paper door.

800-39
800-40

840 - Installing the F4 Forms Device

Note: If the forms device is new, remove any packing material.

1. Press the Stop key.


2. Open the printer access cover and move the print head to the
center.
3. Remove the front paper door.
4. Hold the forms device with both hands and insert it in the printer
behind the platen rod. Lower it in the slots until it stops in the frame.

IBM 4230 and 4232 Printers Maintenance Information Manual 800-40


Ribbons, Forms, and Forms Devices 800-41

5. Look through the front bottom opening of the printer to find the blue
finger grips at the bottom of the forms device. Hold the finger grips
with both hands and pull the device strongly toward you so that the
blue locking tabs on the forms device click into the front bottom
opening.

800-41
800-42

IBM 4230 and 4232 Printers Maintenance Information Manual 800-42


Ribbons, Forms, and Forms Devices 800-43

6. Check the left and right sides of the forms device to ensure the
locking tabs are locked into place and the clips are around the
platen rod.

800-43
800-44

7. Move the blue lever down to close the feed rollers on the forms
device.

8. Close the access cover.


Note: The printer must have a different access cover and front paper
door installed to use the F4 device. For information about installing the
ASF mechanism, refer to Auto Sheet Feeder: General Information.

IBM 4230 and 4232 Printers Maintenance Information Manual 800-44


Ribbons, Forms, and Forms Devices 800-45

842 - Loading Forms (F4)


For automatic loading (Bins 1, 2, and 3):
1. Open the bin lock by rotating it toward the right side of the device as
shown.

800-45
800-46

2. Grip the right paper guide at its base, then move it to the right, out of
the way.
Note: The left paper guides do not move.
The paper supports should be centered between the paper guides.
To feed forms longer than 30.48 cm (12 in.), install paper support
extensions.

IBM 4230 and 4232 Printers Maintenance Information Manual 800-46


Ribbons, Forms, and Forms Devices 800-47

3. Set the width of the paper bins to the width of the paper as follows:
a. Move the paper loading lever toward the printer to release the
pressure plates.

b. Open the bin lock.


c. Push the right paper guide to the right.
4. Prepare the stack of paper by fanning it and ensuring the sides are
flush and in good condition.

800-47
800-48

5. Load the paper in an input bin as follows:


a. Place the prepared stack of paper into the bin between the
plates and the rollers.
b. Place the right paper guide at the right side of the paper so that
the bin pads are just touching the paper.
c. Close the bin lock by rotating it to the left until it is straight up.

IBM 4230 and 4232 Printers Maintenance Information Manual 800-48


Ribbons, Forms, and Forms Devices 800-49

d. Move the lever away from the printer to apply pressure against
the paper stack.

For loading into the manual insertion bin (Bin 4):


1. Set the right paper guide to the correct width.
2. When the printer requests a sheet from the manual bin, place a
sheet of paper (upside down and printed side toward the printer) in
the manual bin.
3. Press Stop and then Start to feed the sheet into the printer.

800-49
800-50

844 - Removing the F4 Forms Device


1. Switch the power Off (O).
2. Remove the paper supports from the ASF mechanism.

IBM 4230 and 4232 Printers Maintenance Information Manual 800-50


Ribbons, Forms, and Forms Devices 800-51

3. Remove the ASF front paper door by tilting the top toward you and
pulling the door up.

800-51
800-52

4. Lift the ASF mechanism off the installing studs and remove the ASF
mechanism from the printer front bottom opening.

IBM 4230 and 4232 Printers Maintenance Information Manual 800-52


Ribbons, Forms, and Forms Devices 800-53

5. Push the blue locking tabs away from you and upward.

6. Lift the forms device out of the printer with both hands.

800-53
800-54

7. If you are removing the F4 forms device to install a different forms


device, you may have to reinstall the standard access cover and
front paper door.

IBM 4230 and 4232 Printers Maintenance Information Manual 800-54


Vital Product Data 900-1

Section 900. Vital Product Data


You can check and change some of the vital product data for the printer.
The two Vital Product Data fields you can change are:
• Serial Number
• Device Specific Information.
Note: Vital Product Data values, unlike most of the other configuration
values, are not saved when you save a Custom Set; they are saved
when you leave the Configuration Menu. If you make a change to one
of these values and switch off the printer before leaving the
Configuration Menu, your changes will not be saved.

Serial Number
The serial number parameter holds the serial number for the printer.
This number is a seven digit alphanumeric value.

To check or change the serial number for the printer, follow these steps:
1. Press Menu.
2. Press Scroll or Scroll until the printer displays

CONFIGURATION MENU
Vital Product Data

3. Press Enter.
4. Press Scroll or Scroll until the printer displays

Vital Product Data


Serial Number

900-1
900-2

5. Press Enter.
The printer displays the existing value for the serial number of the
printer. A cursor (X) appears under the rightmost character of the
value.
6. Press Scroll or Scroll to change the character above the cursor.
7. Press Enter to move the cursor left to the next character.
8. Repeat steps 6 and 7 until the correct value for the serial number is
displayed.
9. Press Start to leave the menu, save any changes, and make the
printer ready
or
Press Return three times to leave the menu, save any changes,
and make the printer not ready.

Displaying Device Specific Information


This parameter stores user defined information for the printer. This
information is a 16-digit alphanumeric value.

To check or change the Device Specific Information for the printer, follow
these steps:
1. Press Menu.
2. Press Scroll or Scroll until the printer displays

CONFIGURATION MENU
Vital Product Data

3. Press Enter.

IBM 4230 and 4232 Printers Maintenance Information Manual 900-2


Vital Product Data 900-3

4. Press Scroll or Scroll until the printer displays

Vital Product Data


Device Specific Information

5. Press Enter.
The printer displays the existing value for device specific
information. A cursor (X) appears under the rightmost character of
the value.
6. Press Scroll or Scroll to change the character above the cursor.
7. Press Enter to move the cursor left to the next character.
8. Repeat steps 6 and 7 until the correct value for the device specific
information is displayed.
9. Press Start to leave the menu, save any changes, and make the
printer ready.
or
Press Return three times to leave the menu, save any changes,
and make the printer not ready.

900-3
900-4

IBM 4230 and 4232 Printers Maintenance Information Manual 900-4


Index X-1

Index
alarm 000-39
Numerics attachment bezel
10 CPI Test 000-82 description 000-46
12 CPI Test 000-81 removal and replacement 400-2
15 CPI Test 000-80 attachment card/bezel
16.7 CPI Test 000-79 description 000-46
17.1 CPI Test 000-78 removal and replacement 400-4,
20 CPI Test 000-77 400-7
attachment connector 100-5, 700-5
attachment storage dump 000-84
A auto forms thickness sensor 000-44,
access cover 100-4
000-45
acoustic cover 100-2
auto sheet feeder device (F4)
adjustments, AFTA
belt and drive gear 650-1
assembly 000-109
description 000-43
advanced printing functions
installing 800-40
bar codes 000-7 lever and lever spring 650-3
graphics 000-6
loading forms 800-45
host loadable symbols 000-7 removing 800-50
large characters 000-8
OCR A and B 000-9
overlays 000-6 B
page segments 000-6 bearing, carrier 300-10
stored images 000-7 belt, carrier drive 300-14
subscripting 000-6 bidirectional adjustment test 000-71
superscripting 000-6 Bin 1 Selection Test 000-85
AFTA assembly 300-26 Bin 2 Selection Test 000-85
AFTA run in test 000-87 Bin 3 Selection Test 000-85
AFTA, perpetual test 000-87 Bin 4 Selection Test 000-86
AFTA, run in test 000-87 board, logic 200-2
air deflectors 100-16 bracket, acoustic cover 100-2

X-1
X-2

brackets, cooling fan 600-4 crossbar, ribbon drive 300-20


CRU
See customer-replaceable unit
C customer-replaceable unit
cable connector locations 700-8 (CRU) 000-47
Cancel Print key 000-34
card
See board D
carrier Darker key 000-30
bearing 300-10 data flow paths 000-11
drive belt 300-14 deflectors, air 100-16
drive motor 300-12 diagnostics
lower bearing 300-10 See tests
motor, location 700-12 digital CE voltmeter 700-13
CE tests Display Address key 000-36
See tests Display Interface Key 000-36
character spacing 000-2 document insertion device (F3)
chute, entry paper 100-12 description 000-42
clear error log 000-88 installing 800-31
coaxial attachment bezel service loading forms 800-37
check 000-114, 000-116 lower forms guide 800-36
connector probe 700-13 removing 800-39
continuous forms device (F1) door open and cover open
description 000-41 sensor 000-45
installing 800-9 switch 300-18
loading forms 800-13 DP Print Quality Test 000-74
removing 800-17 DPT Print Quality Test 000-75
controls 000-38 drive
cooling fan 000-44, 600-4 See forms, ribbon, or print head
cooling fan, location 700-12 drive belt carrier 300-14
cover open dual purpose forms device (F2)
See door open and cover open description 000-42
covers installing 800-18
access 100-5 loading forms 800-23
acoustic 100-2 removing 800-29
printer assembly 100-6

IBM 4230 and 4232 Printers Maintenance Information Manual X-2


Index X-3

forms-handling devices (continued)


E auto sheet feeder device (F4)
electronics, printer 000-10 (continued)
end of forms sensor loading forms 800-45
end of forms, false 000-108, 300-24 removing 800-50
Enter key 000-30 continuous forms device (F1)
entry paper chute 100-12 description 000-10
error log 000-66 installing 800-9
clear 000-88 loading forms 800-13
print 000-87 removing 800-17
error log utilization 000-66 document insertion device (F3)
extended memory card 200-4 description 000-10
installing 800-31
loading forms 800-37
F removing 800-39
false end of forms service
dual purpose forms device (F2)
check 000-108
description 000-10
false forms jam service
installing 800-18, 800-31
check 000-108
loading forms 800-23
fan, cooling 000-44, 600-4
removing 800-29
fast draft quality test 000-76
installation and removal 800-7
fast head test 000-84
frame assembly 100-14
field-replaceable unit (FRU) 000-48
frames
Form Feed key 000-28
See covers
forms feed service check 000-97
front paper door 700-4, 700-6
forms feed units
AFTA assembly 300-26
devices 000-41
drive, description 000-41
G
general printer information 000-1
end of forms sensor 300-24 ground wire, location 700-11
motor 300-22 grounding spring 100-8
forms jam, false 000-108
forms motor 300-22
forms motor test 000-85 H
forms-handling devices head
auto sheet feeder device (F4) See print head
description 000-10
installing 800-40

X-3
X-4

Hex Print key 000-35


L
left margin alignment test 000-61
I Lighter key 000-31
identification, model 000-11 Line Feed key 000-25
installation line spacing 000-3
See removals and replacements Load/Eject key 000-26
locations
access cover 700-6
K acoustic cover 700-6
keys air deflectors 700-7
Cancel Print 000-34 attachment bezel, rear
Darker 000-30 view 700-9
Display Address 000-36 attachment card/bezel, rear
Display Interface 000-36 view 700-9
Enter 000-30 attachment connector 700-5
Form Feed 000-28 cable connectors 700-8
Hex Print 000-35 cooling fan 700-12
Lighter 000-31 door open and cover open switch
Line Feed 000-25 magnet 700-5
Load/Eject 000-26 drive and idler gears 700-7
Menu 000-33 electrostatic shield 700-9
Micro 000-29 end of forms sensor 700-4, 700-6
Micro 000-29 entry paper chute 700-4, 700-6
PA1 000-37 fan assembly, rear view 700-9
PA2 000-38 forms motor 700-12
Quick Reference 000-33 frame assembly 700-11
Return 000-31 front paper door 700-4, 700-6
Scroll 000-29 ground wire 700-11
Scroll 000-29 grounding spring 700-6
Set Top of Form 000-28 idler assembly 700-11
Start 000-24 model type identification 700-4,
Stop 000-24 700-6
Test 000-34 operator panel 700-4, 700-6,
700-7
operator panel bracket
drive belt 700-7

IBM 4230 and 4232 Printers Maintenance Information Manual X-4


Index X-5

locations (continued) Micro key 000-29


operator panel bracket (continued) miniprobe 700-13
motor 700-12 model identification 000-11
power
connector 700-9
cord connector 700-5 N
requirements label 700-5 NLQ 80 ripple pattern 000-73
supply 700-11 NLQ print quality test 000-72
supply LED 700-11
supply, rear view 700-9
switch 700-11 O
offline CE tests
print head 700-7, 700-12
rear shield 700-11 See tests
operator panel
ribbon
cable 750-7
crossbar 700-7, 700-11
drive motor 700-7, 700-12 display 000-20
indicators
serial number 700-4, 700-6
with cover on 700-6 Attention 000-19
log utilization, error 000-66 Format 000-18
Online 000-18
log, error
clear 000-88 Power 000-17
Processing 000-19
print 000-87
logic board, printer 000-46, 750-3 Ready 000-17
lower bearing Unit Check 000-19
keys
carrier 300-10
spring 300-10 Cancel Print 000-34
Darker/Enter 000-30
lower forms guide, new and old
style 800-36 Display Address 000-36
Display Interface 000-36
Form Feed 000-28
M Hex Print 000-35
main sensor cable 750-8 Lighter/Return 000-31
Menu key 000-33 Line Feed 000-25
metric tool supplement 700-13 Load/Eject 000-26
Micro key 000-29 Menu 000-33
Micro /Scroll 000-29
Micro /Scroll 000-29

X-5
X-6

operator panel (continued) panel, operator (continued)


keys (continued) keys (continued)
PA1 000-37 Lighter/Return 000-31
PA2 000-38 Line Feed 000-25
Quick Reference 000-33 Load/Eject 000-26
Set Top of Form 000-28 Menu 000-33
Start 000-24 Micro /Scroll 000-29
Stop 000-24 Micro /Scroll 000-29
Test 000-34 PA1 000-37
overlay 500-2 PA2 000-38
service position 700-3 Quick Reference 000-33
test 000-67 Set Top of Form 000-28
operator panel keys Start 000-24
See keys Stop 000-24
operator test descriptions 000-48 Test 000-34
overlay 500-2
service position 700-3
P paper
PA1 key 000-37 chute 100-12
PA2 key 000-38 present sensor 300-8
panel, operator shield, location 700-12
display 000-20 perpetual AFTA test 000-87
indicators power
Attention 000-19 basic assurance tests
Format 000-18 (BATs) 000-13
Online 000-18 cord connector 700-5
Power 000-17 location 700-12
Processing 000-19 on self-test, description 000-13
Ready 000-17 removal/replacement 600-2
Unit Check 000-19 supply 600-2
keys supply description 000-45
Cancel Print 000-34 supply LED description 000-45
Darker/Enter 000-30 switch 000-38
Display Address 000-36 print error log 000-87
Display Interface 000-36 print head
Form Feed 000-28 cables 300-4
Hex Print 000-35

IBM 4230 and 4232 Printers Maintenance Information Manual X-6


Index X-7

print head (continued) printer (continued)


carrier test
and shaft 300-6 configuration 000-49
belt 300-14 demonstration 000-62
drive motor 300-12 top of form alignment 000-62
removal 300-6 verification 000-62
upper bearing 300-10 printer electronics 000-10
description of print printer service 000-9
mechanism 000-40 printing, advanced functions
door open and cover open bar codes 000-7
sensors, description 000-45 graphics 000-6
switch 300-18 host loadable symbols 000-7
drive large characters 000-8
assembly, description 000-40 OCR A and B 000-9
idler assembly 300-16 overlays 000-6
home position 000-40 page segments 000-6
location 700-12 stored images 000-7
lower bearing 300-10 subscripting 000-6
shaft 300-6 superscripting 000-6
spring 300-10 publications
print modes
data processing (DP) 000-2
data processing text (DPT) 000-2 Q
fast draft (FD) 000-1 quality
near letter quality (NLQ) 000-2 See print quality test
print quality test Quick Reference key 000-33
DP 000-74
DPT 000-75
NLQ 000-72 R
print ROS part numbers test 000-84 rear shield 100-10
print usage metrics test 000-87 removals and replacements
access cover 100-4, 100-5
print wire test 2 000-70
acoustic cover 100-2
printer
AFTA assembly 300-26
logic board
description 000-46 air deflectors 100-16
removal/installation 200-2 attachment bezel 400-2
attachment card/bezel 400-4,
service position 700-1
400-7

X-7
X-8

removals and replacements ribbon (continued)


(continued) units (continued)
carrier drive locations 700-12
belt 300-14 routines
motor 300-12 See tests
cooling fan and bracket 600-4
door open sensor 300-18
end of forms sensor 300-24 S
entry paper chute 100-12 safety
extended memory card 200-4 information
forms motor 300-22 procedures xxiii
frame assembly 100-14 Scroll key 000-29
grounding spring 100-8 Scroll key 000-29
idler assembly 300-16 sensor test 000-68
operator panel 500-1 sensors
operator panel overlay 500-2 auto forms thickness 000-45
power supply 600-2 door open and cover
print head open 000-45
cable 300-4, 750-5 end of forms 000-44, 300-24
carrier and shaft 300-6 paper present 000-44, 000-45
removal and installation 300-2 serial/parallel attachment
printer cover assembly 100-6 card/bezel 000-117
rear shield 100-10 service checks
static eliminator 100-8 coaxial attachment
replaceable units 000-47 bezel 000-114, 000-116
replacements false end of forms 000-108
See removals and replacements false forms jam 000-108
Return key 000-31 forms feed 000-97
ribbon serial/parallel attachment
cartridge card/bezel 000-117
description 000-43 steps to perform 000-89
installation 800-2 twinaxial attachment
removal 800-1 bezel 000-112, 000-115
motor test 000-86 service positions
units opertor panel 700-3
crossbar 300-20 printer logic 700-1
description of drive 000-43

IBM 4230 and 4232 Printers Maintenance Information Manual X-8


Index X-9

service, printer 000-9 tests (continued)


Set Top of Form key 000-28 CPI test
shaft, print head carrier and 300-6 10 000-82
shield 12 000-81
electrostatic 700-9 15 000-80
rear 100-10 16.7 000-79
shields 17.1 000-78
See covers 20 000-77
slow head test 000-83 description of operator
spacing tests 000-48
character 000-2 diagnostics, description of 000-47
line 000-3 display memory locations 000-86
spring, print head 300-10 enable/disable cover
Start key 000-24 sensors 000-86
static brush 100-8 fast draft quality 000-76
Stop key 000-24 fast head test 000-84
switch forms motor verification 000-85
door open 300-18 left margin alignment 000-61
power 000-38 offline CE tests
descriptions 000-63
performing 000-65
T operator panel test 000-67
test equipment perpetual AFTA 000-87
See tools and test equipment power on operator test
Test key 000-34 panel 000-68
tests power-on self test (POST) 000-13
AFTA run in print quality
AFTA setting 000-69 DP 000-74
AFTA setting procedure 000-109 DPT 000-75
attachment storage dump 000-84 NLQ 000-72
bidirectional adjustment 000-71 print ROS part numbers 000-84
bin selection print wire 000-69
Bin 1 000-85 print wire 2 000-70
Bin 2 000-85 printer
Bin 3 000-85 configuration 000-49
Bin 4 000-86 demonstration 000-62
top of form alignment 000-62

X-9
X-10

tests (continued)
printer (continued)
verification 000-62
ribbon motor 000-86
selecting operator 000-48
sensor 000-68
set factory defaults 000-88
slow head test 000-83
text emphasis modes
bold 000-4
double high 000-4
double strike 000-4
double wide 000-4
italicize 000-5
overscore 000-5
overstrike 000-5
underline 000-5
theory and summary 000-1
tools and test equipment
connector probe 700-13
digital CE voltmeter 700-13
metric tool supplement 700-13
miniprobe 700-13
trademarks xiii
twinaxial attachment bezel service
check 000-112, 000-115

V
views
rear 700-9
with cover on 700-6

IBM 4230 and 4232 Printers Maintenance Information Manual X-10