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Lexmark 4227 - Forms Printer B/W Dot-matrix Service Manual

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Edition: January 15, 2007
Lexmark™ Forms Printer
4227-300
• Table of contents
• Start diagnostics
• Safety and notices
• Trademarks
• Index
Lexmark and Lexmark with diamond
design are trademarks of Lexmark
International, Inc., registered in the
United States and/or other countries.

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Summary of Contents for Lexmark 4227 - Forms Printer B/W Dot-matrix

  • Page 1 Edition: January 15, 2007 Lexmark™ Forms Printer 4227-300 • Table of contents • Start diagnostics • Safety and notices • Trademarks • Index Lexmark and Lexmark with diamond design are trademarks of Lexmark International, Inc., registered in the United States and/or other countries.
  • Page 2 Comments may be addressed to Lexmark International, Inc., Department D22/035-3, 740 New Circle Road N.W., Lexington, Kentucky 40550, U.S.A. Lexmark may use or distribute any of the information you supply in any way it believes appropriate without incurring any obligation to you.

  • Page 3: Table Of Contents

    4227-300 Table of contents Table of contents..........ii Safety information .
  • Page 4 4227-300 Operator panel service check ......2-20 Paper feed service check ....... . . 2-21 POST service check .
  • Page 5 4227-300 Operator panel assembly removal ......4-22 Paper Empty sensor/TOF sensor removal....4-22 Paper feed motor removal .
  • Page 6 4227-300 Parts catalog ..........7-1 How to use this parts catalog .

  • Page 7: Safety Information

    4227-300 Safety information • The safety of this product is based on testing and approvals of the original design and specific components. The manufacturer is not responsible for safety in the event of use of unauthorized replacement parts. • The maintenance information for this product has been prepared for use by a professional service person and is not intended to be used by others.
  • Page 8 4227-300 Norme di sicurezza • La sicurezza del prodotto si basa sui test e sull'approvazione del progetto originale e dei componenti specifici. Il produttore non è responsabile per la sicurezza in caso di sostituzione non autorizzata delle parti. • Le informazioni riguardanti la manutenzione di questo prodotto sono indirizzate soltanto al personale di assistenza autorizzato.
  • Page 9 4227-300 Pautas de Seguridad • La seguridad de este producto se basa en pruebas y aprobaciones del diseño original y componentes específicos. El fabricante no es responsable de la seguridad en caso de uso de piezas de repuesto no autorizadas. •...
  • Page 10 4227-300 Informació de Seguretat • La seguretat d'aquest producte es basa en l'avaluació i aprovació del disseny original i els components específics. El fabricant no es fa responsable de les qüestions de seguretat si s'utilitzen peces de recanvi no autoritzades. •...
  • Page 11 4227-300...

  • Page 12: Preface

    4227-300 Preface This manual contains maintenance procedures for service personnel. It is divided into the following chapters: 1. General information contains a general description of the MFP and the maintenance approach used to repair it. Special tools and test equipment are listed, as well as general environmental and safety instructions.

  • Page 13: General Information

    4227-300 1. General information Description The Lexmark™ Form Printer 4227-300 is a dot matrix, electro- mechanical printer that forms characters on a print media using a printhead and fabric ribbon. The printhead is composed of 18 miniature solenoids containing print wires and operates on electromagnetic principles.

  • Page 14: Voltage, Ground, And Continuity Readings

    4227-300 Voltage, ground, and continuity readings Voltage readings All DC voltages must be within +5% through -10% of the values to be considered correct. Unless stated otherwise, all connectors should be connected normally when a voltage measurement is done. When a “line voltage” measurement is to be done, the voltage on United States and Canada machines should be between 100 V ac and 127 V ac.

  • Page 15: Maintenance Approach

    4227-300 Maintenance approach The diagnostic information in this manual leads you to the correct field replaceable unit (FRU) or part. Use the error indication table, symptom/check table, service checks and diagnostic aids to determine the symptom and repair the failure. Begin with “Power-On Self Test (POST)”...

  • Page 16: Abbreviations

    4227-300 Abbreviations Automatic Sheet Feeder ASIC Application-Specific Integrated Circuit Customer Setup DRAM Dynamic Random Access Memory EPROM Erasable Programmable Read-Only Memory Electrostatic Discharge Field Replaceable Unit HVPS High Voltage Power Supply Local Area Network Liquid Crystal Display Light-Emitting Diode LVPS Low Voltage Power Supply NVRAM Nonvolatile Random Access Memory...

  • Page 17: Using The Operator Panel

    4227-300 Using the operator panel This section provides a brief description of the operator panel buttons, lights, and settings. Refer to the User’s Guide for additional information. Note: Application software may allow the user to operate the printer from a computer. Changes made to the printer settings from a software application override settings made from the operator panel, with the exception of the Font and Pitch Lock features.

  • Page 18: Using The Function Menus

    4227-300 Using the function menus Use the Item ↓ and Item ↑ buttons to move through the menu and option directories. Press Next → to move away from the Main Menu to the subordinate directories and choices. Press Prev. ← if you want to go back in a menu or return to the Main Menu.

  • Page 19: Setting Printer Functions

    4227-300 Setting printer functions 1. Press Start/Stop. 2. Press Menu to enter the function menu. 3. Press Item ↓ or Item ↑ until the function menu you want appears on the display. Note: The selectable function menu is different depending on the selected data stream mode (IBM PPDS or Epson emulation) and the Interface mode (Parallel, RS-232 or RS-422).

  • Page 20: Overview Of Function Menus

    4227-300 Overview of function menus Use the Item ↑ and Item ↓ buttons to move through the menu and option directories. Press Next → to move away from the Main Menu to the subordinate directories and choices. Press Prev. ← if you want to go back in a menu or return to the Main Menu.
  • Page 21 4227-300 General information...

  • Page 22: Buttons

    4227-300 Buttons When using the function menus, press Item ↓ or Item ↑ to scroll through the menu items. Press Next → or Prev. ← to move to the next, or previous menu level. Press Menu Enter the function menu. The printer goes offline.

  • Page 23: Lights

    4227-300 Lights Light Description Power (Green) The printer power is on. Ready (Green) The printer is online and ready to print. The following conditions cause the Ready light to turn off: • Pressing Start/Stop • An end-of-form (EOF) • A paper jam •...
  • Page 24 4227-300 1-12 Service Manual...

  • Page 25: Diagnostic Information

    4227-300 2. Diagnostic information Start Make a quick visual check for defects (loose or broken parts, unplugged connectors, or paper jams). If there is no power after turning the printer on, go to the “Power failure service check” on page 2-25.
  • Page 26 4227-300 Display Indication Description/Action 633 Machine Check Timer Interrupt Controller Error. Replace Timer Interrupt Error the main logic board and perform the “Bidirectional print adjustment” on page 4-3 “Printhead-to- . Check the platen gap adjustment” on page 4-2 636 Machine Check Non-Volatile Memory Read/Write Error.

  • Page 27: Symptom Tables

    4227-300 Symptom tables 1. Select the symptom that best describes the problem. 2. Perform the appropriate action before you go to the indicated service check. Diagnostic information...

  • Page 28: Abnormal Indications

    4227-300 Abnormal Indications Symptom Action All LEDs turn on but Disconnect the interface cable from the printer and do not turn off. turn the printer off and then back on. If POST now runs correctly, the problem is in the computer or interface cable.

  • Page 29: Auto Sheet Feeder Problems

    4227-300 Auto Sheet Feeder problems Symptom Action Auto Sheet Feeder Be sure Auto Sheet Feed is set to On in the Paper will not feed paper. Handling Option Menu. Auto Sheet Feeder Be sure the paper select lever is in the cut sheet double feeds.

  • Page 30: Paper Feed Problems

    4227-300 Paper feed problems Symptom Action Paper Empty Be sure the Paper Empty Sensor is not blocked. Add Paper is displayed with There may be a problem with the Paper Select “Paper feed service check” paper in the printer. Sensor. Go to the on page 2-21 Print operation starts without paper.
  • Page 31 4227-300 Symptom Action Lower feed roll shaft Be sure the Paper Select lever is in the correct rotates, but paper position. does not feed. “Paper feed service check” on page Go to the 2-21 Pressing Form Feed does not feed paper. Abnormal noise while feeding Paper jams, skews,...

  • Page 32: Operator Panel Problems

    4227-300 Operator panel problems Symptom Action Start/Stop does not Turn the printer off and then back on. function but no error “Operator panel service check” on is indicated. Go to the page 2-20 Only the Power light comes on. One or more buttons do not function.

  • Page 33: Print Quality Problems

    4227-300 Print quality problems Symptom Action No print, but carrier Be sure the printhead cables are not loose or moves as if printing. damaged. Be sure the interface cable is connected properly. Check the ribbon cartridge for binds or damage. “Print wire drive failure service Go to the check”...

  • Page 34: Ribbon Feed Problems

    4227-300 Symptom Action Wavy vertical lines, Clean and lubricate the carrier shaft. uneven left margin, or character width is If the carrier drive belt is worn or broken, replace “Bidirectional print reduced. the carrier unit. Perform the adjustment” on page 4-3 “Carrier drive service check”...

  • Page 35: Service Checks

    4227-300 Service checks Auto Gap service check Theory of operation The Auto Gap motor and Gap Home sensor automatically set the printhead gap for the thickness of paper being used by rotating the eccentric carrier shaft. The printer detects maximum gap with the Gap Home sensor, and minimum gap by driving the printhead against the platen.
  • Page 36 4227-300 Auto Gap can be set to off to reduce time-to-print if the printer is always used with a single type of paper. With Auto Gap off, the gap can be set to Manual Position 1 (thinnest paper) to 7 (thickest paper).

  • Page 37: Auto Sheet Feeder (Asf) Service Check

    4227-300 Auto Sheet Feeder (ASF) service check Auto Sheet Feeder principles of operation The Auto Sheet Feeder (ASF) feeds into the cut sheet paper entry throat. To use the ASF: • The Paper Select lever must be set to Cut Sheet. •...
  • Page 38 4227-300 Action Paper Feed If the paper does not feed, do the following: • Remove the ASF. • Be sure the base printer feeds paper correctly. • If it does not feed paper correctly, go to the “Paper feed service check” on page 2-21 Gear Train Be sure the ASF drive gear on the inside of the...

  • Page 39: Carrier Drive Service Check

    4227-300 Carrier drive service check Note: When a 637, 638, or 639 error is detected while printing, verify that the same error is detected after removing jammed paper and checking that the ribbon guide is in place. Action 637, 638, 639 Carrier positioning error.

  • Page 40: Intermittent Problem Service Check

    4227-300 Intermittent problem service check FRU/Symptom Action The machine Check for the following: sometimes fails before POST is 1. Loose connectors. Reconnect all connectors complete. to the main and sub logic boards. 2. Electrical noise or static discharge. Check the following items: •...
  • Page 41 4227-300 FRU/Symptom Action Machine power The cause of this problem may be that the sometimes turns power circuit is failing, or the wiring is off. intermittently open. Check the following in sequence: 1. Check the electrical voltage and be sure it is within tolerance.
  • Page 42 4227-300 FRU/Symptom Action The previous The service check has not defined the failure, suggestions have or the machine is having intermittent failures. not corrected the The following may cause undefined or problem intermittent failures: 1. Customer’s electrical voltage. Be sure that it is within the tolerance.

  • Page 43: No Print Or Abnormal Print Service Check

    4227-300 No print or abnormal print service check FRU/Function Action Carrier If the carrier moves, but nothing is printed, go “Print wire drive failure service to the check” on page 2-28 Configuration Enter the user menus and be sure the correct emulation (IBM/EPSON) and interface (parallel/serial) are selected.

  • Page 44: Operator Panel Service Check

    4227-300 Operator panel service check Note: Press any button except Start/Stop, Load/Unload, or FormFeed. If Operator Panel Disabled is displayed, unlock the operator panel by powering up with the Micro↑ and Micro↓ keys pressed. Use the same procedure to re-lock the panel after service is complete.

  • Page 45: Paper Feed Service Check

    4227-300 Paper feed service check Note: If the problem is frequent jams or paper creases, verify that the paper is neither very thick nor very thin. If necessary refer the customer to the User’s Guide for specifications of acceptable papers. FRU/Symptom Action Auto Sheet...
  • Page 46 4227-300 FRU/Symptom Action Gear Train and Remove all paper from the machine. Paper Feed Motor Press FormFeed several times and examine all rotating parts to find the problem. For better visibility, remove the covers and reconnect the operator panel to the main logic board.
  • Page 47 4227-300 FRU/Symptom Action PE Sensor The printer has four sensors in the paper path, TOF Sensor plus one which detects the position of the PSet Sensor Paper Select lever. Enter the Service Menu Jam Sensor and perform the sensor tests. •...

  • Page 48: Post Service Check

    4227-300 FRU/Symptom Action Operator Panel If paper does not move at all, verify the FormFeed button is working correctly by performing the Service Menu Button Test. Main Logic Board If no other problem is found, replace the main logic board. “Bidirectional print adjustment”...

  • Page 49: Power Failure Service Check

    4227-300 Power failure service check For more information see “Voltage, ground, and continuity readings” on page 1-2. Action Operator Panel If the operator panel or cable is damaged or disconnected, the machine is completely inoperable, except for the power supply fan noise.
  • Page 50 4227-300 Action Ribbon Motor Disconnect the carrier motor (CN9 and CN15), Paper Feed Motor the paper feed motor (CN10), the ribbon motor Carrier Motor (CN19) and the (4227-300) carrier motor Sub Logic Board cooling fan (CN17) from the main logic board, 4227-300 Carrier and disconnect the power connector CN-1 Motor Cooling...

  • Page 51: Print Quality Service Check

    4227-300 Print quality service check Action Ribbon and Shield Be sure the ribbon is not worn and feeds smoothly when the knob is turned. Inspect the ribbon shield for dirt or damage. Ribbon Drive Be sure the ribbon drive post rotates when printing.

  • Page 52: Print Wire Drive Failure Service Check

    4227-300 Print wire drive failure service check FRU/Symptom Action Missing Dots Perform the Print Test to determine which wires are not printing. Disconnect the printhead Carrier moves, cables from the sub logic board and check the but there is no resistance for the affected wires.
  • Page 53 4227-300 FRU/Symptom Action 63E Head The printer has stopped to protect the Thermal Error printhead from overheating. Normally this occurs after several hours of continuous heavy use in a warm environment, and only then after going through several stages of thermal slowdown.

  • Page 54: Ribbon Drive Service Check

    4227-300 FRU/Symptom Action Main Logic Board If no other problem is found, replace the main logic board, retaining the old board for reinstallation if the problem is not fixed. “Bidirectional print adjustment” Perform the on page 4-3 “Printhead-to-platen and the gap adjustment”...

  • Page 55: Tractor 2 Service Check

    4227-300 Tractor 2 service check The Tractor 2 sensor opens during installation, when its actuator touches the printer cover. The home sensor detects the position of the slider. • When Tractor 2 is selected, the motor-driven Tractor 2 slider pushes the printer sub slider cam lever to engage the printer gear train, which drives the Tractor 2 tractors.
  • Page 56 4227-300 Action Main Logic Board Remove Tractor 2 from the printer but leave the cable connected. Make sure the slider (the black plastic piece just above the right cover) moves after turning the printer off and then back on. If the slider does not move after turning the printer off and then back on: •...
  • Page 57 4227-300 Tractor 2 installed, but not shown in User Menu Tractor 2 is selected from operator panel but the printer does not detect Tractor 2, or detects that the Tractor 2 mechanism is not installed. Power the printer off and reinstall the Tractor 2. Power the printer on and verify the problem still occurs.
  • Page 58 4227-300 Paper feed problems Action Tractor 2 On the printer, make sure the Tractor 2 driving gear turns freely when the white sub slider cam is not pressed. Be sure the driving gear does not move when the sub slider cam behind the gear is pressed.

  • Page 59: Diagnostic Aids

    4227-300 3. Diagnostic aids The printer contains self tests to help find and solve problems. You do not need to connect the printer to a computer or terminal to run these tests. Types of self tests are as follows: • Power-On Self Test (POST) •...

  • Page 60: Hex Trace Mode

    4227-300 Hex trace mode The hex trace mode can help test and troubleshoot programs. You can use the hex trace procedure to get a hexadecimal printout of the data stream sent to the printer. All data, including control and character data, print in hexadecimal instead of ASCII. To activate hex trace mode: 1.

  • Page 61: Interface Selection

    4227-300 Interface selection Serial or parallel attachment can be selected from the User Menu under Interface Options. If serial attachment is selected, RS-232 or RS-422 can be selected with the switch that is accessible through the rear cover. Serial attachment parameters are set in the Interface Options menu.

  • Page 62: Button Test

    4227-300 Button Test Pressing each operator panel button causes the alarm to beep. Pressing multiple buttons simultaneously results in no beep. Return to the Service Menu by pressing Menu/Quit. Factory Setting Factory Setting allows the selection of the default page length and code page from U.S.

  • Page 63: Print Test

    4227-300 Print Test The Print Test prints: • The ASCII character set • A line from each print wire • The bidirectional print alignment pattern • The contents of NVRAM • The error log Other print tests The following print tests are accessed outside the Service Menu: •...
  • Page 64 4227-300 Service Manual...

  • Page 65: Repair Information

    4227-300 4. Repair information This chapter explains how to make adjustments to the printer and how to remove defective parts. Warning: Read the following before handling electronic parts. Handling ESD-sensitive parts Many electronic products use parts that are known to be sensitive to electrostatic discharge (ESD).

  • Page 66: Adjustments

    4227-300 Adjustments Printhead installation adjustment 1. Hold the printhead down while pressing it toward the platen, and tighten the two printhead mounting screws. 2. Perform the “Printhead-to-platen gap adjustment” on page 4-2. Printhead-to-platen gap adjustment Perform this adjustment: • When the platen, printhead, carrier, carrier shaft, or main logic board is removed or replaced •...

  • Page 67: Bidirectional Print Adjustment

    4227-300 Printhead-to-platen gap electronic setting Be sure there is no paper in the printer. 1. Install a ribbon. 2. Hold down FormFeed and power on the printer. 3. Remove the ribbon guide. 4. Measure the printhead-to-platen gap. The gap specification is between .011 inch (.275 mm) and .015 inch (.375 mm).
  • Page 68 4227-300 The following example shows a printer that needs alignment. The message Choose the Best Alignment appears on the display. 7. Press Next → or Prev. ← to adjust the alignment. Lines 2 and 4 move to align with lines 1 and 3. The printer is aligned correctly when lines 2 and 4 are vertically aligned with lines 1 and 3.

  • Page 69: Removals

    4227-300 Removals Use the following procedures to remove and replace individual FRUs. Top cover removal CAUTION: Be sure to unplug the power cord whenever you are working on the printer with any of the covers removed. 1. Turn the printer off. 2.
  • Page 70 4227-300 6. There are two screws (3) and six latches (4) securing the top cover to the bottom cover. Remove the two top cover (3) mounting screws. 7. Place the printer on its left side. Insert a flat blade screwdriver into the two slots (4) and release the cover by pushing on the left side latches and up on the top cover.
  • Page 71 4227-300 Place the printer on its feet and release the remaining two top cover latches (4). 10. While lifting the top cover slightly, disconnect the operator panel cable from the main logic board, and then remove the top cover. To Reinstall: Be sure that the operator panel cable is correctly aligned and inserted securely.

  • Page 72: Auto Gap Motor Removal

    4227-300 Auto Gap motor removal 1. Remove the top cover. See “Top cover removal” on page 4-5. 2. Disconnect gap adjust motor connector CN20 from the main logic board. 3. Remove the sub logic card. 4. Remove the paper feed motor. 5.

  • Page 73: Auto Sheet Feeder Gears Removal

    4227-300 Auto Sheet Feeder gears removal 1. Remove the right cover (1). 2. Release the latch, and then remove the joint gear (2). 3. Remove the latch, and then remove the idler gear (3). 4. Release the latch, and then remove the pick-up gear (4). 5.

  • Page 74: Auto Sheet Feeder Pick-Up Roller Removal

    4227-300 Auto Sheet Feeder pick-up roller removal 1. Remove the covers and the cut sheet support. 2. Remove the idler gear and the pick-up gear. See “Auto Sheet Feeder gears removal” on page 4-9. 3. Remove the left roller bushing (1). 4.

  • Page 75: Belt Tension Pulley Plate Assembly Removal

    4227-300 Belt tension pulley plate assembly removal 1. Remove the top cover. See “Top cover removal” on page 4-5. 2. Turn the printer so the rear of the printer faces you. 3. Remove both tension pulley plate mounting screws (1). 4.

  • Page 76: Carrier Removal

    4227-300 Carrier removal 1. Remove the top cover. See “Top cover removal” on page 4-5. 2. Remove the printhead. See “Printhead removal” on page 4-32. 3. Remove the carrier roller spring. 4. Remove the sub logic board. See “Sub logic board removal” on page 4-37.
  • Page 77 4227-300 6. Loosen the two tension pulley plate screws (2). Pull up on both sides of the belt to move the tension pulley plate as far as possible toward the center of the printer, and then retighten the large screw. 7.
  • Page 78 4227-300 9. Remove the gear/flag (3) from the end of the carrier shaft. 10. Remove the bearing (4) and its retainer (5) by pulling the bearing free and lifting the end of the carrier shaft. 11. Slide the carrier shaft toward the carrier motor to free the other end.

  • Page 79: Carrier Motor Assembly Removal

    4227-300 Carrier motor assembly removal 1. Remove the top cover. See “Top cover removal” on page 4-5. 2. Disconnect carrier motor connectors CN9 and CN15 from the main logic board. 3. Loosen the two tension pulley plate screws. Pull up on both sides of the belt to move the tension pulley plate as far as possible toward the center of the printer, and then retighten the large screw.

  • Page 80: Carrier Plate Removal

    4227-300 Carrier plate removal 1. Remove the top cover. See “Top cover removal” on page 4-5. 2. Remove the print unit. 3. Remove the carrier. 4. Remove the lower pinch roller. 5. Remove the carrier motor. 6. Remove the Auto Gap motor and its bracket. 7.

  • Page 81: Lower Feed Roller Removal

    4227-300 Lower feed roller removal 1. Remove the top cover. See “Top cover removal” on page 4-5. 2. Remove the print unit. 3. Remove the sub logic board. 4. Remove the paper feed motor. 5. Remove the large gear from the left side frame by prying it from behind with a flat-blade screwdriver.
  • Page 82 4227-300 8. Remove the gear shaft support plate (2) and the two gears with their springs (3). 9. Remove the large screw (4) holding the tension pulley plate to the side frame. 10. Remove the gear, clip, and bearing (5) from the end of the lower feed roller shaft.
  • Page 83 4227-300 11. Release and remove the separator plate spring (6). 12. Release the spring (7) from the right end of the lower pinch roller. 13. Remove the two carrier plate screws (8). One is in the slot in the slider cam. 14.
  • Page 84 4227-300 15. Remove the two platen screws (10). 16. Remove the right side frame. 17. Remove the lower feed roller shaft. Note: The upper feed roller bearing should stay in the side frame. The lower pinch roller bushing is free on the end of the shaft. To reassemble: 1.

  • Page 85: Lower Pinch Roller Removal

    4227-300 Lower pinch roller removal 1. Remove the ribbon cover and the ribbon. 2. Remove the U-shaped ground spring (1). 3. Release the left and right pinch roller springs (2). 4. Move the carrier to the right as far as it will go. 5.

  • Page 86: Memory Module Removal

    4227-300 Memory Module removal The Memory Module is an option. 1. Turn the printer off and disconnect the power cord at the printer. 2. Remove the rear cover. 3. Remove the paper support. 4. Insert a small flat screwdriver under each end of the module and lift gently.
  • Page 87 4227-300 4. To remove the Paper Empty sensor: a. Release the four latches (2) and remove the Paper Empty sensor. b. Carefully grasp the Paper Empty flag with a pair of needle nose pliers and remove the flag by pulling it vertically away from the paper guide.
  • Page 88 4227-300 To replace the TOF Sensor Flag: Unless necessary, do not replace the sensor flag when replacing the sensor. 1. With diagonal pliers, cut the post and two tabs (5) off as flush as possible. 2. Unsnap both ends of the sensor flag from the paper guide. Carefully remove the sensor flag spring (4) from the bottom end of the sensor flag.

  • Page 89: Paper Feed Motor Removal

    4227-300 Paper feed motor removal 1. Remove the top cover. See “Top cover removal” on page 4-5. 2. Disconnect the paper feed motor connector CN10 from the main logic board. 3. Remove the sub logic board. 4. Remove the four screws holding the motor in place and remove the motor.

  • Page 90: Paper Select Sensor Removal

    4227-300 Paper Select sensor removal 1. Remove the top cover. See “Top cover removal” on page 4-5. 2. Remove the print unit. See “Print unit removal” on page 4-29. 3. Use a #1 Phillips screwdriver to remove the two screws (1) holding the Paper Select sensor to the left side frame.

  • Page 91: Paper Separator Removal

    4227-300 Paper separator removal 1. Remove the top cover. See “Top cover removal” on page 4-5. 2. Remove the print unit from the base. See “Print unit removal” on page 4-29. 3. Remove the Paper Select lever. 4. Remove the gear shaft support plate and the two gears with their springs (1).
  • Page 92 4227-300 6. Release and remove the separator plate spring (3) from the right side frame. 7. Remove the paper separator screw (4) from above the slider cam. 8. Remove the two carrier plate screws (5) from the right side frame. One is behind the slider cam. 9.

  • Page 93: Power Supply Removal

    4227-300 Power supply removal CAUTION: The power supply may be hot. 1. Turn off the printer and disconnect the power cord at both ends. 2. Remove the top cover. See “Top cover removal” on page 4-5. 3. Disconnect the power connectors from the sub logic board and main logic board.
  • Page 94 4227-300 7. On the left side, remove the three screws (1) holding the print unit to the base. 8. On the right side, remove the screw (2) holding the print unit to the base. 4-30 Service Manual...
  • Page 95 4227-300 9. Slide the printer partway off the edge of the table. From the bottom, remove the screw (3) holding the front of each side frame to the base. 10.Lift the print unit from the base. To Reinstall For ease of reassembly, remove the flexible signal cable from the main logic board and connect it to the sub logic board before reinstalling the print unit.

  • Page 96: Printhead Removal

    4227-300 Printhead removal 1. Turn the printer off. 2. Disconnect the power cord at the printer. CAUTION: Allow the printhead to cool for 15 minutes. 3. Remove the ribbon cover and ribbon. 4. Remove the two screws (1) on the cable retainer and disconnect the two cables.

  • Page 97: Printhead Cables Removal

    4227-300 Printhead cables removal 1. Remove the top cover. See “Top cover removal” on page 4-5. 2. Remove the two screws on the cable retainer and disconnect the two cables. These are ZIF connectors. 3. Disconnect the other end of the cables from the sub logic board, and then pull the cables from under the ribbon motor.

  • Page 98: Ribbon Drive Motor Assembly Removal

    4227-300 Ribbon drive motor assembly removal 1. Remove the top cover. See “Top cover removal” on page 4-5. 2. Remove the sub logic board. 3. Remove the ribbon drive post cover and the ribbon drive post (1). 4. Remove the Auto Gap sensor (2) from the motor bracket. 5.

  • Page 99: Right Side Frame Removal

    4227-300 Right side frame removal 1. Remove the top cover. See “Top cover removal” on page 4-5. 2. Remove the print unit. 3. Remove the Paper Select lever. 4. Remove the gear shaft support plate (2) and the two gears with their springs (3).
  • Page 100 4227-300 7. Release and remove the separator plate spring (6). 8. Release the spring (7) from the right end of the lower pinch roller. 9. Remove the two carrier plate screws (8). One is in the slot in the slider cam. 10.Remove the support shaft screw (9) and the two platen screws (10).

  • Page 101: Sub Logic Board Removal

    4227-300 11. Remove the right side frame. Note: The upper feed roller bearing should stay in the side frame. The lower pinch roller bushing is free on the end of the shaft. To reassemble 1. Install the side frame first, and then remove the paper separator.

  • Page 102: Upper Feed Roller Removal

    4227-300 Upper feed roller removal 1. Remove the top cover. See “Top cover removal” on page 4-5. 2. Release the latches and remove the gear (1) from the left end of the shaft. 3. Remove the clip from the left end. 4.

  • Page 103: Preventive Maintenance

    4227-300 5. Preventive maintenance This chapter describes procedures for preventive maintenance for the printer. Following these recommendations can help prevent problems and maintain optimum performance. Lubrication Warning: Petroleum-based lubricants can attack polycarbonate parts, causing premature failure. Use only mineral oil-based lubricant.

  • Page 104: Lubrication Points

    4227-300 Lubrication points Lubricate the following contact positions: • Oil felt on carrier shaft (under carrier) • Square tractor shaft, where left end enters left tractor side frame Grease Lubricate the following contact positions: • Two gear mounting studs on the right side frame •...

  • Page 105: Locations And Connectors

    4227-300 6. Locations and connectors 4227-300 Locations and connectors...

  • Page 106: Main Logic Board Connectors

    4227-300 Main Logic Board Connectors Connectors Description Parallel Serial Port Sub Logic Board Flex Cable Paper Select Sensor Paper Empty and TOF Sensors Gap Home Sensor Carrier Motor Cable #1 CN10 Paper Feed Motor CN11 Power Supply CN13 Tractor 2 DIN CN14 Operator Panel CN15...

  • Page 107: Operator Panel Connectors

    4227-300 Printhead Printhead Main Logic Board Flex Cable Power Supply Operator panel connectors Ribbon Cover Sensor LCD Board (soldered) Main Logic Board Locations and connectors...

  • Page 108: Component Locations

    4227-300 Component locations This chapter shows the location of specific parts of the printer. Part name Ref. Part name Ref. Auto Gap Motor Parallel/Serial Interface Connector Auto Gap Sensor Platen Carrier Power Supply Carrier Motor Printhead Carrier Plate Printhead Cables Jam Sensor PSet Sensor Left Side Frame...

  • Page 109: Component Location Illustrations

    4227-300 Component location illustrations Locations and connectors...

  • Page 110: Component Location Illustrations (Continued)

    4227-300 Component location illustrations (Continued) Service Manual...

  • Page 111: Signal Connections

    4227-300 Signal connections Power Supply ->Main Logic Board<-->Sub Logic Board Power Main Logic Board Sub Logic Board Supply CN11 CN4 - 4227-300 +40 V dc Pin 1 +40 V dc Pin 1 +40 V dc +40 V dc Pin 2 +40 V dc Pin 2 +40 V dc...
  • Page 112 4227-300 Main Logic Board<-->Sub Logic Board Main Logic Board Sub Logic Board Pin 1 Pin 22 HCSEL HCSEL Pin 2 Pin 21 Signal Gnd Signal Gnd Pin 3 Pin 20 HDTHERMO HDTHERMO Pin 4 Pin 19 R1COM R1COM Pin 5 Pin 18 L1COM L1COM...

  • Page 113: Main Logic Board<-->Paper Empty & Tof Sensors

    4227-300 Main Logic Board<-->Paper Empty & TOF Sensors Pin 1 PE1P Pin 2 Pin 3 Signal Gnd Pin 4 PE2P Pin 5 Pin 6 Signal Gnd Main Logic Board<-->Auto Gap Sensor Pin 1 +5 V dc Pin 2 AGHPC Pin 3 AGHP Main Logic Board<-->Carrier Motor Cable #1 Pin 1...

  • Page 114: Main Logic Board<-->Tractor 2 Din

    4227-300 Main Logic Board<-->Tractor 2 DIN CN13 Pin 1 +26Vdc Pin 2 +26Vdc Pin 3 Power Gnd Pin 4 PSET Pin 5 +5Vdc Pin 6 DTCOM Pin 7 DSET Pin 8 Signal Gnd Pin 9 DTMTA Pin 10 DTMTB Pin 11 Pin 12 Pin 13 DPOS...

  • Page 115: Main Logic Board<-->Operator Panel

    4227-300 Main Logic Board<-->Operator Panel Main Logic Board Operator Panel Board CN14 Pin 1 +5Vdc Pin 1 +5 V dc Pin 2 SLATCH Pin 2 SLATCH Pin 3 +5Vdc Pin 3 +5 V dc Pin 4 TXD Pin 4 TXD Pin 5 Signal Gnd Pin 5 Signal Gnd Pin 6 RXD...

  • Page 116: Main Logic Board<-->Ribbon Motor

    4227-300 Main Logic Board<-->Ribbon Motor CN19 Pin 1 Pin 2 Pin 3 Pin 4 Pin 5 RBCOM Pin 6 RBCOM Main Logic Board<-->Auto Gap Motor CN20 Pin 1 Pin 2 Pin 3 Pin 4 Pin 5 GPCOM Pin 6 GPCOM Main Logic Board<-->Serial Board Main Logic Board Serial Board...

  • Page 117: Serial Board<-->Serial Cable

    4227-300 Serial Board<-->Serial Cable Pin 1 Chassis Pin 14 Pin 2 Pin 15 -RXD422 Pin 3 Pin 16 Pin 4 Pin 17 +RXD422 Pin 5 -CTS Pin 18 Pin 6 Pin 19 -TXD422 Pin 7 Signal Gnd Pin 20 Pin 8 Pin 21 Pin 9 Pin 22...

  • Page 118: Sub Logic Board<-->Printhead

    4227-300 Sub Logic Board<-->Printhead Pin 1 Pin 1 Pin 2 RH8C Pin 2 RH3C Pin 3 Pin 3 Pin 4 RH9C Pin 4 RH4C Pin 5 Pin 5 Pin 6 Pin6 RH5C Pin 7 RH7C Pin 7 RH2C Pin 8 +5 V dc Pin 8 Pin 9...

  • Page 119: Tractor 2 Cable Connectors

    4227-300 Tractor 2 cable connectors The Tractor 2 cable is soldered to the board at CN1. Mode CN1-1 +26 V dc CN1-2 +26 V dc CN1-3 Frame Gnd CN1-4 Not used. CN1-5 +5 V dc CN1-6 Motor Common CN1-7 D-Set (signal for Tractor 2 plugged in) CN1-8 Signal Gnd CN1-9...

  • Page 120: Connector Block Diagram

    4227-300 Connector block diagram 4227-300 6-16 Service Manual...
  • Page 121 4227-300 6-17 Locations and connectors...
  • Page 122 4227-300 6-18 Service Manual...

  • Page 123: Parts Catalog

    4227-300 7. Parts catalog How to use this parts catalog • Similar Assemblies: If two assemblies contain a majority of identical parts, they are shown on the same list. Common parts are shown by one index number. Parts peculiar to one or the other of the assemblies are listed separately and identified by description.

  • Page 124: Assembly 1: Covers And Operator Panel

    4227-300 Assembly 1: Covers and operator panel Service Manual...
  • Page 125 4227-300 Asm- Part Description Index number 40X3045 Cover assembly, ribbon access 40X3051 Cover, acoustic 40X3130 Paper stand 40X3050 Switch assembly, cover with cover switch plate 40X3118 Cover, rear (4227--300) 40X3043 Cover assembly, front (complete) 40X3126 Guide, paper (right) 40X3131 Guide, cover (front) 40X3106 Cover assembly with logo (top) 40X3094...

  • Page 126: Assembly 2: Paper Feed

    4227-300 Assembly 2: Paper feed Service Manual...
  • Page 127 4227-300 Part Asm- Description number Index 40X3073 Feed roller, upper 40X3098 Bearing kit 40X3075 Frame support shaft 40X3082 TOF & Paper Empty sensors with flags & springs 40X3081 Paper guide/platen assembly 40X3121 Bracket, Auto Gap motor 40X3083 Roller, feed (lower) 40X3132 Roller, pinch (lower) 40X3113...

  • Page 128: Assembly 3: Carrier

    4227-300 Assembly 3: Carrier Service Manual...
  • Page 129 4227-300 Asm- Part Description Index number 40X3071 Sensor, Auto Gap 40X3107 Board and bracket, sub logic 40X3096 Screw, parts packet 40X3057 Motor, paper feed assembly with bracket 40X3098 Bearing kit 40X3105 Gears, parts packet 40X3062 Motor, ribbon drive and gear plate assembly 40X3063 Plate assembly with belt tension pulley 40X3112...

  • Page 130: Assembly 4: Base And Electronics

    4227-300 Assembly 4: Base and electronics Service Manual...
  • Page 131 4227-300 Asm- Part Description Index number 4–1 40X3110 Main logic board without ROM (LV) 40X3109 Main logic board without ROM (HV) 40X3119 ROM kit 40X3125 Power supply, 100 - 240 V ac 40X3990 Ground wire 40X3092 Bracket, tractor cable 40X3091 Cable, tractor 40X3084 Base assembly...

  • Page 132: Assembly 5: Asf Side Frame/Covers

    4227-300 Assembly 5: ASF side frame/covers 7-10 Service Manual...
  • Page 133 4227-300 Asm- Part Description Index number 40X3137 Support, stacking 40X3033 Cover (front) 40X2891 Spring kit, ASF 40X3136 Gear and bearing kit, ASF 40X2892 Screw kit, ASF 40X3135 Cover (right) 7-11 Parts catalog...

  • Page 134: Assembly 6: Asf Roller/Support

    4227-300 Assembly 6: ASF roller/support 7-12 Service Manual...
  • Page 135 4227-300 Asm- Part Description Index number 6 -1 40X3040 Support, cut sheet with guides 40X3023 Roller, feed (upper) 40X3024 Roller, feed (lower) 40X2985 Roller, pickup (left and right) 40X3128 Hopper (left) 40X2928 Support, paper (left) 40X3133 Support, paper (center) 40X3127 Hopper (right) 40X2927 Support, paper (right)

  • Page 136: Assembly 7: Tractor 2 Option

    4227-300 Assembly 7: Tractor 2 option 7-14 Service Manual...
  • Page 137 4227-300 Asm- Part Description Index number 7 -1 40X3033 Cover (front) 40X2881 Paper guide, tractor 40X3093 Tractor and frame assembly 40X3095 Tractor kit (left and right) with sensors 40X2882 Parts packet 40X2959 Shaft, Support 40X2961 Board Asm with cable and Ferrite 40X3039 Cover (right) 40X2880...
  • Page 138 4227-300 7-16 Service Manual...

  • Page 139: Index

    4227-300 Index Abbreviations Handling ESD-sensitive parts Adjustments Bidirectional Print Printhead-to-Platen Lights 1-11 Lubricants Principles of Operation 2-13 Lubrication Lubrication Points Bidirectional Print Adjustment Buttons 1-10 Models available Component Locations Operator Panel, Using Connector Locations Options Connectors Main Logic Board Operator Panel Parts Catalog ASF Roller/Support 7-12...
  • Page 140 4227-300 Carrier 4-12 Print Wire Drive Failure 2-28 Carrier Motor Assembly 4-15 Ribbon Drive 2-30 Carrier Plate 4-16 Tractor 2 2-31 Jammed Label 4-16 Setting Printer Functions Label Jam 4-16 Signal Connections Lower Feed Roller 4-17 Block Diagram (4227-300) 6-16 Main Logic Board 4-21 Main Logic Board...
  • Page 141 4227-300 Tests Button Test Jam / PSet Sensor Test Print Test Printhead Bank Test Using the Operator Panel...
  • Page 142 4227-300 Service Manual...

  • Page 143: Part Number Index

    4227-300 Part number index Description Page 40X0270 Power cord (Japan) ....... . . 40X0271 Power cord (United Kingdom, Malaysia, Singapore) .
  • Page 144 4227-300 40X3056 Gear plate (right) ........40X3057 Motor, paper feed assembly with bracket .
  • Page 145 4227-300 40X3119 ROM kit ......... . 40X3120 Carrier motor cooling fan .
  • Page 146 4227-300 Service Manual...

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