Lexmark 4227-X00 Service Manual
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Lexmark 4227-X00 Service Manual

Lexmark 4227-X00 Service Manual

Forms printer
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Lexmark Forms Printer 4227
4227-X00
• 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-X00

  • Page 1 Lexmark Forms Printer 4227 4227-X00 • 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 3: Table Of Contents

    4227-X00 Service Menu ........3-4 Button Test .
  • Page 4 4227-X00 Printhead Cables Removal..... . . 4-34 Ribbon Drive Motor Assembly Removal... . . 4-35 Right Side Frame Removal .

  • Page 5: Preventive Maintenance

    4227-X00 Preface This manual describes the Lexmark Forms Printer 4227-100 and 4227-200. It contains maintenance procedures for service personnel and is divided into the following chapters: • General Information contains a general description of the printer and the maintenance approach used to repair it. Special tools and test equipment are listed in this chapter, as well as general environmental and safety instructions.
  • Page 6 4227-X00 Preface xi...

  • Page 7: Safety Information

    This product is designed, tested and approved to meet strict global safety standards with the use of specific Lexmark components. The safety features of some parts may not always be obvious. Lexmark is not responsible for the use of other replacement parts. •...
  • Page 8 Lexmark specifici. Le caratteristiche di sicurezza di alcune parti non sempre sono di immediata comprensione. Lexmark non è responsabile per l’utilizzo di parti di ricambio di altri produttori. •...
  • Page 9 Lexmark. As funções de segurança de alguns dos componentes podem não ser sempre óbvias. A Lexmark não é responsável pela utilização de outros componentes de substituição. • As informações de segurança relativas a este produto destinam-se a profissionais destes serviços e não devem ser...
  • Page 10 Lexmark. Les característiques de seguretat d'algunes peces pot ser que no sempre siguin òbvies. Lexmark no es responsabilitza de l'us d'altres peces de recanvi. • La informació pel manteniment d’aquest producte està...
  • Page 11 4227-X00 Service Manual...

  • Page 12: General Information

    4227-X00 1. General Information Description The Lexmark Form Printer 4227-100 and 4227-200 are dot matrix, electro-mechanical printers that form characters on 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 13 4227-X00 This is a versatile printer that combines excellent print quality along with the ability to print several print styles and graphics. Some of the features and functions included with this printer are: Feature Multi-speed Printing Resident Fonts Forms Handling...
  • Page 14 4227-X00 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-X00 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 page 2-1”...
  • Page 16 4227-X00 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...

  • Page 17: Using The Operator Panel

    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-X00 Using the Function Menus Use the Item and Item option directories. Press Next to the subordinate directories and choices. Press Prev. want to go back in a menu or return to the Main Menu. buttons to move through the menu and...

  • Page 19: Setting Printer Functions

    9. Press Quit to exit the function menus. Note: If you have changed any settings, the printer performs a Power-On Self Test, see If you did not change any settings, the printer enters the not-ready state. Service Manual or Item until the function menu you want to enter that menu item.

  • Page 20: Overview Of Function Menus

    Main Menu. Menu items marked with an asterisk (*) may not appear on the operator panel, depending on the printer settings or what printer options are installed b uttons to move through the menu and...
  • Page 21 4227-X00 1-10 Service Manual...
  • Page 22 Start/Stop Load/Unload LineFeed FormFeed or Prev. • Enter the function menu. The printer goes offline. • Exit the function menus. • Run a Power-On Self Test (POST). • Advance the forms to the tear-off position. • Retract the forms to the Top-of-Form (TOF) position when the forms are at the tear-off position.
  • Page 23 Tractor2 (Green) 1-12 Service Manual When you see this light The printer power is on. 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) •...

  • Page 24: Diagnostic Information

    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 Failure Service Check” on page If an error indicator appears, go to the page 2-2 and take the indicated action.

  • Page 25: Error Indication Table

    4227-X00 Error Indication Table The following table describes the service check entries for the printer error indication codes. When an error indication changes after you have entered a service check, you have an intermittent problem. If this occurs, leave the...
  • Page 26 4227-X00 Display Indication 63C Machine Check Auto Gap Error 63D Machine Check Tractor2 HP Error 63E Machine Check Head Thermal Error 63F Machine Check Option RAM Error 640 Machine Check CA Thermal Error Description / Action Auto Gap Error. “Auto Gap Service Check” on...

  • Page 27: Symptom Table

    Service Manual Action Disconnect the interface cable from the printer and turn the printer off and then on. If POST now runs correctly, the problem is in the computer or interface cable. “POST Service Check” on page Go to the...
  • Page 28 4227-X00 Auto Sheet Feeder Problems Symptom Auto sheet feeder will not feed paper. Auto sheet feeder double feeds. Auto sheet feeder has intermittent feed problems. Paper Skews 6XX Error Indications Symptom 6XX Machine Check is displayed. Paper Feed Problems Symptom...
  • Page 29 4227-X00 Symptom Load/Unload does not function. Form feed length is not correct. Load/Unload functions with cut sheets in use. Paper feeds, but Auto Loading does not work. Lower feed roll shaft rotates, but paper does not feed. Pressing Form Feed does not feed paper.
  • Page 30 4227-X00 Operator Panel Problems Symptom Start/Stop does not function but no error is indicated. Only the Power light turns on. One or more buttons do not function. One or more lights do not function. Blank display. Cover open displayed. Power Problems...
  • Page 31 4227-X00 Print Quality Problems Symptom No print, but carrier moves as if printing. Print density is light. Uneven print density across the print line. Specific dots missing. Scattered ink smearing, blurred characters. Fuzzy print. Service Manual Action Be sure the printhead cables are not loose or damaged.
  • Page 32 4227-X00 Symptom Wavy vertical lines, uneven left margin or character width is reduced. Ribbon Feed Problems Symptom Ribbon comes off, becomes loose or folded, or jams. Ribbon feeds correctly but is noisy. Action Clean and lubricate the carrier shaft. If the carrier drive belt is worn or broken, replace the carrier unit.

  • Page 33: Service Checks

    Gap Home Sensor, and minimum gap by driving the printhead against the platen. In addition to compensating for the thickness of the paper itself, the printer must increase the air gap for thicker papers. With Auto Gap On, the following occurs: •...
  • Page 34 4227-X00 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 35 The sheet is then fed to the print line by the ASF’s upper and lower feed rollers and the printer’s lower feed rollers. Although the ASF pick rollers continue to turn as the paper is fed, their drive is disengaged and they are actually being turned by the paper.
  • Page 36 Action 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...

  • Page 37: Carrier Drive Service Check

    If no problems are found replace the carrier motor. The printer has stopped to protect the carrier motor from overheating. Normally this will not occur until after several hours of continuous heavy use in a warm environment, and only then after going through several stages of thermal slowdown.

  • Page 38: Intermittent Problem Service Check

    4227-X00 Intermittent Problem Service Check FRU/Symptom The machine sometimes fails before POST is complete. Action Check for the following: 1. Loose connectors. Reconnect all connectors to the main and sub logic boards. 3. Electrical noise or static discharge. Check the following items: •...
  • Page 39 3. Disconnect the power supply cable from the connectors CN11 on the main logic board and CN1 on the sub logic board. Turn the printer power on and check all dc output voltages at CN11 and CN1. Be sure the output voltages are as follows: CN11-1 (+40 ±4 V dc) &...
  • Page 40 4227-X00 FRU/Symptom If the prior suggestions have not corrected the problem. Problem occurs only in specific customer applications. Action The service check has not defined the failure, or the machine is having intermittent failures. The following may cause undefined or intermittent failures: 1.

  • Page 41: No Print Or Abnormal Print Service Check

    Check” on page 2-28 Enter the user menus and be sure the correct emulation (IBM/EPSON) and interface (parallel/serial) are selected. If the printer is serially attached, be sure the RS232/RS422 switch is in the correct position, and the host communications parameters are correct.

  • Page 42: Operator Panel Service Check

    4227-X00 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 pressed. Use the same procedure to re-lock the panel after service is complete.

  • Page 43: Paper Feed Service Check

    Enter the Paper Handling Options Menu and set “ASF” to off. Verify that the machine works correctly without the ASF installed. If the printer fails only with the Auto Sheet Feeder installed, go to the Feeder (ASF) Service Check” on page 2-12 If the Tractor 2 option is installed, remove it.
  • Page 44 4227-X00 FRU / Symptom Gear Train and Paper Feed Motor Action Remove all paper from the machine. 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 45 Sensor 2-22 Service Manual Action The printer has four sensors in the paper path, plus one which detects the position of the paper select lever. Enter the service menu and perform the sensor tests. • PE Sensor - rounded flag, detects the presence of paper at the platen.
  • Page 46 4227-X00 FRU / Symptom Operator Panel Main Logic Board Action If paper does not move at all, verify the FormFeed button is working correctly by performing the service menu button test. If no other problem is found, replace the main logic board.

  • Page 47: Post Service Check

    Service Manual Action Disconnect the parallel or serial cable and turn power on. If there is no printer activity, go to the Failure Service Check” on page 2-25 If the power supply fan turns on but no LEDs “Operator Panel Service light, go to the Check”...

  • Page 48: Power Failure Service Check

    A 634 Power Failure indicates that the +5 V dc is OK but the +40 V dc is not. Power the printer off, wait 10 seconds, and power back on. If the 634 reappears either the power supply has failed or there is a short in a motor that uses +40 V dc.
  • Page 49 Replace the item that causes the power failure. Disconnect the printhead cables from the sub logic board and turn the printer on. If the power LED lights correctly only with the printhead cables disconnected from the sub logic board, there is a short in the printhead or printhead cables.

  • Page 50: Print Quality Service Check

    4227-X00 Print Quality Service Check Ribbon and Shield Ribbon Drive Auto Gap Auto Gap Motor Bracket Printhead Cables Carrier Belt Adjustment Carrier Movement Bidirectional Print Adjustment Carrier Motor Paper Feed Gears Paper Feed Motor Tractors Feed Roller Surfaces Action Be sure the ribbon is not worn and feeds smoothly when the knob is turned.

  • Page 51: Print Wire Drive Failure Service Check

    4227-X00 Print Wire Drive Failure Service Check FRU/Symptom Missing Dots Carrier moves, but no printing or printhead sound. 63E Head Thermal Error 2-28 Service Manual Action Perform the print test to determine which wires are not printing. Disconnect the printhead cables from the sub logic board and check the resistance for the affected wires.
  • Page 52 A problem with the ribbon shield can keep the print wires too far from the page. Inspect the ribbon shield. When the printer is Ready with the ribbon installed, make sure the ribbon shield can float slightly front to back.

  • Page 53: Ribbon Drive Service Check

    4227-X00 Ribbon Drive Service Check In normal operation, the ribbon knob rotates counterclockwise whenever the carrier moves to the left. FRU/Symptom Action Ribbon Drive Remove and inspect the ribbon. Make sure the Gear Train knob turns with even, moderate force and the ribbon feeds correctly.

  • Page 54: Tractor 2 Service Check

    Tractor 2 gear drive and reengaging the printer tractors. 63D Tractor2 HP Error The Tractor 2 home sensor was never initialized after turning the printer off and then on, or made at the wrong time. (The same error indication is used for carrier home failure.)
  • Page 55 Make sure the slider (the black plastic piece just above the right cover) moves after turning the printer off and then on. If the slider does not move after turning the printer off and then • Make sure the slider and gear train are properly connected and move freely with the power off.
  • Page 56 Tractor 2 selected from operator panel but 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 57 2-34 Service Manual Action 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 58: Diagnostic Aids

    4227-X00 3. Diagnostic Aids The printer contains self tests to help find and solve problems. You need not 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 59: Hex Trace Mode

    The hex trace mode can help the user test and troubleshoot programs. You can use the hex trace procedure to get a hexadecimal printout of the data stream sent to the printer. All data, including control and character data, print in hexadecimal instead of ASCII.
  • Page 60 Options menu. Operation with the Top Cover Removed After removing the top cover, the printer can be operated for service purposes by positioning the cover near the main logic board and reconnecting the operator panel cable. The ribbon cover must be in place on the top cover.

  • Page 61: Service Menu

    Printhead Bank This allows the 18-wire printhead to be set to use the left bank only, the right bank only, or both banks (default). This allows the printer to continue to print with a damaged printhead or cable. Jam / PSet Sensor Test Enables or disables the PSet and Jam sensors on the left tractor.

  • Page 62: Impact Force

    High: This is the highest impact force and over rides the Normal Auto selection. High pin force is used to obtain clearer print on medium thickness forms. Leaving the printer in High can damage the printhead, especially if printing on single sheet forms.

  • Page 63: Error Log

    4227-X00 buttons that are active during this test are the Micro or Micro Print Demo and the Print Settings page are accessed from the user menus. Print Settings prints Macro status and paper handling settings and prints 8 inches wide.

  • Page 64: Repair Information

    4227-X00 4. Repair Information This chapter contains adjustments and removal procedures. Whenever parts are replaced, make sure that all adjustments are correct by running diagnostics procedures and checking adjustments as needed. Handling ESD-Sensitive Parts Many electronic products use parts that are known to be sensitive to electrostatic discharge (ESD).

  • Page 65: Adjustments

    4227-X00 Adjustments Printhead Installation Adjustment 1. Hold the printhead down while pressing it toward the platen and tighten the two printhead mounting screws. 2. Check the “Printhead-to-Platen Gap Adjustment” on page Printhead-to-Platen Gap Adjustment Perform this adjustment: • When the platen, printhead, carrier, carrier shaft, or main logic board is removed or replaced.
  • Page 66 4227-X00 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: •...

  • Page 67: Bidirectional Print Adjustment

    4227-X00 Bidirectional Print Adjustment Perform this adjustment whenever the main logic board, carrier, or printhead is replaced.This test is in the user menu and uses a line length corresponding to the right margin setting. Run the test at both the Draft speed setting and at the Courier speed setting.
  • Page 68 The message Choose the Best Alignment appears on the display. 7. Press Next 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: Removal Procedures

    1. Turn the printer off. 2. Disconnect the power cord and parallel cable at the printer. 3. Remove the front cover [1]. 4. Remove the acoustic and ribbon access covers [2].
  • Page 70 [4] and release the cover by prying down on the left side latches and up on the top cover. 8. Place the printer on its right side and release the two right side latches. Place the printer on its feet and release the remaining two top cover latches.

  • Page 71: Auto Gap Motor

    4227-X00 Auto Gap Motor 1. Remove the top cover. “Top Cover Removal” on page 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. Remove the two gap adjust motor screws [1] through the access holes in the carrier motor mounting bracket and remove the motor [2].

  • Page 72: Auto Sheet Feeder Gears Removal

    4227-X00 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 idler gear [3]. 4. Release the latch and then remove the pick-up gear [4].

  • Page 73: Auto Sheet Feeder Pick-Up Roller Removal

    4227-X00 Auto Sheet Feeder Pick-up Roller Removal 1. Remove the covers and the cut sheet support. 2. Remove the idler gear and pick-up gear. “Auto Sheet Feeder Gears Removal” on page 3. Remove the left roller bushing [1]. 4. Remove the right roller bushing [2].

  • Page 74: Belt Tension Pulley Plate Assembly Removal

    1. Remove the top cover. “Top Cover Removal” on page 2. Turn the printer so you are facing the rear of the printer. 3. Remove both tension pulley plate mounting screws [1]. 4. Manipulate the left side of the tension spring off the lug.

  • Page 75: Carrier Removal

    4227-X00 Carrier Removal 1. Remove the top cover. “Top Cover Removal” on page 2. Remove the printhead. “Printhead Removal” on page 3. Remove the carrier roller spring. 4. Remove the sub logic board. “Sub Logic Board Removal” on page 5. Remove the ribbon drive motor assembly [1].
  • Page 76 7. Remove the belt from the carrier motor pulley. 8. Push the tension pulley toward the outside of the printer and remove its shaft through the large part of the keyhole. Push the pulley upward and remove it to free the carrier belt.
  • Page 77 4227-X00 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 78: Carrier Motor Assembly Removal

    3. Loosen the two tension pulley plate screws. Pull upward on both sides of the belt to move the tension pulley plate as far as possible toward the center of the printer, then retighten the large screw. 4. Remove the three screws [1] holding the motor to its bracket.

  • Page 79: Carrier Plate Removal

    4227-X00 Carrier Plate Removal 1. Remove the top cover. “Top Cover Removal” on page 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.

  • Page 80: Lower Feed Roller Removal

    4227-X00 Lower Feed Roller Removal 1. Remove the top cover. “Top Cover Removal” on page 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 81 4227-X00 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 82 4227-X00 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.
  • Page 83 4227-X00 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.

  • Page 84: Lower Pinch Roller Removal

    4227-X00 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.

  • Page 85: Main Logic Board Removal

    Adjustment” on page 4-4 Adjustment” on page 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 up gently.

  • Page 86: Operator Panel Assembly Removal

    4227-X00 Operator Panel Assembly Removal 1. Remove the top cover. “Top Cover Removal” on page 2. Disconnect the ribbon cover sensor connector from the back of the operator panel. 3. Disconnect the operator panel cable from the back of the operator panel.

  • Page 87: Paper Empty Sensor /Tof Sensor Removal

    4227-X00 4. 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 perpendicularly away from the paper guide. Do not damage or lose the paper empty sensor spring.
  • Page 88 4227-X00 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.

  • Page 89: Paper Feed Motor Removal

    4227-X00 Paper Feed Motor Removal 1. Remove the top cover. “Top Cover Removal” on page 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 Lever Removal

    4227-X00 Paper Select Lever Removal 1. Remove the top cover. “Top Cover Removal” on page 2. Release the latch and then remove the paper select lever from the right side frame. Paper Select Sensor Removal 1. Remove the top cover.

  • Page 91: Paper Separator Removal

    4227-X00 Paper Separator Removal 1. Remove the top cover. “Top Cover Removal” on page 2. Remove the print unit from the base. “Print Unit Removal” on page 3. Remove the paper select lever. 4. Remove the gear shaft support plate and the two gears with their springs [1].
  • Page 92 4227-X00 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.

  • Page 93: Power Supply Removal

    3. Disconnect the power connectors from the sub logic board and main logic board. 4. Remove the five mounting screws and the ground wire screw. 5. Lift the rear edge of the supply and remove it from the printer. Power Supply Fan Removal 1. Remove the power supply.
  • Page 94 4227-X00 7. Remove the three screws [1] from the left side holding the print unit to the base. 8. Remove the screw [2] from the right side holding the print unit to the base 4-31 Repair Information...
  • Page 95 4227-X00 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. Reinstallation: 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-X00 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-X00 Printhead Cables Removal 1. Remove the top cover. “Top Cover Removal” on page 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 pull the cables from under the ribbon motor.

  • Page 98: Ribbon Drive Motor Assembly Removal

    4227-X00 Ribbon Drive Motor Assembly Removal 1. Remove the top cover. “Top Cover Removal” on page 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.

  • Page 99: Right Side Frame Removal

    4227-X00 Right Side Frame Removal 1. Remove the top cover. “Top Cover Removal” on page 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-X00 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.

  • Page 101: Sub Logic Board Removal

    4227-X00 Reassembly: 1. Remove the paper separator while first installing the side frame loosely. Be sure the lower pinch roller spring is above the bushing. 2. Remove the screw from the right end of the paper separator. 3. Install the left end of the paper separator first, then bend the right side frame slightly to get the right end installed.

  • Page 102: Upper Feed Roller Removal

    4227-X00 Upper Feed Roller Removal 1. Remove the top cover. “Top Cover Removal” on page 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. Slide the shaft to the left, making sure the right bearing comes out of the side frame with the shaft.
  • Page 103 4227-X00 4-40 Service Manual...

  • Page 104: Connector Locations

    4227-X00 5. Connector Locations 4227-100 Connector Locations...
  • Page 105 4227-X00 4227-200 Service Manual...

  • Page 106: Main Logic Board Connectors

    4227-X00 Main Logic Board Connectors CN10 CN11 CN13 CN14 CN15 CN17 CN18 CN19 CN20 CN22 CN23 Parallel / Serial Port Sub Logic Board Flex Cable Paper Select Sensor Paper Empty and TOF Sensors Gap Home Sensor Carrier Motor Cable #1...

  • Page 107: Sub Logic Board Connectors

    4227-X00 4227-100 Sub Logic Board Connectors Service Manual Power Supply Main Logic Board Flex Cable Printhead Printhead...

  • Page 108: Operator Panel Connectors

    4227-X00 4227-200 Operator Panel Connectors Printhead Printhead Main Logic Board Flex Cable Power Supply Ribbon Cover Sensor LCD Board (soldered) Main Logic Board Connector Locations...

  • Page 109: Component Locations

    4227-X00 Component Locations This chapter shows the location of specific parts of the printer. Part Name Auto Gap Motor Auto Gap Sensor Carrier Carrier Motor Carrier Plate Jam Sensor Left Side Frame Lower Feed Roller Lower Pinch Roller Main Logic Board...

  • Page 110: Component Location Illustrations

    4227-X00 Component Location Illustrations Connector Locations...
  • Page 111 4227-X00 Component Location Illustrations (Continued) Service Manual...

  • Page 112: Signal Connections

    4227-X00 Signal Connections Power Supply ->Main Logic Board<-->Sub Logic Board Power Supply +40 V dc +40 V dc Power Gnd Power Gnd +5 V dc Signal Gnd Main Logic Board<-->Parallel Interface Cable (4227-100) Pin 1 Strobe Pin 2 Data 1...
  • Page 113 4227-X00 Main Logic Board<-->Parallel Interface Cable (4227-200) Pin 1 Strobe Pin 2 Data1 Pin 3 Data2 Pin 4 Data3 Pin 5 Data4 Pin 6 Data5 Pin 7 Data6 Pin 8 Data7 Pin 9 Data8 Pin 10 -Acknlg Pin 11 Busy...
  • Page 114 4227-X00 Main Logic Board<-->Sub Logic Board (4227-100) Main Logic Board Pin 1 HDTHERMO Pin 2 R7COM Pin 3 L4COM Pin 4 L1COM Pin 5 L8COM Pin 6 L5COM Pin 7 R1COM Pin 8 R4COM Pin 9 R3COM Pin 10 R8COM...
  • Page 115 4227-X00 Main Logic Board<-->Sub Logic Board (4227-200) Main Logic Board Pin 1 HCSEL Pin 2 Signal Gnd Pin 3 HDTHERMO Pin 4 R1COM Pin 5 L1COM Pin 6 R2COM Pin 7 L2COM Pin 8 L3COM Pin 9 R3COM Pin 10...
  • Page 116 4227-X00 Main Logic Board<-->Paper Select Sensor Pin 1 Pin 2 Pin 3 Pin 4 Main Logic Board<-->Paper Empty & TOF Sensors Pin 1 Pin 2 Pin 3 Pin 4 Pin 5 Pin 6 Main Logic Board<-->Auto Gap Sensor Pin 1...
  • Page 117 4227-X00 Main Logic Board<-->Paper Feed Motor Pin 1 Pin 2 Pin 3 Pin 4 Pin 5 Pin 6 Main Logic Board<-->Tractor 2 DIN Pin 1 Pin 2 Pin 3 Pin 4 Pin 5 Pin 6 Pin 7 Pin 8 Pin 9...
  • Page 118 4227-X00 Main Logic Board<-->5 V dc Power (4227-200) Main Logic Board<-->Operator Panel Main Logic Board CN14 Pin 1 +5Vdc Pin 2 SLATCH Pin 3 +5Vdc Pin 4 TXD Pin 5 Signal Gnd Pin 6 RXD Pin 7 Signal Gnd Pin 8 SCLK...
  • Page 119 4227-X00 Main Logic Board<-->Tractor PSet & Jam Sensors Pin 1 Pin 2 Pin 3 Pin 4 Pin 5 Pin 6 Main Logic Board<-->Ribbon Motor Pin 1 Pin 2 Pin 3 Pin 4 Pin 5 Pin 6 Main Logic Board<-->Auto Gap Motor...
  • Page 120 4227-X00 Main Logic Board<-->Serial Board (4227-200) Main Logic Board CN22 Pin 1 Pin 2 Pin 3 Pin 4 Pin 5 Pin 6 Pin 7 Pin 8 Pin 9 Pin 10 Pin 11 Pin 12 Serial Board<-->Serial Cable (4227-200) Pin 1...
  • Page 121 4227-X00 Sub Logic Board<-->Printhead (4227-100) Pin 1 THRMO Pin 2 R5 Pin 3 RH7 Pin 4 RH1C Pin 5 RH9 Pin 6 RH3C Pin 7 RH3 Pin 8 RH7C Pin 9 RH1 Pin 10 RH9C Pin 11 LH1 Pin 12 LH9C...
  • Page 122 4227-X00 Sub Logic Board<-->Printhead (4227-200) Pin 1 Pin 2 RH8C Pin 3 Pin 4 RH9C Pin 5 Pin 6 Pin 7 RH7C Pin 8 +5 V dc Pin 9 RH6C Pin 10 HDTHERMO Pin 11 LH6C Pin 12 Pin 13...

  • Page 123: Connector Block Diagram

    4227-X00 Connector Block Diagram 4227-100 4227-200 5-20 Service Manual...

  • Page 124: Tractor 2 Cable Connectors

    4227-X00 Tractor 2 Cable Connectors The Tractor 2 cable is soldered to the board at CN1. 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).
  • Page 125 4227-X00 5-22 Service Manual...

  • Page 126: Preventive Maintenance

    4227-X00 6. Preventive Maintenance This chapter describes procedures for printer preventive maintenance. 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. The following parts should be lubricated when replaced: •...

  • Page 127: Lubrication Points

    4227-X00 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 128: Parts Catalog

    4227-X00 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 129: Assembly 1: Covers And Operator Panel

    4227-X00 Assembly 1: Covers and Operator Panel Service Manual...
  • Page 130 4227-X00 Asm- Part Description Index Number 1 -1 11A6201 Cover Assembly, Ribbon Access 11A6208 Cover, Acoustic 79F4782 Paper Stand 1333164 Extender, Paper Guide (Left) 1333166 Extender, Paper Guide (Center) 1333165 Extender, Paper Guide (Right) 11A6207 Switch Assembly, Cover with Cover Switch Plate...

  • Page 131: Assembly 2: Paper Feed

    4227-X00 Assembly 2: Paper Feed Service Manual...
  • Page 132 4227-X00 Asm- Part Description Index Number 2 -1 11A6231 Feed Roller, Upper 11A6257 Bearing Kit 11A6233 Frame Support Shaft 11A6240 TOF & Paper Empty Sensors with Flags & Springs 11A6239 Paper Guide / Platen Assembly 11A6234 Bracket, Auto-Gap Motor (4227-100)

  • Page 133: Assembly 3: Carrier

    4227-X00 Assembly 3: Carrier Service Manual...
  • Page 134 4227-X00 Asm- Part Description Index Number 3 -1 11A6229 Sensor, Auto Gap 11A6216 Board and Bracket, Sub Logic (4227-100) 12G0214 Board and Bracket, Sub Logic (4227-200) 11A6255 Screw, Parts Packet 11A6215 Motor, Paper Feed Assembly, with Bracket 11A6257 Bearing, Parts Packet...

  • Page 135: Assembly 4: Base And Electronics

    4227-X00 Assembly 4: Base and Electronics Service Manual...
  • Page 136 4227-X00 Asm- Part Description Index Number 4 -1 11A6246 Main Logic Board without ROM (LV)(4227-100) 12G0217 Main Logic Board without ROM (LV)(4227-200) 11A6247 Main Logic Board without ROM (HV) (4227-100) 12G0216 Main Logic Board without ROM (HV) (4227-200) 11G0023 ROM Kit (4227-100)

  • Page 137: Assembly 5: Asf Side Frame / Covers

    4227-X00 Assembly 5: ASF Side Frame / Covers 7-10 Service Manual...
  • Page 138 4227-X00 Asm- Part Description Index Number 5 -1 95F6901 Support, Stacking 95F6903 Cover, (Front) 95F6899 Side Frame, (Right) 95F6893 Spring Kit, ASF 95F6892 Gear and Bearing Kit, ASF 95F6894 Screw Kit, ASF 95F6882 Cover, (Right) 7-11 Parts Catalog...

  • Page 139: Assembly 6: Asf Roller / Support

    4227-X00 Assembly 6: ASF Roller / Support 7-12 Service Manual...
  • Page 140 4227-X00 Asm- Part Description Index Number 6 -1 11A3334 Support, Cut Sheet with Guides 95F6896 Roller, Feed (Upper) 65F6897 Roller, Feed (Lower) 1333275 Roller, Pickup (Left and Right) 1333280 Hopper, (Left) 1333279 Support, Paper (Left) 95F6880 Support, Paper (Center) 1333277...

  • Page 141: Assembly 7: Tractor 2 Option

    4227-X00 Assembly 7: Tractor 2 Option 7-14 Service Manual...

  • Page 142: Index

    4227-X00 Asm- Part Description Index Number 7 -1 95F6903 Cover, (Front) 11A3343 Paper Table W/ Guides 11A3338 Paper Guide, Tractor 11A6252 Tractor and Frame Assembly 11A6254 Tractor Kit (Left and Right), with Sensors 11A3341 Parts Packet 11A3284 Shaft, Support 11A3336...
  • Page 143 4227-X00 7-16 Service Manual...
  • Page 144 4227-X00 Index Abbreviations Adjustments Bidirectional Print Printhead-to-Platen Principles of Operation Bidirectional Print Adjustment 1-11 Buttons Component Locations 5-1, 5-7, Connector Locations 5-8, 5-9 Connectors 5-7, 5-8 Illustrations Main Logic Board Operator Panel Sub Logic Board Diagnostic Aids Button Test Error Log...
  • Page 145 4227-X00 4-22 Memory Module 4-23 Operator Panel Paper Empty Sensor 4-26 Paper Feed Motor 4-26 Paper Guide Paper Guide/Platen Paper Select Lever Paper Select Sensor 4-28 Paper Separator Pinch Roller (Lower) 4-30 Power Supply 4-30 Power Supply Fan 4-30 Print Unit...
  • Page 146 4227-X00 Sub Logic Board - Printhead (4227-200) Symptom Checks Abnormal Indications Abnormal Print Problems ASF Problems Operator Panel Problems Paper Feed Problems Power Problems Print Quality Problems 6XX Error Indications Tests Button Test Jam / PSet Sensor Test Print Test...
  • Page 147 4227-X00 12G0210 12G0211 12G0212 12G0213 12G0214 12G0215 12G0216 12G0217 12G0218 12G0220 12G0221 12G0222 12G0223 12G0224 12G0225 12G0226 12G0227 12G0228 12G0229 12G0230 12G0231 12G0232 1333152 7-13 1333161 7-13 1333162 1333164 1333165 1333166 1333167 7-13 1333275 7-13 1333277 7-13 1333278 7-13 1333279...
  • Page 148 U.S. - P/N 12G0185 June 1999 You may use this form to communicate your comments about this publication, with the understanding that Lexmark may use or distribute whatever information you supply in any way it believes appropriate without incurring any obligation to you.
  • Page 149 BUSINESS REPLY MAIL FIRST CLASS MAIL PERMIT NO. 2659 LEXINGTON, KY POSTAGE WILL BE PAID BY ADDRESSEE LEXMARK INTERNATIONAL INC DEPARTMENT D22A BUILDING 035 3 740 NEW CIRCLE ROAD NW LEXINGTON KY 40511 9954 | | | | | |...

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