Lexmark 4227-100 Service Manual
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Lexmark 4227-100 Service Manual

Lexmark 4227-100 Service Manual

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Forms Printer 4227
4227-100
• Table of Contents
• Start Diagnostics
• Safety and Notices
• Trademarks
• Index
• Main Menu
Lexmark is a trademark of Lexmark
International, Inc., registered in the
United States and/or other countries.

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Summary of Contents for Lexmark 4227-100

  • Page 1 Forms Printer 4227 4227-100 • Table of Contents • Start Diagnostics • Safety and Notices • Trademarks • Index • Main Menu Lexmark is a trademark of Lexmark International, Inc., registered in the United States and/or other countries.
  • Page 2 Lexmark is a trademark of Lexmark International, Inc., registered in the United States and/or other countries. Other trademarks are the property of their respective owners.

  • Page 3: Table Of Contents

    4227-100 Contents Notices ..........vi Safety Information.
  • Page 4 4227-100 Diagnostic Aids ........3-1 Power-On Self Test (POST) .
  • Page 5 4227-100 Removal Procedures (continued) Power Supply Removal ......4-28 Power Supply Fan Removal..... . 4-28 Print Unit Removal .

  • Page 6: Notices

    4227-100 Notices Safety Information • The maintenance information for this product has been prepared for use by a professional service person and is not intended to be used by others. • There may be an increased risk of electric shock and personal injury during disassembly and servicing of this product.
  • Page 7 4227-100 Consignes de Sécurité • Les consignes d'entretien et de réparation de ce produit s'adressent uniquement à un personnel de maintenance qualifié. • Le démontage et l'entretien de ce produit pouvant présenter certains risques électriques, le personnel d'entretien qualifié devra prendre toutes les précautions nécessaires.
  • Page 8 4227-100 Pautas de Seguridad • La información sobre el mantenimiento de este producto fue escrita para el personal de mantenimiento cualificado y no para cualquier otro usuario. • Existen mayores riesgos de descargas eléctricas y daños personales durante el desmontaje y la reparación de la máquina.
  • Page 9 4227-100 Informações de Segurança • As informações de segurança relativas a este produto destinam-se a profissionais destes serviços e não devem ser utilizadas por outras pessoas. • Risco de choques eléctricos e ferimentos graves durante a desmontagem e manutenção deste produto. Os profissionais destes serviços devem estar avisados deste facto e tomar os...
  • Page 10 4227-100 Korean Safety Information...

  • Page 11: Preface

    4227-100 Preface This manual is divided into the following chapters: • General Information contains a general description of the printer and the maintenance approach used to repair it. Special tools and test equipment are listed in this chapter, as well as general environmental and safety instructions.

  • Page 12: General Information

    4227-100 1. General Information Description The Lexmark 4227-100 printer 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:...

  • Page 13: Voltage, Ground, And Continuity Readings

    4227-100 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 14: Maintenance Approach

    4227-100 Maintenance Approach The diagnostic information in this manual leads you to the correct field replaceable unit (FRU) or part. Use the error indication table, symptom/check table, service checks and diagnostic aids to determine the symptom and repair the failure. Begin with “Start” on page 2-1.

  • Page 15: Abbreviations

    4227-100 Abbreviations 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...

  • Page 16: Using The Operator Panel

    4227-100 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 17: Using The Function Menus

    4227-100 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 18: Setting Printer Functions

    4227-100 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 19: Buttons

    4227-100 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 this button: Menu • Enter the function menu. The printer goes offline.

  • Page 20: Lights

    4227-100 Press this button: LineFeed • Advance the paper to the next line. FormFeed • Advance the paper to the TOF position on the next page. • Load the forms to the TOF position. Lights Light When you see this light Power (Green) The printer power is on.

  • Page 21: Diagnostic Information

    4227-100 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 2-26.

  • Page 22: Error Indication Table

    4227-100 Error Indication Table The following table describes the service check entries for the printer error indication codes. When an error indication changes after you have entered a service check, you have an intermittent problem. If this occurs, leave the service check and go to “Symptom Table”...
  • Page 23 4227-100 Display Indication Description / Action 63C Machine Check Auto Gap Error. Auto Gap Error Go to the “Auto Gap Service Check” on page 2-10. 63D Machine Check Tractor 2 Home Position Error. Tractor2 HP Error Go to the “Tractor 2 Service Check” on page 2-32.

  • Page 24: Symptom Table

    4227-100 Symptom Table 1. Select the symptom that best describes the problem. 2. Perform the appropriate action before you go to the indicated service check. Abnormal Indications Symptom Action All LEDs turn on but Disconnect the interface cable from the printer and do not turn off.
  • Page 25 4227-100 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 26 4227-100 Symptom Action Load/Unload Be sure the paper select lever is in the correct does not function. position. Form feed length is There may be a problem with the paper select not correct. sensor. Go to the “Paper Feed Service Check” on page 2-21.
  • Page 27 4227-100 Operator Panel Problems Symptom Action Start/Stop does not Turn the printer off and then on. function but no error is indicated. Go to the “Operator Panel Service Check” on page 2-20. Only the Power light turns on. One or more buttons do not function.
  • Page 28 4227-100 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.
  • Page 29 4227-100 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 reduced. the carrier unit. Check the “Bidirectional Print Adjustment” on page 4-4.

  • Page 30: Service Checks

    4227-100 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 31 4227-100 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 32: Auto Sheet Feeder (Asf) Service Check

    4227-100 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 33 4227-100 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 “Paper Feed Service Check” on page 2-21.

  • Page 34: Carrier Drive Service Check

    4227-100 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 35 4227-100 Action The printer has stopped to protect the carrier CA Thermal Error 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 36: Intermittent Problem Service Check

    4227-100 Intermittent Problem Service Check FRU/Symptom Action The machine Check for the following: sometimes fails before POST is 1. Loose connectors. Reconnect all complete. connectors to the main and sub logic boards. 2. Electrical noise or static discharge. Check the following items: •...
  • Page 37 4227-100 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 38 4227-100 FRU/Symptom Action If the prior 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 39: No Print Or Abnormal Print Service Check

    4227-100 No Print or Abnormal Print Service Check FRU/Function Action Carrier If the carrier moves, but nothing is printed, go to the “Print Wire Drive Failure Service Check” on page 2-29. Configuration Enter the user menus and be sure the correct emulation (IBM/EPSON) and interface (parallel/serial) are selected.

  • Page 40: Operator Panel Service Check

    4227-100 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 41: Paper Feed Service Check

    4227-100 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.
  • Page 42 4227-100 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 43 4227-100 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 and Jam Sensor perform the sensor tests.
  • Page 44 4227-100 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.

  • Page 45: Post Service Check

    4227-100 POST Service Check Action Power Disconnect the parallel or serial cable and turn power on. If there is no printer activity, go to the “Power Failure Service Check” on page 2-26. Operator Panel If the power supply fan turns on but no LEDs light, go to the “Operator Panel Service Check”...

  • Page 46: Power Failure Service Check

    4227-100 Power Failure Service Check Refer to the “Voltage, Ground, and Continuity Readings” on page 1-2, for additional information. 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 47 4227-100 Action Printhead Cables Disconnect the printhead cables from the sub Printhead 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 48: Print Quality Service Check

    4227-100 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 49: Print Wire Drive Failure Service Check

    4227-100 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, but cables from the sub logic board and check no printing or the resistance for the affected wires. The printhead sound.
  • Page 50 4227-100 FRU/Symptom Action Auto Gap If printhead is firing, manually rotate the carrier shaft during printing by pushing down on the auto gap home sensor flag. If printing starts and is correct, go to the “Auto Gap Service Check” on page 2-10.

  • Page 51: Ribbon Drive Service Check

    4227-100 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 52: Tractor 2 Service Check

    4227-100 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 53 4227-100 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 on. If the slider does not move after turning the printer off and then •...
  • Page 54 4227-100 Tractor 2 installed, but not shown in User Menu 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 55 4227-100 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 56: Diagnostic Aids

    4227-100 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 57: Hex Trace Mode

    4227-100 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 58: Interface Selection

    4227-100 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 59: Service Menu

    4227-100 Service Menu Enter the Service Menu by pressing Menu/Quit during POR. Release the button when the carrier strikes the left side frame. Exit the service menu by pressing Menu/Quit. • Sensor Test 1: Tests PSet, Jam, PE & TOF sensors.

  • Page 60: Print Test

    4227-100 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 61: Error Log

    4227-100 Error Log The Error Log printout is part of the Service Menu test print page. Error indicators print on the top line of the Error Log and their corresponding counters print below. The error indicators are the last two digits of the "6XX Machine Check" display indication. An error indicator 00 indicates no errors are registered in the counter.

  • Page 62: Repair Information

    4227-100 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 63: Adjustments

    4227-100 Adjustments CAUTION: Be sure to unplug the power cord whenever you are working on the printer with any of the covers removed. Printhead Installation Adjustment 1. Hold the printhead down while pressing it toward the platen and tighten the two printhead mounting screws.
  • Page 64 4227-100 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 .013 inch (.33 mm) and .0165 inch (.42 mm).

  • Page 65: Bidirectional Print Adjustment

    4227-100 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 66 4227-100 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 67: Removal Procedures

    4227-100 Removal Procedures Use the following procedures to remove and replace individual FRUs. CAUTION: Be sure to unplug the power cord whenever you are working on the printer with one of the covers removed. Auto Gap Motor 1. Remove the top cover.

  • Page 68: Auto Sheet Feeder Gears Removal

    4227-100 Auto Sheet Feeder Gears Removal 1. Remove the right cover. 2. Release the latch and then remove the joint gear [1]. 3. Remove the idler gear [2]. 4. Release the latch and then remove the idler gear [3]. 5. Release the latch and then remove the pick-up gear [4].

  • Page 69: Auto Sheet Feeder Pick-Up Roller Removal

    4227-100 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 4-7. 3. Remove the left roller bushing [1]. 4. Remove the right roller bushing [2].

  • Page 70: Belt Tension Pulley Plate Assembly Removal

    4227-100 Belt Tension Pulley Plate Assembly Removal 1. Remove the top cover. “Top Cover Removal” on page 4-37. 2. Turn the printer so you are facing the rear of the printer. 3. Remove both tension pulley plate mounting screws [1].

  • Page 71: Carrier Removal

    4227-100 Carrier Removal 1. Remove the top cover. “Top Cover Removal” on page 4-37. 2. Remove the printhead. “Printhead Removal” on page 4-31. 3. Remove the carrier roller spring. 4. Remove the sub logic board. “Sub Logic Board Removal” on page 4-36.
  • Page 72 4227-100 6. Loosen the two tension pulley plate screws [2]. 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. 7. Remove the belt from the carrier motor pulley.
  • Page 73 4227-100 9. Remove the gear / flag [3] from the end of the carrier shaft. 10. Remove the bearing and its retainer 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 74: Carrier Motor Assembly Removal

    4227-100 Carrier Motor Assembly Removal 1. Remove the top cover. “Top Cover Removal” on page 4-37. 2. Disconnect carrier motor connectors CN9 and CN15 from the main logic board. 3. Loosen the two tension pulley plate screws. Pull upward on both...

  • Page 75: Carrier Plate Removal

    4227-100 Carrier Plate Removal 1. Remove the top cover. “Top Cover Removal” on page 4-37. 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 76: Lower Feed Roller Removal

    4227-100 Lower Feed Roller Removal 1. Remove the top cover. “Top Cover Removal” on page 4-37. 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 77 4227-100 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 the lower feed roller shaft.
  • Page 78 4227-100 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 79 4227-100 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 roll bushing is free on the end of the shaft.

  • Page 80: Lower Pinch Roller Removal

    4227-100 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 81: Main Logic Board Removal

    4227-100 Main Logic Board Removal 1. Remove the top cover. “Top Cover Removal” on page 4-37. 2. Disconnect all cables connected to the main logic board. 3. Remove the three screws at the rear edge of the board and remove the board.

  • Page 82: Operator Panel Assembly Removal

    4227-100 Operator Panel Assembly Removal 1. Remove the top cover. “Top Cover Removal” on page 4-37. 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 83 4227-100 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 84 4227-100 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 85: Paper Feed Motor Removal

    4227-100 Paper Feed Motor Removal 1. Remove the top cover. “Top Cover Removal” on page 4-37. 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 86: Paper Select Lever Removal

    4227-100 Paper Select Lever Removal 1. Remove the top cover. “Top Cover Removal” on page 4-37. 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 87: Paper Separator Removal

    4227-100 Paper Separator Removal 1. Remove the top cover. “Top Cover Removal” on page 4-37. 2. Remove the print unit from the base. “Print Unit Removal” on page 4-28. 3. Remove the paper select lever. 4. Remove the gear shaft support plate and the two gears with their springs [1].
  • Page 88 4227-100 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 89: Power Supply Removal

    4227-100 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. “Top Cover Removal” on page 4-37. 3. Disconnect the power connectors from the sub logic board and main logic board.
  • Page 90 4227-100 6. Remove the three screws [1] from the left side. 7. Remove the screw [2] from the right side holding the print unit to the base. 4-29...
  • Page 91 4227-100 8. 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. 9. 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 92: Printhead Removal

    4227-100 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 93: Printhead Cables Removal

    4227-100 Printhead Cables Removal 1. Remove the top cover. “Top Cover Removal” on page 4-37. 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 94: Ribbon Drive Motor Assembly Removal

    4227-100 Ribbon Drive Motor Assembly Removal 1. Remove the top cover. “Top Cover Removal” on page 4-37. 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 95: Right Side Frame Removal

    4227-100 Right Side Frame Removal 1. Remove the top cover. “Top Cover Removal” on page 4-37. 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 96 4227-100 6. Release and remove the separator plate spring [6]. 7. Release the spring [7] from the right end of the lower pinch roller. 8. Remove the two carrier plate screws [8]. One is in the slot in the slider cam.

  • Page 97: Sub Logic Board Removal

    4227-100 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 98: Top Cover Removal

    4227-100 Top Cover Removal 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]. 5. Set the paper select lever to the cut sheet position.
  • Page 99 4227-100 8. Place the printer on its left side. Insert a flat blade screwdriver into the two slots [4] and release the cover by prying down on the left side latches and up on the top cover. 9. Place the printer on its right side and release the two right side latches.

  • Page 100: Upper Feed Roller Removal

    4227-100 Upper Feed Roller Removal 1. Remove the top cover. “Top Cover Removal” on page 4-37. 2. Release the latches and remove the gear [1] from the left end of the shaft. 3. Remove the clip from the left end.

  • Page 101: Connector Locations

    4227-100 5. Connector Locations Connector Locations 5-1...

  • Page 102: Main Logic Board Connectors

    4227-100 Main Logic Board Connectors Parallel / Serial Port Not Used Sub Logic Board Flex Cable Paper Select Sensor Not Used Not Used Paper Empty and TOF Sensors Gap Home Sensor Carrier Motor Cable #1 CN10 Paper Feed Motor CN11...

  • Page 103: Sub Logic Board Connectors

    4227-100 Sub Logic Board Connectors Power Supply Main Logic Board Flex Cable Printhead Printhead Operator Panel Connectors Ribbon Cover Sensor LCD Board (soldered) Main Logic Board Connector Locations 5-3...

  • Page 104: Component Locations

    4227-100 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...

  • Page 105: Component Location Illustrations

    4227-100 Component Location Illustrations Connector Locations 5-5...
  • Page 106 4227-100 Component Location Illustrations (Continued)

  • Page 107: Signal Connections

    4227-100 Signal Connections Main Logic Board <--> Sub Logic Board Main Logic Board Sub Logic Board CN11 Pin 1 Pin 1 +40 V dc +40 V dc Pin 2 Pin 2 +40 V dc +40 V dc Pin 3 Pin 3...
  • Page 108 4227-100 Main Logic Board <--> Sub Logic Board Main Logic Board Sub Logic Board Pin 1 Pin 38 HDTHERMO HDTHERMO Pin 2 Pin 37 R7COM R7COM Pin 3 Pin 36 L4COM L4COM Pin 4 Pin 35 L1COM L1COM Pin 5...
  • Page 109 4227-100 Main Logic Board <--> Paper Select Sensor Pin 1 Not Used Signal Gnd Pin 2 Pin 3 FRETRA Pin 4 Signal Gnd Main Logic Board <--> Paper Empty & TOF Sensors Pin 1 PE1P Pin 2 Pin 3 Signal Gnd...
  • Page 110 4227-100 Main Logic Board <--> Paper Feed Motor CN10 Pin 1 Pin 2 Pin 3 Pin 4 Pin 5 FDCOM Pin 6 FDCOM Main Logic Board <--> Tractor 2 DIN CN13 Pin 1 +26Vdc Pin 2 +26Vdc Pin 3 Power Gnd...
  • Page 111 4227-100 Main Logic Board <--> Operator Panel Main Logic Board Operator Panel Board CN14 Pin 1 +5 V dc Pin 1 +5Vdc Pin 2 SLATCH Pin 2 SLATCH Pin 3 +5Vdc Pin 3 +5 V dc Pin 4 TXD Pin 4 TXD...
  • Page 112 4227-100 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...
  • Page 113 4227-100 Sub Logic Board <--> Printhead Pin 1 THRMO Pin 1 PH6 Pin 2 PH2C Pin 2 P5 Pin 3 PH7 Pin 3 PH8 Pin 4 PH1C Pin 4 PH4C Pin 5 PH9 Pin 5 PH5 Pin 6 PH3C Pin 6 PH5C...

  • Page 114: Connector Block Diagram

    4227-100 Connector Block Diagram 5-14...

  • Page 115: Tractor 2 Cable Connectors

    4227-100 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).

  • Page 116: Preventive Maintenance

    4227-100 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 117: Lubrication Points

    4227-100 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 118: Parts Catalog

    7. Parts Catalog How to Use This Parts Catalog • SIMILAR ASSEMBLIES: If two assemblies contain a majority of identical parts, they are broken down 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 119: Assembly 1: Covers And Operator Panel

    Assembly 1: Covers and Operator Panel Parts Catalog 7-2...
  • Page 120 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 11A6203 Cover, Rear 11A6189...

  • Page 121: Assembly 2: Paper Feed

    Assembly 2: Paper Feed Parts Catalog 7-4...
  • Page 122 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 11A6241 Roller, Feed (Lower) 79F4832 Roller, Pinch (Lower) 11A6235...

  • Page 123: Assembly 3: Carrier

    Assembly 3: Carrier Parts Catalog 7-6...
  • Page 124 Asm- Part Description Index Number 3 -1 11A6229 Sensor, Auto Gap 11A6216 Board and Bracket, Sub Logic 11A6255 Screw, Parts Packet 11A6215 Motor, Paper Feed Assembly, with Bracket 11A6257 Bearing, Parts Packet 11A6256 Gears, Parts Packet 11A6220 Motor, Ribbon Drive and Gear Plate Assembly Included with Side Plate Assembly, (Left and Right) 11A6221 Plate Assembly, Belt Tension Pulley...

  • Page 125: Assembly 4: Base And Electronics

    Assembly 4: Base and Electronics Parts Catalog 7-8...
  • Page 126 Asm- Part Description Index Number 4 -1 11A6246 Main Logic Board without ROM (LV) 11A6247 Main Logic Board without ROM (HV) 11A6248 ROM Kit 11A6243 Power Supply, 100 - 240 V ac 11A6244 Fuse, Power Supply 11A6245 Fan, Power Supply 11A6249 Ground Wire 11A6251...

  • Page 127: Assembly 5: Asf Side Frame / Covers

    Assembly 5: ASF Side Frame / Covers Parts Catalog 7-10...
  • Page 128 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...

  • Page 129: Assembly 6: Asf Roller / Support

    Assembly 6: ASF Roller / Support Parts Catalog 7-12...
  • Page 130 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 Hopper, (Right) 1333278 Support, Paper (Right) 95F6881...

  • Page 131: Assembly 7: Tractor 2 Option

    Assembly 7: Tractor 2 Option Parts Catalog 7-14...
  • Page 132 Asm- Part Description Index Number 7 -1 95F6903 Cover, (Front) 11A3343 Paper Table W/ Guides 11A3338 Paper Guide, Tractor 11A6252 Tractor and Frame Assembly 11A6211 Tractor Kit (Left and Right), with Sensors 11A3341 Parts Packet 11A3284 Shaft, Support 11A3336 Board Asm W/Cable and Ferrite 11A3332 Cover, (Right) 11A3337...

  • Page 133: Index

    4227-100 Index Abbreviations Lights Adjustments Lubricants Bidirectional Print Lubrication Printhead-to-Platen Lubrication Points Principles of Operation 2-12 Models available Bidirectional Print Adjustment Buttons Operator Panel, Using Options Component Locations Connector Locations Parts ASF Roller/Support 7-13 Connectors ASF Side Frame / Covers...
  • Page 134 4227-100 Removal Procedures Safety Information Removals Service Checks 2-10 ASF Gears Abnormal Print 2-19 ASF Pick-up Roller ASF Auto Sheet Feeder 2-12 Auto Gap Motor Auto Gap 2-10 Bottom Cover Auto Sheet Feeder 2-12 Carrier 4-10 Carrier Drive 2-14 Carrier Motor Assembly...

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