Lexmark and Lexmark with diamond
design are trademarks of Lexmark
International, Inc., registered in the
United States and/or other countries.
4227-X00
Edition: October 2000
The following paragraph does not apply to any country where such provisions are
inconsistent with local law: LEXMARK INTERNATIONAL, INC. PROVIDES THIS
PUBLICATION “AS IS” WITHOUT WARRANTY OF ANY KIND,EITHER EXPRESS OR
IMPLIED,INCLUDING, BUT NOT LIMITED TO, THE IMPLIED WARRANTIES OF
MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. Some states do
not allow disclaimer of express or implied warranties in certain transactions, therefore, this
statement may not apply to you.
This publication could include technical inaccuracies or typographical errors. Changes are
periodically made to the information herein; these changes will be incorporated in later
editions. Improvements or changes in the products or the programs described may be
made at any time.
A form for reader’s comments is provided at the back of this publication. If the form has
been removed, 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. You can purchase additional copies of publications
related to this product by calling 1-800-553-9727. In other countries, contact your point of
purchase.
Lexmark and Lexmark with diamond design are trademarks of Lexmark International,
Inc., registered in the United States and/or other countries.
Color Jetprinter is a trademark of Lexmark International, Inc.
Other trademarks are the property of their respective owners.
This software and documentation are provided with RESTRICTED RIGHTS. Use,
duplication or disclosure by the Government is subject to restrictions as set forth in
subparagraph (c)(1)(ii) of the Rights in Technical Data and Computer Software clause at
DFARS252.227-7013 and in applicable FAR provisions: Lexmark International, Inc.,
Lexington, KY 40550.
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.
• Diagnostic Information contains error code table, symptom
table,and service checks used to isolate failing field replaceable
units (FRUs).
• Diagnostic Aids contains tests and checks used to locate or
repeat symptoms of printer problems.
• Repair Information provides instructions for making printer
adjustments and removing and installing FRUs.
• Connector Locations uses illustrations to identify the major
and maintenance information to prevent problems and maintain
optimum performance.
• Parts Catalog contains illustrations and part numbers for
individual FRUs.
x Service Manual
4227-X00
Preface xi
4227-X00
Notices
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.
• 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. Professional service personnel should understand
this and take necessary precautions.
Consignes de Sécurité
Ce produit a été conçu, testé et approuvé pour respecter les
•
normes strictes de sécurité globale lors de l'utilisation de
composants Lexmark spécifiques. Les caractéristiques de
sécurité de certains éléments ne sont pas toujours évidentes.
Lexmark ne peut être tenu responsable de l'utilisation
d'autres pièces de rechange.
• 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.
xiiService Manual
4227-X00
Norme di sicurezza
Il prodotto è stato progettato, testato e approvato in
•
conformità a severi standard di sicurezza e per l’utilizzo con
componenti 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.
• Le informazioni riguardanti la manutenzione di questo
prodotto sono indirizzate soltanto al personale di assistenza
autorizzato.
• Durantelo smontaggio e la manutenzione di questo prodotto,
il rischio di subire scosse elettriche e danni alla persona è più
elevato. Il personale di assistenza autorizzato, deve, quindi,
adottare le precauzioni necessarie.
Sicherheitshinweise
Dieses Produkt und die zugehörigen Komponenten wurden
•
entworfen und getestet, um beim Einsatz die weltweit
gültigen Sicherheitsanforderungen zu erfüllen. Die
sicherheitsrelevanten Funktionen der Bauteile und Optionen
sind nicht immer offensichtlich. Sofern Teile eingesetzt
werden, die nicht von Lexmark sind, wird von Lexmark
keinerlei Verantwortung oder Haftung für dieses Produkt
übernommen.
• Die Wartungsinformationen für dieses Produkt sind
ausschließlich für die Verwendung durch einen
Wartungsfachmann bestimmt.
• Während des Auseinandernehmens und der Wartung des
Geräts besteht ein zusätzliches R isiko eines elektrischen
Schlags und körperlicher Verletzung. Das zuständige
Fachpersonal sollte entsprechende Vorsichtsmaßnahmen
treffen.
Notices xiii
4227-X00
Pautas de Seguridad
Este producto se ha diseñado, verificado y aprobado para
•
cumplir los más estrictos estándares de seguridad global
usando los componentes específicos de Lexmark. Puede
que las características de seguridad de algunas piezas no
sean siempre evidentes. Lexmark no se hace responsable
del uso de otras piezas de recambio.
• La información sobre el mantenimiento de este producto
está dirigida exclusivamente al personal cualificado de
mantenimiento.
• Existe mayor riesgo de descarga eléctrica y de daños
personales durante el desmontaje y la reparación de la
máquina. El personal cualificado debe ser consciente de este
peligro y tomar las precauciones necesarias.
Informações de Segurança
Este produto foi concebido, testado e aprovado para
•
satisfazer os padrões globais de segurança na utilização de
componentes específicos da 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
utilizadas por outras pessoas.
• Risco de choques eléctricos e ferimentos graves durante a
desmontagem e manutenção deste produto.Os profissionais
destes serviços devem estar avisados deste facto e tomar os
cuidados necessários.
xivService Manual
4227-X00
Informació de Seguretat
• Aquest producte està dissenyat, comprovat i aprovat per tal
d'acomplir les estrictes normes de seguretat globals amb la
utililització de components específics de 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
orientada exclusivament a professionals i no està destinada
a ningú que no ho sigui.
• El risc de xoc elèctric i de danys personals pot augmentar
durant el procés de desmuntatge i de servei d’aquest
producte. El personal professional ha d’estar-ne assabentat i
prendre les mesures convenients.
Notices xv
4227-X00
xviService Manual
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. When a solenoid is energized, the small
print wire pin is “fired” toward the ribbon to make a dot on the paper.
The printer receives commands in the form of an electronic data
stream from the PC through the parallel or serial port connector.The
printer logic receives and translates the electronic data stream into
carrier returns, line spacing, characters, or graphics as instructed.
General Information 1-1
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:
Courier and Gothic (NLQ) - 150 cps (4227-200)
Resident FontsFastDraft,Draft, Courier and Gothic
Forms HandlingForms (straight paper path)
Automatic tear-off
Automatic paper loading/unloading
Cut SheetsManual
Optional Auto Sheet Feeder
Multiple Part Forms6-Part Forms (carbon and carbonless)
(4227-200 - up to 8-Part Forms)
Interface ConnectionParallel, Serial RS-422, Serial RS-232
Auto GapWhen Auto Gap is set to On, the printer
automatically adjusts to the thickness of paper
you are using.
1-2 Service Manual
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. On World Trade machines, the voltage is according to
each country’s specification.
Ground Checks
To check for a correct ground, measure the voltage between the
ground and a known good voltage source. The voltage
measurement must be the same as the source voltage to consider
the ground is correct. Continuity measurements may be used to
check grounds, however, be sure to measure to a known good
ground using the lowest ohms scale and check for zero ohms.
Note: Always unplug the power cord before doing any continuity
measurement.
Continuity Readings
When measuring continuity, be sure no back circuits affect the
measurement. If necessary, unplug connectors to remove any back
circuits. Zero the ohm range on the lowest scale (X1). An open
circuit will read infinity. A circuit with correct continuity will read zero
ohms.
General Information 1-3
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 ““Start” on
page 2-1”
Options
The following options may be installed:
• Auto Sheet Feeder (ASF)
• Tractor 2
• Extended Cut-sheet Paper Guides
• 32kb Memor y Module
• Extended National Language Support modules (Non-U.S. only)
Tools
The basic tools needed are:
• Basic CE tool kit
• #1 magnetic Phillips screwdriver
• #2 magnetic Phillips screwdriver
• Feeler gauges 0.35 mm (0.014 in.) 0.4 mm (0.016 in.)
• Analog or digital volt-ohmmeter
1-4 Service Manual
4227-X00
Abbreviations
ASFAutomatic Sheet Feeder
ASICApplication-Specific Integrated Circuit
CSUCustomer Setup
DRAMDynamic Random Access Memory
EPROMErasable Programmable Read-Only Memory
ESDElectrostatic Discharge
FRUField Replaceable Unit
HVPSHigh Voltage Power Supply
LANLocal Area Network
LCDLiquid Crystal Display
LEDLight-Emitting Diode
LVPSLow Voltage Power Supply
NVRAMNonvolatile Random Access Memory
OEMOriginal Equipment Manufacturer
PORPower-On Reset
POSTPower-On Self Test
PQETPrint Quality Enhancement Technology
ROSRead-Only Storage
SRAMStatic Random Access Memory
UPRUsed Parts Replacement
V acVolts alternating current
V dcVolts direct current
General Information 1-5
4227-X00
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.
Changeable printer functions include:
• Set Top of Form
• Tractor selection
• Character options
• Paper handling options
• Interface options
• Emulation options
• Macro definition and selection
• Print tests
• Auto Gap functions
1-6 Service Manual
4227-X00
Using the Function Menus
Use the Itemand Itembuttons to move through the menu and
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.
to move away from the Main Menu
if you
General Information 1-7
4227-X00
Setting Printer Functions
1. Press Start/Stop.
2. Press Menu to enter the function menu.
3. Press Item
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).
4. Press Next
5. Press Item
display.
6. Press Store to save the selected value.
Note: The currently selected default value is displayed with an
asterisk (*).
If you have to change the optional value in another function menu,
repeat steps 3 through 5. Otherwise, go to the next step.
7. To print the function setting, press ItemPrint Settings message appears on the display.
8. Press Start/Stop to print the current setting values.
9. Press Quit to exit the function menus.
or Itemuntil the function menu you want
to enter that menu item.
or Itemuntil the value you want appears on the
or Itemuntil the
Note: If you have changed any settings, the printer performs a
Power-On Self Test, see “Power-On Self Test (POST)” on page 3-1.
If you did not change any settings, the printer enters the not-ready
state.
1-8 Service Manual
4227-X00
Overview of Function Menus
Use the Itemand 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.
Menu items marked with an asterisk (*) may not appear on the
operator panel, depending on the printer settings or what printer
options are installed
buttons to move through the menu and
to move away from the Main Menu
if you
General Information 1-9
4227-X00
1-10 Service Manual
4227-X00
Buttons
When using the function menus, press Itemor Itemto scroll
through the menu items. Press Next
next, or previous menu level.
Press this button:To:
Menu• Enter the function menu. The printer goes
offline.
Quit• Exit the function menus.
• Run a Power-On Self Test (POST).
or Prev.to move to the
Tear Off• Advance the forms to the tear-off position.
Store• Save the values selected in the menus.
Font• Select a font.
Item
Pitch• Select a pitch.
Item
Micro
Next
Micro
Prev.
Start/Stop• Used to return to Ready and to Start/Stop.
Load/Unload• Load paper (cut or continuous forms) to the
• Retract the forms to the Top-of-Form (TOF)
position when the forms are at the tear-off
position.
• Scroll down.
•Scrollup.
• Advance the forms down 0.35 mm (1/72 in.).
• Scroll forward.
• Advance the forms up 0.35 mm (1/72 in.).
• Return to the previous function menu.
• Load the forms to TOF position with the
ready light on.
TOF position.
• Retract the forms to the tractor position.
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.
General Information 1-11
4227-X00
Lights
Light
Power (Green)The printer power is on.
Ready (Green)The printer is online and ready to print.
Check (Yellow)Any of the following conditions may have
Auto Gap (Green)Auto Gap is on. Auto Gap automatically adjusts
When you see this light
The following conditions cause the Ready light
to turn off:
•PressingStart/Stop
• An end-of-form (EOF)
• A paper jam
• A cover open
• A hardware error
• A Power-OnSelf Test failure.
• The printer is offline.
occurred:
• An end-of-form (EOF)
• A paper jam
• A cover open
• A hardware error
• A data transmission error
• An interface mode error
• A Power-On Self Test (POST)
failure.
the printer according to the thickness of the
paper you are using.
Tractor2 (Green)The Tractor 2 Feederis selected. (The Tractor 2
Feeder option must be installed.)
1-12 Service Manual
4227-X00
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.
If an error indicator appears, go to the “Error Indication Table” on
page 2-2 and take the indicated action.
Run the “Print Test” on page 3-5 and refer to the “Error Log” on page
3-6 for details of error indication information. If no error indication
appears, refer to the “Symptom Table” on page 2-4.
Diagnostic Information 2-1
4227-X00
Error Indication Table
The following tabledescribes the service check entries forthe 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
servicecheckandgoto“Symptom Table” on page 2-4.
Display IndicationDescription / Action
631 Machine Check
Display RAM Error
632 Machine Check
System RAM Error
633 Machine Check
Timer Interrupt Error
636 Machine Check
NOVRAM Error
637 Machine Check
CA Drive Error
638 Machine Check
CA Drive Error
Display RAM Read/Write Error. This error
is detected only during POST. Replace the
operator panel.
System RAM Read/Write Error.
Replace the main logic board and
adjust the
Adjustment” on page 4-4
“Bidirectional Print
.Checkthe
“Printhead-to-Platen Gap Adjustment”
on page 4-2
Timer Interrupt Controller Error. Replace
the main logic board and adjust the
.
“Bidirectional Print Adjustment” on
page 4-4
.Checkthe“Printhead-to-
Platen Gap Adjustment” on page 4-2
Non-Volatile Memory Read/Write Error.
Replace the main logic board and adjust
“Bidirectional Print Adjustment” on
the
page 4-4
.Checkthe“Printhead-to-
Platen Gap Adjustment” on page 4-2
Home Timeout Error. Go to the
Drive Service Check” on page 2-14
Carrier Drive Error.
No emitter pulse detected. Go to the
“Carrier
.
“Carrier Drive Service Check” on page
.
2-14
.
.
639 Machine Check
CA Drive Error
63B Machine Check
Key Scan Error
2-2 Service Manual
Carrier Drive Error.
Carrier positioning error. Go to the
“Carrier
Drive Service Check” on page 2-14
Button Scanning Error.
Go to the
Check” on page 2-19
“Operator Panel Service
.
.
4227-X00
Display IndicationDescription / Action
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
Auto Gap Error.
Go to the
page 2-10
Tractor 2 Home Position Error.
Go to the
page 2-31
Head Thermal Sensor Error.
Go to the
“Auto Gap Service Check” on
.
“Tractor 2 Service Check” on
.
“Print Wire Drive Failure
Service Check” on page 2-28.
Option RAM Read/Write Error.
Replace the 32Kb Memory Module.
Carrier Thermal Sensor Error.
Go to the
on page 2-14
“Carrier Drive Service Check”
.
Diagnostic Information 2-3
4227-X00
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
SymptomAction
AllLEDsturnonbut
do not turn off.
The Power LED is
on, but POST will
not run.
Disconnect the interfacecable 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.
Go to the
2-24
“POST Service Check” on page
.
Abnormal Print Operation Problems
SymptomAction
Printer will not print,
or become Ready.
Abnormal operation,
incorrect characters,
or incorrect line
width.
Printer is ready but
will not print from the
computer correctly.
Undefined or
incorrect characters.
Be sure the interface cable is connected properly.
Go to the
“No Print or Abnormal Print Service
Check” on page 2-18
.
2-4 Service Manual
4227-X00
Auto Sheet Feeder Problems
SymptomAction
Auto sheet feeder
will not feed paper.
Auto sheet feeder
double feeds.
Auto sheet feeder
has intermittent feed
problems.
Paper Skews
Be sure Auto Sheet Feed is set to On in the Paper
Handling Option Menu.
Be sure the paper select lever is in the cut sheet
position.
Go to the
2-10
Isolate the problem by removing the auto sheet
feeder and feeding paper, using the manual feed
tray.Gotothe
Service Check” on page 2-12
6XX Error Indications
SymptomAction
6XX Machine Check
is displayed.
Turn the printer off and then on.
Go to
Paper Feed Problems
“Auto Gap Service Check” on page
.
“Auto Sheet Feeder (ASF)
.
“Error Indication Table” on page 2-2.
SymptomAction
Paper Empty
Add Paper
is displayed with
paper in the printer.
Be sure the paper empty sensor is not blocked.
There may be a problem with the paper select
sensor. Go to the
on page 2-20
Printoperationstarts
without paper.
“Paper Feed Service Check”
.
Diagnostic Information 2-5
4227-X00
SymptomAction
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.
PressingFormFeed
does not feed paper.
Abnormal noise
while feeding.
Paper jams, skews
or creases.
Be sure the paper select lever is in the correct
position.
There may be a problem with the paper select
sensor. Go to the
on page 2-20
Be sure the paper select lever is in the cut sheet
position.
Be sure Auto Cut Sheet is enabled in the Paper
Handling Option Menu.
Go to the
“Paper Feed Service Check” on
page 2-20
Be sure the paper select lever is in the correct
position.
Go to the
“Paper Feed Service Check” on
page 2-20
“Paper Feed Service Check”
.
.
.
Incorrect or no line
spacing: wider,
narrower, or
overlapping lines.
Incorrect Top of
Form positioning.
2-6 Service Manual
4227-X00
Operator Panel Problems
SymptomAction
Start/Stop does not
function but no error
is indicated.
Turn the printer off and then on.
Go to the
page 2-19
Only the Power light
turns on.
One or more buttons
do not function.
Oneormorelights
do not function.
Blank display.
Cover open
displayed.
Power Problems
SymptomAction
When the power
switch is on, the
Power light does not
turn on or the printer
does not start.
Check the continuity of the power cord and the
voltage of the electrical outlet.
Go to the
page 2-25
“Operator Panel Service Check” on
.
“Power Failure Service Check” on
.
The Power light
blinks or changes
intensity.
Diagnostic Information 2-7
4227-X00
Print Quality Problems
SymptomAction
No print, but carrier
movesasifprinting.
Print density is light.If the ribbon has reached its end of life or is worn,
Unevenprint density
across the print line.
Specific dots
missing.
Be sure the printhead cables are not loose or
damaged.
Be sure the interface cable is connected properly.
Check the ribbon cartridge for binds or damage.
Go to the
Check” on page 2-28
the ribbon cartridge needs to be replaced.
Go to the
2-10
Drive Service Check” on page 2-30
Be sure the printhead cables are connected
correctly to the printhead and the sub logic board.
Clean the printhead.
Set the Auto Gap to On in the user menus and run
the print test. If the print is light at one edge and
uniformly gets darker across the page to the other
edge, perform the
Adjustment” on page 4-2
Go to the
Check” on page 2-28
“Print Wire Drive Failure Service
.
“Auto Gap Service Check” on page
. If no problem is found, go to the“Ribbon
.
“Printhead-to-Platen Gap
.
“Print Wire Drive Failure Service
.
Scattered ink
smearing, blurred
characters.
Fuzzy print.
2-8 Service Manual
Clean the printhead nose.
Clean the ribbon guide and shield.
If the ribbon has reached its end of life or is worn,
the ribbon cartridge needs to be replaced.
Go to the
page 2-27
“Print Quality Service Check” on
.
4227-X00
SymptomAction
Wavy vertical lines,
unevenleft margin or
character width is
reduced.
Clean and lubricate the carrier shaft.
If the carrier drive belt is worn or broken, replace
the carrier unit. Check the
Adjustment” on page 4-4
Go to the
page 2-14
Ribbon Feed Problems
SymptomAction
Ribbon comes off,
becomes loose or
folded, or jams.
Ribbon feeds
correctly but is noisy.
Check the ribbon cartridge for binds or damage.
Go to the
page 2-30
“Bidirectional Print
.
“Carrier Drive Service Check” on
.
“Ribbon Drive Service Check” on
.
Diagnostic Information 2-9
4227-X00
Service Checks
Auto Gap Service Check
Theory of Operation:
The Auto Gap Motor and Gap Home S ensor 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. 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:
• POST.
• Auto Gap resets.
• The printer unloads paper if it is loaded, to prepare to measure
the travel span.
• The auto gap motor drives the printhead against the platen to
measure the total travel span.
• Auto Gap resets again, to make room for paper to be loaded.
• The paper feeds to the print line.
• The auto gap motor drives the printhead against the paper to
measure the total travel span minus the paper thickness.
• Auto Gap resets again.
• The printhead moves to the appropriate gap position for the
installed paper.
• The Ready LED turns on, the carrier centers, and the paper
moves to the tearoff position.
2-10 Service Manual
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). With Auto Gap Off, Single Auto Gap has two selections:
• Fixed - the printhead gap is never changed.
• Open - the gap is opened when loading forms.
Note: If there is a 63C Auto Gap Error, the gap home sensor did not
detect that the carrier shaft homed, or detected that the carrier shaft
homed at the wrong time.
FRUAction
1Auto Gap SensorInspect the gap home flag on the end of the
carrier shaft and make sure it blocks the sensor
when the gap is at its largest. Power up the
printer and watch the carrier shaft and the gap
home flag. If the shaft rotates before the error
occurs, the sensor may have failed. Perform
the Sensor 2 Test in the Service Menu and test
the gap home sensor.
2AutoGapMotor
Gear Train
If the carrier shaft does not rotate, look for an
auto gap motor or auto gap gear train problem.
Disconnect CN20 from the main logic board.
Check the resistance of pins:
1 and 5, 2 and 6, 3 and 5, and 4 and 6.
All resistances should be 180
No pin should have continuity to ground.
If there is no 63C Auto Gap Error but there is a
gap problem (light print or no print, or paper
catching on the printhead or ribbon shield),
enter the user menus to make sure the gap
settings are appropriate for the paper being
used. If Auto Gap is Off, Manual Position 1
should be used only with single-part 16 lb. or
20 lb. forms. Refer the customer to the user's
guide for the appropriate Manual Position
settings.
± 5ohms.
Diagnostic Information 2-11
4227-X00
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.
• Auto Sheet Feeder must be selected in the display menu.
Continuous forms can be used with the ASF installed by moving the
paper select leverto continuous forms and pressing Start to feed the
continuous forms to the first print line.
The ASF contains no electrical parts. It is driven from the gear on
the inside of the printer’s right side frame.
The combination lock mechanism is a clutch that causes the ASF
pick rollers to feed only one sheet of paper at a time. When AutoSheet Feeder is selected on the Paper Handling Options Menu, the
cut sheet paper drive reverses itself for a short distance during
paper loading. This engages the clutch and engages the paper pick
rollers, which feed the top sheet from the cut sheet paper stack. The
sheet is fed about 5 inches (125 mm) and the paper path briefly
reverses again; this disengages the clutch and the pick rollers. 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.
FRUAction
1Paper Select
Sensor
2-12 Service Manual
With the paper select lever in the cut sheet
position, do the following:
• Try to load a sheet with Load/Unload.
(This button should not work)
• If the paper loads go to the
Check” on page 2-24
“POST Service
.
4227-X00
FRUAction
2Paper FeedIf the paper does not feed, do the following:
•RemovetheASF.
• Be sure the base printer feeds paper
correctly.
• If it does not feed paper correctly,go to the
“Paper Feed Service Check” on page
.
2-20
3Gear TrainBe sure the ASF drive gear on the inside of the
printer’s right frame rotates.
Inspect the right side gear train for damage or
debris.
Remove the ASF right cover and ensure that
all gears are in good condition.
4Combination Lock
Mechanism
5Left and Right
Hoppers
6Pick Rollers
Paper Guides
Feed Rollers
Install the ASF and press FormFeed.
If the pick drive shaft does not rotate, replace
the combination lock mechanism.
If the ASF pick rollers rotate but a single sheet
is not picked, inspect the springs and corner
separators on the left and right hoppers.
Make sure the paper load lever is in the correct
position.
Paper skew can be caused by worn, dirty or
binding pick and feed rollers. Remove the auto
sheet feeder,load paper and hand cycle the
feeder while observing the pick and feed
rollers. If the skew problem is in the base
machine, examine all feed rollers for wear.
Diagnostic Information 2-13
4227-X00
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.
FRUAction
1637, 638, 639
CA Drive Error
2640
CA Thermal Error
Carrier positioning error.
Inspect the following
• Tension pulley plate
•Carrier
• Carrier belt.
Loosen and tighten the tension pulley plate
screws to make sure the carrier belt is tight.
Disconnect CN9 and move the carrier
manually from left to right and check for
smooth movement.
With CN9 disconnected, check for 5 to 8 ohms
between pins 1 and 2 on the motor cable. If the
reading is incorrect, replace the motor.
Check for motor pins shorted to the housing. If
you find a pin shorted to the housing, replace
the motor.
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.
If the machine was not being used heavily
before the error occurred, or if the error returns
when the machine is cool, replace the carrier
motor.
4227-X00
Intermittent Problem Service Check
FRU/SymptomAction
1Themachine
sometimes fails
before POST is
complete.
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:
• Power supply ground.
• Machine frame ground.
• Printer interface cable is grounded and
shielded.
2. Intermittently low voltages. Check for ac and
all dc voltages and short circuits on the main
and sub logic boards.
a. Check the electrical voltage and ensure
that it is within tolerance.
b. Check the continuity of the power
cord.
c. 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.
Ensure the output voltages are:
CN11-1 (+40 ±4 V dc) & CN11-3 (GND)
CN11-2 (+40 ±4 V dc) & CN11-3 (GND)
CN11-5 (+5 ±0.5 V dc) & CN11-6 (Signal GND)
CN 1-1 (+40 ±4 V dc) & CN1-3 (GND)
CN 1-2 (+40 ±4 V dc) & CN1-3 (GND)
CN 1-5 (+5 ±0.5 V dc) & CN1-6 (SignalGND)
If the voltages are not correct, replace the
Power Supply Unit.
If the failure remains, replace the main logic
board and sub logic board.
Note: When replacing the main logic board,
always set the
Adjustment” on page 4-4
“Bidirectional Print
and the
“Printhead-to-Platen Gap Adjustment” on
page 4-2
.
Diagnostic Information 2-15
4227-X00
FRU/SymptomAction
2Machine power
sometimes turns
off.
3Intermittently poor
print quality.
The cause of this problem may be that the
power circuit is failing, or the wiring is
intermittently open. Check the following in
sequence:
1. Check the electrical voltage and be sure it is
within tolerance.
2. Check the continuity of the power cord.
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) & CN11-3 (GND)
CN11-2 (+40 ±4 V dc) & CN11-3 (GND)
CN11-5 (+5 ±0.5 V dc) & CN11-6 (Signal GND)
CN 1-1 (+40 ±4 V dc) & CN1-3 (GND)
CN 1-2 (+40 ±4 V dc) & CN1-3 (GND)
CN 1-5 (+5 ±0.5 V dc) & CN1-6 (SignalGND)
If one of the voltages is 0, go to the “Power
FailureService Check” on page 2-25
.Ifthe
voltagesare not 0 but are incorrect, replace the
power supply unit.
Do the following
:
• Remove paper jams from the paper path.
• Clean all feed roller surfaces.
• Clean the ribbon shield and printhead.
• Clean the platen surface.
• Install the ribbon cartridge correctly.
• If the ribbon end of life has been reached,
have the customer replace the ribbon
cartridge.
2-16 Service Manual
4227-X00
FRU/SymptomAction
4Iftheprior
suggestions have
not corrected the
problem.
5Problem occurs
only in specific
customer
applications.
The service check has not defined the failure,
or the machine is having intermittent failures.
The following may cause undefined or
intermittent failures:
1. Customer’s electrical voltage. Be sure that it
is within the tolerance.
2. Loose connector pins or keys that fail to
contact.
Check the following:
a. Reconnect the connectors of all FRUs
and printer interface cables.
b. Check the continuity of the line cord.
3. Electrical noise.
Check the following:
a. Power supply ground.
b. Machine frame ground.
c. Printer interface cable is grounded
or shielded.
4. Undefined data in customer applications.
Check the baud rate at the controller. Check
that the printer interface cable matches the
printer.
Perform the Trace Print (hexadecimal printing)
by the following procedure and check the data
streams.
1. Press Menu.
2. Press Item
3. Press Start.
4. Have the customer print the failing job.
5. To stop printing, turn the power switch off.
to display Trace Mode.
If the failure still occurs, set the
Print Adjustment” on page 4-4
“Bidirectional
and the
“Printhead-to-Platen Gap Adjustment” on
page 4-2
.
Diagnostic Information 2-17
4227-X00
No Print or Abnormal Print Service Check
FRU/FunctionAction
1CarrierIf the carrier moves, but nothing is printed, go
“Print Wire Drive Failure Service
to the
Check” on page 2-28
2ConfigurationEnter 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.
3Main Logic BoardIf the Print Test does not print, or prints
incorrectly, do the following:
.
• Replace the main logic board.
•Setthe
on page 4-4
“Bidirectional Print Adjustment”
and the “Printhead-to-
Platen Gap Adjustment” on page 4-2
.
2-18 Service Manual
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.
FRUAction
1Operator PanelIf there is a 631 Display RAM Error, replace the
operator panel.
If there is a 63B Key Scan Error, one or more
buttons are being detected as pressed during
power-up.
Replace the operator panel.
and Microkeys
2PrinterCable
Operator Panel
3CoverSwitchIfCover Open is displayed, check the cover
4Main Logic BoardIf the symptom has not changed, replace the
During power-up, all LEDs and all LCD pels
should turn on briefly.
Enter the Service Menu and perform the
Button Test. If there are missing or extra pels
displayed,or if any of these tests fail, check the
condition and continuity of the operator panel
cable.
Replace the cable or the operator panel.
switch.
Jumper the cover switch connector on the
operator panel. If Cover Open is displayed,
check the condition and continuity of the
operator panel cable. Replace the cable or the
operator panel.
main logic board.
Diagnostic Information 2-19
4227-X00
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 / SymptomAction
1Auto Sheet
Feeder
If the Auto Sheet Feeder is installed, remove it.
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
“Auto Sheet
Feeder (ASF) Service Check” on page
.
2-12
2Tractor 2If the Tractor 2 option is installed, remove it.
Verify that the machine works correctly without
Tractor 2 installed.
If the printer fails only with Tractor 2 installed,
go to the
page 2-31
3Paper Feed MotorIf there is no paper motion, disconnect the
paper feed motor connector CN10 from the
main logic board.
Check the resistance of pins:
CN-1 and 6, 2 and 5, 3 and 6, and 4 and 5.
All resistances should be 5.8
pin should have continuity to ground.
“Tractor 2 Service Check” on
.
± 0.5 ohms. No
2-20 Service Manual
4227-X00
FRU / SymptomAction
4Gear Train and
Paper Feed Motor
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.
The upper and lower feed rollers and the upper
and lower pinch rollers should all be clean and
in good condition, and should all rotate during
Form Feed.
To turn the gear train manually,turn the right
end of the lower feed roller shaft with a 6 mm
wrench.
Diagnostic Information 2-21
4227-X00
FRU / SymptomAction
5PESensor
TOF Sensor
PSet Sensor
Jam Sensor
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.
• TOFSensor - sharp flag, determines TOF at
paper load.
• PSet Sensor - paper set, detects presence
of paper in the tractors and looks for end of
forms.
• Jam Sensor - senses the holes in the paper
and detects paper jams by the lack of paper
movement.
When the PSet sensor detects EOF, it lets
printing continue to the bottom of the form.
When the PE sensor detects no paper, it stops
print within a few lines.
The jam sensor stops printing after about
50 mm of no signal change; for example, if 50
mm of pinfeed is removed from a sheet, the
sensor stops printing. Less than 50 mm will
probably be ignored. Therefore, the paper
motion must have stopped for the equivalent of
about 12 printed lines to cause a jam.
If either the PE or the PSet sensor detects no
paper during print, printing stops at the end of
the current page.
6Paper Select
Sensor
2-22 Service Manual
The Tractor 2 option also has PSet and Jam
sensors on the left tractor.
Enter the service menu and perform the sensor
tests.
Replace any failed or damaged sensors.
Enter the service menu and perform the
Sensor Test 2 for “Lever.”
Move the paper select leverto test the sensor.
Replace any sensor if failed or damaged.
4227-X00
FRU / SymptomAction
7OperatorPanelIf paper does not move at all, verify the
FormFeed button is working correctly by
performing the service menu button test.
8Main Logic BoardIf no other problem is found, replace the main
logic board.
Set the
page 4-4
“Bidirectional Print Adjustment” on
,and“Printhead-to-Platen Gap
Adjustment” on page 4-2
.
Diagnostic Information 2-23
4227-X00
POST Service Check
FRUAction
1PowerDisconnectthe parallel or serial cable and turn
power on.
If there is no printer activity, go to the
Failure Service Check” on page 2-25
2Operator PanelIf the power supply fan turns on but no LEDs
light,gotothe
Check” on page 2-19
3Main Logic BoardIf the Power LED turns on but POST does not
complete, replace the main logic board.
Readjust the
Adjustment” on page 4-4
“Operator Panel Service
.
“Bidirectional Print
and check the
“Power
.
“Printhead-to-Platen Gap Adjustment” on
page 4-2
4Printer CableIf POST completes, reconnect the parallel or
serial cable and turn power on again.
If POST now fails, there is a problem with the
cable, or the parallel connector on the main
logic board.
.
2-24 Service Manual
4227-X00
Power Failure Service Check
Refer to the “Voltage, Ground, and Continuity Readings” on page
1-3, for additional information.
FRUAction
1Operator PanelIf the operator panel or cable is damaged or
disconnected, the machine is completely
inoperable, except for the power supply fan
noise.
If the power LED is not on steady, check the
cable continuity and replace the cable or the
operator panel.
2Power Supply
Fuse
If the printer is completely inoperable,
disconnect the power cables from the main
logic board (CN11) and the sub logic board
(CN1).
Turn the power on and measure
5 V dc at the sub logic board cable CN1-
+5 ±
5 and +40 ± 4 V dc at CN1-1 and CN1-2. If
there is no voltage, check the internal fuse
before replacing the power supply.
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.
Diagnostic Information 2-25
4227-X00
FRUAction
3Ribbon Motor
Paper Feed Motor
Carrier Motor
Sub Logic Board
4227-200 Carrier
Motor Cooling Fan
4Printhead Cables
Printhead
5Main Logic BoardIf all the above items have been examined and
Disconnect the carrier motor (CN9 and CN15),
the paper feed motor (CN10), ribbon motor
(CN19) and the (4227-200) carrier motor
cooling fan (CN17) from the main logic board,
and disconnect the power connector CN-1
from the sub logic board. Turn the power on
again. If there is still a power problem, replace
the main logic board.
If the machine posts a different error, one of
theseitemsisshortedandisholdingdownthe
+40 V dc line. Reconnect them one at a time,
turning the printer on in between each
connection.
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.
there is still a power problem, replace the main
logic board. (Retain the old board for
reinstallation if the problem is not fixed.)
Adjust the
on page 4-4
Platen Gap Adjustment” on page 4-2
“Bidirectional Print Adjustment”
and check the “Printhead-to-
.
2-26 Service Manual
4227-X00
Print Quality Service Check
FRUAction
1Ribbon and ShieldBe sure the ribbon is not worn and feeds
smoothly when the knob is turned. Inspect the
ribbon shield for dirt or damage.
2Ribbon DriveBe sure the ribbon drive post rotates when
printing.
3AutoGap
Check the
Adjustment” on page 4-2
be sure the manual position setting is
appropriate for the paper used.
Auto Gap Motor
Bracket
4Printhead CablesInspect both ends of the printhead cables for
5CarrierBelt
Adjustment
6Carrier MovementWith power off, manually move the carrier from
7Bidirectional Print
Adjustment
8Carrier MotorThe carrier motor should turn smoothly and
9Paper Feed GearsInspect the paper feed gears for wear and tear.
10Paper Feed MotorThe paper feed motor should turn smoothly
11TractorsInspect the tractors for damage or looseness.
If the failure remains, replace the Auto Gap
Motor Bracket.
proper connection.
Loosen and tighten the tension pulley plate
screws to make sure the carrier belt is tight.
side to side to inspect for drag or binds.
Check the
on page 4-4
quietly when printing.
and quietly when printing.
“Printhead-to-Platen Gap
. If Auto Gap is off,
“Bidirectional Print Adjustment”
.
12Feed Roller
Surfaces
Inspect the feed roller surfaces for dirt or wear.
Diagnostic Information 2-27
4227-X00
Print Wire Drive Failure Service Check
FRU/SymptomAction
1MissingDots
Carriermoves,but
no printing or
printhead sound.
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. The
resistance for each wire should be around
If the resistance for the affected wires is
incorrect, disconnect the printhead cables from
the printhead and measure the resistance of
the printhead for the same wires. The
resistance should be around 7.9 ohms.
• If the resistance is correct, replace the
printhead cables.
• If the resistance is incorrect, replace the
printhead.
263EHead
Thermal Error
2-28 Service Manual
The printer has stopped to protect the
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.
If the machine was not being used heavily
before the error occurred, or if the error returns
when the machine is cool, replace the
printhead.
4227-X00
FRU/SymptomAction
3Auto GapIfprinthead is firing, manuallyrotatethe 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.
4Printhead CablesInspect for improper connection or damage.
5Sub Logic BoardIf there is carrier motion but no printhead noise,
6RibbonA problem with the ribbon shield can keep the
7PrintheadThe printhead probably is not the problem if
8Main Logic BoardIf no other problem is found, replace the main
and the printhead cables do not appear to be
the problem, replace the sub logic board.
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.
thereisnoprinting.
Check the winding resistances as described
above and look for open circuits or shorts
between neighboring pins.
Do not replace the printhead unless a specific
problem is found.
logic board, retaining the old board for
reinstallation if the problem is not fixed.
Set the
page 4-4
“Bidirectional Print Adjustment” on
and the “Printhead-to-Platen Gap
Adjustment” on page 4-2
Diagnostic Information 2-29
.
4227-X00
Ribbon Drive Service Check
In normal operation, the ribbon knob rotates counterclockwise
whenever the carrier moves to the left.
FRU/SymptomAction
1RibbonDrive
Gear Train
2Ribbon MotorIf printing seems normal, but the ribbon is not
Removeand inspect the ribbon. Make sure the
knob turns with even, moderate force and the
ribbon feeds correctly.
Inspect the gear train from the ribbon motor to
the ribbon drive post.
Check the
Adjustment” on page 4-2
moving, remove the ribbon and turn power on.
The ribbon drive post should turn severaltimes
during POST. Disconnect the ribbon motor
connector CN19 from the main logic board.
The winding resistance should be
118 ohms ±
1 and 6, 3 and 5, 2 and 6, 4 and 6.
No other combination of pins should have
continuity. If a problem is found, replace the
ribbon motor and gear plate assembly.
“Printhead-to-Platen Gap
.
5 between pins:
2-30 Service Manual
4227-X00
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.
• When the Tractor 2 is deselected, the motor retracts the slider,
disengaging the Tractor 2 gear drive and reengaging the printer
tractors.
63D Tractor2 HP Error
The Tractor 2 home sensor was never initialized after turning the p rinter off
and then on, or made at the wrong time.
(The same error indication is used for carrier home failure.)
FRUAction
1Tractor2
Home Sensor
Remove the Tractor 2 and turn the printer off
and then on again to determine if the fault is in
the printer or Tractor 2.
If the gear teeth chatter just before the error is
displayed, replace the home sensor.
Diagnostic Information 2-31
4227-X00
FRUAction
2Main Logic BoardRemoveTractor 2 from the printer but leavethe
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
on:
• Make sure the slider and gear train are
properly connected and move freely with the
power off.
• Make sure the Tractor 2 board is receiving:
+26 V dc on CN1-1 and
+ 5 V dc on CN1-5.
If not, check the cable connection and the
voltages at main logic board CN13-1.
The upper right pin at CN13 is pin 1 (+26 V dc)
and the pin just beneath it is pin 5 (+5 V dc).
If these voltages are not present replace the
main logic board.
3Tractor 2 Motor
Board /Cable Asm
2-32 Service Manual
Checkthe following resistances of the Tractor 2
motor windings:
101 ± 5 ohms between pins:
1 and 6,3 and 6,2 and 5,4 and 5.
If the motor is good, replace the board/cable
assembly.
For information on the Tractor2 cable
connectors, see
Connectors” on page 5-21
“Tractor 2 Cable
.
4227-X00
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.
FRUAction
1Tractor2
Board/CableAsm.
2Main Logic BoardCheck the cable connection from Tractor 2 to
Check the Tractor 2 sensor or the cable
connection.
The sensor actuator extends through the
Tractor 2 cover and rests on the printer cover
when Tractor 2 is installed.
Removethe Tractor 2 cover and make sure the
sensor opens when the Tractor 2 is installed.
The voltage at Tractor 2 CN1-13 should be +5
V dc with the sensor open and 0 with it closed.
Replace the Tractor 2 board/cable asm if the
sensor signal is wrong.
For information on the Tractor 2 cable
connectors, see
Connectors” on page 5-21
the printer.
If possible, try the Tractor2 with another printer
to determine if the problem is the Tractor 2
board/cable assembly or the printer main logic
board.
“Tractor 2 Cable
.
Diagnostic Information 2-33
4227-X00
Paper Feed Problems
FRUAction
1Tractor 2On 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.
Remove Tractor 2 from the printer and remove
all paper. With the paper select lever in the
continuous forms position, press LineFeed;
the tractors should rotate.
Press the sub slider cam below the ASF/
Tractor 2 drive gear and press LineFeed again;
the tractors should not rotate but the drive gear
should.
Check the condition of the pin feed belts. With
the power off, make sure the slider does not
bind.
:
Verify
2-34 Service Manual
• When the slider is to the rear,the white gear
drives the tractors;
• When the slider is to the front the gear and
tractors are not connected.
Remove the Tractor2 cover and reinstall
Tractor 2 in the printer (if necessary removethe
printer covers also). Note that the small idler
gear just below the slider is held in place by the
cover;withthecoverremoveditwilltendto
move off the stud. Also note that when
operating the Tractor 2 with the printer cover
removed, the Tractor 2 sensor must be held
open.
Turn the printer on and look for mechanical
problems.
For information on the Tractor2 cable
connectors, see
Connectors” on page 5-21
“Tractor 2 Cable
.
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)
• Hex Trace Mode (a computer or terminal is needed)
• Print Tests
• Error Log
Power-On Self Test (POST)
The Power-On Self Tests diagnose the basic hardware printer
functions and initialize the default value settings. POST starts
automatically when power to the printer is turned on, or when the
printer receives an INIT signal from the controller.
• Power supply fan turns on.
• LED Test - All LEDs turn on briefly.
• LCD Test - All pels of the display are activated twice, then
"initialize" is displayed.
• RAM Test - Checks that the CPU can write/read the RAM.
• ROM Test - Checks that the ROM data is correct.
• Timer/Interrupt Controller Test - Checks this function is working.
• Button Scan Test - Scans all operator panel buttons.
• NVRAM Test - Checks that the NVRAM data is correct.
• Ribbon motor feeds ribbon.
• Carrier moves to the left side frame and back to the right.
• Auto Gap sequence occurs.
If any errors occur during the POST tests, an error indicator shows
which test failed. See “Start” on page 2-1.
Diagnostic Aids 3-1
4227-X00
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.
To activate hex trace mode:
1. Press Menu.
2. Press Item
3. Press Start.
Hex Trace Mode Sample
until Trace Mode is shown on the operator panel.
3-2 Service Manual
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Interface Selection (4227-100)
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.
Operation with the Top Cover Removed
After removing the top cover, the pr inter 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. Or, remove the operator panel and cable,
jumper the two pins of the ribbon cover sensor connector CN1
together on the back of the panel, and reconnect the operator panel
flex cable to the main logic board.
Note: Printing without the top cover affects print quality and may
cause paper jams since the upper feed rollers on the ribbon cover do
not help restrain and feed paper.
Diagnostic Aids 3-3
4227-X00
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.
• Sensor Test 2: Tests Paper Select, Gap Home, and Cover
sensors.
These tests display an underline (_) if the sensor is open or a block
) if the sensor is blocked. Use paper, tools or fingers to block and
(
unblock the sensors to verify that each is functional. Return to the
ServiceMenubypressingMenu/Quit.
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. defaults(11", Code Page 437, Character Set 1)
to Non-U.S. defaults (12", Code Page 850, Character Set 2).
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.
3-4 Service Manual
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Impact Force
Impact Force enables the striking force of the printhead pins to be
changed. Three selections are possible.
• Normal Auto: This is the default value. Impact force of the
printhead pins is adjusted automatically for paper thickness.
• 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.
• Normal 1P: Disables the automatic setting of the impact force.
Normal 1P is used to print in normal force when thicker print
media is used such as labels.
Log Clear
Clears the error log.
Print Test
The Print Test prints:
• The ASCII character set.
• Alinefromeachprintwire.
• 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:
• A draft only 8 inch wide continuous print test. This test is
activated by turning the printer on with the Load/Unload and
LineFeed buttons pressed.
• A draft only 13.6 inch wide continuous print test. This test is
activated by turning the printer on with the LineFeed and
FormFeed buttons pressed.
Note: These tests print a running page count at the bottom of each
page. Use the Start/Stop button to start and stop the test. Other
Diagnostic Aids 3-5
4227-X00
buttons that are active during this test are the
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.
or Micro, Load/Unload, LineFeed and FormFeed.
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. Each
new error appears in the left-most position and the previous error
indicator shifts one position to the right. If the new error indicator is
the same as the previous error indicator,the counter is increased by
1. The maximum count number for the same error is 256, and the
counter remains at this value (X'FF'). No more than 16 most recent
error indicators can be printed in the error log area.
3-6 Service Manual
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). To prevent damage to ESD-sensitive
parts, follow the instructions below in addition to all the usual
precautions, such as turning off power before removing logic boards:
• Keep the ESD-sensitive part in its original shipping container
(a special “ESD bag”) until you are ready to install the part into
the machine.
• Make the least-possible movements with your body to prevent
an increase of static electricity from clothing fibers, carpets, and
furniture.
• Put the ESD wrist strap on your wrist. Connect the wrist band to
the system ground point. This discharges any static electricity in
your body to the machine.
• Hold the ESD-sensitive part by its edge connector shroud
(cover); do not touch its pins. If you are removing a pluggable
module, use the correct tool.
• Do not place the ESD-sensitive part on the machine cover or on
a metal table; if you need to put down the ESD-sensitive part for
any reason, first put it into its special bag.
• Machine covers and metal tables are electrical grounds. They
increase the risk of damage because they make a discharge
path from your body through the ESD-sensitive part. (Large
metal objects can be discharge paths without being grounded.)
• Prevent ESD-sensitive parts from touching other personnel.
Install machine covers when not working on the machine, and
do not put unprotected ESD-sensitive parts on a table.
• Keep all ESD-sensitive parts in a grounded metal cabinet
(case).
• Low humidity increases static electricity during cold weather.
Repair Information 4-1
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 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.
• When the print density varies across the page.
There are two adjustments to this procedure.
Printhead-to-Platen Gap Left and Right
1. Turn the power off.
2. Remove the top cover.
3. Remove the ribbon.
4. Position the carrier to the left.
5. Using a .014 inch (.35 mm) feeler gauge as the Go gauge and a
.016 inch (.40 mm) feeler gauge as the No-Go gauge, rotate the
carrier shaft and measure the printhead to platen gap.
6. Position the carrier to the right.
7. Adjust the carrier shaft bearing on the right side frame so the
right gap matches the left gap.
4-2 Service Manual
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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:
• (4227-100) - between .013 inch (.33 mm) and .0165 inch
(.42 mm).
• (4227-200) - between .011 inch (.275 mm) and .015 inch
(.375 mm).
5. Use the Micro
Micro
button will decrease the clearance.
6. Install the ribbon guide.
7. Press Start/Stop to reset the gap to the new “Pos” setting.
8. Remove the ribbon guide and check the setting with a feeler
gauge.
9. Repeat steps 5 through 8 until the gap is within the
specification.
10. Press Store to save the setting in NVRAM.
button will increase the clearance and the Micro
or Microto change the "Pos" setting. The
Repair Information 4-3
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.
The following steps illustrate how to adjust the alignment of the print
wires, and assumes macros are disabled.
1. Load continuous forms.
2. Press Menu.
3. Press Item
4. Press Next
5. Press Item
each alignment pattern once (uni-directional). Courier prints
each alignment pattern twice (bidirectional).
6. Press Start/Stop to print the alignment pattern.
until Print Adjust appears on the display.
.
or Itemto choose Draft or Courier. Draft prints
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The following example shows a printer that needs alignment.
The message Choose the B est 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.
• Press Item
• Press Item
8. Press Store to save the selected value.
9. Press Start/Stop to print the alignment pattern. The example
below shows proper alignment.
or Prev.to adjust the alignment.
to move lines 2 and 4 to the right.
to move lines 2 and 4 to the left.
10. Press Quit to exit the menu.
Repair Information 4-5
4227-X00
Removal Procedures
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. 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.
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.
4-6 Service Manual
4227-X00
7. 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.
8. Place the printer on its right side and release the two right side
latches.
9.Place the printer on its feet and release the remaining two top
cover latches.
10. While lifting the top cover slightly,disconnect the operator panel
cable from the main logic board and then remove the top cover.
Reinstallation:
Be sure that the operator panel cable is correctly aligned and
inserted securely.
WARNING: Damage to the operator panel cable may cause failure
of other electrical components of the printer. Be sure not to crimp or
pinch this cable while reinstalling the top cover.
CAUTION: Be sure to unplug the power cord whenever you are
working on the printer with one of the covers removed.
Repair Information 4-7
4227-X00
Auto Gap Motor
1. Remove the top cover.
See “Top Cover Removal” on page 4-6.
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].
4-8 Service Manual
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].
5. Release the latch and then remove the combination lock
mechanism [5].
Repair Information 4-9
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.
See “Auto Sheet Feeder Gears Removal” on page 4-9.
3. Remove the left roller bushing [1].
4. Remove the right roller bushing [2].
5. Move the pick-up roller [3] to both ends of the shaft, and then
remove them.
4-10 Service Manual
4227-X00
Belt Tension Pulley Plate Assembly Removal
1. Remove the top cover.
See “Top Cover Removal” on page 4-6.
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.
5. Slide the pulley plate to the right and off the carrier plate.
6. Slide the pin out of the pulley and manipulate the belt out of the
tension pulley plate.
Base Assembly Removal
1. Remove the tractor assembly.
2. Remove the top cover.
See “Top Cover Removal” on page 4-6.
3. Remove the print unit.
4. Remove the power supply.
5. Remove the main logic board.
6. Remove the tractor cable and bracket.
7. If replacing the bottom cover, write the machine serial number
and part number on the blank label.
Repair Information 4-11
4227-X00
Carrier Removal
1. Remove the top cover.
See “Top Cover Removal” on page 4-6.
2. Remove the printhead.
See “Printhead Removal” on page 4-33.
3. Remove the carrier roller spring.
4. Remove the sub logic board.
See “Sub Logic Board Removal” on page 4-38.
5. Remove the ribbon drive motor assembly [1].
4-12 Service Manual
4227-X00
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.
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.
Repair Information 4-13
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.
Reinstallation:
1. The bearing and retainer must be on the shaft when the shaft is
lowered into place. Make sure the bearing flange goes behind
the black double gear.
2. Rotate the shaft to get the bearing to seat in the side frame.
3. After reinstalling, check the “Printhead-to-Platen Gap
Adjustment” on page 4-2.
4-14 Service Manual
4227-X00
Carrier Motor Assembly Removal
1. Remove the top cover.
See “Top Cover Removal” on page 4-6.
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
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.
5. Remove the carrier motor.
Reinstallation:
1. Be sure the motor pulley goes inside the belt as the motor is
being reinstalled.
2. The shaft bearing should be under the ribbon motor plate,
mounted to the carrier motor shaft.
3. Ribbon motor screws should be loosened when reinstalling the
carrier motor.
4. Tighten the carrier motor screws before you tighten the ribbon
motor assembly mounting screws.
Repair Information 4-15
4227-X00
Carrier Plate Removal
1. Remove the top cover.
See “Top Cover Removal” on page 4-6.
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. Remove the carrier motor bracket.
8. Remove the right side frame.
9. Remove the two screws holding the carrier plate to the left side
frame, and remove the carrier plate.
Label Jam Removal
When a pressure-sensitive label separates from its protective
backing and jams and sticks to the paper separator below the carrier
plate, the following procedure should be used to remove the label.
1. Remove the top cover.
See “Upper Feed Roller Removal” on page 4-39.
2. Remove the tractor assembly.
3. Remove the print unit.
See “Print Unit Removal” on page 4-30.
4. Remove the paper separator.
See “Paper Separator Removal” on page 4-28.
5. Carefully remove the label from the paper separator.If the label
is jammed below the carrier plate or on the lower portion of the
paper guide/platen assembly, carefully remove the label without
scratching either surface.
4-16 Service Manual
4227-X00
Lower Feed Roller Removal
1. Remove the top cover.
See “Top Cover Removal” on page 4-6.
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.
6. Remove the support bracket [1] from the back of the platen.
7. Remove the paper select lever.
Repair Information 4-17
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
thesideframe.
10. Remove the gear,clip and bearing [5] from the end of the lower
feed roller shaft.
4-18 Service Manual
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.
14. Remove the support shaft screw [9].
Repair Information 4-19
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.
Reassembly:
1. Remove the paper separator while first installing the side frame
loosely. Make 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 flex the right
side frame slightly to get the right end installed.
4. Reinstall the screw through the hole above the slider cam.
4-20 Service Manual
4227-X00
LowerPinchRollerRemoval
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. Lift the left end of the lower pinch roller and move it to the left
until the right end clears the carrier. Be sure not to lose the right
bearing.
6. Remove the shaft to the right.
Repair Information 4-21
4227-X00
Main Logic Board Removal
1. Remove the top cover.
See “Top Cover Removal” on page 4-6.
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.
4. Remove the EPROM from the old board and install it on the new
one.
Reinstallation:
After replacing the main logic board, recheck the “Bidirectional Print
Adjustment” on page 4-4 and the “Printhead-to-Platen Gap
Adjustment” on page 4-2.
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. Do not insert the screwdriver too deep, or the
main logic board may be damaged.
Note: Be careful not to bend the pins when you re-install the
module.
4-22 Service Manual
4227-X00
Operator Panel Assembly Removal
1. Remove the top cover.
See “Top Cover Removal” on page 4-6.
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.
4. Push up on the lower latches to free the operator panel from the
top cover.
Paper Empty Sensor /TOF Sensor Removal
1. Remove the top cover.
See “Top Cover Removal” on page 4-6.
2. Remove the print unit. See “Print Unit Removal” on page 4-30.
3. Remove the right screw [1] in the support shaft.
Repair Information 4-23
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
awayfrom the paper guide. Do not damage or lose the paper
empty sensor spring.
5. Unsnap the TOF sensor from the back of the paper guide using
a screwdriver as illustrated [3].
4-24 Service Manual
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.
Carefully remove the sensor flag spring [4] from the bottom end
of the sensor flag.
3. Pivot the upper tip of the sensor flag downward through the
open area just to the right of the center feed roll
and lift the lower end of the flag until it becomes free.
4. The sensor flag spring hooks over the lower arm of the flag. Be
sure the point of the sensor flag is kept in the paper path by the
spring force. Be sure the leaf spring is in contact with the lower
feed roller shaft.
Repair Information 4-25
4227-X00
Paper Feed Motor Removal
1. Remove the top cover.
See “Top Cover Removal” on page 4-6.
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.
5. Remove the double gear from the shaft on the face of the motor.
Reinstallation:
Hold the bottom screw in place in the motor bracket with the
screwdriver. This screw is difficult to reach once the motor is in
place.
Paper Guide Removal
1. Remove the front cover and place it front down on a flat surface.
2. Pry under the front part of the guide to release the two latches,
and remove the paper guide.
Paper Guide / Platen Assembly Removal
1. Remove the top cover.
See “Top Cover Removal” on page 4-6. Remove the print unit.
2. Remove the sub logic card.
3. Remove the large gear on the left side frame by prying it from
behind with a flat-blade screwdriver.
4. Remove the support shaft screw and the two platen screws
from the left side frame.
5. Remove the right side frame.
6. Remove the paper guide/platen assembly.
4-26 Service Manual
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Paper Select Lever Removal
1. Remove the top cover.
See “Top Cover Removal” on page 4-6.
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.
See “Top Cover Removal” on page 4-6.
2. Remove the print unit.
See “Print Unit Removal” on page 4-30.
3. Use a #1 Phillips screwdriver to remove the two screws [1]
holding the paper select sensor to the left side frame.
Repair Information 4-27
4227-X00
Paper Separator Removal
1. Remove the top cover.
See “Top Cover Removal” on page 4-6.
2. Remove the print unit from the base.
See “Print Unit Removal” on page 4-30.
3. Remove the paper select lever.
4. Remove the gear shaft support plate and the two gears with
their springs [1].
5. Remove the large screw [2] holding the tension pulley plate to
thesideframe.
4-28 Service Manual
4227-X00
6. Release and removethe 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]fromtherightside
frame. One is behind the slider cam.
9. Loosen several turns but do not remove the support shaft screw
[6] and the two platen screws.
10. Wiggle the right side frame and pull it about 2 mm to the right.
11. Flex the front of the side frame outward slightly to free the right
end of the paper separator [7].
12. Remove the paper separator.
Repair Information 4-29
4227-X00
Power Supply Removal
CAUTION: Thepowersupplymaybehot.
1. Turn off the printer and disconnect the power cord at both ends.
2. Remove the top cover.
See “Top Cover Removal” on page 4-6.
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.
2. Remove the four screws holding the power supply board to the
cover.
3. Pivot the board out of the cover far enough to disconnect the fan
connector.
4. Remove the three screws holding the fan to the cover.
PrintUnitRemoval
1. Remove the top cover.
See “Top Cover Removal” on page 4-6.
2. Disconnect the tractor connector.
3. Disconnect the flexible signal cable and the power cable from
the sub logic card.
4. Remove the ground leads from the four corners of the print unit.
5. Disconnect the following connectors from the main logic board:
CN4, CN7, CN8, CN9, CN10, CN15, CN18, CN19, and CN20.
6. (4227-200) Disconnect CN17. Remove the upper screw from
the serial port card mounting bracket.
4-30 Service Manual
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
Repair Information 4-31
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.
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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. These are ZIF connectors.
5. Remove the two screws [2] holding the printhead to the carrier
and lift the printhead out.
Reinstallation:
1. Fold the printhead cables under the printhead to prevent the
tension pulley plate from interfering with the cables.
2. Hold the printhead down while pressing it toward the platen and
tighten the two printhead mounting screws.
3. Check the “Printhead-to-Platen Gap Adjustment” on page 4-2.
Repair Information 4-33
4227-X00
Printhead Cables Removal
1. Remove the top cover.
See “Top Cover Removal” on page 4-6.
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.
4. The cables are attached to the carrier plate with double-faced
tape.
Reinstallation:
Be sure the tension pulley plate does not interfere with the printhead
cables.
4-34 Service Manual
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Ribbon Drive Motor Assembly Removal
1. Remove the top cover.
See “Top Cover Removal” on page 4-6.
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]fromthemotorbracket.
5. Disconnect ribbon motor connector CN19 from the main logic
board.
6. Remove the c arrier motor bearing retainer and bearing [3]from
the ribbon motor bracket.
7. Remove the three screws [4] holding the ribbon drive motor
bracket and remove the ribbon drive motor assembly.
Repair Information 4-35
4227-X00
Right Side Frame Removal
1. Remove the top cover.
See “Top Cover Removal” on page 4-6.
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].
5. Remove the large screw [4] holding the tension pulley plate to
thesideframe.
6. Remove the gear, clip and bearing [5] from the end of the lower
feed roller shaft.
4-36 Service Manual
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