Lexmark 4227-200, 4227-100 Service Manual

Lexmark Forms Printer 4227
• Table of Contents
• Start Diagnostics
• Safety and Notices
4227-X00
• Index
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.
©CopyrightLexmarkInternational,Inc.1996, 2000. All rights reserved.
UNITED STATES GOVERNMENT RESTRICTED RIGHTS
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.
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Table of Contents
GeneralInformation...................................1-1
Description....................................... 1-1
Voltage, Ground, and Continuity Readings .............. 1-3
Maintenance Approach.............................. 1-4
Options.......................................... 1-4
Tools............................................ 1-4
Abbreviations..................................... 1-5
Using the Operator Panel . . .......................... 1-6
Using the Function Menus . .......................... 1-7
SettingPrinterFunctions......................... 1-8
OverviewofFunctionMenus...................... 1-9
Buttons...................................... 1-11
Lights....................................... 1-12
DiagnosticInformation ................................2-1
Start............................................ 2-1
ErrorIndicationTable............................... 2-2
SymptomTable.................................... 2-4
ServiceChecks................................... 2-10
AutoGapServiceCheck........................ 2-10
Auto Sheet Feeder (ASF) Service Check............ 2-12
CarrierDriveServiceCheck...................... 2-14
IntermittentProblemServiceCheck ............... 2-15
No Print or Abnormal Print Service Check ........... 2-18
Operator Panel Service Check.................... 2-19
Paper Feed Service Check ...................... 2-20
POSTServiceCheck........................... 2-24
PowerFailureServiceCheck..................... 2-25
PrintQualityServiceCheck...................... 2-27
PrintWireDriveFailureServiceCheck............. 2-28
Ribbon Drive Service Check ..................... 2-30
Tractor2ServiceCheck......................... 2-31
DiagnosticAids ......................................3-1
Power-OnSelfTest(POST).......................... 3-1
HexTraceMode................................... 3-2
HexTraceModeSample......................... 3-2
InterfaceSelection(4227-100)........................ 3-3
OperationwiththeTopCoverRemoved................ 3-3
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ServiceMenu..................................... 3-4
ButtonTest................................... 3-4
FactorySetting ................................ 3-4
Printhead Bank ................................ 3-4
Jam/PSetSensorTest.......................... 3-4
ImpactForce.................................. 3-5
LogClear..................................... 3-5
PrintTest..................................... 3-5
OtherPrintTests............................... 3-5
ErrorLog..................................... 3-6
RepairInformation....................................4-1
Handling ESD-Sensitive Parts ........................ 4-1
Adjustments...................................... 4-2
Printhead Installation Adjustment . . . ............... 4-2
Printhead-to-Platen Gap Adjustment. ............... 4-2
Bidirectional Print Adjustment ..................... 4-4
RemovalProcedures............................... 4-6
TopCoverRemoval............................. 4-6
AutoGapMotor................................ 4-8
Auto Sheet Feeder Gears Removal . ............... 4-9
Auto Sheet Feeder Pick-up Roller Removal ......... 4-10
BeltTensionPulleyPlateAssemblyRemoval........ 4-11
BaseAssemblyRemoval........................ 4-11
CarrierRemoval .............................. 4-12
CarrierMotorAssemblyRemoval................. 4-15
CarrierPlateRemoval.......................... 4-16
Label Jam Removal............................ 4-16
LowerFeedRollerRemoval..................... 4-17
LowerPinchRollerRemoval..................... 4-21
Main Logic Board Removal ...................... 4-22
MemoryModuleRemoval....................... 4-22
Operator Panel Assembly Removal . .............. 4-23
Paper Empty Sensor /TOF Sensor Removal......... 4-23
Paper Feed Motor Removal ..................... 4-26
Paper Guide Removal. . . ....................... 4-26
Paper Guide / Platen Assembly Removal ........... 4-26
Paper Select Lever Removal..................... 4-27
Paper Select Sensor Removal ................... 4-27
Paper Separator Removal....................... 4-28
Power Supply Removal. . ....................... 4-30
Power Supply Fan Removal ..................... 4-30
PrintUnitRemoval............................. 4-30
Printhead Removal ............................ 4-33
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Printhead Cables Removal....................... 4-34
Ribbon Drive Motor Assembly Removal............. 4-35
RightSideFrameRemoval ...................... 4-36
SubLogicBoardRemoval....................... 4-38
Upper Feed Roller Removal...................... 4-39
ConnectorLocations ..................................5-1
4227-200 . . ................................... 5-2
Main Logic Board Connectors ..................... 5-3
4227-100 . . ................................... 5-4
SubLogicBoardConnectors...................... 5-4
4227-200 . . ................................... 5-5
Operator Panel Connectors ....................... 5-5
ComponentLocations............................... 5-6
Component Location Illustrations . ................. 5-7
Signal Connections................................. 5-9
Connector Block Diagram ....................... 5-20
Tractor 2 Cable Connectors ...................... 5-21
Preventive Maintenance ...............................6-1
Lubrication ....................................... 6-1
Specified Lubricants. . . .......................... 6-1
Lubrication Points............................... 6-2
PartsCatalog ........................................7-1
HowtoUseThisPartsCatalog........................ 7-1
Assembly1:CoversandOperatorPanel................ 7-2
Assembly 2: Paper Feed . . .......................... 7-4
Assembly3:Carrier ................................ 7-6
Assembly4:BaseandElectronics..................... 7-8
Assembly5:ASFSideFrame/Covers ................ 7-10
Assembly 6: ASF Roller / Support .................... 7-12
Assembly7:Tractor2Option........................ 7-14
Index............................................... X-1
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Preface
This manual describes the Lexmark Forms Printer 4227-100 and 4227-200. It contains maintenance procedures for service personnel and is divided into the following chapters:
General Information contains a general description of the
printer and the maintenance approach used to repair it. Special tools and test equipment are listed in this chapter, as well as general environmental and safety instructions.
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
components and test points on the printer.
Preventive Maintenance contains lubrication specifications,
and maintenance information to prevent problems and maintain optimum performance.
Parts Catalog contains illustrations and part numbers for
individual FRUs.
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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.
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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
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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.
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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
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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
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This is a versatile printer that combines excellent print quality along with the ability to print several print styles and graphics. Some of the features and functions included with this printer are:
Feature Function
Multi-speed Printing FastDraft- 533 cps (4227-100)
Draft - 400 cps (4227-100) Courier and Gothic (NLQ) - 100 cps (4227-100) FastDraft -720 cps (4227-200) Draft - 600 cps (4227-200))
Courier and Gothic (NLQ) - 150 cps (4227-200) Resident Fonts FastDraft,Draft, Courier and Gothic Forms Handling Forms (straight paper path)
Automatic tear-off
Automatic paper loading/unloading Cut Sheets Manual
Optional Auto Sheet Feeder Multiple Part Forms 6-Part Forms (carbon and carbonless)
(4227-200 - up to 8-Part Forms) Interface Connection Parallel, Serial RS-422, Serial RS-232 Auto Gap When Auto Gap is set to On, the printer
automatically adjusts to the thickness of paper
you are using.
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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
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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
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Abbreviations

ASF Automatic Sheet Feeder ASIC Application-Specific Integrated Circuit CSU Customer Setup DRAM Dynamic Random Access Memory EPROM Erasable Programmable Read-Only Memory ESD Electrostatic Discharge FRU Field Replaceable Unit HVPS High Voltage Power Supply LAN Local Area Network LCD Liquid Crystal Display LED Light-Emitting Diode LVPS Low Voltage Power Supply NVRAM Nonvolatile Random Access Memory OEM Original Equipment Manufacturer POR Power-On Reset POST Power-On Self Test PQET Print Quality Enhancement Technology ROS Read-Only Storage SRAM Static Random Access Memory UPR Used Parts Replacement V ac Volts alternating current V dc Volts direct current
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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
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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
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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 Item Print 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 Itemuntil 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.
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Overview of Function Menus

Use the Itemand Item option directories. Press Next to the subordinate directories and choices. Press Prev. want to go back in a menu or return to the Main Menu.
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
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Buttons

When using the function menus, press Itemor 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.
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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.)
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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
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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 Indication Description / 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
.
.
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Display Indication Description / 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”
.
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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
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
Symptom Action
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
.
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Auto Sheet Feeder Problems
Symptom Action
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
Symptom Action 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.
Symptom Action 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”
.
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Symptom Action 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.
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Operator Panel Problems
Symptom Action 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
Symptom Action
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.
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Print Quality Problems
Symptom Action
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
Symptom Action
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
Symptom Action
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.
FRU Action
1 Auto Gap Sensor Inspect 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 Auto Sheet 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.
FRU Action
1 Paper 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
FRU Action
2 Paper Feed If 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
3 Gear Train Be 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.
4 Combination Lock
Mechanism
5 Left and Right
Hoppers
6 Pick 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.
FRU Action
1 637, 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.
:
2-14 Service Manual
Waitforthemachinetocoolandseeiftheerror goes away.
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/Symptom Action
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/Symptom Action
2 Machine power
sometimes turns off.
3 Intermittently 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/Symptom Action
4Iftheprior
suggestions have not corrected the problem.
5 Problem 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/Function Action
1 Carrier If the carrier moves, but nothing is printed, go
“Print Wire Drive Failure Service
to the
Check” on page 2-28
2 Configuration Enter the user menus and be sure the correct
emulation (IBM/EPSON) and interface (parallel/serial) are selected.
If the printer is serially attached, be sure the RS232/RS422 switch is in the correct position, and the host communications parameters are correct.
3 Main Logic Board If 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.
FRU Action
1 Operator Panel If 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
3CoverSwitch IfCover Open is displayed, check the cover
4 Main Logic Board If 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 / Symptom Action
1 Auto 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
2 Tractor 2 If 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
3 Paper Feed Motor If 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 / Symptom Action
4 Gear 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 / Symptom Action
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.
6 Paper 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 / Symptom Action
7 OperatorPanel If paper does not move at all, verify the
FormFeed button is working correctly by performing the service menu button test.
8 Main Logic Board If 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

FRU Action
1 Power Disconnectthe parallel or serial cable and turn
power on. If there is no printer activity, go to the
Failure Service Check” on page 2-25
2 Operator Panel If the power supply fan turns on but no LEDs
light,gotothe
Check” on page 2-19
3 Main Logic Board If 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
4 Printer Cable If 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.
FRU Action
1 Operator Panel If 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.
2 Power 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
FRU Action
3 Ribbon Motor
Paper Feed Motor Carrier Motor Sub Logic Board
4227-200 Carrier Motor Cooling Fan
4 Printhead Cables
Printhead
5 Main Logic Board If 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

FRU Action
1 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.
2 Ribbon Drive Be 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
4 Printhead Cables Inspect both ends of the printhead cables for
5CarrierBelt
Adjustment
6 Carrier Movement With power off, manually move the carrier from
7 Bidirectional Print
Adjustment
8 Carrier Motor The carrier motor should turn smoothly and
9 Paper Feed Gears Inspect the paper feed gears for wear and tear.
10 Paper Feed Motor The paper feed motor should turn smoothly
11 Tractors Inspect 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”
.
12 Feed Roller
Surfaces
Inspect the feed roller surfaces for dirt or wear.
Diagnostic Information 2-27
4227-X00

Print Wire Drive Failure Service Check

FRU/Symptom Action
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
8.5 ohms. Left Bank Right Bank
Wire 1 CN3-11 & CN3-18 CN3- 9 & CN3- 4 Wire 2 CN4-11 & CN4-20 CN4- 9 & CN4- 2 Wire 3 CN3-13 & CN3-16 CN3- 7 & CN3- 6 Wire 4 CN4-13 & CN4-18 CN4- 7 & CN4- 4 Wire 5 CN4-15 & CN4-16 CN4- 5 & CN4- 6 Wire 6 CN4-17 & CN4-14 CN4- 1 & CN4- 8 Wire 7 CN3-15 & CN3-14 CN3- 3 & CN3- 8 Wire 8 CN4-19 & CN4-12 CN4- 3 & CN4-10 Wire 9 CN3-17 & CN3-12 CN3- 5 & CN3-10
Note: 4227-200 connectors will be CN1 and CN2.
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.
Waitforthemachinetocoolandseeiftheerror goes away.
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/Symptom Action
3 Auto Gap Ifprinthead 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.
4 Printhead Cables Inspect for improper connection or damage. 5 Sub Logic Board If there is carrier motion but no printhead noise,
6 Ribbon A problem with the ribbon shield can keep the
7 Printhead The printhead probably is not the problem if
8 Main Logic Board If 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/Symptom Action
1RibbonDrive
Gear Train
2 Ribbon Motor If 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.)
FRU Action
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
FRU Action
2 Main Logic Board RemoveTractor 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.
3 Tractor 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.
FRU Action
1Tractor2
Board/CableAsm.
2 Main Logic Board Check 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
FRU Action
1 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.
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.
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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.
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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.
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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.
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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
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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.
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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
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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.
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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
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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
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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.
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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
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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].
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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
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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.
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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
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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].
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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
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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.
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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
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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.
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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
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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.
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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
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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.
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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.
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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].
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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.
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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.
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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
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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.
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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.
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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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