Lexmark 4227-X00 User Manual
Lexmark Forms Printer 4227
• Table of Contents
• Start Diagnostics
• Safety and Notices
• Trademarks
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
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
viii
4227-X00
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
ix
4227-X00
Preface
This manual describes the Lexmark Forms Printer 4227-100 and
4227-200. It contains maintenance procedures for service personnel
and is divided into the following chapters:
• General Information contains a general description of the
printer and the maintenance approach used to repair it. Special
tools and test equipment are listed in this chapter, as well as
general environmental and safety instructions.
• 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.
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 electr ic 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.
xii Service 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.
• Durante lo 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.
xiv Service 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
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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:
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.
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
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
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 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 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 Tractor2
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 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
.
.
4227-X00
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”
.
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
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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4227-X00
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”
.
Diagnostic Information 2-5
4227-X00
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.
2-6 Service Manual
4227-X00
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.
Diagnostic Information 2-7
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