Lexmark Forms Printer Service Manual

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Edition: January 15, 2007

Lexmark™ Forms Pr inter

• Table of contents

• Start diagnostics

4227-300

• Safety and notices

• Trademarks

•Index

Lexmark and Lexmark with diamond design are trade ma rks of Lexmark International, Inc., registered in the United States and/or ot her countries.

4227-300

Edition: January 15, 2007 The following paragraph does not apply to any country where such provisions are

inconsistent with local law: LEXMARK INTER N ATIONAL, 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 i n certain transactions, therefore, this statement may not apply to you.

This p ublic ation could inc lude technical inaccuracies or typographi cal 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 tim e.

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 inform ation you supply in any way it believes appropriate without incur ring any obligation to you.

Lexmark and Lexmark with diamond design are trademar ks of Lexmark International, Inc., registered in the United States and/or other countries.

Color Jetprinter is a trademark of Lexmark International, Inc. All other trademarks are the pr operty of their respective o wners.

UNITED STATES GOVERNMENT RIGHTS

This software and any accompanying documentation provided under this agreement are commercial computer sof tware and documentati on developed exclusively at priva te expense.

12G9625

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Table of contents. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ii

Safety information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-vi

Preface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .xi

Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xi

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-xi

General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

Voltage, ground, and continuity readings . . . . . . . . . . . . . . . . . . . . . . . . 1-2

Voltage readings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

Ground checks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

Continuity readings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

Maintenance approach . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

Using the operator panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5

Using the function menus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6

Setting printer functions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7

Overview of function menus. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8

Buttons. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10

Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11

Diagnostic informati on . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

Error indication table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

Symptom tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

Abnormal Indications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

Abnormal print operati on problems . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

Auto Sheet Feeder problems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5

6XX Error indications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5

Paper feed problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6

Operator panel problems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8

Power Problems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8

Print quality problems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9

Ribbon feed problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10

Service checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11

Auto Gap service check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11

Auto Sheet Feeder (ASF) service check . . . . . . . . . . . . . . . . . . . . . 2-13

Auto Sheet Feeder princip les of operation. . . . . . . . . . . . . . . . . . . . 2-13

Carrier drive service check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15

Intermittent problem service check . . . . . . . . . . . . . . . . . . . . . . . . . 2-16

No print or abnormal print service check . . . . . . . . . . . . . . . . . . . . . 2-19

Table of contents

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Operator panel ser vice check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-20

Paper feed servic e check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-21

POST service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-24

Power fa ilu r e s er v ic e che c k . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-25

Print quality service check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-27

Print wire drive fai lur e service check. . . . . . . . . . . . . . . . . . . . . . . . .2-28

Ribbon drive service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-30

Tractor 2 service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-31

Diagnostic aids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1

Power-On Self Test (POST) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1

Hex trace mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-2

Hex trace mode sample. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-2

Interface se lection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-3

Operation with the top cover removed . . . . . . . . . . . . . . . . . . . . . . . . . . .3-3

Service Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-3

Button Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-4

Factory Setting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-4

Printhead Bank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-4

Jam/PSet Sensor Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-4

Impact fo rce. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-4

Log clear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-4

Print Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-5

Other print tests. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-5

Error log. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-5

Repair in fo r m a t io n . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-1

Handling ESD-sensitive parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-1

Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-2

Printhead installation adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-2

Printhead-to-platen gap adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . .4-2

Bidirectional pri nt adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-3

Removals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-5

Top cover removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-5

Auto Gap m o to r re mo v al . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-8

Auto Sheet Feeder gears removal. . . . . . . . . . . . . . . . . . . . . . . . . . . .4-9

Auto Sheet Feeder pick-up roller removal. . . . . . . . . . . . . . . . . . . . .4-10

Belt tension pull ey plate assembly remov al. . . . . . . . . . . . . . . . . . . .4-11

Base assembly removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-11

Carrie r re m o v a l . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-12

Carrie r m o to r a ss e mb ly re m o va l . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-15

Carrier plate removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-16

Label jam removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-16

Lower feed roller re mo val . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-17

Lower pinch roller removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-21

Main logic board rem oval. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-21

Memory Module removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-22

iii Service Manual

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Operator panel assembly removal. . . . . . . . . . . . . . . . . . . . . . . . . . 4-22

Paper Empty sensor/TOF sensor removal. . . . . . . . . . . . . . . . . . . . 4-22

Paper feed motor removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-25

Paper guide removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-25

Paper guide/platen assembly removal. . . . . . . . . . . . . . . . . . . . . . . 4-25

Paper Select lever removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-25

Paper Select sensor removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-26

Paper separator removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-27

Power supply removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-29

Power supply fan removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-29

Print unit removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-29

Printhead removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-32

Printhead cables removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-33

Ribbon drive motor assembly removal. . . . . . . . . . . . . . . . . . . . . . . 4-34

Right side frame removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-35

Sub logic board removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-37

Upper feed roller removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-38

Preventive maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

Specified lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

Lubrication point s. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2

Locations and connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

4227-300 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

Main Logic Board Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2

Operator panel connectors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3

Component location s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4

Component location illustrations . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5

Component location illustrations (Continued) . . . . . . . . . . . . . . . . . . 6-6

Signal connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7

Main Logic Board<-->Paper Empty & TOF Sensors . . . . . . . . . . . . . 6-9

Main Logic Board<-->Carr ier Motor Cable #1 . . . . . . . . . . . . . . . . . . 6-9

Main Logic Board<-->Paper Feed Motor . . . . . . . . . . . . . . . . . . . . . . 6-9

Main Logic Board<-->Tractor 2 DIN . . . . . . . . . . . . . . . . . . . . . . . . 6-10

Main Logic Board<-->Carr ier Motor Cooling Fan. . . . . . . . . . . . . . . 6-10

Main Logic Board<-->5 V dc Power . . . . . . . . . . . . . . . . . . . . . . . . 6-10

Main Logic Board<-->Operator Panel . . . . . . . . . . . . . . . . . . . . . . . 6-11

Main Logic Board<-->Tractor PSet & Jam Sensors . . . . . . . . . . . . 6-11

Main Logic Board<-->Ribbon Motor . . . . . . . . . . . . . . . . . . . . . . . . 6-12

Main Logic Board<-->Auto Gap M otor . . . . . . . . . . . . . . . . . . . . . . 6-12

Main Logic Board<-->Serial Board . . . . . . . . . . . . . . . . . . . . . . . . . 6-12

Serial Board<-->Serial Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-13

Sub Logic Board<-->Print head. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14

Operator Panel Board<-->Ribbon Cover Sensor . . . . . . . . . . . . . . 6-14

Tractor 2 cable connectors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-15

Connector block diagram. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-16

Table of contents iv

4227-300

Parts catalog . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-1

How to use this parts catalog . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-1

Assembly 1: Covers and oper ator panel . . . . . . . . . . . . . . . . . . . . . . . . .7-2

Assembly 2: Paper feed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-4

Assembly 3: Ca r rie r . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-6

Assembly 4: Base and electronics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-8

Assembly 5: ASF side fram e/covers . . . . . . . . . . . . . . . . . . . . . . . . . . .7-10

Assembly 6: ASF roller/support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-12

Assembly 7: Tract or 2 opt ion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-14

Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I-1

Part number index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I-5

v Service Manual

Safety information

• The safety of this product is based on testing and approvals of the

original design and specific components. The manufacturer is not responsibl e for safety in the event of use of unauthorized replacement parts.

• The maintenance informati on for this product has been prepared for

use by a p rofessio nal 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 t ake necessary precautions.

• CAUTION: When you see this symbol, there is a danger

from hazardous voltage in the area of the product where you are working. Unplug the product before you begin, or use caution if the product must receive power in ord er t o perform the task.

Consig n es de sécu ri té

• La sécurité de ce produit repose sur des te sts et des

agréations portant sur sa conception d'origine et sur des composants particuliers. Le fabricant n'assume aucune responsabilité concernant la sécurité en cas d'utilisation de pièces de rechange non agréées.

• Les consignes d'entretien et de réparation de ce pro duit s'adressent

uniquement à un personnel de ma intenance qualifi é.

• Le démontage et l'entretien de ce pr oduit pouvant présenter certains

risques électriques , le personnel d'ent retien qualifié devra prend re toutes les précautions nécessaires.

• ATTENTION : Ce symbole indique la présence

d'une tension dangereuse dans la partie du produi t sur laquelle v ous travaillez. Débranchez le produit avant de commencer ou f aites preuve de vigi lance si l'exécution de la tâche exige que le produit reste sous tension.

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Norme di sicurezza

• La sicurezza del prodotto si basa sui test e sull'approvazione del

progetto originale e dei componenti specific i. Il pr oduttore non è responsabile per la sicurezza in caso di sost ituzione non autorizzata delle parti.

• Le informazioni riguardanti la manutenzione di questo prodotto sono

indirizzate soltanto al personale di assistenza autorizzato.

• Durante lo smont aggio e la manutenzi one di questo prodotto,

il rischio di subir e sc osse el ettri che e dan ni alla persona è pi ù elevat o. I l personale di assistenza autorizzato deve, quindi, adottare le precauzioni neces sarie.

• ATTENZIONE: Questo simbol o indica la presenza

di tensione pericolosa nell'area del prodotto. Scollegare il prodotto prima di iniziare o usar e cautela se il prodotto de ve essere alimentato per eseguire l'intervento.

Sicherheitshinweise

• Die Sicherheit dieses Produkts basiert auf Tests und Zulassungen de s

ursprünglich en Mod ells und bestimmter Bauteile. Bei Verwendung nicht genehmigter Ersatzteile wird vom Herstell er keine Verantwortung oder Haftung für die Sicherheit übernommen.

• Die Wartungsin formationen für dieses Produkt sind ausschließlich für

die Verwendung durch einen Wartungsf achmann bestimmt.

• Während des A u seinandernehmens und der Wartung des Geräts

besteht ein zusätzliches Risiko eines elektrischen Schlags und körperlicher Verletzung. Das zuständige Fachpersonal sollte entsprechende Vorsichtsmaßnahmen treffen.

• ACHTUNG: Dieses Symbol weist auf eine gefährliche

elektrische Spannung hin, die in diesem Bereich des Produkts auftreten kann. Ziehen Sie vor den Arbeiten am Gerät den Netzstec ker des Geräts, bzw. arbeiten Sie mit großer Vorsicht, wenn das Produkt für die Ausführung der Arbeiten an den Strom angeschlossen sein muß.

vii Ser vice Ma nual

Pautas de Seguridad

• La seguridad de este producto se basa en pruebas y aprobacion es del

diseño original y componentes específicos. El fabricante no es responsable de la seguridad en caso de uso de piezas de repuest o no autorizadas.

• La información sobre el manten imiento 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.

• PRECAUCIÓN: est e símbolo indica que el voltaje de la

parte del equipo con la que está trabajando es peligroso. Antes de empezar, desenchufe el equipo o tenga cuidado si, para trabajar con él, debe conectarlo.

Informações de Segurança

• A segurança deste produto baseia-se em testes e aprovações do

modelo original e de compon entes específicos. O fabricante não é responsável pela segunran ça, no caso de uso de peças de substituição não autorizadas.

• As informações de segurança relativas a este produto destinam-se a

profissionais destes serviços e não devem ser util izadas por outras pessoas.

• Risco de choques eléctricos e feri m entos graves durante a

desmontagem e manutenção deste produto. Os profissionais destes serviços devem estar avisados deste facto e tomar os cuidados necessários.

• CUIDADO: Quando vir este símbolo, existe a possível

presença de uma potencial tensão perigosa na zona do produto em que está a trabalhar. Antes de começar, desligue o produto da tomada eléctrica ou seja cuidadoso caso o produto tenha de est ar l igado à corrente eléctrica para realizar a tar efa necessári a.

4227-300

viii

4227-300

Inf ormació de Seguretat

• La seguretat d'aquest producte es basa en l'avaluació i aprovació del

disseny original i els components espec íf ics. El fabricant no es fa responsable de les qüestions de seguretat si s'uti litzen peces de recanvi no autoritz ades.

• La informació pel manteniment d’aquest producte està orientada

exclusivament a prof essionals 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 m e s ures conve nients.

• PRECAUCIÓ: aquest símbol indica que el voltatge de la

part de l'equip amb la qual esteu treballant és perillós. Abans de començar , desendolleu l'equip o extremeu les precaucions si, per treballar amb l'equip, l'heu de connectar.

ix Service Manual

4227-300

Preface

This manual contains maintenance procedures f or service personnel. It is divided into the following chapters:

1. General informatio n contains a general description of the MFP and the maintenance approach used to repair it. Special tools and test equipment are listed, as well as general environmental and safety instructions.

2. Diagnostic information contains an error indicator table, symptom tables, and service checks used to isolate failing field replaceable units (FRUs).

3. Diagnostic aids contains tests and checks used to locate or repeat symptoms of MFP problems.

4. Repair information provi des inst ructio ns f or maki ng MFP adj ustment s and removing and inst alling FRUs .

5. Connector locations uses illustrations to identify the connector locations and test points on the printer.

6. Preventive maintenance contains the lubrication specificat ions and recommendations to prevent problems.

7. Parts catalog contains illustrations and part numbers for individual FRUs.

Definitions

Note: A note provides additional information. Warning: A warning identifies something that might damage the product

hardware or software. CAUTION: A caution identifies something that might cause a servicer

harm.

CAUTION: When you see this sy mbol, the re is a danger from hazardous voltage in the area of the product where you are working. Unplug the product before you begin, or use cauti on if the product must receive po wer in order to perf orm the tas k.

xi Service Manu al

4227-300

1. Gen e r a l informa tion

Description

The Lexmark™ Form Printer 4227-300 is a dot matrix, electromechanical printer that forms characters on a print media using a printhead and fabric ribbon. The printhead is composed of 18 miniature solenoids containing print wires and operates on electromagnetic principle s. 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.

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 Fas tDraft -720 cps

Draft - 600 cps

Courier and Gothic (NLQ) - 150 cps Resident Font s Fas tDr aft, Draft, Courier, and Gothic Forms Handling Forms (straight paper path)

Automatic tear-off

Automatic paper loading/unloading Cut Sheets Manual

Optional Auto Sheet Feed er Multiple Part Forms 6-part Forms (carbon and carbonless)

(4227-300 - 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.

General inf ormation 1-1

4227-300

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.

WARNI NG: 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 co ntinuity will r ead zero ohms.

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Maint en an ce ap proa ch

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 “Power-On

Self Test (POST )” on page 3-1.

Options

The following options may be installed:

• Automatic Sheet Feeder (ASF)

• Tractor 2

• Extended Cut-sheet Paper Guides

• 32kb Memory Module

• Extended National Language Support modules (Non-U.S. only)

Tools

The basic tools needed are:

• Basic CE tool kit

• #1 magnetic Phillip s screwdriver

• #2 magnetic Phillip s screwdriver

• Feeler gauges 0.35 mm (0.014 in.) 0.4 mm (0.016 in.)

• Analog or digital volt-ohmmeter

General inf ormation 1-3

4227-300

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 Fi eld Replaceable Unit HVPS High Voltage Power Supply LAN Local Area Network LCD Liquid Crystal Display LED Ligh t-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

• Pri n t tests

• Auto Gap functions

General inf ormation 1-5

4227-300

Using the function menus

Use the Item ↓ and Item ↑ buttons to move through the menu and option directories. Press Next → to move away from the Main Menu to the subordinate directories and choices. Press Prev. ← if you want to go back in a menu or return to the Main Menu.

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Sett ing printer functions

1. Press Start/Stop.

2. Press Menu to enter the function menu.

3. Press Item ↓ or Item ↑ until the function menu you want appears on the display.

Note: The selectable function menu is different depending on the selected data stream mode (IBM PPDS or Epson emulation) and the Interface mode (Parallel, RS-232 or RS-422).

4. Press Next → to enter that menu item.

5. Press Item ↓ or Item ↑ until the value you want appears on the display.

6. Press Store to save the selected value.

Note: The currently selected default value is displayed with an asterisk (*).

If you want 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 ↓ or Item ↑ until the 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.

Note: If you have changed any settings, the printer performs a Power-On Self Test. For more information, see “Power-On Self Test

(POST)” on page 3-1. If you did not change any settings, the printer

enters the not-ready state.

General inf ormation 1-7

4227-300

Overview of function menus

Use the Item ↑ and Item ↓ buttons to move through the menu and option directories. Press Next → to move away from the Main Menu to the subordinate directories and choices. Press Prev . ← if yo u w a nt 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.

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General inf ormation 1-9

4227-300

Buttons

When using the function menus, press Item ↓ or Item ↑ to scrol l through the menu items. Press Next → or Prev. ← to move to the next, or previous menu level.

Press To

Menu Enter the function menu. The printer goes

Quit • Exit the function menus.

Tear Off • Advance the forms to the tear-of f posi tion.

Store Save the values selected in the menus. Font Select a font. Item

↓ Scroll down.

Pitch Select a pitch. Item

↑ Scroll up.

Micro

↓ Advance the forms down 0.35 mm (1/72 in.).

→ Scroll forward.

Next Micro

↑ Advance the forms up 0.35 mm (1/72 in.).

Prev.

← Return to the previous function menu.

Start/Stop • To return to Ready and to Start/Stop.

offline.

• Run a Powe r-On Se l f Test (POS T ).

• Retract the forms to the Top-of-Form (TOF) position when the forms are at the tear-of f position.

• Load the forms to TOF position wit h the ready light on.

Load/Unload • Load paper (cut or con ti nuous forms) to t he

LineFeed Advance the paper to the next line . FormFeed • Advance the paper to the TOF position on

TOF posi tion.

• Retract the forms to the tractor position.

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

Description

The foll owing conditions cause the Ready light to turn off:

• Pressing Start/Stop

• An end-of-form (EOF)

• A paper jam

• A cover op en

• A hardwa re er ro r

• A Power-On Self Test failure

• The printer is offline.

occurred:

• An end-of-form (EOF)

• A paper jam

• A cover op en

• A hardwa re er ro r

• 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 usi ng.

Tractor 2 (Green) The Tractor 2 Feeder is select ed. (The Tractor

2 Feeder option must be install ed.)

General information 1-11

4227-300

1-12 Service Manual

4227-300

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 2-1 and take the indicated action.

Run the “Print Tes t” on page 3-5 and refer to the “Error lo g” on page

3-5 for details of error indication information. If no error indication

appears, refer to “Symptom tables” on page 2-3.

Error indication table

The following table describes the service check entries for the printer error indication codes.

When an error indication changes after you have entered a service check, you have an intermittent problem. If this occurs, leave the service check and go to “Symptom tables” on page 2-3.

Display Indication Description/Action

631 Machine Check Display RAM Error

632 Machine Check System RAM Error

Display RAM Read/Write Error. This error is detected only duri ng PO ST. Replace the operator panel.

System RAM Read/Write Error. Replace the main logic board and perform the

adjustment” on page 4-3 “Printhead-to-platen gap adjustment” on page 4-2

“Bidirectional print

. Check the

Diagnostic information 2-1

4227-300

Display Indicati on Description/Action

633 Machine Check Timer Interrupt Error

636 Machine Check NOVRAM Error

637 Machine Check CA Drive Error

638 Machine Check CA Drive Error

639 Machine Check CA Drive Error

63B Machine Check Key Scan Error

63C Machine Check Auto Gap Error

Timer Interrupt Controller Error. Replace the main logic board and perform the

“Bidirectional print adjustment” on page 4-3 platen gap adjustment” on page 4-2

Non-Volatile Memory Read/W rite Error. Replace the main logic board and perform the

page 4-3

. Check the “Printhead-to-

“Bidirectional print adjustment” on

. Check the “Printhead-to-

platen gap adjustment” on page 4-2.

Home Timeout Error. Go to the

“Carrier

drive service check” on page 2-15.

Carrie r D rive Error . No emitter pulse detected. Go to the

“Carrier drive service check” on page 2-15.

Carrie r D rive Error . Carrier positioning error. Go to the

“Carrier drive service check” on page

2-15

Button Scanning Error. Go to the

check” on page 2-20

Auto Gap Error. Go to the

page 2-11

“Operator panel service

“Auto Gap service check” on

63D Machine Check Tractor 2 HP Error

63E Machine Check Head Thermal Error

63F Machine Check Option RAM Error

640 Machine Check CA Thermal Error

2-2 S ervice Manual

Tractor 2 Home Position Er ror. Go to the

“Tractor 2 service check” on

page 2-31.

Head Thermal Sensor Error. Go to the

service check” on page 2-28

Option RAM Read/Write Error. Replace the 32Kb Memory Module.

Carrier Thermal Sensor Error. Go to the

“Print wire drive failure

“Carrier drive service check”

on page 2-15.

4227-300

Symptom tables

1. Select the symptom that best describes the problem.

2. Perform the appropriate action before you go to the indicated service check.

Diagnostic information 2-3

4227-300

Abnormal Indications

Symptom Action

All LEDs turn on but do not turn off.

The Power LED is on, but POST will not run.

Disconnect the inter f ace c ab le from the p rinter and turn the printer off and then back on. If POST now runs correctly, the problem is in the computer or interface cable.

Go to the

“POST service check” on page 2-24.

Abnormal print operation problems

Symptom Action

Printer will not print, or become Ready.

Abnormal operation, incorrect cha ra cters , 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 2-19.

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4227-300

Auto Sheet Feeder problems

Symptom Action

Auto Sheet Feeder will not feed paper.

Auto Sheet Feeder double feeds.

Auto Sheet Feeder has intermit tent f eed problems.

Paper skews .

Be sure Auto Sheet Feed is set to On i n the Paper Handling Option Men u.

Be sure the paper select lever is in the cut sheet position.

Go to the

2-11

Isolate the problem by removing the Auto Sheet Feeder and then feed paper using the manual feed tray. Go to the

service check” on page 2-13

6XX Error indications

Symptom Action

6XX Machine Check is displayed.

Turn the printer off and then on. Go to

“Auto Gap service check” on page

“Auto Sheet Feeder (ASF)

“Error indication table” on page 2-1.

Diagnostic information 2-5

4227-300

Paper feed problems

Symptom Action

Paper Empty Add Paper

is displayed with paper in the printer.

Print operation starts without paper.

Load/Unload does not function.

Form feed length is not correct.

Load/Unload

functions with cut shee ts in us e.

Paper feeds, but Auto Loading does not work.

Be sure the Paper Empty Sensor is not blocked. There may be a problem with the Paper Select

Sensor. Go to the

on page 2-21

Be sure the Paper Sel ect leve r is in the correct position.

There may be a problem with the Paper Select Sensor. Go to the

“Paper feed service check”

on page 2-21.

Be sure the Paper Select lev er 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

2-21.

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4227-300

Symptom Action

Lower feed roll shaft rotates, but paper does not feed.

Pressing Form Feed does not feed paper.

Abnormal noise while fe eding

Paper jams, skews, or creases.

Incorrect or no li ne spacing: wider, narrower, or overlapping lines.

Incorrect Top of Form positioning

Be sure the Paper Select lever is in the correct position.

Go to the

2-21

“Paper feed service check” on page

Diagnostic information 2-7

4227-300

Operator panel problems

Symptom Action Start/Stop does not

function but no error is indicat e d.

Turn the printer off and then back on. Go to the

page 2-20

Only the Power light comes on.

One or more b utto ns do not function.

One or more lights do not function.

Blank displa y Cover open

displayed.

Power Problems

Symptom Action

When the power switch is on, the Power light does not come on or the printer does not start.

“Operator panel service check” on

Check the contin uity of the power cor d and the voltage of the electrical outlet.

Go to the

check” on page 2-25

“Power failure serv ic e

The Power light blinks or chan ges intensity.

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4227-300

Print quality problems

Symptom Action

No print, but carrier moves as i f printi ng.

Be sure the printhead cables are not loose or damaged.

Be sure the interface cable i s connected properly. Check the ribbon cartridge for binds or damage. Go to the

“Print wire drive failure service

check” on page 2-28.

Print density is light. If the ribbon has reached its end of life or is worn,

the ribbon cartridge needs to be replac ed.

Unev en print densit y across th e print line

Specific dots missing.

Go to the

2-11 drive service check” on page 2-30

Be sure the printhead cables are connecte d 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 i s 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

“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

Clean the printhead nose. Clean the ribbon guide and shi eld. If the ribbon has reached i ts end of life or is w orn,

the ribbon cartridge needs to be replac ed. Go to the

“Print quality service check” on page

2-27.

Diagnostic information 2-9

4227-300

Symptom Action

Wavy vertical lines, unev en left 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. Perform the

adjustment” on page 4-3

Go to the

page 2-15

Ribbon feed problems

Symptom Action

Ribbon comes off, becomes loose or folded, or jams.

Ribbon feeds correctly but is noisy.

Check the ribbon cartridge f or binds or damage. Go to the

page 2-30

“Bidirectional print

“Carrier drive service check” on

“Ribbon drive service check” on

2-10 Service Manual

4227-300

Servi ce checks

Auto Gap service check

Theory of operation

The Auto Gap motor and Gap Home sensor automatically set the printhead gap for the thickness of paper being used by rotating the eccentric carrier shaft. The printer detects maximum gap with the Gap Home sensor, and minimum gap by driving the printhead against the platen. 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 comes on, the carrier centers, and the paper

moves to the tearoff position.

Diagnostic information 2-11

4227-300

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 ga p can be set to Manual Position 1 (thinnest paper) to 7 (thickest paper). With Auto Gap off, Single Au to Gap ha s t wo s e l e c tions:

• Fixed—The printhead gap is never changed.

• Open—The gap is opened when loading form s.

Note: If there is a 63C Auto Gap Error, the Gap Home sensor did

not detect that the carrier shaft homed, or it detected that the carrier shaft homed at the wrong time.

FRU Action

1 Auto Gap Sensor Inspect the Gap Home fl ag on the end of the

carrier shaft and make sure it blocks the sensor when the gap is at its largest. Turn the printer on and watch the carrier shaft and the Gap Home flag. If the sh aft rotates before the error occurs, the sensor may have failed. Perform the Sensor 2 Test in the Servic e M enu and test the Gap Home sensor.

2 Auto Gap Motor

Gear Train

2-12 Service Manual

If the carrier shaf t does not rotate, l ook for an Auto Gap motor or Auto Gap gear train problem. Disconnect CN20 from the main logic board.

Check the resi s t a n ce of pi ns : 1 and 5, 2 and 6, 3 and 5, and 4 and 6.

All resistances should be 180 No pin should have continuit y to ground.

If there is no 63C Auto Gap Error but there is a gap problem (l ight print or no print, or paper catching on the printhead or ribbon shield), enter the user menus to make sure the gap settings are a ppropriate for the paper being used. If Auto Gap is off, Manual Posi tion 1 should be used only wi th si ngle-part 16 lb. or 20 lb. forms. Refer the customer to the User's Guide for the appropriate Manual Position settings.

± 5 ohms.

4227-300

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 lever to 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 f eed 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

With the Paper Select lever in the Cut Sheet position, do the f ollowing:

• Try to load a sheet with Load/Unload. (This button should not work.)

• If the paper loads , go t o t he “P OST service

check” on page 2-24

Diagnostic information 2-13

4227-300

FRU Action

2 Paper Feed If the paper does not feed, do the following:

• Remov e the ASF.

• Be sure the base prin ter feeds paper correctly.

• If it does not f eed paper correctly, go to the

“Paper feed service check” on page

2-21

3 Gear Tr ain Be sure the ASF driv e gear on the insi de of the

4 Combination Lock

Mechanism

5 Left and Right

Hoppers

6 Pick Rollers

Paper Guides Feed Rollers

printe r’s rig h t fra m e ro ta te s. Inspect the right si de gear train for damage or

debris. Remove the ASF right cover and ensure that

all gears are in good condition. Install the ASF and press FormFeed. If the pick drive shaft does not rotate, replace

the combinati on lock mechanism. If the ASF pick rollers rotate b ut a si ngle sheet

is not pick ed, inspect the spri ngs and corner separators on the left and right hoppers .

Make sure the paper load lever is in the correct position.

Paper skew can be cause d by worn, dirty, or binding pi ck 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.

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4227-300

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 f o llowing:

• Tension pulley plate

• Carrier

• Carrier belt Loosen and tighten the tension pulley pl ate screws to make sure the carrier belt is tight.

Disconnect CN9 and move the carrier manually from le ft to right and check f or smooth movement.

With CN9 disconnected, check for 5 to 8 ohms between pins 1 and 2 on the motor c able. 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 ar e 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.

Wait for the machine to coo l and see if the error goes away.

If the machine was not being used heavily before the er ror occu rred, or if the error returns when the machine is cool, repl ace the carrier motor.

Diagnostic information 2-15

4227-300

Intermittent problem service check

FRU/Symptom Action

1 The machine

sometimes fails before POST is complete.

Check for the follo w ing:

1. Loose connectors. Reconnect all connector s to the main and sub logic boards.

2. Electrical noise or static discharge. Check the following items:

• Power supply ground

• Machine frame ground

• Printer inter face cable is grounded and

shielded.

3. Intermittently lo w voltages . Check for ac and all dc v olt ages and short-c ircuit s o n the m ain 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 out put voltages at CN11 and CN1.

Ensure the output v oltages 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 (Signal GND)

2-16 Service Manual

If the voltages are not correct, replace the power supply unit. If the fa il ure remains, replace the main logic board and sub logic board. Note: When replacing the main logic board, always perform the

adjustment” on page 4-3

“Bidirectional print

and the

“Printhead-to-platen gap adjustm ent” on page 4-2.

4227-300

FRU/Symptom Action

2 M achi ne 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 t he electrical voltage and be sure it is within tolerance.

2. Check th e conti nuity of the power cord.

3. D isconnect 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 ch eck all dc output voltages at CN11 and CN1. Be sure the output voltages are as foll ows:

CN11-1 (+40 ±4 V dc) & CN11-3 (GND) CN11-2 (+40 ±4 V dc) & CN11-3 (GND) CN11-5 (+5 ±0.5 V d c ) & 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 (Signal GND)

If one of the voltages is 0, go to the “Power

failure service check” on page 2-25. If the

voltages ar e not 0 b ut ar e incorrect , repl ace the power supply unit.

Do the following:

• Remove paper jam s fr om the paper path.

• C lean all feed roll er surfac e s .

• 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 cu stomer replace the ribbo n cartridge.

Diagnostic information 2-17

4227-300

FRU/Symptom Action

4 The previous

suggestions have not corrected the problem

5 Problem occurs

only in specific customer applications.

The service check has not defined the f ailure, or the machine is ha ving intermittent failures. The following may cause undefined or intermittent failures:

1. Customer’s electrical vo lt age. Be sure th at i t is within the tolerance.

2. Loose connector pins or keys that f a il 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 grou nd b. Machine frame ground c. Printer interface cable is grounded

or shielded.

4. Undefined data in customer appl ications. Check the baud rate at the controller. Check that the printer in ter face 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.

2-18 Service Manual

If the failure still occurs, perform the

“Bidirectional print adjustment” on page

and the “Printhead-to-platen gap

4-3 adjustment” on page 4-2.

4227-300

No print or abnormal print service check

FRU/Function Action

1 C arrie r If the carri e r m ove s, but nothing is print e d, go

to the

“Print wire drive failure service

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 serial ly attached, be sure the RS232/RS422 swit ch is in the correct position, and the host communications paramet ers are correct.

3 Main Logic Board If the Print Test does not print, or prints

incorrectly, do the following:

• Replace the main logic board.

• Perform the

adjustment” on page 4-3 “Printhead-to-platen gap adjustment” on page 4-2

“Bidirectional print

and the

Diagnostic information 2-19

4227-300

Operator panel service check

Note: Press any button except Start/Stop, Load/Unload, or FormFeed. If Operator Panel Disabled is displayed, unlock the

operator panel by powering up with the Micro↑ and Micro↓ keys pressed. Use the same procedure to re-lock the panel after service is complete.

FRU Action

1 Operator Panel If there is a 631 Display RAM Error, replace the

2 Printer Cable

Operator Panel

3 Cover Switch If Cover Open is displayed, check the cover

4 Main Logic Board If the symptom has not changed, 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 oper ator panel. 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 displa y ed, or i f an y of these t ests fail, chec k the condition and continuity of the operator panel cable.

Replace the cable or the operator panel.

switch. Jumper the cover swit ch connector on the

operator panel. If Cover Open is displayed, check the condition and continuity of the operator panel cable. Repl ace the cable or the operator panel.

main logic boar d.

2-20 Service Manual

4227-300

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 F eeder is inst alled, remo v e it. Enter the Paper Handling Options Menu and set ASF to off. Verify that the machine works correctly witho ut 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

2-13

2 T ractor 2 If the Tractor 2 option is instal led, remove i t.

Verify that the machine works correctly without Tra ctor 2 installed.

If the printer fails only with Tractor 2 installed, go to the

2-31

3 Paper Feed Moto r If there is no paper motio n, di sconnect the

paper feed motor connector CN10 from the main logic board.

Check the resis tance of pins: CN-1 and 6, 2 and 5, 3 and 6, and 4 and 5.

All resista nces should be 5.8 pin should have continuity to ground.

“Tractor 2 service check” on page

± 0.5 ohms. No

Diagnostic information 2-21

4227-300

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 t he main logic board.

The upper and lower f eed r ollers and the upper and lower pi nch rollers should al l be clean and in good condition, and should all rota te duri ng Form Feed.

To turn the gear train manually, turn the right end of the lower feed roller shaf t with a 6 mm wrench.

2-22 Service Manual

4227-300

FRU/Symptom Action

5 PE Sensor

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 lev er. Enter the Service Menu and perform the sensor tests.

• PE Sensor—Rounded flag, detects the presence of paper at the platen.

• TOF Sensor—Sharp flag, det ermines TOF at paper load.

• PSet Sensor—Paper set, detects presen ce of paper in the tractors and looks for end of forms.

• Jam Sensor—Senses the ho les in the paper and detects paper jams b y the lack of paper movement.

When the PSet sensor detect s 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 re mo ved from a sheet, the sensor stops printing. Less than 50 mm will probably be ign ored. Therefore, the paper motion must hav e st opped f or the equiv alen t of about 12 printed lines to cause a jam.

If either the PE or the PSet sensor detects no paper during print, printi ng stops at the end of the current page.

6 Paper Select

Sensor

The Tractor 2 option also has PSet and Jam sensors on the left tractor.

Enter the service menu and perf orm 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 lever to test the sensor. Replace any sensor i f failed or damaged.

Diagnostic information 2-23

4227-300

FRU/Symptom Action

7 Operator Panel If paper does n ot move at all, verify the

FormFeed button is wo rkin g c orrect ly by performing the Service Menu Button Test.

8 Main Logic Board If no other problem is found, replace the main

logic board. Perform the

on page 4-3 adjustment” on page 4-2

“Bidirectional print adjustment”

, and “Printhead-to-platen gap

POST service check

FRU Action

1 Power Disconnect t he parallel or serial cabl e and turn

2 Operator Panel If the power supply fan turns on but no LEDs

3 Main Logic Board If the Power LED turns on but POST does not

4 Printer Cable If POST completes, reconnect the paralle l or

the power on. If there is no printer activity, go to the

failure service check” on page 2-25.

light, go to the

check” on page 2-20

complete, replace the main logi c board. Perform the

on page 4-3

“Operator panel service

“Bidirectional print adjustment”

and check the

“Printhead-to-platen gap adjustm ent” on page 4-2.

serial cable and turn power on again.

“Power

2-24 Service Manual

If POST now fails, there is a problem with the cable, or the parallel connector on the main logic board.

4227-300

Power failure service check

For more information see “Voltage, ground, and continuity readings”

on page 1-2.

FRU Action

1 Operator Panel If the operator panel or cab le is damaged or

2 Power Supply

Fuse

disconnected, the machine is completely inoperable, except for the power supply fan noise.

If the power LED is not on steady, check the cable conti nuity and replace the cable or the operator panel.

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 ± 0.5 V dc at the sub logic board cable CN1-5 and +40 ± 4 V dc at CN1-1 and CN1-2. If there is no voltage, check the internal fuse before repl acing the power supply.

A 634 Power Failure indicates th at t he +5 V dc is OK but the +40 V dc is not. P o wer the printer off, wait 10 seconds, and power back on. If the 634 reappears eith er the power suppl y has failed or ther e is a short in a motor that uses +40 V dc.

Diagnostic information 2-25

4227-300

FRU Action

3 Ribbon Motor

Paper Feed Motor Carrier Motor Sub Logic Board 4227-300 Carrier Motor Cooling Fan

4 Printhead Cables

Printhead

5 Main Logic Board If all the above item s have been examined and

Disconnect t he carrier motor (CN9 and CN15), the paper feed motor (CN10), the ribb on m otor (CN19) and the (4227-300) carrier motor cooling f an (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 i s sti ll a power problem, replace the main logic boa rd.

If the machine post s a different er ror, one of these items i s shorted and is holding do wn the +40 V dc line. Reconn ect them one at a time, turning the printer on in between each connection.

Replace the i tem that causes t he po w er f ail ure. Disconnect the printhead cables from the sub

logic board and turn the print er on. I f the po wer LED lights correctly only with the printhead cables disconnected from the sub logic board, there is a short in the printhead or print head cables.

there is still a power problem, replace the main logic board. (Retain the old board for reinstal lation if the problem is not fixed. )

Perform the

on page 4-3

“Bidirectional print adjustment”

and check the “Printhead-to-

platen gap adjustment” on page 4-2.

2-26 Service Manual

4227-300

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.

3Auto Gap

Check the

“Printhead-to-platen gap

adjustment” on page 4-2. If Auto Gap is off,

be sure the manual position setting is appropriate for the paper used.

Auto Gap Motor Bracket

4 Printhead Cabl es Inspect both ends of the printhead cables fo r

5 Carrier Belt

Adjustment

6 Carrier Movement With the power off, manually move the carrier

7 Bidirect io nal Pr in t

Adjustment

8 Carrier Motor The carrier motor should turn smoothly and

9 Paper Feed

Gears

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 pl ate

screws to make sure the carrier belt is tight.

from side to side to inspect for drag or binds. Perform the

on page 4-3

quietly when printing. Inspect the paper feed ge ars for wear and tear.

and quietly when printing.

“Bidirectional print adjustment”

12 Feed Roller

Surfaces

Inspect the feed roller surf aces for di rt or wear.

Diagnostic information 2-27

4227-300

Print wire drive failure service check

FRU/Symptom Action

1 Missing Dots

Car r i e r m ove s, but there is no printing or printhead sound.

Perform the Print Test to determine which wires are not printing. Disc onnect the pri nthead cables f rom t he sub l ogic bo ard and chec k t he resistance for the affected wires. The resistanc e for each wire shou ld be ar ound

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 CCN4- 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

2-28 Service Manual

Note: 4227-300 connectors will be CN1 and CN2.

If the resistance for the affected wires i s incorrect , di sconnect th e print head cab l es fro m the printhead and measure the resistanc e of the printhead for the same wires. The resistance should be around 7.9 ohms.

• If the resistance is correct, replace the printhead cabl es.

• If the resistance is incorrect, replace the printhead.

4227-300

FRU/Symptom Action

2 63E He ad

Thermal Error

3 Auto Gap If the printhead is firing, manually rotate the

4 Printhead Cables Inspect for improper connecti on or damage. 5 Sub Logic Board If there is carrier moti on but no printhead noi se,

6 Ribbon A problem with the ribbon shield can keep the

The printer has stopped to protect the printhead from overheating. Normally this occurs after several hours of cont inuous heavy use in a warm env ironm ent, and only then af ter going through severa l stages of thermal slowdown.

Wait for the machine to coo l and see if the error goes away.

If the machine was not being used heavily before the er ror occu rred, or if the error returns when the machine is cool, repl ace the printhead.

carrier shaft during printing by pushing down on the Auto Gap Home senso r fl ag.

If printing sta rts and i s correct, go to the

Gap service check” on page 2-11

and the printhead cab les do not appear to be the problem, r eplace the sub logic board.

print wires too far fr om the page.

“Auto

Inspect the ribbon shield. When the printer is Ready with the ribbon in stalled, make sure the ribbon shield can float slightly front to back.

7 Printhead The printhead probab ly is not the problem if

there is no printing. 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 f ound.

Diagnostic information 2-29

4227-300

FRU/Symptom Action

8 Main Logic Board If no other problem is found, replace the main

logic board, ret aining the old board f or reinstal lation if the problem is not fixed.

Perform the

“Bidirectional print adjustment” on page 4-3 and the “Printhead-to-platen gap adjustment” on page 4-2

Ribbon drive service check

In normal operation, the ribbon knob rotates counterclockwise whenever the carrier moves to the left.

FRU/Symptom Action

1 Ribbon Drive

Gear Train

2 Ribbon Motor If printing seems normal, but the ribbon is not

Remove and insp ect 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 driv e post should t urn se ve ra l times

during POST. Disconnect the ribbon motor connector CN19 from the main logic board.

“Printhead-to-platen gap

2-30 Service Manual

The winding resistance should be 118 ohms ± 5 between pins: 1 and 5, 3 and 5, 2 and 6, 4 and 6.

Pin 5 should show an open circuit to pins 2, 4 and 6. Pin 6 should show an open circuit to pins 1, 3, and 5.

4227-300

Tractor 2 service check

The Tr actor 2 sensor opens dur ing 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 T ract or 2 is deselected, the motor retracts the slider,

disengaging the Tractor 2 gear drive and reengaging the printer tractors.

63D Tractor 2 HP error

The Trac tor 2 Home sen sor was never initialized after turning the printer off and then on, or made at the wrong time. (The same error indication is used for carrier home failure.)

FRU Action

1Tractor 2

Home Sensor

Remove the Tractor 2 and turn the printer off and then back on again to determin e whether the fault is in the pri nter or in Tractor 2.

If the gear teeth chatter just before the error is displayed, replace the home sensor.

Diagnostic information 2-31

4227-300

FRU Action

2 Main Logic Board Remove Tractor 2 from the printer but leave

the cable connected. Make sure t he sli der (the black plastic piece

just above the right cover) moves after turning the printer off and t hen back on. If the slid er does not mov e after turning the printer off and then back on:

• Make sure the slider and gear train are properly connected an d mov e f reely with th e power off .

• Make sur e the Tract or 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 boar d.

3 Tractor 2 Motor

Board/Cable Asm

2-32 Service Manual

Check the 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, r eplace the board/cable assembly.

For more information on the Tractor 2 cable connectors, see

“Tractor 2 cable

connectors” on page 6-15.

4227-300

Tractor 2 installed, but not shown in User Menu

Tractor 2 is selected from operator panel but the 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. P ower the printer on and verify the problem still occurs.

FRU Action

1Tractor 2

Board/Cable Asm.

Check the Tractor 2 sensor or the cable connection.

The sensor actuator extends throu gh the Tra ctor 2 cover and rests on the printer cover when Tractor 2 is installed.

Remove the Tractor 2 cover and mak e sur e 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 cl osed.

Replace the Tractor 2 board/cable asm if the sensor signal is wrong.

For more information on the Tractor 2 cable connectors, see

“Tractor 2 cable

connectors” on page 6-15.

2 Main Logic Board Check the cable connection from Tractor 2 to

the printer. If possib le, try the Tractor 2 with anot her printer

to determine if the problem is the Tractor 2 board/cable assembly or the printer main logic board.

Diagnostic information 2-33

4227-300

Paper feed problems

FRU Action

1 Tractor 2 On the printer, make sure the Tractor 2 driving

gear turns f reely when t he white sub sli der cam is not pressed. B e sure t he driv ing gear does not move when the sub slider cam behind the gear is pressed.

Remove Tract or 2 from the printer and remove all paper. With the paper sel ect lev er 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 rot ate 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:

• When the slider is t o the rear, the white gear drives the tractors.

• When the slider is t o the f ront, the gear and tractors are not connected.

Remove the Tractor 2 cover and reinstall Tractor 2 in the printer (if necessary remove the printer covers also) . Note that the small idler gear just below the slider is hel d in pl ace by the cover; w ith the cover removed it will tend to move off the stud. Also note that when operating the Tractor 2 with the printer cov er remov ed, the Tractor 2 sensor must be held open.

2-34 Service Manual

Turn the printer on and look for mechanical problems.

For more information on the Tractor 2 cable connectors, see

connectors” on page 6-15

“Tractor 2 cable

4227-300

3. Diagnostic aids

The printer contains self tests to help find and solve problems. Yo u do not need to 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 Te sts diagnose the basic hardware printer functions and initialize the default value settings. POST star ts automatically when power to the printer is turned on, or when the printer receives an INIT signal from the controller.

• The power supply fan comes on.

• LED Test —A ll LEDs turn on bri efly.

• LCD Te st—Al l pels of the display are activated twice, and 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 that this function is

working.

• Button Scan Test—Scans all operator panel buttons.

• NVRAM Te st— Checks that the NVRAM data is correct.

• The ribbon motor feeds ribbon.

• The carrier moves to the left side frame, and then back to the

right.

• The auto Gap sequence occurs.

If any errors occur during the POST tests, an error indicator shows which test failed. See “Start” on page 2-1.

Diagnostic aids 3-1

4227-300

Hex trace m ode

The hex trace mode can help 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 ↓ until Trace Mode appears on the operator panel.

3. Press Start.

Hex trace mode sample

3-2 S ervice Manual

4227-300

Interfac e sel ect io n

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 you remove the top cover, the printer can be operated for service purposes by positioning the cover near the main logic board and reconnecting the operator panel cable. The ribbon cover must be in place on the top cover. Or, you can 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.

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 Service Menu by pressing Menu/Quit.

Diagnostic aids 3-3

4227-300

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

This test enables or disables the PSet and Jam sensors on the left tractor.

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 overrides 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.

3-4 S ervice Manual

4227-300

Print Test

The Print Test prints:

• The ASCII character set

• A line from each print wire

• The bidirectional print alignment pattern

• The contents of NVRAM

• The error log

Other print tests

The following print tests are accessed outside the Service Menu:

• 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 buttons that are active during this test are the Micro ↓ or Micro ↑ ,

Load/Unload, LineFeed and FormFeed buttons. 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.

Error log

The Error Log printout is part of the Service M enu test pr int 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.

Diagnostic aids 3-5

4227-300

3-6 S ervice Manual

4227-300

4. Rep a ir in fo r m a t i on

This chapter ex plains how to make adjustments to the printer and how to remove defective parts.

Warning: Read the following before handling electronic parts.

Handling ESD-sensitive parts

Many electronic products use parts that are known to be sensitive to electrostati c discharge (ESD). To prevent damage to ESD-sensitive parts, follow the instructions below:

• Keep the ESD-sensitiv e part in it s original shippin g cont ainer (a specia l

“ESD bag”) until you are ready to install the part into the machine.

• Make as few mov em ents as possible with your body to prevent an

increase of static electricity fr om clot hing fibers, carpet s, and furniture.

• Put the ESD wrist strap on your wrist. Connect the wrist band to the

system ground point . This disc harges any static elect ricit y in your body to the mac h in e.

• Hold the ESD-sensitive part by its edge connec tor shroud (cover); do

not touch its pins. If you are removi ng a pluggable module, use the correc t to o l.

• Do not place the ESD-sensitive part on the machine cover or on a

metal table ; if you need to put down the ESD-sensi tive part for an y reason, first put it into its special bag.

• Machine covers and metal t ables are electrical grounds. They incr ease

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 being accidentally touched by other

personnel. Install machine covers when you are not working on the machine, and do not put unprotected ESD-sensitive parts on a table.

• If possible, keep all ESD-sensitiv e parts in a grounded metal cabinet

(case).

• Be extra careful in working with ESD-se nsitive parts when cold-

weather heati ng is used, because low humidi ty increases stati c electricity.

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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. Perform 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 between .011 inch (.275 mm) and .015 inch (.375 mm).

5. Use the Micro↑ or Micro↓ to change the printhead-to-platen gap setting. The Micro↑ button increases the clearance and the Micro↓ button decreases the clearance.

6. Install the ribbon guide.

7. Press Start/Stop to reset the new printhead-to-platen gap 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.

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 the Courier speed setting.

The following steps tell how to adjust the alignment of the print wires, and assumes that macros are disabled.

1. Load continuous forms.

2. Press Menu.

3. Press Item ↓ unt il Print Adjust appears on the display.

4. Press Next →.

5. Press Item ↓ or Item ↑ to choose Draft or Courier. Draft prints each alignment pattern once (unidirectional). Courier prints each alignment pattern twice (bidirectiona l).

6. Press Start/Stop to print the alignment pattern.

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The following example shows a printer that needs alignment.

The message Choose the Best Alignment appears on the display.

7. Press Next → or Prev. ← to adjust the alignment. Lines 2 and 4 move to align with lines 1 and 3. The printer is aligned correctly when lines 2 and 4 are vertically aligned with lines 1 and 3.

• Press Item ↑ to move lines 2 and 4 to the right.

• Press Item ↓ to move lines 2 and 4 to the left.

8. Press Store to save the selected value.

9. Press Start/Stop to print the alignm ent pattern. The example below shows proper alignment.

10. Press Quit to exit the menu.

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Removals

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.

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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.

7. Place the printer on its left side. Insert a flat blade screwdriver into the two slots (4) and release the cover by pushing 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 (4).

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9. Place the printer on its feet and release the remaining two top cover latches (4).

10. While lifting the top cover slightly, disconnect the operator panel cable from the main logic board, and then remove the top cover.

To Reinstall:

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.

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Auto Gap motor removal

1. Remove the top cover. See “Top cover removal” on page 4-5.

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 latch, and then 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).

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Auto Sheet Feeder pick-up roller removal

1. Remove the covers and the cut sheet suppor t.

2. Remove the idler gear and the 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 4-5.

2. Turn the printer so the rear of the printer faces you.

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 4-5.

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 you are replacing the bottom cover, write the machine serial number and part number on the blank label.

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Carrier removal

1. Remove the top cover. See “Top cover removal” on page 4-5.

2. Remove the printhead. See “Printhead removal” on page 4-32.

3. Remove the carrier roller spring.

4. Remove the sub logic board. See “Sub logic board removal” on

page 4-37.

5. Remove the ribbon drive motor assembly (1).

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6. Loosen the two tension pulley plate screws (2). Pull up on both sides of the belt to move the tension pulley plate as far as possible toward the center of the printer, and 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 up and remove it to free the carrier belt.

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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.

To reinstall:

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, perform 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 4-5.

2. Disconnect carrier motor connectors CN9 and CN15 from the main logic board.

3. Loosen the two tension pulley plate screws. Pull up on both sides of the belt to move the tension pulley plate as far as possible toward the center of the printer, and then retighten the large screw.

4. Remove the three screws (1) holding the motor to its bracket.

5. Remove the carrier motor.

To reinstall:

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. The 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.

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Carrier plate removal

1. Remove the top cover. See “Top cover removal” on page 4-5.

2. Remove the print unit.

3. Remove t he carri er.

4. Remove the lower pinch roller.

5. Remove t he carri er 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 then 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, use the following procedure to remove the label.

1. Remove the top cover. See “Upper feed roller removal” on page

4-38.

2. Remove the tractor assembly .

3. Remove the print unit. See “Print unit removal” on page 4-29.

4. Remove the paper separator. See “Paper separator removal”

on page 4-27.

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 4-5.

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.

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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 the side frame.

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).

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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.

To reassemble:

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, and 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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Lower pinch roller removal

1. Remove the ribbon cover and the ribbon.

2. Remove the U-shaped ground spring (1).

3. Release the left and right pinch roller springs (2).

4. Move the carrier to the right as far as it will go.

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.

Main logic board removal

1. Remove the top cover. See “Top cover removal” on page 4-5.

2. Disconnect all cables connected to the main logic board.

3. Remove the three screws at the rear edge of the board, and then remove the board.

4. Remove the EPROM from the old board and install it on the new one.

To reinstall:

After replacing the main logic board, recheck the “Bidirectional print

adjustment” on page 4-3 and the “Pr inthead-to-platen gap adjustment” on page 4-2.

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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. Inser t a small flat screwdriver under each end of the module and lift gently. Do not insert the screwdriver too far, or the main logic board may be damaged.

Note: Be careful not to bend the pins when you reinstall the module.

Operator panel assembly removal

1. Remove the top cover. See “Top cover removal” on page 4-5.

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 lat ches t o f ree t he operat or panel f rom the top cover.

Paper Empty sensor/TOF sensor removal

1. Remove the top cover. See “Top cover removal” on page 4-5.

2. Remove the print unit. See “Print unit removal” on page 4-29.

3. Remove the right screw (1) in the support shaft.

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4. To remove the 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 vertically away from 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 illustrate d ( 3) .

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To replace t he 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.

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Paper feed motor removal

1. Remove the top cover. See “Top cover removal” on page 4-5.

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.

To reinstall

With the screwdriver, hold the bottom screw in place in the motor bracket. 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 par t of the guide to release the two latches, and then remove the paper guide.

Paper guide/platen assembly removal

1. Remove the top cover. See “Top cover removal” on page 4-5. 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.

Paper Select lever removal

1. Remove the top cover. See “Top cover removal” on page 4-5.

2. Release the latch, and then remove the Paper Select le v er from the right side frame.

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Paper Select sensor removal

1. Remove the top cover. See “Top cover removal” on page 4-5.

2. Remove the print unit. See “Print unit removal” on page 4-29.

3. Use a #1 P h illi p s scr ewdriver to remove the tw o s c rew s (1) holding the Paper Select sensor to the left side frame.

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Paper separator removal

1. Remove the top cover. See “Top cover removal” on page 4-5.

2. Remove the print unit from the base. See “Print unit removal” on

page 4-29.

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 the side frame.

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6. Release and remove the separator plate spring (3) from the right side frame.

7. Remove the paper separator screw (4) from above the slider cam.

8. Remove the two carrier plate screws (5) from the right side frame. One is behind the slider cam.

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.

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Power supply removal

CAUTION: The power supply may be hot.

1. Turn off the printer and disconnect the power cord at both ends.

2. Remove the top cover. See “Top cover removal” on page 4-5.

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.

Print unit removal

1. Remove the top cover. See “Top cover removal” on page 4-5.

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, CN17, CN18, CN19, and CN20.

6. Remove the upper screw from the serial port card mounting bracket.

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7. On the left side, remove the three screws (1) holding the print unit to the base.

8. On the right side, remove the screw (2) holding the print unit to the base.

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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.

To Reinstall

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 then lift the printhead out.

To reinstall

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 then tighten the two printhead mounting screws.

3. Perform the “Printhead-to-platen gap adjustment” on page 4-2.

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Printhead cables removal

1. Remove the top cover. See “Top cover removal” on page 4-5.

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 then pull the cables from under the ribbon motor.

4. The cables are attached to the carrier plate with double-faced tape.

To reinstall

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 4-5.

2. Remove the sub logic board.

3. Remove the ribbon drive post cover and the ribbon drive post (1).

4. Remove the Auto Gap sensor (2) from the motor bracket.

5. Disconnect ribbon motor connector CN19 from the main logic board.

6. Remove the carrier motor bearing retainer and bearing (3) from the ribbon motor bracket.

7. Remove the three screws (4) holding the ribbon drive motor bracket, and then remove the ribbon drive motor assembly.

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Right side frame removal

1. Remove the top cover. See “Top cover removal” on page 4-5.

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 the side frame.

6. Remove the gear, clip , and bearing (5) from the end of the lower feed roller shaft.

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7. Release and remove the separator plate spring (6).

8. Release the spring (7) from the right end of the lower pinch roller.

9. Remove the two carrier plate screws (8). One is in the slot in the slider cam.

10.Remove the suppor t shaft screw (9) and the two platen screws (10).

4-36 Service Manual

Lexmark Forms Printer Service Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Table of contents

Safety information

Preface

1. Gen e r a l informa tion

Description

Voltage, ground, and continuity readings

Voltage readings

Ground checks

Continuity readings

Maint en an ce ap proa ch

Options

Tools

Abbreviations

Using the operator panel

Using the function menus

Sett ing printer functions

Overview of function menus

Buttons

Lights

2. Diagnostic information

Start

Error indication table

Symptom tables

Abnormal Indications

Abnormal print operation problems

Auto Sheet Feeder problems

6XX Error indications

Paper feed problems

Operator panel problems

Power Problems

Print quality problems

Ribbon feed problems

Servi ce checks

Auto Gap service check

Theory of operation

Carrier drive service check

Intermittent problem service check

No print or abnormal print service check

Operator panel service check

Paper feed service check

POST service check

Power failure service check

Print quality service check

Print wire drive failure service check

Ribbon drive service check

Tractor 2 service check

63D Tractor 2 HP error

Tractor 2 installed, but not shown in User Menu

Paper feed problems

3. Diagnostic aids

Power-On Self Test (POST)

Hex trace m ode

Hex trace mode sample

Interfac e sel ect io n

Operation with the top cover removed

Service Menu

Button Test

Factory Setting

Printhead Bank

Jam/PSet Sensor Test

Impact force

Log clear

Print Test

Other print tests

Error log

4. Rep a ir in fo r m a t i on

Handling ESD-sensitive parts

Adjustments

Printhead installation adjustment

Printhead-to-platen gap adjustment

Printhead-to-platen gap left and right

Printhead-to-platen gap electronic setting

Bidirectional print adjustment

Removals

Top cover removal

To Reinstall: