Lexmark Forms Printer Service Manual
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.
© 1996, 2006 Lexmark International, Inc.
All rights reserved.
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
4227-300
Table of contents
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
ii
4227-300
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
4227-300
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.
4227-300
vi
4227-300
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
x
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.
1-2 S ervice Manual
4227-300
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
1-4 S ervice Manual
4227-300
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.
1-6 S ervice Manual
4227-300
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.
1-8 S ervice Manual
4227-300
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.
1-10 Service Manual
4227-300
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.
2-4 S ervice Manual
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”
.
“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.
2-6 S ervice Manual
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