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Lexmark Forms Printer 4227

4227-X00

· Table of Contents · Start Diagnostics · Safety and Notices · Trademarks · Index · Manuals Menu

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

4227-X00

Table of Contents
General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 Voltage, Ground, and Continuity Readings . . . . . . . . . . . . . . 1-3 Maintenance Approach. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4 Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4 Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5 Using the Operator Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6 Using the Function Menus . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7 Setting Printer Functions . . . . . . . . . . . . . . . . . . . . . . . . . 1-8 Overview of Function Menus . . . . . . . . . . . . . . . . . . . . . . 1-9 Buttons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11 Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12 Diagnostic Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1 Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 Error Indication Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 Symptom Table. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4 Service Checks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10 Auto Gap Service Check . . . . . . . . . . . . . . . . . . . . . . . . 2-10 Auto Sheet Feeder (ASF) Service Check. . . . . . . . . . . . 2-12 Carrier Drive Service Check. . . . . . . . . . . . . . . . . . . . . . 2-14 Intermittent Problem Service Check . . . . . . . . . . . . . . . 2-15 No Print or Abnormal Print Service Check . . . . . . . . . . . 2-18 Operator Panel Service Check. . . . . . . . . . . . . . . . . . . . 2-19 Paper Feed Service Check . . . . . . . . . . . . . . . . . . . . . . 2-20 POST Service Check . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-24 Power Failure Service Check . . . . . . . . . . . . . . . . . . . . . 2-25 Print Quality Service Check . . . . . . . . . . . . . . . . . . . . . . 2-27 Print Wire Drive Failure 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 Selection (4227-100) . . . . . . . . . . . . . . . . . . . . . . . . 3-3 Operation with the Top Cover Removed . . . . . . . . . . . . . . . . 3-3

vii

4227-X00 Service Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4 Button Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4 Factory Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4 Printhead Bank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4 Jam / PSet Sensor Test. . . . . . . . . . . . . . . . . . . . . . . . . . 3-4 Impact Force . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5 Log Clear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5 Print Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5 Other Print Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5 Error Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6 Repair Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 Handling ESD-Sensitive Parts . . . . . . . . . . . . . . . . . . . . . . . . 4-1 Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2 Printhead Installation Adjustment . . . . . . . . . . . . . . . . . . 4-2 Printhead-to-Platen Gap Adjustment. . . . . . . . . . . . . . . . 4-2 Bidirectional Print Adjustment . . . . . . . . . . . . . . . . . . . . . 4-4 Removal Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6 Top Cover Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6 Auto Gap Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8 Auto Sheet Feeder Gears Removal . . . . . . . . . . . . . . . . 4-9 Auto Sheet Feeder Pick-up Roller Removal . . . . . . . . . 4-10 Belt Tension Pulley Plate Assembly Removal. . . . . . . . 4-11 Base Assembly Removal. . . . . . . . . . . . . . . . . . . . . . . . 4-11 Carrier Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12 Carrier Motor Assembly Removal . . . . . . . . . . . . . . . . . 4-15 Carrier Plate Removal . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16 Label Jam Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16 Lower Feed Roller Removal . . . . . . . . . . . . . . . . . . . . . 4-17 Lower Pinch Roller Removal . . . . . . . . . . . . . . . . . . . . . 4-21 Main Logic Board Removal . . . . . . . . . . . . . . . . . . . . . . 4-22 Memory Module Removal . . . . . . . . . . . . . . . . . . . . . . . 4-22 Operator Panel Assembly Removal . . . . . . . . . . . . . . . 4-23 Paper Empty Sensor /TOF Sensor Removal. . . . . . . . . 4-23 Paper Feed Motor Removal . . . . . . . . . . . . . . . . . . . . . 4-26 Paper Guide Removal . . . . . . . . . . . . . . . . . . . . . . . . . . 4-26 Paper Guide / Platen Assembly Removal . . . . . . . . . . . 4-26 Paper Select Lever Removal. . . . . . . . . . . . . . . . . . . . . 4-27 Paper Select Sensor Removal . . . . . . . . . . . . . . . . . . . 4-27 Paper Separator Removal . . . . . . . . . . . . . . . . . . . . . . . 4-28 Power Supply Removal . . . . . . . . . . . . . . . . . . . . . . . . . 4-30 Power Supply Fan Removal . . . . . . . . . . . . . . . . . . . . . 4-30 Print Unit Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-30 Printhead Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-33 viii

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Printhead Cables Removal. . . . . . . . . . . . . . . . . . . . . . . 4-34 Ribbon Drive Motor Assembly Removal. . . . . . . . . . . . . 4-35 Right Side Frame Removal . . . . . . . . . . . . . . . . . . . . . . 4-36 Sub Logic Board Removal . . . . . . . . . . . . . . . . . . . . . . . 4-38 Upper Feed Roller Removal. . . . . . . . . . . . . . . . . . . . . . 4-39 Connector Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1 4227-200 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2 Main Logic Board Connectors . . . . . . . . . . . . . . . . . . . . . 5-3 4227-100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4 Sub Logic Board Connectors . . . . . . . . . . . . . . . . . . . . . . 5-4 4227-200 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5 Operator Panel Connectors . . . . . . . . . . . . . . . . . . . . . . . 5-5 Component Locations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6 Component Location Illustrations . . . . . . . . . . . . . . . . . . 5-7 Signal Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9 Connector Block Diagram . . . . . . . . . . . . . . . . . . . . . . . 5-20 Tractor 2 Cable Connectors . . . . . . . . . . . . . . . . . . . . . . 5-21 Preventive Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-1 Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 Specified Lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 Lubrication Points. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2 Parts Catalog . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-1 How to Use This Parts Catalog. . . . . . . . . . . . . . . . . . . . . . . . 7-1 Assembly 1: Covers and Operator Panel . . . . . . . . . . . . . . . . 7-2 Assembly 2: Paper Feed . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4 Assembly 3: Carrier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6 Assembly 4: Base and Electronics . . . . . . . . . . . . . . . . . . . . . 7-8 Assembly 5: ASF Side Frame / Covers . . . . . . . . . . . . . . . . 7-10 Assembly 6: ASF Roller / Support . . . . . . . . . . . . . . . . . . . . 7-12 Assembly 7: Tractor 2 Option . . . . . . . . . . . . . . . . . . . . . . . . 7-14 Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X-1

ix

4227-X00

Preface
This manual describes the Lexmark Forms Printer 4227-100 and 4227-200. It contains maintenance procedures for service personnel and is divided into the following chapters:

·

· · · · · ·

General Information contains a general description of the printer and the maintenance approach used to repair it. Special tools and test equipment are listed in this chapter, as well as general environmental and safety instructions. Diagnostic Information contains error code table, symptom table, and service checks used to isolate failing field replaceable units (FRUs). Diagnostic Aids contains tests and checks used to locate or repeat symptoms of printer problems. Repair Information provides instructions for making printer adjustments and removing and installing FRUs. Connector Locations uses illustrations to identify the major components and test points on the printer. Preventive Maintenance contains lubrication specifications, and maintenance information to prevent problems and maintain optimum performance. Parts Catalog contains illustrations and part numbers for individual FRUs.

x Service Manual

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Preface xi

4227-X00

Notices
Safety Information ·
This product is designed, tested and approved to meet strict global safety standards with the use of specific Lexmark components. The safety features of some parts may not always be obvious. Lexmark is not responsible for the use of other replacement parts. The maintenance information for this product has been prepared for use by a professional service person and is not intended to be used by others. There may be an increased risk of electric shock and personal injury during disassembly and servicing of this product. Professional service personnel should understand this and take necessary precautions.

· ·

Consignes de Sécurité ·
Ce produit a été conçu, testé et approuvé pour respecter les normes strictes de sécurité globale lors de l'utilisation de composants Lexmark spécifiques. Les caractéristiques de sécurité de certains éléments ne sont pas toujours évidentes. Lexmark ne peut être tenu responsable de l'utilisation d'autres pièces de rechange. Les consignes d'entretien et de réparation de ce produit s'adressent uniquement à un personnel de maintenance qualifié. Le démontage et l'entretien de ce produit pouvant présenter certains risques électriques, le personnel d'entretien qualifié devra prendre toutes les précautions nécessaires.

· ·

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4227-X00

Norme di sicurezza ·
Il prodotto è stato progettato, testato e approvato in conformità a severi standard di sicurezza e per l'utilizzo con componenti Lexmark specifici. Le caratteristiche di sicurezza di alcune parti non sempre sono di immediata comprensione. Lexmark non è responsabile per l'utilizzo di parti di ricambio di altri produttori. Le informazioni riguardanti la manutenzione di questo prodotto sono indirizzate soltanto al personale di assistenza autorizzato. Durante lo smontaggio e la manutenzione di questo prodotto, il rischio di subire scosse elettriche e danni alla persona è più elevato. Il personale di assistenza autorizzato, deve, quindi, adottare le precauzioni necessarie.

· ·

Sicherheitshinweise ·
Dieses Produkt und die zugehörigen Komponenten wurden entworfen und getestet, um beim Einsatz die weltweit gültigen Sicherheitsanforderungen zu erfüllen. Die sicherheitsrelevanten Funktionen der Bauteile und Optionen sind nicht immer offensichtlich. Sofern Teile eingesetzt werden, die nicht von Lexmark sind, wird von Lexmark keinerlei Verantwortung oder Haftung für dieses Produkt übernommen. Die Wartungsinformationen für dieses Produkt sind ausschließlich für die Verwendung durch einen Wartungsfachmann bestimmt. Während des Auseinandernehmens und der Wartung des Geräts besteht ein zusätzliches Risiko eines elektrischen Schlags und körperlicher Verletzung. Das zuständige Fachpersonal sollte entsprechende Vorsichtsmaßnahmen treffen.

· ·

Notices xiii

4227-X00

Pautas de Seguridad ·
Este producto se ha diseñado, verificado y aprobado para cumplir los más estrictos estándares de seguridad global usando los componentes específicos de Lexmark. Puede que las características de seguridad de algunas piezas no sean siempre evidentes. Lexmark no se hace responsable del uso de otras piezas de recambio. La información sobre el mantenimiento de este producto está dirigida exclusivamente al personal cualificado de mantenimiento. Existe mayor riesgo de descarga eléctrica y de daños personales durante el desmontaje y la reparación de la máquina. El personal cualificado debe ser consciente de este peligro y tomar las precauciones necesarias.

· ·

Informações de Segurança ·
Este produto foi concebido, testado e aprovado para satisfazer os padrões globais de segurança na utilização de componentes específicos da Lexmark. As funções de segurança de alguns dos componentes podem não ser sempre óbvias. A Lexmark não é responsável pela utilização de outros componentes de substituição. As informações de segurança relativas a este produto destinam-se a profissionais destes serviços e não devem ser utilizadas por outras pessoas. Risco de choques eléctricos e ferimentos graves durante a desmontagem e manutenção deste produto. Os profissionais destes serviços devem estar avisados deste facto e tomar os cuidados necessários.

· ·

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4227-X00

Informació de Seguretat ·
Aquest producte està dissenyat, comprovat i aprovat per tal d'acomplir les estrictes normes de seguretat globals amb la utililització de components específics de Lexmark. Les característiques de seguretat d'algunes peces pot ser que no sempre siguin òbvies. Lexmark no es responsabilitza de l'us d'altres peces de recanvi. La informació pel manteniment d'aquest producte està orientada exclusivament a professionals i no està destinada a ningú que no ho sigui. El risc de xoc elèctric i de danys personals pot augmentar durant el procés de desmuntatge i de servei d'aquest producte. El personal professional ha d'estar-ne assabentat i prendre les mesures convenients.

· ·

Notices xv

4227-X00

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Service Manual

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1. General Information
Description
The Lexmark Form Printer 4227-100 and 4227-200 are dot matrix, electro-mechanical printers that form characters on print media using a printhead and fabric ribbon. The printhead is composed of 18 miniature solenoids containing print wires and operates on electromagnetic principles. When a solenoid is energized, the small print wire pin is "fired" toward the ribbon to make a dot on the paper. The printer receives commands in the form of an electronic data stream from the PC through the parallel or serial port connector. The printer logic receives and translates the electronic data stream into carrier returns, line spacing, characters, or graphics as instructed.

General Information 1-1

4227-X00 This is a versatile printer that combines excellent print quality along with the ability to print several print styles and graphics. Some of the features and functions included with this printer are:
Feature Multi-speed Printing Function FastDraft - 533 cps (4227-100) Draft - 400 cps (4227-100) Courier and Gothic (NLQ) - 100 cps (4227-100) FastDraft -720 cps (4227-200) Draft - 600 cps (4227-200)) Courier and Gothic (NLQ) - 150 cps (4227-200) FastDraft, Draft, Courier and Gothic Forms (straight paper path) Automatic tear-off Automatic paper loading/unloading Manual Optional Auto Sheet Feeder 6-Part Forms (carbon and carbonless) (4227-200 - up to 8-Part Forms) Parallel, Serial RS-422, Serial RS-232 When Auto Gap is set to On, the printer automatically adjusts to the thickness of paper you are using.

Resident Fonts Forms Handling

Cut Sheets Multiple Part Forms Interface Connection Auto Gap

1-2 Service Manual

4227-X00

Voltage, Ground, and Continuity Readings
Voltage Readings All DC voltages must be within +5% through -10% of the values to be considered correct. Unless stated otherwise, all connectors should be connected normally when a voltage measurement is done. When a "Line Voltage" measurement is to be done, the voltage on United States and Canada machines should be between 100 V ac and 127 V ac. On World Trade machines, the voltage is according to each country's specification. Ground Checks To check for a correct ground, measure the voltage between the ground and a known good voltage source. The voltage measurement must be the same as the source voltage to consider the ground is correct. Continuity measurements may be used to check grounds, however, be sure to measure to a known good ground using the lowest ohms scale and check for zero ohms. Note: Always unplug the power cord before doing any continuity measurement. Continuity Readings When measuring continuity, be sure no back circuits affect the measurement. If necessary, unplug connectors to remove any back circuits. Zero the ohm range on the lowest scale (X1). An open circuit will read infinity. A circuit with correct continuity will read zero ohms.

General Information 1-3

4227-X00

Maintenance Approach
The diagnostic information in this manual leads you to the correct field replaceable unit (FRU) or part. Use the error indication table, symptom/check table, service checks and diagnostic aids to determine the symptom and repair the failure. Begin with ""Start" on page 2-1"

Options
The following options may be installed:

· · · · ·

Auto Sheet Feeder (ASF) Tractor 2 Extended Cut-sheet Paper Guides 32kb Memory Module Extended National Language Support modules (Non-U.S. only)

Tools
The basic tools needed are:

· · · · ·

Basic CE tool kit #1 magnetic Phillips screwdriver #2 magnetic Phillips screwdriver Feeler gauges 0.35 mm (0.014 in.) 0.4 mm (0.016 in.) Analog or digital volt-ohmmeter

1-4 Service Manual

4227-X00

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

General Information 1-5

4227-X00

Using the Operator Panel
This section provides a brief description of the operator panel buttons, lights and settings. Refer to the User's Guide for additional information. Note: Application software may allow the user to operate the printer from a computer. Changes made to the printer settings from a software application override settings made from the operator panel, with the exception of the Font and Pitch Lock features. Changeable printer functions include:

· · · · · · · · ·

Set Top of Form Tractor selection Character options Paper handling options Interface options Emulation options Macro definition and selection Print tests Auto Gap functions

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4227-X00

Using the Function Menus

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

General Information 1-7









4227-X00

Setting 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). to enter that menu item. 4. Press Next 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 have to change the optional value in another function menu, repeat steps 3 through 5. Otherwise, go to the next step. 7. To print the function setting, press Item 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, see "Power-On Self Test (POST)" on page 3-1. If you did not change any settings, the printer enters the not-ready state.

1-8 Service Manual













4227-X00

Overview of Function Menus
Use the Item and Item buttons to move through the menu and to move away from the Main Menu option directories. Press Next if you to the subordinate directories and choices. Press Prev. want to go back in a menu or return to the Main Menu. Menu items marked with an asterisk (*) may not appear on the operator panel, depending on the printer settings or what printer options are installed

General Information 1-9









4227-X00

1-10 Service Manual

4227-X00

Buttons
When using the function menus, press Item or Item to scroll or Prev. to move to the through the menu items. Press Next next, or previous menu level. Press this button:
Menu Quit Tear Off

To:
· Enter the function menu. The printer goes offline. · Exit the function menus. · Run a Power-On Self Test (POST). · Advance the forms to the tear-off position. · Retract the forms to the Top-of-Form (TOF) position when the forms are at the tear-off position. · Save the values selected in the menus. · Select a font. · Scroll down. · Select a pitch. · Scroll up. · Advance the forms down 0.35 mm (1/72 in.). · Scroll forward. · Advance the forms up 0.35 mm (1/72 in.). · Return to the previous function menu. · Used to return to Ready and to Start/Stop. · Load the forms to TOF position with the ready light on. · Load paper (cut or continuous forms) to the TOF position. · Retract the forms to the tractor position. · Advance the paper to the next line. · Advance the paper to the TOF position on the next page. · Load the forms to the TOF position.

Store Font

Pitch

Start/Stop

Load/Unload

LineFeed FormFeed



Prev.



Micro



Next



Micro



Item



Item

General Information 1-11









4227-X00

Lights
Light
Power (Green) Ready (Green)

When you see this light
The printer power is on. The printer is online and ready to print. The following conditions cause the Ready light to turn off: · Pressing Start/Stop · An end-of-form (EOF) · A paper jam · A cover open · A hardware error · A Power-On Self Test failure. · The printer is offline. Any of the following conditions may have occurred: · An end-of-form (EOF) · A paper jam · A cover open · A hardware error · A data transmission error · An interface mode error · A Power-On Self Test (POST) failure. Auto Gap is on. Auto Gap automatically adjusts the printer according to the thickness of the paper you are using. The Tractor 2 Feeder is selected. (The Tractor 2 Feeder option must be installed.)

Check (Yellow)

Auto Gap (Green)

Tractor2 (Green)

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2. Diagnostic Information Start
Make a quick visual check for defects (loose or broken parts, unplugged connectors, or paper jams). If there is no power after turning the printer on, go to the "Power Failure Service Check" on page 2-25. If an error indicator appears, go to the "Error Indication Table" on page 2-2 and take the indicated action. Run the "Print Test" on page 3-5 and refer to the "Error Log" on page 3-6 for details of error indication information. If no error indication appears, refer to the "Symptom Table" on page 2-4.

Diagnostic Information 2-1

4227-X00

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 Table" on page 2-4.
Display Indication 631 Machine Check Display RAM Error 632 Machine Check System RAM Error Description / Action Display RAM Read/Write Error. This error is detected only during POST. Replace the operator panel. System RAM Read/Write Error. Replace the main logic board and adjust the "Bidirectional Print Adjustment" on page 4-4. Check the

"Printhead-to-Platen Gap Adjustment" on page 4-2.
633 Machine Check Timer Interrupt Error Timer Interrupt Controller Error. Replace the main logic board and adjust the

"Bidirectional Print Adjustment" on page 4-4. Check the "Printhead-toPlaten Gap Adjustment" on page 4-2.
636 Machine Check NOVRAM Error Non-Volatile Memory Read/Write Error. Replace the main logic board and adjust the "Bidirectional Print Adjustment" on page 4-4. Check the "Printhead-toPlaten Gap Adjustment" on page 4-2. Home Timeout Error. Go to the "Carrier Drive Service Check" on page 2-14. Carrier Drive Error. No emitter pulse detected. Go to the

637 Machine Check CA Drive Error 638 Machine Check CA Drive Error

"Carrier Drive Service Check" on page 2-14.
639 Machine Check CA Drive Error 63B Machine Check Key Scan Error Carrier Drive Error. Carrier positioning error. Go to the "Carrier Drive Service Check" on page 2-14. Button Scanning Error. Go to the "Operator Panel Service Check" on page 2-19.

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4227-X00
Display Indication 63C Machine Check Auto Gap Error 63D Machine Check Tractor2 HP Error 63E Machine Check Head Thermal Error 63F Machine Check Option RAM Error 640 Machine Check CA Thermal Error Description / Action Auto Gap Error. Go to the "Auto Gap Service Check" on page 2-10. Tractor 2 Home Position Error. Go to the "Tractor 2 Service Check" on page 2-31. Head Thermal Sensor Error. Go to the "Print Wire Drive Failure Service Check" on page 2-28. Option RAM Read/Write Error. Replace the 32Kb Memory Module. Carrier Thermal Sensor Error. Go to the "Carrier Drive Service Check" on page 2-14.

Diagnostic Information 2-3

4227-X00

Symptom Table
1. Select the symptom that best describes the problem. 2. Perform the appropriate action before you go to the indicated service check. Abnormal Indications
Symptom All LEDs turn on but do not turn off. The Power LED is on, but POST will not run. Action Disconnect the interface cable from the printer and turn the printer off and then on. If POST now runs correctly, the problem is in the computer or interface cable. Go to the "POST Service Check" on page

2-24. Abnormal Print Operation Problems
Symptom Printer will not print, or become Ready. Abnormal operation, incorrect characters, or incorrect line width. Printer is ready but will not print from the computer correctly. Undefined or incorrect characters. Action Be sure the interface cable is connected properly. Go to the "No Print or Abnormal Print Service Check" on page 2-18.

2-4 Service Manual

4227-X00 Auto Sheet Feeder Problems
Symptom Auto sheet feeder will not feed paper. Auto sheet feeder double feeds. Auto sheet feeder has intermittent feed problems. Paper Skews Isolate the problem by removing the auto sheet feeder and feeding paper, using the manual feed tray. Go to the "Auto Sheet Feeder (ASF) Service Check" on page 2-12. Action Be sure Auto Sheet Feed is set to On in the Paper Handling Option Menu. Be sure the paper select lever is in the cut sheet position. Go to the "Auto Gap Service Check" on page

2-10.

6XX Error Indications
Symptom 6XX Machine Check is displayed. Action Turn the printer off and then on. Go to "Error Indication Table" on page 2-2.

Paper Feed Problems
Symptom Paper Empty Add Paper is displayed with paper in the printer. Print operation starts without paper. Action Be sure the paper empty sensor is not blocked. There may be a problem with the paper select sensor. Go to the "Paper Feed Service Check" on page 2-20.

Diagnostic Information 2-5

4227-X00
Symptom Load/Unload does not function. Form feed length is not correct. Load/Unload functions with cut sheets in use. Paper feeds, but Auto Loading does not work. Be sure the paper select lever is in the cut sheet position. Be sure Auto Cut Sheet is enabled in the Paper Handling Option Menu. Go to the "Paper Feed Service Check" on page 2-20. Lower feed roll shaft rotates, but paper does not feed. Pressing Form Feed does not feed paper. Abnormal noise while feeding. Paper jams, skews or creases. Incorrect or no line 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 "Paper Feed Service Check" on page 2-20. Action Be sure the paper select lever is in the correct position. There may be a problem with the paper select sensor. Go to the "Paper Feed Service Check" on page 2-20.

2-6 Service Manual

4227-X00 Operator Panel Problems
Symptom Start/Stop does not function but no error is indicated. Only the Power light turns on. One or more buttons do not function. One or more lights do not function. Blank display. Cover open displayed. Action Turn the printer off and then on. Go to the "Operator Panel Service Check" on page 2-19.

Power Problems
Symptom When the power switch is on, the Power light does not turn on or the printer does not start. The Power light blinks or changes intensity. Action Check the continuity of the power cord and the voltage of the electrical outlet. Go to the "Power Failure Service Check" on page 2-25.

Diagnostic Information 2-7

4227-X00 Print Quality Problems
Symptom No print, but carrier moves as if printing. Action Be sure the printhead cables are not loose or damaged. Be sure the interface cable is connected properly. Check the ribbon cartridge for binds or damage. Go to the "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 replaced. Go to the "Auto Gap Service Check" on page 2-10. If no problem is found, go to the"Ribbon Drive Service Check" on page 2-30. Uneven print density across the print line. Specific dots missing. Be sure the printhead cables are connected correctly to the printhead and the sub logic board. Clean the printhead. Set the Auto Gap to On in the user menus and run the print test. If the print is light at one edge and uniformly gets darker across the page to the other edge, perform the "Printhead-to-Platen Gap Adjustment" on page 4-2. Go to the "Print Wire Drive Failure Service Check" on page 2-28. Scattered ink smearing, blurred characters. Fuzzy print. Clean the printhead nose. Clean the ribbon guide and shield. If the ribbon has reached its end of life or is worn, the ribbon cartridge needs to be replaced. Go to the "Print Quality Service Check" on page 2-27.

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4227-X00
Symptom Wavy vertical lines, uneven left margin or character width is reduced. Action Clean and lubricate the carrier shaft. If the carrier drive belt is worn or broken, replace the carrier unit. Check the "Bidirectional Print Adjustment" on page 4-4. Go to the "Carrier Drive Service Check" on page 2-14.

Ribbon Feed Problems
Symptom Ribbon comes off, becomes loose or folded, or jams. Ribbon feeds correctly but is noisy. Action Check the ribbon cartridge for binds or damage. Go to the "Ribbon Drive Service Check" on page 2-30.

Diagnostic Information 2-9

4227-X00

Service 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 turns on, the carrier centers, and the paper moves to the tearoff position.

2-10 Service Manual

4227-X00 Auto Gap can be set to Off to reduce time-to-print if the printer is always used with a single type of paper. With Auto Gap Off, the gap can be set to Manual Position 1 (thinnest paper) to 7 (thickest paper). With Auto Gap Off, Single Auto Gap has two selections:

· ·

Fixed - the printhead gap is never changed. Open - the gap is opened when loading forms.

Note: If there is a 63C Auto Gap Error, the gap home sensor did not detect that the carrier shaft homed, or detected that the carrier shaft homed at the wrong time.
FRU 1 Auto Gap Sensor Action Inspect the gap home flag on the end of the carrier shaft and make sure it blocks the sensor when the gap is at its largest. Power up the printer and watch the carrier shaft and the gap home flag. If the shaft rotates before the error occurs, the sensor may have failed. Perform the Sensor 2 Test in the Service Menu and test the gap home sensor. If the carrier shaft does not rotate, look for an auto gap motor or auto gap gear train problem. Disconnect CN20 from the main logic board. Check the resistance of pins: 1 and 5, 2 and 6, 3 and 5, and 4 and 6. All resistances should be 180 ± 5 ohms. No pin should have continuity to ground. If there is no 63C Auto Gap Error but there is a gap problem (light print or no print, or paper catching on the printhead or ribbon shield), enter the user menus to make sure the gap settings are appropriate for the paper being used. If Auto Gap is Off, Manual Position 1 should be used only with single-part 16 lb. or 20 lb. forms. Refer the customer to the user's guide for the appropriate Manual Position settings.

2

Auto Gap Motor Gear Train

Diagnostic Information 2-11

4227-X00

Auto Sheet Feeder (ASF) Service Check
Auto Sheet Feeder Principles of Operation The auto-sheet feeder (ASF) feeds into the cut sheet paper entry throat. To use the ASF:

· ·

The paper select lever must be set to cut sheet. Auto Sheet Feeder must be selected in the display menu.

Continuous forms can be used with the ASF installed by moving the paper select 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 feed rollers. Although the ASF pick rollers continue to turn as the paper is fed, their drive is disengaged and they are actually being turned by the paper.
FRU 1 Paper Select Sensor Action With the paper select lever in the cut sheet position, do the following: · Try to load a sheet with Load/Unload. (This button should not work) · If the paper loads go to the "POST Service Check" on page 2-24.

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4227-X00
FRU 2 Paper Feed Action If the paper does not feed, do the following: · Remove the ASF. · Be sure the base printer feeds paper correctly. · If it does not feed paper correctly, go to the

"Paper Feed Service Check" on page 2-20.
3 Gear Train Be sure the ASF drive gear on the inside of the printer's right frame rotates. Inspect the right side gear train for damage or debris. Remove the ASF right cover and ensure that all gears are in good condition. 4 Combination Lock Mechanism Install the ASF and press FormFeed. If the pick drive shaft does not rotate, replace the combination lock mechanism. 5 Left and Right Hoppers If the ASF pick rollers rotate but a single sheet is not picked, inspect the springs and corner separators on the left and right hoppers. Make sure the paper load lever is in the correct position. 6 Pick Rollers Paper Guides Feed Rollers Paper skew can be caused by worn, dirty or binding pick and feed rollers. Remove the auto sheet feeder, load paper and hand cycle the feeder while observing the pick and feed rollers. If the skew problem is in the base machine, examine all feed rollers for wear.

Diagnostic Information 2-13

4227-X00

Carrier Drive Service Check
Note: When a 637, 638 or 639 error is detected while printing, verify that the same error is detected after removing jammed paper and checking that the ribbon guide is in place.

FRU 1 637, 638, 639 CA Drive Error

Action Carrier positioning error. Inspect the following: · Tension pulley plate · Carrier · Carrier belt. Loosen and tighten the tension pulley plate screws to make sure the carrier belt is tight. Disconnect CN9 and move the carrier manually from left to right and check for smooth movement. With CN9 disconnected, check for 5 to 8 ohms between pins 1 and 2 on the motor cable. If the reading is incorrect, replace the motor. Check for motor pins shorted to the housing. If you find a pin shorted to the housing, replace the motor. If no problems are found replace the carrier motor.

2

640 CA Thermal Error

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 cool and see if the error goes away. If the machine was not being used heavily before the error occurred, or if the error returns when the machine is cool, replace the carrier motor.

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4227-X00

Intermittent Problem Service Check
FRU/Symptom 1 The machine sometimes fails before POST is complete. Action Check for the following: 1. Loose connectors. Reconnect all connectors to the main and sub logic boards. 3. Electrical noise or static discharge. Check the following items: · Power supply ground. · Machine frame ground. · Printer interface cable is grounded and shielded. 2. Intermittently low voltages. Check for ac and all dc voltages and short circuits on the main and sub logic boards. a. Check the electrical voltage and ensure that it is within tolerance. b. Check the continuity of the power cord. c. Disconnect the power supply cable from the connectors CN11 on the main logic board and CN1 on the sub logic board. Turn the printer power on and check all dc output voltages at CN11 and CN1. Ensure the output voltages are:
CN11-1 (+40 ±4 V dc) & CN11-3 (GND) CN11-2 (+40 ±4 V dc) & CN11-3 (GND) CN11-5 (+5 ±0.5 V dc) & CN11-6 (Signal GND) CN 1-1 (+40 ±4 V dc) & CN1-3 (GND) CN 1-2 (+40 ±4 V dc) & CN1-3 (GND) CN 1-5 (+5 ±0.5 V dc) & CN1-6 (Signal GND)

If the voltages are not correct, replace the Power Supply Unit. If the failure remains, replace the main logic board and sub logic board. Note: When replacing the main logic board, always set the "Bidirectional Print Adjustment" on page 4-4 and the

"Printhead-to-Platen Gap Adjustment" on page 4-2.

Diagnostic Information 2-15

4227-X00
FRU/Symptom 2 Machine power sometimes turns off. Action The cause of this problem may be that the power circuit is failing, or the wiring is intermittently open. Check the following in sequence: 1. Check the electrical voltage and be sure it is within tolerance. 2. Check the continuity of the power cord. 3. Disconnect the power supply cable from the connectors CN11 on the main logic board and CN1 on the sub logic board. Turn the printer power on and check all dc output voltages at CN11 and CN1. Be sure the output voltages are as follows:
CN11-1 (+40 ±4 V dc) & CN11-3 (GND) CN11-2 (+40 ±4 V dc) & CN11-3 (GND) CN11-5 (+5 ±0.5 V dc) & CN11-6 (Signal GND) CN 1-1 (+40 ±4 V dc) & CN1-3 (GND) CN 1-2 (+40 ±4 V dc) & CN1-3 (GND) CN 1-5 (+5 ±0.5 V dc) & CN1-6 (Signal GND)

If one of the voltages is 0, go to the "Power Failure Service Check" on page 2-25. If the voltages are not 0 but are incorrect, replace the power supply unit. 3 Intermittently poor print quality. Do the following: · · · · · · Remove paper jams from the paper path. Clean all feed roller surfaces. Clean the ribbon shield and printhead. Clean the platen surface. Install the ribbon cartridge correctly. If the ribbon end of life has been reached, have the customer replace the ribbon cartridge.

2-16 Service Manual

4227-X00
FRU/Symptom 4 If the prior suggestions have not corrected the problem. Action The service check has not defined the failure, or the machine is having intermittent failures. The following may cause undefined or intermittent failures: 1. Customer's electrical voltage. Be sure that it is within the tolerance. 2. Loose connector pins or keys that fail to contact. Check the following: a. Reconnect the connectors of all FRUs and printer interface cables. b. Check the continuity of the line cord. 3. Electrical noise. Check the following: a. Power supply ground. b. Machine frame ground. c. Printer interface cable is grounded or shielded. 4. Undefined data in customer applications. Check the baud rate at the controller. Check that the printer interface cable matches the printer. 5 Problem occurs only in specific customer applications. Perform the Trace Print (hexadecimal printing) by the following procedure and check the data streams. 1. Press Menu. 2. Press Item to display Trace Mode. 3. Press Start. 4. Have the customer print the failing job. 5. To stop printing, turn the power switch off. If the failure still occurs, set the "Bidirectional Print Adjustment" on page 4-4 and the "Printhead-to-Platen Gap Adjustment" on page 4-2.



Diagnostic Information 2-17

4227-X00

No Print or Abnormal Print Service Check
FRU/Function 1 Carrier Action If the carrier moves, but nothing is printed, go to the "Print Wire Drive Failure Service Check" on page 2-28. Enter the user menus and be sure the correct emulation (IBM/EPSON) and interface (parallel/serial) are selected. If the printer is serially attached, be sure the RS232/RS422 switch is in the correct position, and the host communications parameters are correct. 3 Main Logic Board If the Print Test does not print, or prints incorrectly, do the following: · Replace the main logic board. · Set the "Bidirectional Print Adjustment" on page 4-4 and the "Printhead-toPlaten Gap Adjustment" on page 4-2.

2

Configuration

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4227-X00

Operator Panel Service Check
Note: Press any button except Start/Stop, Load/Unload, or FormFeed. If "Operator Panel Disabled" is displayed, unlock the operator panel by powering up with the Micro and Micro keys pressed. Use the same procedure to re-lock the panel after service is complete.
FRU 1 Operator Panel Action If there is a 631 Display RAM Error, replace the operator panel. If there is a 63B Key Scan Error, one or more buttons are being detected as pressed during power-up. Replace the operator panel. 2 Printer Cable Operator 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 displayed, or if any of these tests fail, check the condition and continuity of the operator panel cable. Replace the cable or the operator panel. 3 Cover Switch If Cover Open is displayed, check the cover switch. Jumper the cover switch connector on the operator panel. If Cover Open is displayed, check the condition and continuity of the operator panel cable. Replace the cable or the operator panel. 4 Main Logic Board If the symptom has not changed, replace the main logic board.

Diagnostic Information 2-19





4227-X00

Paper Feed Service Check
Note: If the problem is frequent jams or paper creases, verify that the paper is neither very thick nor very thin. If necessary refer the customer to the User's Guide for specifications of acceptable papers.
FRU / Symptom 1 Auto Sheet Feeder Action If the Auto Sheet Feeder is installed, remove it. Enter the Paper Handling Options Menu and set "ASF" to off. Verify that the machine works correctly without the ASF installed. If the printer fails only with the Auto Sheet Feeder installed, go to the "Auto Sheet

Feeder (ASF) Service Check" on page 2-12.
2 Tractor 2 If the Tractor 2 option is installed, remove it. Verify that the machine works correctly without Tractor 2 installed. If the printer fails only with Tractor 2 installed, go to the "Tractor 2 Service Check" on page 2-31. 3 Paper Feed Motor If there is no paper motion, disconnect the paper feed motor connector CN10 from the main logic board. Check the resistance of pins: CN-1 and 6, 2 and 5, 3 and 6, and 4 and 5. All resistances should be 5.8 ± 0.5 ohms. No pin should have continuity to ground.

2-20 Service Manual

4227-X00
FRU / Symptom 4 Gear Train and Paper Feed Motor Action Remove all paper from the machine. Press FormFeed several times and examine all rotating parts to find the problem. For better visibility, remove the covers and reconnect the operator panel to the main logic board. The upper and lower feed rollers and the upper and lower pinch rollers should all be clean and in good condition, and should all rotate during Form Feed. To turn the gear train manually, turn the right end of the lower feed roller shaft with a 6 mm wrench.

Diagnostic Information 2-21

4227-X00
FRU / Symptom 5 PE Sensor TOF Sensor PSet Sensor Jam Sensor Action The printer has four sensors in the paper path, plus one which detects the position of the paper select lever. Enter the service menu and perform the sensor tests. · PE Sensor - rounded flag, detects the presence of paper at the platen. · TOF Sensor - sharp flag, determines TOF at paper load. · PSet Sensor - paper set, detects presence of paper in the tractors and looks for end of forms. · Jam Sensor - senses the holes in the paper and detects paper jams by the lack of paper movement. When the PSet sensor detects EOF, it lets printing continue to the bottom of the form. When the PE sensor detects no paper, it stops print within a few lines. The jam sensor stops printing after about 50 mm of no signal change; for example, if 50 mm of pinfeed is removed from a sheet, the sensor stops printing. Less than 50 mm will probably be ignored. Therefore, the paper motion must have stopped for the equivalent of about 12 printed lines to cause a jam. If either the PE or the PSet sensor detects no paper during print, printing stops at the end of the current page. The Tractor 2 option also has PSet and Jam sensors on the left tractor. Enter the service menu and perform the sensor tests. Replace any failed or damaged sensors. 6 Paper Select Sensor Enter the service menu and perform the Sensor Test 2 for "Lever." Move the paper select lever to test the sensor. Replace any sensor if failed or damaged.

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4227-X00
FRU / Symptom 7 Operator Panel Action If paper does not move at all, verify the FormFeed button is working correctly by performing the service menu button test. If no other problem is found, replace the main logic board. Set the "Bidirectional Print Adjustment" on page 4-4, and "Printhead-to-Platen Gap Adjustment" on page 4-2.

8

Main Logic Board

Diagnostic Information 2-23

4227-X00

POST Service Check
FRU 1 Power Action Disconnect the parallel or serial cable and turn power on. If there is no printer activity, go to the "Power Failure Service Check" on page 2-25. 2 Operator Panel If the power supply fan turns on but no LEDs light, go to the "Operator Panel Service Check" on page 2-19. If the Power LED turns on but POST does not complete, replace the main logic board. Readjust the "Bidirectional Print Adjustment" on page 4-4 and check the

3

Main Logic Board

"Printhead-to-Platen Gap Adjustment" on page 4-2.
4 Printer Cable If POST completes, reconnect the parallel or serial cable and turn power on again. If POST now fails, there is a problem with the cable, or the parallel connector on the main logic board.

2-24 Service Manual

4227-X00

Power Failure Service Check
Refer to the "Voltage, Ground, and Continuity Readings" on page 1-3, for additional information.
FRU 1 Operator Panel Action If the operator panel or cable is damaged or disconnected, the machine is completely inoperable, except for the power supply fan noise. If the power LED is not on steady, check the cable continuity and replace the cable or the operator panel. 2 Power Supply 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 ± 5 V dc at the sub logic board cable CN15 and +40 ± 4 V dc at CN1-1 and CN1-2. If there is no voltage, check the internal fuse before replacing the power supply. A 634 Power Failure indicates that the +5 V dc is OK but the +40 V dc is not. Power the printer off, wait 10 seconds, and power back on. If the 634 reappears either the power supply has failed or there is a short in a motor that uses +40 V dc.


Fuse

Diagnostic Information 2-25

4227-X00
FRU 3 Ribbon Motor Paper Feed Motor Carrier Motor Sub Logic Board Action Disconnect the carrier motor (CN9 and CN15), the paper feed motor (CN10), ribbon motor (CN19) and the (4227-200) carrier motor cooling fan (CN17) from the main logic board, and disconnect the power connector CN-1 from the sub logic board. Turn the power on again. If there is still a power problem, replace the main logic board. If the machine posts a different error, one of these items is shorted and is holding down the +40 V dc line. Reconnect them one at a time, turning the printer on in between each connection. Replace the item that causes the power failure. 4 Printhead Cables Printhead Disconnect the printhead cables from the sub logic board and turn the printer on. If the power LED lights correctly only with the printhead cables disconnected from the sub logic board, there is a short in the printhead or printhead cables. If all the above items have been examined and there is still a power problem, replace the main logic board. (Retain the old board for reinstallation if the problem is not fixed.) Adjust the "Bidirectional Print Adjustment" on page 4-4 and check the "Printhead-toPlaten Gap Adjustment" on page 4-2.

4227-200 Carrier Motor Cooling Fan

5

Main Logic Board

2-26 Service Manual

4227-X00

Print Quality Service Check

FRU 1 Ribbon and Shield

Action Be sure the ribbon is not worn and feeds smoothly when the knob is turned. Inspect the ribbon shield for dirt or damage. Be sure the ribbon drive post rotates when printing. 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.

2 3

Ribbon Drive Auto Gap

Auto Gap Motor Bracket 4 5 6 7 8 9 10 11 12 Printhead Cables Carrier Belt Adjustment Carrier Movement Bidirectional Print Adjustment Carrier Motor Paper Feed Gears Paper Feed Motor Tractors Feed Roller Surfaces

If the failure remains, replace the Auto Gap Motor Bracket. Inspect both ends of the printhead cables for proper connection. Loosen and tighten the tension pulley plate screws to make sure the carrier belt is tight. With power off, manually move the carrier from side to side to inspect for drag or binds. Check the "Bidirectional Print Adjustment" on page 4-4. The carrier motor should turn smoothly and quietly when printing. Inspect the paper feed gears for wear and tear. The paper feed motor should turn smoothly and quietly when printing. Inspect the tractors for damage or looseness. Inspect the feed roller surfaces for dirt or wear.

Diagnostic Information 2-27

4227-X00

Print Wire Drive Failure Service Check
FRU/Symptom 1 Missing Dots Carrier moves, but no printing or printhead sound. Action Perform the print test to determine which wires are not printing. Disconnect the printhead cables from the sub logic board and check the resistance for the affected wires. The resistance for each wire should be around 8.5 ohms. Left Bank Right Bank Wire 1 CN3-11 & CN3-18 CN3- 9 & CN3- 4 Wire 2 CN4-11 & CN4-20 CN4- 9 & CN4- 2 Wire 3 CN3-13 & CN3-16 CN3- 7 & CN3- 6 Wire 4 CN4-13 & CN4-18 CN4- 7 & CN4- 4 Wire 5 CN4-15 & CN4-16 CN4- 5 & CN4- 6 Wire 6 CN4-17 & CN4-14 CN4- 1 & CN4- 8 Wire 7 CN3-15 & CN3-14 CN3- 3 & CN3- 8 Wire 8 CN4-19 & CN4-12 CN4- 3 & CN4-10 Wire 9 CN3-17 & CN3-12 CN3- 5 & CN3-10

Note: 4227-200 connectors will be CN1 and CN2.
If the resistance for the affected wires is incorrect, disconnect the printhead cables from the printhead and measure the resistance of the printhead for the same wires. The resistance should be around 7.9 ohms. · If the resistance is correct, replace the printhead cables. · If the resistance is incorrect, replace the printhead. 2 63E Head Thermal Error The printer has stopped to protect the printhead from overheating. Normally this occurs after several hours of continuous heavy use in a warm environment, and only then after going through several stages of thermal slowdown. Wait for the machine to cool and see if the error goes away. If the machine was not being used heavily before the error occurred, or if the error returns when the machine is cool, replace the printhead.

2-28 Service Manual

4227-X00
FRU/Symptom 3 Auto Gap Action If printhead is firing, manually rotate the carrier shaft during printing by pushing down on the auto gap home sensor flag. If printing starts and is correct, go to the "Auto

Gap Service Check" on page 2-10.
4 5 Printhead Cables Sub Logic Board Inspect for improper connection or damage. If there is carrier motion but no printhead noise, and the printhead cables do not appear to be the problem, replace the sub logic board. A problem with the ribbon shield can keep the print wires too far from the page. Inspect the ribbon shield. When the printer is Ready with the ribbon installed, make sure the ribbon shield can float slightly front to back. 7 Printhead The printhead probably 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 found. 8 Main Logic Board If no other problem is found, replace the main logic board, retaining the old board for reinstallation if the problem is not fixed. Set the "Bidirectional Print Adjustment" on page 4-4 and the "Printhead-to-Platen Gap Adjustment" on page 4-2.

6

Ribbon

Diagnostic Information 2-29

4227-X00

Ribbon Drive Service Check
In normal operation, the ribbon knob rotates counterclockwise whenever the carrier moves to the left.

FRU/Symptom 1 Ribbon Drive Gear Train

Action Remove and inspect the ribbon. Make sure the knob turns with even, moderate force and the ribbon feeds correctly. Inspect the gear train from the ribbon motor to the ribbon drive post. Check the "Printhead-to-Platen Gap Adjustment" on page 4-2.

2

Ribbon Motor

If printing seems normal, but the ribbon is not moving, remove the ribbon and turn power on. The ribbon drive post should turn several times during POST. Disconnect the ribbon motor connector CN19 from the main logic board. The winding resistance should be 118 ohms ± 5 between pins: 1 and 6, 3 and 5, 2 and 6, 4 and 6. No other combination of pins should have continuity. If a problem is found, replace the ribbon motor and gear plate assembly.


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4227-X00

Tractor 2 Service Check
The Tractor 2 sensor opens during installation, when its actuator touches the printer cover. The home sensor detects the position of the slider.

· ·

When Tractor 2 is selected, the motor-driven Tractor 2 slider pushes the printer sub slider cam lever to engage the printer gear train which drives the Tractor 2 tractors. When the Tractor 2 is deselected, the motor retracts the slider, disengaging the Tractor 2 gear drive and reengaging the printer tractors.

63D Tractor2 HP Error
The Tractor 2 home sensor was never initialized after turning the printer off and then on, or made at the wrong time. (The same error indication is used for carrier home failure.) FRU 1 Tractor 2 Home Sensor Action Remove the Tractor 2 and turn the printer off and then on again to determine if the fault is in the printer or Tractor 2. If the gear teeth chatter just before the error is displayed, replace the home sensor.

Diagnostic Information 2-31

4227-X00
FRU 2 Main Logic Board Action Remove Tractor 2 from the printer but leave the cable connected. Make sure the slider (the black plastic piece just above the right cover) moves after turning the printer off and then on. If the slider does not move after turning the printer off and then on: · Make sure the slider and gear train are properly connected and move freely with the power off. · Make sure the Tractor 2 board is receiving: +26 V dc on CN1-1 and + 5 V dc on CN1-5. If not, check the cable connection and the voltages at main logic board CN13-1. The upper right pin at CN13 is pin 1 (+26 V dc) and the pin just beneath it is pin 5 (+5 V dc). If these voltages are not present replace the main logic board. 3 Tractor 2 Motor Board /Cable Asm 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, replace the board/cable assembly. For information on the Tractor 2 cable connectors, see "Tractor 2 Cable Connectors" on page 5-21.

2-32 Service Manual

4227-X00 Tractor 2 installed, but not shown in User Menu Tractor 2 selected from operator panel but printer does not detect Tractor 2 or detects that the Tractor 2 mechanism is not installed. Power the printer off and reinstall the Tractor 2. Power the printer on and verify the problem still occurs.
FRU 1 Tractor 2 Board/Cable Asm. Action Check the Tractor 2 sensor or the cable connection. The sensor actuator extends through the Tractor 2 cover and rests on the printer cover when Tractor 2 is installed. Remove the Tractor 2 cover and make sure the sensor opens when the Tractor 2 is installed. The voltage at Tractor 2 CN1-13 should be +5 V dc with the sensor open and 0 with it closed. Replace the Tractor 2 board/cable asm if the sensor signal is wrong. For information on the Tractor 2 cable connectors, see "Tractor 2 Cable Connectors" on page 5-21. 2 Main Logic Board Check the cable connection from Tractor 2 to the printer. If possible, try the Tractor 2 with another printer to determine if the problem is the Tractor 2 board/cable assembly or the printer main logic board.

Diagnostic Information 2-33

4227-X00 Paper Feed Problems
FRU 1 Tractor 2 Action On the printer, make sure the Tractor 2 driving gear turns freely when the white sub slider cam is not pressed. Be sure the driving gear does not move when the sub slider cam behind the gear is pressed. Remove Tractor 2 from the printer and remove all paper. With the paper select lever in the continuous forms position, press LineFeed; the tractors should rotate. Press the sub slider cam below the ASF/ Tractor 2 drive gear and press LineFeed again; the tractors should not rotate but the drive gear should. Check the condition of the pin feed belts. With the power off, make sure the slider does not bind. Verify: · When the slider is to the rear, the white gear drives the tractors; · When the slider is to the front the gear and tractors are not connected. Remove the 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 held in place by the cover; with the cover removed it will tend to move off the stud. Also note that when operating the Tractor 2 with the printer cover removed, the Tractor 2 sensor must be held open. Turn the printer on and look for mechanical problems. For information on the Tractor 2 cable connectors, see "Tractor 2 Cable Connectors" on page 5-21.

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4227-X00

3. Diagnostic Aids
The printer contains self tests to help find and solve problems. You need not connect the printer to a computer or terminal to run these tests. Types of self tests are as follows:

· · · ·

Power-On Self Test (POST) Hex Trace Mode (a computer or terminal is needed) Print Tests Error Log

Power-On Self Test (POST)
The Power-On Self Tests diagnose the basic hardware printer functions and initialize the default value settings. POST starts automatically when power to the printer is turned on, or when the printer receives an INIT signal from the controller.

· · · · · · · · · · ·

Power supply fan turns on. LED Test - All LEDs turn on briefly. LCD Test - All pels of the display are activated twice, then "initialize" is displayed. RAM Test - Checks that the CPU can write/read the RAM. ROM Test - Checks that the ROM data is correct. Timer/Interrupt Controller Test - Checks this function is working. Button Scan Test - Scans all operator panel buttons. NVRAM Test - Checks that the NVRAM data is correct. Ribbon motor feeds ribbon. Carrier moves to the left side frame and back to the right. Auto Gap sequence occurs.

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

Diagnostic Aids 3-1

4227-X00

Hex Trace Mode
The hex trace mode can help the user test and troubleshoot programs. You can use the hex trace procedure to get a hexadecimal printout of the data stream sent to the printer. All data, including control and character data, print in hexadecimal instead of ASCII. To activate hex trace mode: 1. Press Menu. 2. Press Item until Trace Mode is shown on the operator panel. 3. Press Start.

Hex Trace Mode Sample

3-2 Service Manual



4227-X00

Interface Selection (4227-100)
Serial or parallel attachment can be selected from the user menu under Interface Options. If serial attachment is selected, RS-232 or RS-422 can be selected with the switch that is accessible through the rear cover. Serial attachment parameters are set in the Interface Options menu.

Operation with the Top Cover Removed
After removing the top cover, the 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, remove the operator panel and cable, jumper the two pins of the ribbon cover sensor connector CN1 together on the back of the panel, and reconnect the operator panel flex cable to the main logic board. Note: Printing without the top cover affects print quality and may cause paper jams since the upper feed rollers on the ribbon cover do not help restrain and feed paper.

Diagnostic Aids 3-3

4227-X00

Service Menu
Enter the Service Menu by pressing Menu/Quit during POR. Release the button when the carrier strikes the left side frame. Exit the service menu by pressing Menu/Quit.

· ·

Sensor Test 1: Tests PSet, Jam, PE & TOF sensors. Sensor Test 2: Tests Paper Select, Gap Home, and Cover sensors.

These tests display an underline (_) if the sensor is open or a block ( ) if the sensor is blocked. Use paper, tools or fingers to block and unblock the sensors to verify that each is functional. Return to the Service Menu by pressing Menu/Quit.

Button Test
Pressing each operator panel button causes the alarm to beep. Pressing multiple buttons simultaneously results in no beep. Return to the Service Menu by pressing Menu/Quit.

Factory Setting
Factory Setting allows the selection o