Lexmark 4227 Service Manual

Lexmark 4227 - Forms Printer B/W Dot-matrix Manual

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  • Lexmark 4227 | Service Manual - Page 1
    Edition: January 15, 2007 Lexmark™ Forms Printer 4227-300 • Table of contents • Start diagnostics • Safety and notices • Trademarks • Index Lexmark and Lexmark with diamond design are trademarks of Lexmark International, Inc., registered in the United States and/or other countries.
  • Lexmark 4227 | Service Manual - Page 2
    4227-300 Edition: January 15, 2007 The following paragraph does not apply to any country where such provisions are inconsistent with local law: LEXMARK INTERNATIONAL This publication could include technical inaccuracies or typographical errors. Changes are periodically made to the information herein
  • Lexmark 4227 | Service Manual - Page 3
    print operation 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
  • Lexmark 4227 | Service Manual - Page 4
    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 force 3-4 Log clear 3-4 Print Test 3-5 Other print tests 3-5 Error log 3-5 Repair information 4-1 Handling ESD-sensitive parts 4-1 Adjustments 4-2 Printhead installation
  • Lexmark 4227 | Service Manual - Page 5
    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
  • Lexmark 4227 | Service Manual - Page 6
    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 I-1 Part number index I-5 v Service Manual
  • Lexmark 4227 | Service Manual - Page 7
    4227-300 Safety information • The safety of this product is based on testing and approvals of the original design and specific components. The manufacturer is not responsible for safety in the event of use of unauthorized replacement parts. • The maintenance information for this product has
  • Lexmark 4227 | Service Manual - Page 8
    4227-300 Norme di sicurezza • La sicurezza del prodotto si basa sui test e sull'approvazione del progetto originale e dei componenti specifici. Il produttore non è responsabile per la sicurezza das Produkt für die Ausführung der Arbeiten an den Strom angeschlossen sein muß. vii Service Manual
  • Lexmark 4227 | Service Manual - Page 9
    4227-300 Pautas de • PRECAUCIÓN: este símbolo indica que el voltaje de la parte del equipo con la que está trabajando es peligroso. Antes . Informações de Segurança • A segurança deste produto baseia-se em testes e aprovações do modelo original e de componentes específicos. O fabricante
  • Lexmark 4227 | Service Manual - Page 10
    4227-300 Informació de Seguretat • La seguretat d'aquest producte es basa en l'avaluació i assabentat i prendre les mesures convenients. • 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
  • Lexmark 4227 | Service Manual - Page 11
    4227-300 x
  • Lexmark 4227 | Service Manual - Page 12
    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 provides instructions for making MFP
  • Lexmark 4227 | Service Manual - Page 13
    , and Gothic Forms (straight paper path) Automatic tear-off Automatic paper loading/unloading Manual Optional Auto Sheet Feeder 6-part Forms (carbon and carbonless) (4227-300 - up to 8-part Forms) Parallel, Serial RS-422, Serial RS-232 When Auto Gap is set to On, the printer automatically adjusts to
  • Lexmark 4227 | Service Manual - Page 14
    4227-300 Voltage, ground, and continuity readings Voltage 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. correct continuity will read zero ohms. 1-2 Service Manual
  • Lexmark 4227 | Service Manual - Page 15
    4227-300 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 "Power-On Self
  • Lexmark 4227 | Service Manual - Page 16
    4227-300 Abbreviations ASF ASIC CSU DRAM EPROM 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
  • Lexmark 4227 | Service Manual - Page 17
    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 General information
  • Lexmark 4227 | Service Manual - Page 18
    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 Service Manual
  • Lexmark 4227 | Service Manual - Page 19
    4227-300 Setting printer functions 1. Press Start/Stop. 2. Press Menu to 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
  • Lexmark 4227 | Service Manual - Page 20
    4227-300 Overview of function menus Use the Item ↑ and Item ↓ buttons to move through the menu and option directories. 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 Service Manual
  • Lexmark 4227 | Service Manual - Page 21
    4227-300 General information 1-9
  • Lexmark 4227 | Service Manual - Page 22
    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. 1-10 Service Manual
  • Lexmark 4227 | Service Manual - Page 23
    ) Auto Gap (Green) Tractor 2 (Green) Description 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
  • Lexmark 4227 | Service Manual - Page 24
    4227-300 1-12 Service Manual
  • Lexmark 4227 | Service Manual - Page 25
    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 Test" on page
  • Lexmark 4227 | Service Manual - Page 26
    Check Auto Gap Error 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 Description/Action Timer Interrupt Controller Error. Replace the main logic board and perform the "Bidirectional print adjustment" on
  • Lexmark 4227 | Service Manual - Page 27
    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
  • Lexmark 4227 | Service Manual - Page 28
    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 Printer will not print, or become Ready. Abnormal operation, incorrect characters, or incorrect line width
  • Lexmark 4227 | Service Manual - Page 29
    "Auto Gap service check" on page 2-11. Isolate the problem by removing the Auto Sheet Feeder and then feed paper using the manual feed tray. Go to the "Auto Sheet Feeder (ASF) service check" on page 2-13. 6XX Error indications Symptom 6XX Machine Check is displayed. Action Turn the printer off
  • Lexmark 4227 | Service Manual - Page 30
    4227-300 Paper feed problems Symptom 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 sheets in use. Paper feeds, but Auto Loading does not work. Action
  • Lexmark 4227 | Service Manual - Page 31
    4227-300 Symptom 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 Action Be sure the
  • Lexmark 4227 | Service Manual - Page 32
    4227-300 Operator panel problems Symptom Start/Stop does not function but no error is indicated. Only the Power light comes 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 back on. Go to the "
  • Lexmark 4227 | Service Manual - Page 33
    2-11. If no problem is found, go to the"Ribbon drive service check" on page 2-30. Be sure the printhead cables are connected correctly to the printhead and the sub logic board. Clean the printhead. Set the Auto Gap to On in the user menus and run the print test. If the print is light at one edge and
  • Lexmark 4227 | Service Manual - Page 34
    to the "Carrier drive service check" on page 2-15. 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. 2-10 Service Manual
  • Lexmark 4227 | Service Manual - Page 35
    4227-300 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
  • Lexmark 4227 | Service Manual - Page 36
    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
  • Lexmark 4227 | Service Manual - Page 37
    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
  • Lexmark 4227 | Service Manual - Page 38
    4227-300 FRU Action 2 Paper Feed If the paper does not feed, do the following: 3 Gear Train • 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 2-21. Be sure the ASF drive gear on the inside of
  • Lexmark 4227 | Service Manual - Page 39
    4227-300 Carrier drive service check Note: When a 637, 638, or 639 error is detected while printing, verify that the same error is detected after removing jammed paper and checking that the ribbon guide is in place. FRU Action 1 637, 638, 639 CA Drive Error Carrier positioning error. Inspect the
  • Lexmark 4227 | Service Manual - Page 40
    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 perform the "Bidirectional print adjustment" on page 4-3 and the "Printhead-to-platen gap adjustment" on page 4-2. 2-16 Service Manual
  • Lexmark 4227 | Service Manual - Page 41
    : print quality. • 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
  • Lexmark 4227 | Service Manual - Page 42
    ↑ 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, perform the "Bidirectional print adjustment" on page 4-3 and the "Printhead-to-platen gap adjustment" on page 4-2. 2-18 Service Manual
  • Lexmark 4227 | Service Manual - Page 43
    host communications parameters are correct. If the Print Test does not print, or prints incorrectly, do the following: • Replace the main logic board. • Perform the "Bidirectional print adjustment" on page 4-3 and the "Printhead-to-platen gap adjustment" on page 4-2. Diagnostic information 2-19
  • Lexmark 4227 | Service Manual - Page 44
    is a 63B Key Scan Error, one or more buttons are being detected as pressed during power-up. 2 Printer Cable Operator Panel Replace the 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
  • Lexmark 4227 | Service Manual - Page 45
    4227-300 Paper feed service check Note: If the problem is frequent jams or paper creases, verify that the paper is neither very thick nor very thin. If necessary refer the customer to the User's Guide for specifications of acceptable papers. FRU/Symptom Action 1 Auto Sheet Feeder If the Auto
  • Lexmark 4227 | Service Manual - Page 46
    4227-300 FRU/Symptom Action 4 Gear Train and Remove all paper from the machine. Paper Feed Motor 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
  • Lexmark 4227 | Service Manual - Page 47
    4227-300 FRU/Symptom 5 PE Sensor TOF Sensor PSet Sensor Jam Sensor 6 Paper Select 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
  • Lexmark 4227 | Service Manual - Page 48
    paper does not move at all, verify the FormFeed button is working correctly by performing the Service Menu Button Test. 8 Main Logic Board If no other problem is found, replace the main logic board. Perform the "Bidirectional print adjustment" on page 4-3, and "Printhead-to-platen gap adjustment
  • Lexmark 4227 | Service Manual - Page 49
    4227-300 Power failure service check For more information see "Voltage, ground, and continuity readings" on page 1-2. FRU 1 Operator Panel 2 Power Supply Fuse Action If the operator panel or cable is damaged or disconnected, the machine is completely inoperable, except for the power supply fan
  • Lexmark 4227 | Service Manual - Page 50
    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.) Perform the "Bidirectional print adjustment" on page 4-3 and check the "Printhead-toplaten gap adjustment" on page 4-2. 2-26 Service Manual
  • Lexmark 4227 | Service Manual - Page 51
    Be sure the ribbon drive post rotates when printing. 3 Auto Gap Check the "Printhead-to-platen gap adjustment" on page 4-2. If Auto Gap is off, be sure the manual position setting is appropriate for the paper used. Auto Gap Motor Bracket If the failure remains, replace the Auto Gap motor bracket
  • Lexmark 4227 | Service Manual - Page 52
    4227-300 Print wire drive failure service check FRU/Symptom 1 Missing Dots Carrier moves, but there is 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
  • Lexmark 4227 | Service Manual - Page 53
    4227-300 FRU/Symptom 2 63E Head Thermal Error 3 Auto Gap 4 Printhead Cables 5 Sub Logic Board 6 Ribbon 7 Printhead Action 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
  • Lexmark 4227 | Service Manual - Page 54
    4227-300 FRU/Symptom Action 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. Perform the "Bidirectional print adjustment" on page 4-3 and the "Printhead-to-platen gap adjustment" on page 4-2.
  • Lexmark 4227 | Service Manual - Page 55
    4227-300 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
  • Lexmark 4227 | Service Manual - Page 56
    4227-300 FRU Action 2 Main Logic Board 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 back on. If the slider does not move after turning the printer off and
  • Lexmark 4227 | Service Manual - Page 57
    4227-300 Tractor 2 installed, but not shown in User Menu Tractor 2 is selected from operator panel but the printer does not detect Tractor 2, or detects that the Tractor 2 mechanism is not installed. Power the printer off and reinstall the Tractor 2. Power the printer on and verify the problem still
  • Lexmark 4227 | Service Manual - Page 58
    4227-300 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
  • Lexmark 4227 | Service Manual - Page 59
    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
  • Lexmark 4227 | Service Manual - Page 60
    4227-300 Hex trace mode The hex trace mode can help test and troubleshoot programs. You can use the hex trace procedure to get a hexadecimal printout of the data stream sent to the printer. All data, including control and character data, print in hexadecimal instead of ASCII. To activate hex trace
  • Lexmark 4227 | Service Manual - Page 61
    panel flex cable to the main logic board. Note: Printing without the top cover affects print quality and may cause paper jams, since the upper feed rollers on the ribbon cover do not help restrain and feed paper. Service Menu Enter the Service Menu by pressing Menu/Quit during POR. Release the
  • Lexmark 4227 | Service Manual - Page 62
    the printer in High can damage the printhead, especially if printing on single-sheet forms. • Normal 1P-Disables the automatic setting of the impact force. Normal 1P is used to print in normal force when thicker print media is used, such as labels. Log clear Clears the error log. 3-4 Service Manual
  • Lexmark 4227 | Service Manual - Page 63
    Demo and the Print Settings page are accessed from the user menus. Print Settings prints Macro status and paper handling settings and prints 8 inches wide. Error log The Error Log printout is part of the Service Menu test print page. Error indicators print on the top line of the Error Log and their
  • Lexmark 4227 | Service Manual - Page 64
    4227-300 3-6 Service Manual
  • Lexmark 4227 | Service Manual - Page 65
    4227-300 4. Repair information This chapter explains how to make adjustments to the printer and how to remove defective parts. Warning: Read the following before handling electronic parts. Handling ESD-sensitive parts Many electronic products use parts that are known to be sensitive to electrostatic
  • Lexmark 4227 | Service Manual - Page 66
    shaft, or main logic board is removed or replaced • When the print density varies across the page There are two adjustments to this procedure. Printhead-to-platen gap left and right 1. Turn the power off. 2. Remove the top cover. 3. Remove the ribbon. 4. Position the carrier to the left. 5. Using
  • Lexmark 4227 | Service Manual - Page 67
    4227-300 Printhead-to-platen gap electronic setting Be sure there is no paper in the printer. 1. Install a ribbon. 2. Hold down FormFeed and power on the printer. 3. Remove the ribbon guide. 4. Measure the printhead-to-platen gap. The gap specification is between .011 inch (.275 mm) and .015 inch (.
  • Lexmark 4227 | Service Manual - Page 68
    lines 2 and 4 to the right. • Press Item ↓ to move lines 2 and 4 to the left. 8. Press Store to save the selected value. 9. Press Start/Stop to print the alignment pattern. The example below shows proper alignment. 10. Press Quit to exit the menu. 4-4 Service Manual
  • Lexmark 4227 | Service Manual - Page 69
    on the printer with any of the covers removed. 1. Turn the printer off. 2. Disconnect the power cord and parallel cable at the printer. 3. Remove the front cover (1). 4. Remove the acoustic and ribbon access covers (2). 5. Set the Paper Select lever to the cut sheet position. Repair information 4-5
  • Lexmark 4227 | Service Manual - Page 70
    (3) mounting screws. 7. Place the printer on its left side. Insert a flat blade screwdriver into the two slots (4) and release the cover by pushing on the left side latches and up on the top cover. 8. Place the printer on its right side and release the two right side latches (4). 4-6 Service Manual
  • Lexmark 4227 | Service Manual - Page 71
    4227-300 9. Place the printer on its feet and release the remaining two top cover latches (4). securely. WARNING: Damage to the operator panel cable may cause failure of other electrical components of the printer. Be sure not to crimp or pinch this cable while reinstalling the top cover. CAUTION: Be
  • Lexmark 4227 | Service Manual - Page 72
    page 4-5. 2. Disconnect gap adjust motor connector CN20 from the main logic board. 3. Remove the sub logic card. 4. Remove the paper feed motor. 5. Remove the two gap adjust motor screws (1) through the access holes in the carrier motor mounting bracket, and remove the motor (2). 4-8 Service Manual
  • Lexmark 4227 | Service Manual - Page 73
    4227-300 Auto Sheet Feeder gears removal 1. Remove the right cover (1). 2. Release the latch, and then remove the joint gear (2). 3. Remove the 4. Release the latch, and then remove the pick-up gear (4). 5. Release the latch, and then remove the combination lock mechanism (5). Repair information 4-9
  • Lexmark 4227 | Service Manual - Page 74
    the cut sheet support. 2. Remove the idler gear and the pick-up gear. See "Auto Sheet Feeder gears removal" on page 4-9. 3. Remove the left roller bushing (1). 4. Remove the right roller bushing (2). 5. Move the pick-up roller (3) to both ends of the shaft, and then remove them. 4-10 Service Manual
  • Lexmark 4227 | Service Manual - Page 75
    . See "Top cover removal" on page 4-5. 3. Remove the print unit. 4. Remove the power supply. 5. Remove the main logic board. 6. Remove the tractor cable and bracket. 7. If you are replacing the bottom cover, write the machine serial number and part number on the blank label. Repair information 4-11
  • Lexmark 4227 | Service Manual - Page 76
    Remove the top cover. See "Top cover removal" on page 4-5. 2. Remove the printhead. See "Printhead removal" on page 4-32. 3. Remove the carrier roller spring. 4. Remove the sub logic board. See "Sub logic board removal" on page 4-37. 5. Remove the ribbon drive motor assembly (1). 4-12 Service Manual
  • Lexmark 4227 | Service Manual - Page 77
    4227-300 6. Loosen the two tension pulley plate screws (2). Pull up on both sides of the belt to move the tension pulley plate as far as possible toward the center of the printer, and then retighten the large screw. 7. Remove the belt from the carrier motor pulley. 8. Push the tension pulley toward
  • Lexmark 4227 | Service Manual - Page 78
    4227-300 9. Remove the gear/flag (3) from the end of the carrier shaft. 10. Remove the bearing (4) and its retainer (5) gear. 2. Rotate the shaft to get the bearing to seat in the side frame. 3. After reinstalling, perform the "Printhead-to-platen gap adjustment" on page 4-2. 4-14 Service Manual
  • Lexmark 4227 | Service Manual - Page 79
    4227-300 move the tension pulley plate as far as possible toward the center of the printer, and then retighten the large screw. 4. Remove the three screws (1) holding bearing should be under the ribbon motor plate, mounted to the carrier motor shaft. 3. The ribbon motor screws should be loosened
  • Lexmark 4227 | Service Manual - Page 80
    separator. See "Paper separator removal" on page 4-27. 5. Carefully remove the label from the paper separator. If the label is jammed below the carrier plate or on the lower portion of the paper guide/platen assembly, carefully remove the label without scratching either surface. 4-16 Service Manual
  • Lexmark 4227 | Service Manual - Page 81
    4227-300 Lower feed roller removal 1. Remove the top cover. See "Top cover removal" on page 4-5. 2. Remove the print unit. 3. Remove the sub logic board. 4. Remove the paper feed motor. 5. Remove the large gear from the left side frame by prying it from behind with a flat-blade screwdriver. 6.
  • Lexmark 4227 | Service Manual - Page 82
    4227-300 8. Remove the gear shaft support plate (2) and the two gears with their springs (3). 9. Remove the large screw (4) holding the tension pulley plate to the side frame. 10. Remove the gear, clip, and bearing (5) from the end of the lower feed roller shaft. 4-18 Service Manual
  • Lexmark 4227 | Service Manual - Page 83
    4227-300 11. Release and remove the separator plate spring (6). 12. Release the spring (7) from the right end of the lower pinch roller. 13. Remove the two carrier plate screws (8). One is in the slot in the slider cam. 14. Remove the support shaft screw (9). Repair information 4-19
  • Lexmark 4227 | Service Manual - Page 84
    4227-300 15. Remove the two platen screws (10). 16. Remove the right side frame. 17. Remove the lower feed roller shaft. Note: The upper feed roller bearing should stay in the side frame. The lower pinch roller bushing is free on the end of the shaft. To reassemble: 1. Remove the paper separator
  • Lexmark 4227 | Service Manual - Page 85
    4227-300 Lower pinch roller removal 1. Remove the ribbon cover and the ribbon. 2. Remove the U-shaped ground spring : After replacing the main logic board, recheck the "Bidirectional print adjustment" on page 4-3 and the "Printhead-to-platen gap adjustment" on page 4-2. Repair information 4-21
  • Lexmark 4227 | Service Manual - Page 86
    lower latches to free the operator panel from the top cover. Paper Empty sensor/TOF sensor removal 1. Remove the top cover. See "Top cover removal" on page 4-5. 2. Remove the print unit. See "Print unit removal" on page 4-29. 3. Remove the right screw (1) in the support shaft. 4-22 Service Manual
  • Lexmark 4227 | Service Manual - Page 87
    4227-300 4. To remove the Paper Empty sensor: a. Release the four latches (2) and remove the Paper Empty sensor. b. Carefully grasp the Paper Empty flag with a pair of needle nose pliers and remove the flag by pulling it vertically away from the paper guide. Do not damage or lose the Paper Empty
  • Lexmark 4227 | Service Manual - Page 88
    4227-300 To replace the TOF Sensor Flag: Unless necessary, do not replace the sensor flag when replacing the sensor. 1. With diagonal pliers, cut the post and two tabs (5) off as flush as possible. 2. Unsnap both ends of the sensor flag from the paper guide the paper path by the spring force. Be
  • Lexmark 4227 | Service Manual - Page 89
    it front down on a flat surface. 2. Pry under the front part of the guide to release the two latches, and then remove the paper guide. Paper guide/platen assembly removal 1. Remove the top cover. See "Top cover removal" on page 4-5. Remove the print unit. 2. Remove the sub logic card. 3. Remove the
  • Lexmark 4227 | Service Manual - Page 90
    -300 Paper Select sensor removal 1. Remove the top cover. See "Top cover removal" on page 4-5. 2. Remove the print unit. See "Print unit removal" on page 4-29. 3. Use a #1 Phillips screwdriver to remove the two screws (1) holding the Paper Select sensor to the left side frame. 4-26 Service Manual
  • Lexmark 4227 | Service Manual - Page 91
    4227-300 Paper separator removal 1. Remove the top cover. See "Top cover removal" on page 4-5. 2. Remove the print unit from the base. See "Print unit removal" on page 4-29. 3. Remove the Paper Select lever. 4. Remove the gear shaft support plate and the two gears with their springs (1). 5. Remove
  • Lexmark 4227 | Service Manual - Page 92
    but do not remove the support shaft screw (6) and the two platen screws. 10. Wiggle the right side frame and pull it about 2 mm to the right. 11. Flex the front of the side frame outward slightly to free the right end of the paper separator (7). 12. Remove the paper separator. 4-28 Service Manual
  • Lexmark 4227 | Service Manual - Page 93
    4227-300 Power supply removal CAUTION: The power supply may be hot. 1. Turn off the printer and disconnect the power cord at both the fan to the cover. Print unit removal 1. Remove the top cover. See "Top cover removal" on page 4-5. 2. Disconnect the tractor connector. 3. Disconnect the flexible
  • Lexmark 4227 | Service Manual - Page 94
    4227-300 7. On the left side, remove the three screws (1) holding the print unit to the base. 8. On the right side, remove the screw (2) holding the print unit to the base. 4-30 Service Manual
  • Lexmark 4227 | Service Manual - Page 95
    4227-300 9. Slide the printer partway off the edge of the table. From the bottom, remove the screw (3) holding the front of each side frame to the base. 10.Lift the print unit from the base. To Reinstall For ease of reassembly, remove the flexible signal cable from the main logic board and connect
  • Lexmark 4227 | Service Manual - Page 96
    4227-300 Printhead removal 1. Turn the printer off. 2. Disconnect the power cord at the printer. CAUTION: Allow the printhead to cool for 15 minutes. 3. Remove the ribbon cover and ribbon. 4. Remove the two screws (1) on the cable retainer and disconnect the two cables. These are ZIF connectors. 5.
  • Lexmark 4227 | Service Manual - Page 97
    4227-300 Printhead cables removal 1. Remove the top cover. See "Top cover removal" on page 4-5. the other end of the cables from the sub logic board, and then pull the cables from under the ribbon motor. 4. The cables are attached to the carrier plate with double-faced tape. To reinstall Be sure the
  • Lexmark 4227 | Service Manual - Page 98
    4227-300 Ribbon drive motor assembly removal 1. Remove the top cover. See "Top cover removal" on page 4-5. 2. Remove the sub logic board. 3. Remove the ribbon drive post cover and the ribbon drive post (1). 4. Remove the Auto Gap sensor (2) from the motor bracket. 5. Disconnect ribbon motor
  • Lexmark 4227 | Service Manual - Page 99
    4227-300 Right side frame removal 1. Remove the top cover. See "Top cover removal" on page 4-5. 2. Remove the print unit. 3. Remove the Paper Select lever. 4. Remove the gear shaft support plate (2) and the two gears with their springs (3). 5. Remove the large screw (4) holding the tension pulley
  • Lexmark 4227 | Service Manual - Page 100
    4227-300 7. Release and remove the separator plate spring (6). 8. Release the spring (7) from the right end of the lower pinch roller. 9. Remove the two carrier plate screws (8). One is in the slot in the slider cam. 10.Remove the support shaft screw (9) and the two platen screws (10). 4-36 Service
  • Lexmark 4227 | Service Manual - Page 101
    separator. 3. Install the left end of the paper separator first, and then bend the right side frame slightly to get the right end installed. 4. Reinstall the separator screw through the hole above the slider cam. 5. Set the printhead to platen gap. Sub logic board removal 1. Remove the top cover
  • Lexmark 4227 | Service Manual - Page 102
    4227-300 Upper feed roller removal 1. Remove the top cover. See "Top cover removal" on page 4-5. 2. Release the latches and remove the gear (1) from the left end shaft. 5. Lift the shaft out to the right. Be sure not to lose the bearings; they are both free to come off the shaft. 4-38 Service Manual
  • Lexmark 4227 | Service Manual - Page 103
    4227-300 5. Preventive maintenance This chapter describes procedures for preventive maintenance for the printer. Following these recommendations can help prevent problems and maintain optimum performance. Lubrication Warning: Petroleum-based lubricants can attack polycarbonate parts, causing
  • Lexmark 4227 | Service Manual - Page 104
    frame • Mounting studs for Auto Gap gears • Lower pinch roller and ground spring • Right ASF side frame studs and all gears • Left ASF side frame studs and upper feed roll shaft • ASF pick-up roller Shaft and L & R roller bushings • Tractor 2 right side frame studs and all gears 5-2 Service Manual
  • Lexmark 4227 | Service Manual - Page 105
    4227-300 6. Locations and connectors 4227-300 Locations and connectors 6-1
  • Lexmark 4227 | Service Manual - Page 106
    Select Sensor Paper Empty and TOF Sensors Gap Home Sensor Carrier Motor Cable #1 Paper Feed Motor Power Supply Tractor 2 DIN Operator Panel Carrier Motor Cable #2 Carrier Motor Cooling Fan Tractor PSet & Jam Sensors Ribbon Motor Auto Gap Motor Serial Port Serial Interface 5 V dc 6-2 Service Manual
  • Lexmark 4227 | Service Manual - Page 107
    4227-300 CN1 CN2 CN3 CN4 Printhead Printhead Main Logic Board Flex Cable Power Supply Operator panel connectors CN1 CN2 CN3 Ribbon Cover Sensor LCD Board (soldered) Main Logic Board Locations and connectors 6-3
  • Lexmark 4227 | Service Manual - Page 108
    4227-300 Component locations This chapter shows the location of specific parts of the printer. Part name Ref. Part name Ref. Auto Gap Motor W Parallel/Serial Interface Y Connector Auto Gap Sensor V Platen B Carrier P Power Supply BB Carrier Motor K Printhead Q Carrier Plate Jam
  • Lexmark 4227 | Service Manual - Page 109
    4227-300 Component location illustrations Locations and connectors 6-5
  • Lexmark 4227 | Service Manual - Page 110
    4227-300 Component location illustrations (Continued) 6-6 Service Manual
  • Lexmark 4227 | Service Manual - Page 111
    connections Power Supply ->Main Logic BoardSub Logic Board Power Supply Main Logic Board CN11 Sub Logic Board CN4 - 4227-300 +40 V dc +40 V dc Power Gnd Power Gnd +5 V dc Signal Gnd Pin 1 Pin 2 Pin 3 Signal Gnd Signal Gnd -INIT -Error Signal Gnd NC +5 V dc -SE Locations and connectors 6-7
  • Lexmark 4227 | Service Manual - Page 112
    4227-300 Main Logic BoardSub Logic Board Main Logic Board CN3 Pin 1 Pin 2 Pin 3 Pin 4 Pin 5 Pin 6 R7COM Pin 5 L8COM Pin 4 R8COM Pin 3 L9COM Pin 2 R9COM Pin 1 BUZZER Main Logic BoardPaper Select Sensor Pin 1 Pin 2 Pin 3 Pin 4 CN4 Not Used Signal Gnd FRETRA Signal Gnd 6-8 Service Manual
  • Lexmark 4227 | Service Manual - Page 113
    4227-300 Main Logic BoardPaper Empty & TOF Sensors Pin 1 Pin 2 Pin 3 Pin 4 Pin 5 Pin 6 CN7 PE1P PE1 Signal Gnd PE2P PE2 Signal Gnd Main Logic BoardAuto Gap Sensor Pin 1 Pin 2 Pin 3 CN8 +5 V dc AGHPC AGHP Main Logic BoardCarrier Motor Cable #1 Pin 1 Pin 2 CN9 CA+ CA- Main Logic
  • Lexmark 4227 | Service Manual - Page 114
    4227-300 Main Logic BoardTractor 2 DIN Pin 1 Pin 2 Pin 3 Pin 4 Pin 5 Pin 6 Pin 7 Pin 8 Pin 9 Pin 10 Pin 11 Pin 12 Pin 13 CN13 +26Vdc +26Vdc Power Gnd PSET +5Vdc DTCOM DSET Signal Gnd DTMTA DTMTB JAM DHP DPOS Main Logic BoardCarrier Motor Cooling Fan Pin 1 Pin 2 CN17 Fan+ Fan- Main
  • Lexmark 4227 | Service Manual - Page 115
    4227-300 Main Logic BoardOperator Panel Main Logic Board CN14 Pin 1 +5Vdc Pin 2 SLATCH Pin 4 Pin 5 Pin 6 Pin 7 CN15 +5Vdc EA Gnd EB Gnd CATHM Not Used Main Logic BoardTractor PSet & Jam Sensors Pin 1 Pin 2 Pin 3 Pin 4 Pin 5 Pin 6 CN18 TRPSS TRPSG TRJMP TRJAM TRJMG DSET Locations and
  • Lexmark 4227 | Service Manual - Page 116
    4227-300 Main Logic BoardRibbon Motor Pin 1 Pin 2 Pin 3 Pin 4 Pin 5 Pin 6 CN19 RBD RBC RBB RBA RBCOM RBCOM Main Logic BoardAuto Gap Motor Pin 1 Pin 2 Pin 3 Pin 4 Pin 5 Pin 6 CN20 GPD 2 Pin 1 +TXD422 -RXD422 +RXD42 -TXD422 DTR Signal Gnd DSR -CTS RTS RXD TXD SBSET 6-12 Service Manual
  • Lexmark 4227 | Service Manual - Page 117
    4227-300 Serial BoardSerial Cable Pin 1 Pin 2 Pin 3 Pin 4 Pin 5 Pin 6 Pin 7 Pin 8 Pin 9 Pin 10 Pin 11 Pin 12 Pin 13 CN1 Chassis Gnd Pin
  • Lexmark 4227 | Service Manual - Page 118
    4227-300 Sub Logic BoardPrinthead Pin 1 Pin 2 Pin 3 Pin 4 Pin 5 Pin 6 Pin 7 Pin 8 Pin 9 Pin 10 Pin 11 Pin 12 Pin 13 Pin 14 LH4 LH1 Pin 16 LH5C Pin 17 LH2 Pin 18 Pin 19 Pin 20 LH4C LH3 LH3C Operator Panel BoardRibbon Cover Sensor Pin 1 Pin 2 CN1 C-Open Signal Gnd 6-14 Service Manual
  • Lexmark 4227 | Service Manual - Page 119
    4227-300 Tractor 2 cable connectors The Tractor 2 cable is soldered to the board at CN1. Pin CN1-1 CN1-2 CN1-3 CN1-4 CN1-5 CN1-6 CN1-7 CN1-8 CN1-9 CN1-10 CN1-11 CN1-12 CN1-13 Mode +26 V dc +26 V dc Frame Gnd Not used. +5 V dc Motor Common D-Set (signal for Tractor 2 plugged in) Signal Gnd Motor
  • Lexmark 4227 | Service Manual - Page 120
    4227-300 Connector block diagram 4227-300 6-16 Service Manual
  • Lexmark 4227 | Service Manual - Page 121
    4227-300 Locations and connectors 6-17
  • Lexmark 4227 | Service Manual - Page 122
    4227-300 6-18 Service Manual
  • Lexmark 4227 | Service Manual - Page 123
    4227-300 7. Parts catalog How to use this parts catalog • Similar Assemblies: If two assemblies contain a majority of identical parts, they are shown on the same list. Common parts are shown by one index number. Parts peculiar to one or the other of the assemblies are listed separately and
  • Lexmark 4227 | Service Manual - Page 124
    4227-300 Assembly 1: Covers and operator panel             7-2 Service Manual
  • Lexmark 4227 | Service Manual - Page 125
    12 Part number 40X3045 40X3051 40X3130 40X3050 40X3118 40X3043 40X3126 40X3131 40X3106 40X3094 40X3048 40X3049 Description Cover assembly, ribbon access Cover, acoustic Paper stand Switch assembly, cover with cover switch plate Cover, rear (4227--300) Cover assembly, front (complete) Guide, paper
  • Lexmark 4227 | Service Manual - Page 126
    4227-300 Assembly 2: Paper feed 7-4 Service Manual
  • Lexmark 4227 | Service Manual - Page 127
    Frame support shaft TOF & Paper Empty sensors with flags & springs Paper guide/platen assembly Bracket, Auto Gap motor Roller, feed (lower) Roller, pinch (lower) Side frame assembly (left) Sensor, Paper Select Gear kit Separator, paper Latch, ribbon Side frame assembly (right) Screw, parts packet
  • Lexmark 4227 | Service Manual - Page 128
    4227-300 Assembly 3: Carrier 7-6 Service Manual
  • Lexmark 4227 | Service Manual - Page 129
    Screw, parts packet Motor, paper feed assembly with bracket Bearing kit Gears, parts packet Motor, ribbon drive and gear plate assembly Plate assembly with belt tension pulley Motor, Auto Gap Roller, lower pinch Spring kit Bracket, carrier motor Motor, carrier assembly Cable, printhead and retainer
  • Lexmark 4227 | Service Manual - Page 130
    4227-300 Assembly 4: Base and electronics 7-8 Service Manual
  • Lexmark 4227 | Service Manual - Page 131
    4227-300 AsmIndex 4-1 1 2 3 4 5 6 7 8 8 8 8 8 8 8 8 8 8 8 8 9 NS NS NS NS NS NS NS Part Power supply, 100 - 240 V ac Ground wire Bracket, tractor cable Cable, tractor Base assembly Power cord (U.S., Canada, AFE (LV), Saudi Arabia Paper guide Mylar strip Fuse, power supply Fan, power supply Main logic
  • Lexmark 4227 | Service Manual - Page 132
    4227-300 Assembly 5: ASF side frame/covers        7-10 Service Manual
  • Lexmark 4227 | Service Manual - Page 133
    4227-300 AsmIndex 5-1 2 3 4 5 6 Part number 40X3137 40X3033 40X2891 40X3136 40X2892 40X3135 Description Support, stacking Cover (front) Spring kit, ASF Gear and bearing kit, ASF Screw kit, ASF Cover (right) Parts catalog 7-11
  • Lexmark 4227 | Service Manual - Page 134
    4227-300 Assembly 6: ASF roller/support                  7-12 Service Manual
  • Lexmark 4227 | Service Manual - Page 135
    4227-300 AsmIndex 6 -1 2 3 4 5 6 7 8 9 10 11 12 13 14 Part number 40X3040 40X3023 40X3024 40X2985 40X3128 40X2928 40X3133 40X3127 40X2927 40X3134 40X3136 40X2891 40X2892 40X2891 Description Support, cut sheet with guides Roller, feed (upper) Roller, feed (lower) Roller, pickup (left and right)
  • Lexmark 4227 | Service Manual - Page 136
    4227-300 Assembly 7: Tractor 2 option           7-14 Service Manual
  • Lexmark 4227 | Service Manual - Page 137
    4227-300 AsmIndex 7 -1 2 3 4 5 6 7 8 9 Part number 40X3033 40X2881 40X3093 40X3095 40X2882 40X2959 40X2961 40X3039 40X2880 Description Cover (front) Paper guide, tractor Tractor and frame assembly Tractor kit (left and right) with sensors Parts packet Shaft, Support Board Asm with cable and
  • Lexmark 4227 | Service Manual - Page 138
    4227-300 7-16 Service Manual
  • Lexmark 4227 | Service Manual - Page 139
    D Diagnostic Aids 3-1 Button Test 3-4 Error Log 3-5 Factory Setting 3-4 Hex Trace Mode 3-2 Impact Force 3-4 Interface Selection 3-3 Jam/PSet Sensor Test 3-4 Log Clear 3-4 Other Print Tests 3-5 POST 3-1 Print Test 3-5 Printhead Bank Test 3-4 Service Menu 3-3 E ESD-sensitive parts 4-1 F Function Menus
  • Lexmark 4227 | Service Manual - Page 140
    2-15 Intermittent Problem 2-16 No Print 2-19 Operator Panel 2-20 Paper Feed 2-21 POST 2-24 Power Failure 2-25 Print Quality 2-27 I-2 Service Manual Print Wire Drive Failure 2-28 Ribbon Drive 2-30 Tractor 2 2-31 Setting Printer Functions 1-7 Signal Connections 6-7 Block Diagram (4227-300) 6-16 Main
  • Lexmark 4227 | Service Manual - Page 141
    T Tests Button Test 3-4 Jam / PSet Sensor Test 3-4 Print Test 3-5 Printhead Bank Test 3-4 U Using the Operator Panel 1-5 4227-300 I-3
  • Lexmark 4227 | Service Manual - Page 142
    4227-300 I-4 Service Manual
  • Lexmark 4227 | Service Manual - Page 143
    Part number index 4227-300 Paper guide, tractor 7-15 40X2882 Parts packet 7-15 40X2891 Spring 7-13 40X2891 Spring kit, ASF 7-11, 7-13 40X2892 Screw kit, ASF 7-11, 7-13 40X2904 Power cord (Japan 7-9 40X2905 Paper Guide, Tractor 7-5 40X2927 Support, paper (right 7-13 40X2928 Support, paper
  • Lexmark 4227 | Service Manual - Page 144
    ROM (HV 7-9 Main logic board without ROM (LV 7-9 Torroid 7-9 Motor, Auto Gap 7-7 Side frame assembly (left 7-5 Serial port card and bracket asm 7-9 Serial port card to main logic board cable 7-9 Printhead 7-7 Cable, printhead and retainer 7-7 Cover, rear (4227--300 7-3 I-6 Service Manual
  • Lexmark 4227 | Service Manual - Page 145
    4227-300 40X3119 ROM kit 7-9 40X3120 Carrier motor cooling fan 7-5 40X3121 Bracket, Auto Gap motor 7-5 40X3122 Bracket, carrier motor 7-7 40X3123 Motor, carrier assembly 7-7 40X3124 Carrier asm. with belt & head cooling gum 7-7 40X3125 Power supply, 100 - 240 V ac 7-9 40X3126 Guide, paper (
  • Lexmark 4227 | Service Manual - Page 146
    4227-300 I-8 Service Manual
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4227-300
Lexmark™ Forms Printer
Lexmark and Lexmark with diamond
design are trademarks of Lexmark
International, Inc., registered in the
United States and/or other countries.
• Table of contents
• Index
• Safety and notices
• Trademarks
• Start diagnostics
Edition: January 15, 2007