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Lexmark Dot Matrix 23XX - Printer Parts Exchange

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2. 5 10 Signal Connections Power Supply lt gt Main Logic Board lt gt Sub Logic Board Power Supply Main Logic Board Sub Logic Board CN1 CN11 CN1 Pin 1 SIGNAL GND Pin 4 SIGNAL GND Pin 4 SIGNAL GND Pin 2 5 Pin 3 5 Pin 3 5 Pin 3 POWER GND Pin 2 POWER GND Pin 2 POWER GND Pin 4 26 V Pin 1 26 V Pin 1 26 V Connector Locations 5 11 Main Logic Board lt gt Parallel Interface Cable Main Logic Board CN1 Pin Pin Pin Pin Pin Pin Pin Pin Pin Pin 10 Pin 11 Pin 12 Pin 13 Pin 14 Pin 15 Pin 16 Pin 17 Pin 18 Pin 19 Pin 20 Pin 21 Pin 22 Pin 23 Pin 24 Pin 25 Pin 26 Pin 27 Pin 28 Pin 29 Pin 30 Pin 31 Pin 32 Pin 33 Pin 34 Pin 35 Pin 36 O1 STROBE DATA 0 DATA 1 DATA 2 DATA 3 DATA 4 DATA 5 DATA 6 DATA 7 ACKNLG BUSY PE SELECT AUTO FEED Not Used SIGNAL GND CHASSIS GND Not Used SIGNAL GND SIGNAL GND SIGNAL GND SIGNAL GND SIGNAL GND SIGNAL GND SIGNAL GND SIGNAL GND SIGNAL GND SIGNAL GND SIGNAL GND SIGNAL GND INIT ERROR SIGNAL GND Not Used Not Used SELECT IN 000000000000000000 000000000000000000 se 5 12 Main Logic Board lt gt Sub Logic Board Model 001 23XX 001 238X 001 239X 001 Main Logic Board Sub Logic Board Sub Logic Board CN3 CN2 CN2 Pin 1 SCLK Pin 34 SCLK Pin 34 SCLK Pin 2 LEDD Pin 33 LEDD Pin 33 L
3. 10 10 11 11 12 12 1180860 1333164 1180861 1333165 1180862 1333166 1332972 1332973 Left Extended Paper Guide Option Left Extended Paper Guide Option Right Extended Paper Guide Option Right Extended Paper Guide Option 23XX 002 003 Center Extended Paper Guide Option 23XX 001 Center Extended Paper Guide Option 23XX 002 003 Acoustics Kit Option 2380 amp 2390 Acoustics Kit Option 2381 amp 2391 23XX 001 23XX 002 003 23XX 001 Parts Catalog 7 9 Assembly 3 Carrier 7 10 Asm Part Index Number Description 79F4796 Carrier Unit 2380 001 79F4820 Carrier Unit 2381 001 79F4848 Carrier Unit 2390 001 79F4861 Carrier Unit 2391 001 1333195 Carrier Unit 2380 002 003 1333196 Carrier Unit 2381 002 003 1333197 Carrier Unit 2390 002 003 1333198 Carrier Unit 2391 002 003 1333234 Carrier Roller Set 79F4792 Printhead 2380 amp 2381 79F4818 Printhead 239X 001 1333220 Printhead 239X 002 003 79F4793 Printhead Cable 2380 79F4819 Printhead Cable 2381 79F4828 Printhead Cable 2390 79F4829 Printhead Cable 2391 1180877 Carrier Shaft 2380 amp 2390 1180878 Carrier Shaft 2381 amp 2391 79F4814 Paper Select Lever 23XX 001 1333154 Paper Select Lever 23XX 002 003 79 4805 Tension Pulley Plate Assembly 23XX 001 002 11A3346 Tensio
4. Power Supply Tractor Unit Pull Tractor Actuator Ribbon Cartridge Ribbon Drive Rack Gear Pinch Roller Lower Feed Roller Lower Printhead Printhead Cables Carrier Tension Pulley Plate Feed Roller Upper Platen Side Frame Right Side Frame Left lt Cl Al d Oo Z FS Alc Carrier Plate Connector Locations 5 1 Front View lt 5 2 Rear View Connector Locations 5 3 Tractor 2 Cable Connectors The Tractor 2 cable is soldered to the board at CN1 there is no connector Connector Mode CN1 1 26 V de CN1 2 26 V dc CN1 3 Frame GND CN1 4 Not Used CN1 5 5 V dc CN1 6 Motor Common CN1 7 D Set Signal for Tractor 2 Plugged in CN1 8 Signal GND CN1 9 Motor Phase 0 V except when Tractor 2 motor is on CN1 10 Motor Phase 5 V when Tractor 2 not in use 0 V de when Tractor 2 is in use CN1 11 Not used CN1 12 Slider Home Sensor 5 V de when open 0 V dc when closed CN1 13 Tractor 2 In Place Sensor 5 V dc when open 0 V de when closed 5 4 iring Block Diagram 238X 001 Josueg 1 1 uondo Josueg JOJO 1940 1edeg OL
5. Service Manual Lexmark 23XX Series 23XX XXX e Table of Contents e Start Diagnostics e Safety and Notices e Trademarks e Index e Manuals Menu LEXMARK Edition April 2000 THE FOLLOWING PARAGRAPH DOES NOT APPLY TO THE UNITED KINGDOM OR ANY COUNTRY WHERE SUCH PROVISIONS ARE INCONSISTENT WITH LOCAL LAW LEXMARK INTERNATIONAL INC PROVIDES THIS PUBLICATION AS IS WITHOUT WARRANTY OF ANY KIND EITHER EXPRESS OR IMPLIED INCLUDING BUT NOT LIMITED TO THE IMPLIED WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE Some states do not allow disclaimer of express or implied warranties in certain transactions therefore this statement may not apply to you This publication could include technical inaccuracies or typographical errors Changes are periodically made to the information herein these changes will be incorporated in later editions of the publication Improvements or changes in the products or the programs described in this publication may be made at any time Publications are not stocked at the address given below requests for publications should be made to your point of purchase A form for reader s comments is provided at the back of this publication If the form has been removed comments may be addressed to Lexmark International Inc Department F95 032 2 740 New Circle Road NW Lexington Kentucky 40511 U S A Lexmark may use or distribute any of the information you supply in any way it bel
6. 21601 016 840 1402 soyeredo CN SNO 91607 Edo 249 uondo ON 9d9 SNO INO edd 795 549 Josueg 401504 uondo Josueg 10915 eoeyeiu jeues eoeyelu lusy Jaded Josueg Connector Locations 5 9 10805 1814 Block Diagram 239X 003 Kal SON JOJOW saweg pom INS Ido 50240 6 0 ZNO See LINZ Josueg w104 jo 401 8 N9 LE LdO 6849 uond LNO INO 6 8NO PN JOSUAS JOJOBA 21607 qnS 442 190 YNO SNO 91607 940 EIN Edi d9 545 10SU8S uonisod uondo Josuag 199 95 Jemog 1odeJ Josueg uondo
7. CN9 CNS3 239X 002 003 Sub Logic Board 5 12 CN6 2 12 18 1 10 EE CN7 z 4 i CN3 Power Supply Power Supply F2 CN1 F1 F3 23XX 002 003 Printers have jumper place of To Main Logic Board Serial Interface Option CN1 parallel connector Older Design Newer Design To _To Main Logic Main Board Logic CN1 parallel Board connector CNS 13 1 13 1 2 14 25 14 Connector Locations 5 25 Operator Panel Operator Panel CN1 9 for 23XX 001 10 for 23XX 002 003 gt 5 26 6 Preventive Maintenance This chapter describes procedures for printer preventive maintenance Following these recommendations can help prevent problems and maintain optimum performance Lubrication Warning Petroleum based lubricants can attack polycarbonate parts causing premature failure Use only mineral oil based lubricant The following parts should be lubricated when replaced Oil felt carrier block Tractor unit Side frame left Side frame right e Pinch roller lower Pinch roller spring left Pinch rol
8. 5 5 Block Diagram 239 001 5 6 Block Diagram 238X 002 eia opea ied die ds 5 7 Block Diagram 239 002 5 8 Block Diagram 238X 008 4 cs sss sees mm va mur 5 9 Block Diagram 239 003 5 10 Signal Connections Hide eme int ea 5 11 Connector LOGSIOFIS iar radar oerte dea dde 5 20 Main Logic Board 23XX 001 5 20 Main Logic Board 23XX 002 5 21 Main Logic Board 23XX 003 5 22 SUD Logic BOSE iua 5 23 Power SUP s saos eco memh EE es 5 25 Operator Panel dede Qu eae ame 5 26 Preventive Maintenance 6 1 steak 6 1 Specified L bricants ss uso bre der sabre de sang 6 1 Lubrication POMS 551 6 2 Lubrication Points x Rm ha 6 3 Lubrication Points Grease 6 4 Contents vii Catalog 7 1 viii How Use This Parts 00 7 1 Assembly 1 Major Components 7 2 Assembly 2 CONVERSE 7 6 Assembly 3 7 10 Assembly 4 Paper Guide Platen Feed Roller 7 16 Assembly 5 Electonics i254 29 7 20 Assem
9. o elo 2 Ole 8 2 gt o 1 CN3 34 d 2 c o a 2 G i as 5 20 Main Logic Board 23XX 002 CN12 CN11 4 1 en 2 gt em t 2 eo 2 en Socket For 0 Memory Module 2 o Option D z o z Oller CN1 1 CN3 34 19 Main Logic Board 23XX 002 28 for 238X 002 Connector Locations 5 21 Main Logic Board 23XX 003 5 22 23XX 003 Main Logic Board CN12 CN11 4 N 5 em 5 o er Socket For wile Memory Module 2 Option 2 2 5 x 2 Olen Z o ge gt o 1 CNS 34 RO De ee 28 for 238X 003 Sub Logic Boards 238X 001 Sub Logic Board CN3 1 CN5 T CN2 12 239X 001 DE Sub Logic Board CN5 T CN2 12 CN6 CN7 2 Connector Locations 5 23 5 24 238X 002 003 Sub Logic Board 10 cmm CN8 CN5 2 6 lt 1 2
10. Be sure to get the carrier shaft correctly through the oil felt Perform the Printhead to Platen Gap Adjustment see Printhead to Platen Gap Adjustment on page 4 2 Repair Information 4 13 4 14 This Page Intentionally Blank Repair Information 4 15 Carrier Motor Assembly Removal 1 Remove the top cover see Top Cover Removal on page 4 61 2 Remove the sub logic board see Sub Logic Board Removal on page 4 59 3 Move the carrier to the center of the printer Remove the belt tension spring 1 and loosen the screw 2 5 Remove the carrier belt 3 from the tension pulley and the carrier motor pulley gt 4 16 6 Disconnect the carrier motor cable 4 from connector 9 on the main logic board 7 Remove the screws 5 and 6 and then remove the carrier motor assembly from the left side frame Repair Information 4 17 Carrier Plate Removal 1 2 10 11 12 13 17 18 19 20 4 18 Remove the tractor assembly see Push Tractor Assembly Removal on page 4 53 Remove the top cover see Top Cover Removal on page 4 61 Remove the paper select lever see Paper Select Lever Removal on page 4 42 Remove the printhead see Printhead Removal on page 4 48 Remove the printhead cables see Printhead Cables Removal on page 4 49 Remove the sub logic board see Sub Logic Board Removal
11. Lubrication Points Grease Gear mounting studs on the right side frame 2 The lower pinch roller 2 6 4 Lubrication Points Grease Continued Gear mounting studs on the left side frame 2 Preventive Maintenance 6 5 Lubrication Points Grease Continued Gear mounting studs on the left ASF side frame 2 Gear mounting studs on the right ASF side frame 2 6 6 7 Parts Catalog How To Use This Parts Catalog SIMILAR ASSEMBLIES If two assemblies contain a majority of identical parts they are broken down 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 identified by description AR As Required in the Units column indicates that the quantity is not the same for all machines NP Non Procurable in the Units column indicates that the part is non procurable and that the individual parts or the next higher assembly should be ordered NR Not Recommended in the Units column indicates that the part is procurable but not recommended for field replacement and that the next higher assembly should be ordered R Restricted in the Units column indicates that the part has a restricted availability NS Not Shown in the Asm Index column indicates that the part is procurable but is not pictured in the illustration PP Parts Packet in the Description column indicates that the part is contained in a
12. 5 1333214 Operator Panel Asm with English Overlay 238X 002 5 1333215 Operator Panel Asm with English Overlay 239X 002 5 11A3302 Operator Panel Asm with English Overlay 238X 003 5 11A3303 Operator Panel Asm with English Overlay 239X 003 6 95F5314 Operator Panel Flat Cable 23XX 001 6 1333216 Operator Panel Flat Cable 23XX 002 Parts Catalog 7 3 Assembly 1 Major Components Continued 7 4 Asm Part Index Number Description 1 7 79F4838 Tractors L and R 23XX 001 7 1333160 Tractors and 23 002 003 8 79F4837 Tractor Side Frame R 23XX 001 8 1333159 Tractor Side Frame R 23XX 002 003 9 79F4836 Tractor Side Frame L 23XX 001 9 1333158 Tractor Side Frame L 23 002 003 10 79F4810 Gear and Bushing Kit 238X 001 002 10 79F4806 Gear and Bushing Kit 239X 001 002 10 11A3272 Gear and Bushing Kit 238X 003 10 11A3273 Gear and Bushing Kit 239X 003 11 79F4770 Side Frame Locking Plates 12 79F4860 Screw Washer amp Clip Kit 23XX 001 12 1333219 Screw Washer amp Clip Kit 23XX 002 12 11A3344 Screw Washer amp Clip Kit 23XX 003 13 79F4830 Tractor Paper Support 2381 amp 2391 14 1368701 Serial Interface Adapter L L Parts Catalog 7 5 Assembly 2 Covers Asm Part Index Number Description 2 1 79F4780 Ribbon Access Cover Unit 2380 001 amp 2390 001 1 79F48
13. One or more buttons do not function One or more lights do not function Power Problems Symptom Action When the power Check continuity of the power cord and the voltage switch is on the of the user s outlet Power light does not turn on or the printer Go to the Power Service Check on page 2 32 does not start The Power light blinks or changes intensity 2 10 Print Quality Problems Symptom Action No print but carrier moves as if printing Adjust the form thickness lever to a lower number Be sure the printhead cables are not loose or damaged Be sure the interface cable is connected properly Be sure the serial interface adapter is installed correctly and the dip switches are set correctly Check the ribbon cartridge for binds or damage Go to the Print Speed Service Check on page 2 34 Print density is light Verify that the ribbon density control knob on the ribbon cartridge is not set to 0 If the ribbon has reached its end of life or is worn the ribbon cartridge needs to be replaced Go to the Carrier Drive Home Position Sensor Ribbon Feed Service Check on page 2 17 Uneven print density across the print line Specific dots missing Extra dots or lines printing Be sure the printhead cables are connected correctly to the printhead and the sub logic board Clean the printhead Set the form thickness lever to
14. Ribbon Drive Rack Gear 2380 amp 2390 7 79F4834 Ribbon Drive Rack Gear 2381 amp 2391 8 1368031 Carrier Plate 2380 amp 2390 8 1368032 Carrier Plate 2381 amp 2391 9 79F4801 Feed Roller Lower 2380 amp 2390 9 79F4833 Feed Roller Lower 2381 amp 2391 10 79F4809 Paper Separator 2380 amp 2390 10 79F4839 Paper Separator 2381 amp 2391 10A 1368003 Label Guide Bar 2380 amp 2390 10A 1368004 Label Guide Bar 2381 amp 2391 11 79F4788 Paper Select Sensor 12 79F4812 Side Frame Left 23XX 001 12 1333233 Side Frame Left 23XX 002 12 11A3345 Side Frame Left 23XX 003 14 79F4787 Pull Tractor Sensor Parts Catalog 7 15 Assembly 4 Paper Guide Platen Feed Roller Cont 7 16 Asm Part Index Number Description 4 15 79 4810 Gear and Bushing Kit 2380 001 002 amp 2381 001 002 15 79F4806 Gear and Bushing Kit 2390 001 002 amp 2391 001 002 15 11A3272 Gear and Bushing Kit 238X 003 15 11A3273 Gear and Bushing Kit 239X 003 16 79F4811 Spring Kit 23XX 001 2381 002 2391 002 16 1333228 Spring Kit 2380 002 amp 2390 002 16 11A3308 Spring Kit 2380 003 amp 2390 003 16 11A3309 Spring Kit 2381 003 amp 2391 003 17 79F4860 Screw Washer and Clip Kit 23XX 001 17 1333219 Screw Washer and Clip Kit 23XX 002 17 11A3344 Screw Washer and Clip Kit 23 003 18 95F3
15. or the machine is having intermittent failures The following may cause undefined or intermittent failures 1 2 Customer s outlet voltage Be sure that it is within the tolerance 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 Electrical noise Check the following a Power supply ground b Machine frame ground c Printer interface cable is grounded or shielded Undefined data in customer applications Check the baud rate at the controller Check that the printer interface cable matches the printer Problem occurs only in specific customer applications Perform the Trace Print hexadecimal printing by the following procedure and check the data streams 1 2 3 4 Turn the power off Turn the power on while pressing and holding Alt Have the customer print the failing job To stop printing turn the power switch off If the failure still occurs replace the main logic board Be sure to reset the bidirectional print adjustment refer to the Bidirectional Print Adjustment on page 4 5 2 22 No Print or Abnormal Print Service Check FRU Function Action 1 Main Logic Board Ifthe Print Test does not complete correctly do the following Replace the main logic board Reset the bidirectional print adjustment Re
16. 10 95F6888 Hopper L All others 11 1333161 Paper Load Lever 2381 003 2391 003 11 95F6890 Paper Load Lever All others 12 1333162 Paper Load Link 2381 003 2391 003 12 95F6891 Paper Load Link All others 13 95F6881 Cover L 14 95F6892 Gear and Bushing Kit ASF 15 95F6893 Spring Kit ASF 16 95F6894 Screw Kit ASF 17 95F6898 Side Frame L Parts Catalog 7 25 Assembly 7 ASF Side Frame Covers 7 26 Part Index Number Description 7 1 95F6893 Spring Kit ASF 2 95F6892 Gear and Bushing Kit ASF 3 95F6882 Cover R 4 95F6894 Screw Kit ASF 5 95F6899 Side Frame R 6 95F6901 Stacking Support 7 95F6902 Front Cover 2380 amp 2390 7 95F6903 Front Cover 2381 amp 2391 Parts Catalog 7 27 Assembly 8 Tractor 2 Option 7 28 Part Number Description oO Jo S WwW v i i 11A3342 Paper Table W Guides Narrow 11A3343 Paper Table W Guides Wide 11A3338 Tractor Paper Guide 11A3339 Tractor and Frame Asm Narrow 11A3340 Tractor and Frame Asm Wide 1333160 Tractor Kit L amp 11A3335 Board Asm W Cable and Ferrite Narrow 11A3336 Board Asm W Cable and Ferrite Wide 11A3337 Motor 11A3341 Parts Packet 11A3332 Right Cover 95F6902 Front Cover Narrow 95F6903 Front Cover Wide 11A3283 Support Shaft Narrow 11A3284 Support Shaft Wide Parts Catalog 7
17. 129 95 Jemog jeueg eoepelu 5 6 Block Diagram 238 002 Josueg Aduz aiqeo Hla Jedeq egeo JO OW samep SION A ddns IN 4 LNO 149 peeujuud OLNO 6 ZNO Josueg w104 jo 401 8N2 LINZ 1 6d9 pseog uondo INO 6 0 gno eNO 108 JOJOBA ENZ 91607 One 8d 189 ENZ DN 91607 9 249 uodo 949 SNO INO 549 Sd 108095 50 uondo Josueg l jeueg eoeyelu wsy EE Josueg deo Connector Locations 5 7 Block Diagram 239X 002 Josueg w104 jo 901 Jemog uondo 10SU8S 1010241 pieog uondo uondo
18. 4 34 This Page Intentionally Blank Repair Information 4 35 Paper Empty Sensor And Spring Removal 4 36 Te Remove the tractor assembly see Push Tractor Assembly Removal on page 4 53 Remove the top cover see Top Cover Removal on page 4 61 Remove the print unit see Print Unit Removal on page 4 47 Remove the paper select lever see Paper Select Lever Removal on page 4 42 Release the four latches 1 and then remove the paper empty sensor Carefully remove the paper empty sensor cable to avoid cable damage Disconnect the paper empty sensor cable from the latch on the paper guide Carefully grasp the paper empty lever at 2 with a pair of needle nose pliers and remove the paper empty lever by pulling it perpendicular away from the paper guide Do not damage or lose the paper empty sensor spring 3 Detach the paper empty sensor spring 3 Repair Information 4 37 Paper Feed Motor Removal 1 2 Remove the top cover see Top Cover Removal on page 4 61 Remove the sub logic board see Sub Logic Board Removal on page 4 59 Disconnect the paper feed motor cable 1 from connector CN10 on the main logic board Remove the screw 3 Rotate the paper feed motor 2 clockwise then remove it The paper feed motor plate 4 can also be removed at this time as it is held in place only by the motor 2 238X 001 The head gap sensor ma
19. Lower Pinch Roller Removal Note The lower pinch roller and the pinch roller gear must be ordered separately 1 c1 4 32 Remove the top cover see Top Cover Removal on page 4 61 Remove the center pinch roller ground spring Remove the left and right pinch roller springs 1 Move the carrier to the right as far as it will go Slide the left end of the lower pinch roller to the front of the printer and lift it up and to the left to remove it Be sure to perform the Printhead to Platen Gap Adjustment procedure see Printhead to Platen Gap Adjustment on page 4 2 Main Logic Board Removal 1 Remove the top cover see Top Cover Removal on page 4 61 2 Disconnect all cables connected to the main logic board connectors may not be exactly as shown Note Do not twist the flexible cable when disconnecting 3 Remove the two screws 1 and then remove the main logic board by pulling it out towards the back 4 Replace the main logic board 5 Be sure to check the Bidirectional Print Adjustment after you install the board Repair Information 4 33 Operator Panel Assembly Removal 1 Remove the top cover see Top Cover Removal on page 4 61 2 Release the two latches 1 and then remove the operator panel assembly Note Be sure the flexible cable is correctly aligned and inserted securely The end with the 90 degree fold connects to the sub logic board
20. Sensor Remove all paper from the printer and place the tractor in the push position Make sure the Auto Sheet Feed ASF is set to OFF in the Setup Mode Press Form Feed and time how long the gear train rotates With the paper select lever in the cut sheet position sensor open the gear train should rotate for less than 2 seconds with the lever in the continuous forms position sensor closed the gear train should rotate for more than 3 seconds If the printer does not do this inspect the sensor to make sure it is being opened and closed by the paper separator Disconnect 5 from the sub logic board and measure the paper selector sensor resistance from CP5 1 to CP5 2 Replace the sensor if the resistance does not change from zero to infinite as the paper select lever is moved from cut sheet to continuous forms If the sensor is good but the gear train does not run the right length of time set the head gap to position 1 and disconnect the short flexible cable from CN3 on the main logic board Check the continuity between CP3 6 paper select sensor and GND while actuating the paper select lever Cut Sheet Continuous Forms 23XX 001 23XX 002 1K 0 5K ohms OK 0 5K ohms 12K 0 5K ohms 3 5K 0 5K ohms If the resistance is correct replace the main logic board If the resistance is incorrect replace the sub logic board 2 30 FRU Action 2 Pull Tractor A failed pull tracto
21. on page 4 59 Remove the paper feed motor see Paper Guide Platen Assembly Removal on page 4 40 Remove the carrier motor assembly see Carrier Motor Assembly Removal on page 4 16 Remove the tension pulley plate assembly see Tension Pulley Plate Assembly on page 4 60 Remove the carrier see Carrier Removal on page 4 12 23XX 002 003 Remove the tractor idler gear 23XX 002 003 Remove the support plate Remove the lower pinch roller see Lower Pinch Roller Removal on page 4 32 Remove the gears on the right side frame see Right Side Frame Gears Removal on page 4 58 Remove the ribbon drive rack gear see Ribbon Drive Rack Gear Removal on page 4 54 Remove the home position sensor see Home Position Sensor Removal on page 4 25 Remove the paper separator spring 2 Remove the screw 3 from the paper separator 23XX 001 002 Release the latch and then remove the release slider cam 4 from the right side frame 23XX 003 Remove the slider cam screw and spring Remove the sub slider cam and the slider cam from the right side frame Remove the two screws 5 and the screw 6 Right Side Repair Information 4 19 21 Gently bend both side frames outward to release tabs 7 from the slots 8 Lift and remove the carrier plate Left Side 4 20 Download or Print Buffer Module Removal Notes Turn the printer and disconnect the
22. 29 7 30 Abbreviations 1 5 Adjustments 4 2 Print 4 5 Principles of Operation 2 15 B Bidirectional Print Adjustment 4 5 Connector Locations 5 1 E ESD sensitive parts 4 1 Irrecoverable Operator Errors Paper Empty Sensor 2 13 Paper Select Sensor 2 13 L Lubrication 6 1 Models available 1 1 Operator Errors Irrecoverable 2 13 Parts Auto Sheet Feeder Covers 7 28 Roller 7 26 Side Frame 7 28 Support 7 26 Carrier 7 10 Covers 7 6 7 8 Electronics 7 20 Feed Roller 7 16 Paper Guide 7 16 Platen 7 16 Tractor 2 Option 7 30 Parts catalog Howtouse 7 1 Preventive Maintenance 6 1 Lubrication 6 1 Lubrication Points 6 2 Specified Lubricants 6 1 R Removal Procedures 4 7 Removals ASF Pick up Roller 4 9 Auto Sheet Feeder Gears 4 8 Bottom Cover 4 10 Carrier 4 12 Carrier Motor Assembly 4 16 Carrier Plate 4 18 Download Buffer 4 21 Form Thickness Lever 4 22 Head Gap Sensor 23XX 002 4 24 238X 001 4 23 Home Position Sensor 4 25 Jammed Label 4 26 Label Jam 4 26 Left Side Frame 4 28 Lower Feed Roller 4 30 Main Logic Board 4 33 Operator Panel 4 34 Paper Empty Sensor 4 36 Paper Empty Spring 4 36 Paper Feed Motor 4 38 Paper Guide Platen 4 40 Paper Select Lever 4 42 Paper Select Sensor 4 43 Paper Separator 4 44 Pinch Roller Lower 4 32 Power Supply 4 46 Print Buffer 4 21 Print Unit 4 47 Printhead 4 48 Printhead Cables 4 49 Pull Tractor Actuator 4 51 Pull Tractor Sensor 4 52 Push
23. 4 43 Paper Separator Removal Te Remove the tractor assembly see Push Tractor Assembly Removal on page 4 53 Remove the top cover see Top Cover Removal on page 4 61 Remove the print unit see Print Unit Removal on page 4 47 Remove the carrier shaft retention ground spring 1 located on the right side frame Position the paper select lever in the continuous forms position down Remove the two spring loaded gears from the right side frame see Right Side Frame Gears Removal on page 4 58 Release the paper separator spring from the screw 2 Remove the separator screw 2 and the two screws 3 that hold the carrier plate to the right side frame Warning The following two steps must be performed with extreme care to avoid damaging the side frames 9 4 44 While holding the front portion of the right side frame and the carrier plate gently spread the right side frame away from the carrier plate enough to allow the right paper separator pivot 4 to be disengaged from the right side frame pivot hole and into the cutout in the side frame Again gently spread the right side frame away from the carrier plate enough to allow the left paper separator pivot to be disengaged from the left side frame pivot hole Remove the paper separator Repair Information 4 45 Power Supply Removal CAUTION The power supply may be hot 1 2 3 4 5 6 Turn off t
24. Ait To Notices and Safety Information xi Korean Safety Information FA SSN AE Ss AoSe Sue 22 420 BAS BALE SAS US 21910 AH ASAE ol ALS deii West okt AXE SWAR oui e ew erase ET Tos Tee SST HALL EE BAS Lal ABS Xii Preface This manual 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 Preface xiii Xiv 1 General Informatio
25. Empty Sensor Action Check Remove all paper from the printer Turn the power on Paper Out blinks when paper does not exist Paper Out turns off when paper exists Go to the Paper Empty Sensor Service Check on page 2 26 Paper Select Sensor Action Check Turn the power off Install the Push Tractor Set the paper select lever to the tractor position and load the continuous forms Turn the power on Alt Park Load function correctly Go to the Paper Select Sensor Service Check on page 2 30 Remove the continuous forms Set the paper select lever to the cut sheet position and insert a cut sheet When Auto Loading is enabled paper feeds automatically When Auto Loading is disabled press Form Feed to load a cut sheet Check that Alt Park Load does not function Go to the Paper Select Sensor Service Check on page 2 30 Diagnostic Information 2 13 Service Checks Abnormal Noise Service Check Check the entire printer for loose parts FRU Action Ribbon Cartridge Remove and reinstall the ribbon cartridge Printhead Disconnect the printhead cables Run the print test do not fold or damage the cables during the test Replace the printhead if the noise is gone Carrier Motor Disconnect the carrier motor connector CN9 Ribbon Drive from the main logic board and turn the printer Mechanism off and
26. Le d montage et l entretien de ce produit pouvant pr senter certains risques lectriques le personnel d entretien qualifi devra prendre toutes les pr cautions n cessaires Les normes de s curit de certaines pi ces n tant pas toujours explicites les pi ces de rechange doivent tre identiques ou conformes aux caract ristiques des pi ces d origine Notices and Safety Information ix Norme di sicurezza 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 piu elevato Il personale di assistenza autorizzato deve quindi adottare le precauzioni necessarie Poich non tutti i pezzi di ricambio garantiscono la stessa sicurezza questi devono avere caratteristiche identiche o equivalenti a quelle dei pezzi originali Pautas de Seguridad La informaci n sobre el mantenimiento de este producto est dirigida exclusivamente al personal cualificado de mantenimiento Existe mayor riesgo de descarga el ctrica y de da os personales durante el desmontaje y la reparaci n de la m quina El personal cualificado debe ser consciente de este peligro y tomar las precauciones necesarias Los dispositivos de seguridad de algunas piezas no siempre pueden reconocerse a simple vista Por lo tanto los recambios deben poseer caracter sticas id
27. Op Panel Cable operator panel cable continuity and replace the cable or the operator panel Carrier Motor Disconnect the carrier motor from main logic board CN9 and turn the printer off and then on If the power LED lights correctly only with the carrier motor disconnected replace the carrier motor Paper Feed Motor Disconnect the paper feed motor from main logic board CN10 and turn the printer off and then on If the power LED lights correctly only with the paper feed motor disconnected replace the paper feed motor Printhead Disconnect the printhead cable from the sub Printhead Cables 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 Disconnect the printhead cable from the sub logic board and make sure none of the leads on the cable are shorted to ground Main Logic Board Ifno problem is found with other components but the printer still has a power problem replace the main logic board Reset the bidirectional print adjustment refer to Bidirectional Print Adjustment on page 4 5 Diagnostic Information 2 33 Print Speed Service Check Reduced speed while printing the top 2 inch 51 mm of a job is normal for Model 003 printers the slow down can be eliminated by entering Setup Mode and disabling TOF Read The speed of the 23XX printers varies w
28. Pin 27 LEDD Pin 33 LEDD Pin 3 SWD Pin 26 SWD Pin 32 SWD Pin 4 SW LTCH Pin 25 SW LTCH Pin 31 SW LTCH Pin 5 GAP SW Pin 24 GAP SW Pin 30 GAP SW Pin 6 PUL CSF Pin 23 PUL CSF Pin 29 PUL CSF Pin 7 HP Pin 22 HP Pin 28 HP Pin 8 THRMO Pin 21 THRMO Pin 27 THRMO Pin 9 HD8 Pin 20 HD8 Pin 26 HD8 Pin 10 HD6 Pin 19 HD6 Pin 25 HD6 Pin 11 HD4 Pin 18 HD4 Pin 24 HD4 Pin 12 HD2 Pin 17 HD2 Pin 23 HD2 Pin 13 HD1 Pin 16 HD1 Pin 22 HD1 Pin 14 HD3 Pin 15 HD3 Pin 21 HD3 Pin 15 HD5 Pin 14 HD5 Pin 20 HD5 Pin 16 HD7 Pin 13 HD7 Pin 19 HD7 Pin 17 HD9 Pin 12 HD9 Pin 18 HD9 Pin 18 HD11 Pin 11 HD11 Pin 17 HD11 Pin 19 HD13 Pin 10 HD13 Pin 16 HD13 Pin 20 HD15 Pin 9 HD15 Pin 15 HD15 Pin 21 HD17 Pin 8 HD17 Pin 14 HD17 Pin 22 HD18 Pin 7 HD18 Pin 13 HD18 Pin 23 HD16 Pin 6 HD16 Pin 12 HD16 Pin 24 HD14 Pin 5 HD14 Pin 11 HD14 Pin 25 HD12 Pin 4 HD12 Pin 10 HD12 Pin 26 HD10 Pin 3 HD10 Pin 9 HD10 Pin 27 HD21 Pin 2 HD21 Pin 8 HD21 Pin 28 MSW Pin 1 MSW Pin 7 MSW Pin 29 HDCOM Pin 6 HDCOM Pin 30 HD19 Pin 5 HD19 Pin 31 HD23 Pin 4 HD23 Pin 32 HD24 Pin 3 HD24 Pin 33 HD22 Pin 2 HD22 Pin 34 HD20 Pin 1 HD20 5 14 Main Logic Board lt gt Pull Tractor Sensor CN4 Pin 1 PUL TRA Pin 2 SIGNAL GND Main Logic Board lt gt Serial Interface Card option CN5 Pin 1 5 V Pin 2 SIGNAL GND Main Logic Board lt gt Paper Empty Sensor CN7 Pint Pin2 Pin 3 SIGNAL GND Main Logi
29. Tractor Assembly 4 53 Ribbon Drive Rack Gear 4 54 Right Side Frame 4 56 Side Frame Right Gears 4 58 Sub Logic 4 59 Tension Pulley Plate 4 60 Top Cover 4 61 Top of Form Sensor 4 64 Top of Form Sensor Flag 4 64 Top of Form Spring 4 64 Upper Feed Roller 4 66 S Serial Interface Adapters 1 7 Switches 1 8 Service Checks Abnormal Noise 2 14 Abnormal Print 2 23 Auto Sheet Feeder 2 15 Carrier Drive 2 17 Home Position Sensor 2 17 Intermittent Problem 2 20 No Print 2 23 Operator Panel 2 24 Paper Empty Sensor 2 26 PaperFeed 2 27 Paper Select Sensor 2 30 POST 2 31 Power 2 32 Print Speed 2 34 Printhead 2 36 Pull Tractor Sensor 2 38 Ribbon Feed 2 17 Top of Forms Problem 2 39 Tractor 2 2 40 Setup Mode 1 6 Symptom Checks Abnormal Indications 2 6 Abnormal Noise Problems 2 6 Abnormal Print Problems 2 7 ASF Problems 2 7 Error Indications 2 8 Operator Panel Problems 2 10 Paper Feed Problems 2 8 Power Problems 2 10 Print Quality Problems 2 11
30. and Clip Kit 23XX 001 15 1333219 Screw Washer and Clip Kit 23XX 002 15 11A3344 Screw Washer and Clip Kit 23XX 003 NS 1333229 ESD Kit 238X 002 003 NS 1333230 ESD Kit 239X 002 003 16 79F4797 Feed Motor Plate 17 79F4800 Release Slider Cam 23XX 001 23XX 002 17 11A3310 Release Slider Cam 23XX 003 17 11A3311 Sub Slider Cam 23XX 003 18 79F4794 Head Gap Sensor 238X 001 19 1333237 Head Gap Sensor Assembly 23XX 002 003 20 1333235 Support Plate left side 23 002 003 21 11A3271 Shaft Support Plate 23XX 003 Parts Catalog 7 13 Assembly 4 Paper Guide Platen Feed Roller 7 14 sud d M Description 4 1 79F4803 Paper Guide Platen Assembly 2380 2390 001 1 1333231 Paper Guide Platen Assembly 2380 2390 002 003 1 1333232 Paper Guide Platen Assembly 2381 2391 001 1 1333232 Paper Guide Platen Assembly 2381 2391 002 003 2 79F4786 Paper Empty Sensor 3 79F4798 Feed Roller Upper 2380 001 amp 2390 001 3 79F4831 Feed Roller Upper 2381 001 amp 2391 001 3 1333226 Feed Roller Upper 2380 002 003 amp 2390 002 003 3 1333227 Feed Roller Upper 2381 002 003 amp 2391 002 003 4 79F4799 Pinch Roller Lower 2380 amp 2390 4 79F4832 Pinch Roller Lower 2381 amp 2391 5 79F4808 Pull Tractor Actuator Kit 6 1180927 Side Frame Right with Slider Cam 23XX 001 002 6 11A3312 Side Frame Right 23 003 7 79F4802
31. forms thickness lever to position 1 Position the carrier midway between the two rack mounting tabs 1 shown Remove the stop 2 if present Release the snap 3 and move the rack 4 to the right Press the tab on the right and move the rack down to disengage the rack from the ribbon drive gear This Page Intentionally Blank Repair Information 4 55 Right Side Frame Removal 16 17 18 4 56 1 2 Remove the tractor assembly see Push Tractor Assembly Removal on page 4 53 Remove the top cover see Top Cover Removal on page 4 61 Remove the paper select lever see Paper Select Lever Removal on page 4 42 Remove the sub logic board see Sub Logic Board Removal on page 4 59 Remove the paper feed motor and paper feed motor plate see Paper Guide Platen Assembly Removal on page 4 40 Remove the ground spring and the platen to power supply ground leg from the right side of the printer Remove the print unit see Print Unit Removal on page 4 47 Release the spring tension on the carrier belt by loosening the screw and pushing the assembly toward the center carrier plate tighten the screw to hold it in position Rotate the left carrier adjustment bushing to unlock it from the left side frame Release the latch on the forms thickness lever and slide the carrier shaft half way out so it is free of the right side frame Do not lose the small bu
32. it toward you Repair Information 4 11 Carrier Removal 4 12 1 2 M O Remove the top cover see Top Cover Removal on page 4 61 Remove the printhead see Printhead Removal on page 4 48 Remove the printhead cables from the carrier assembly see Printhead Cables Removal on page 4 49 Remove the sub logic board see Sub Logic Board Removal on page 4 59 Remove the paper feed motor and the paper feed motor plate see Paper Guide Platen Assembly Removal on page 4 40 Move the carrier to the center of the printer Remove the belt tension spring 1 from the hook closest to the tension pulley Loosen the screw 4 securing the tension pulley plate asm 2 Remove the carrier belt 3 from the tension pulley 10 11 12 13 14 15 16 Release the ground spring 11 from the end of the carrier shaft the spring need not be removed Rotate the left carrier bushing Remove the lever stop bracket from the carrier motor bracket not present on all machines Release the latch 8 and slide the carrier shaft and forms thickness lever to the left and remove them together from the printer Do not to lose the gap set collar 15 attached to the right end of the carrier shaft Lift the rear of the carrier 12 to disengage the carrier ribbon drive gears then remove the carrier Do not to lose the oil felt 14
33. nticas o equivalentes a las de las piezas originales Informa es de Seguran a As informa es de seguran a relativas a este produto destinam se a profissionais destes servi os e n o devem ser utilizadas por outras pessoas Risco de choques el ctricos e ferimentos graves durante a desmontagem e manuten o deste produto Os profissionais destes servi os devem estar avisados deste facto e tomar os cuidados necess rios Os dispositivos de seguran a de algumas pe as poder o n o ser sempre suficientemente evidentes Assim as pe as sobressalentes devem possuir caracter sticas id nticas ou equivalentes s pe as originais Informaci de Seguretat Lainformaci pel manteniment d aquest producte est orientada exclusivament a professionals i no est destinada a ning que no ho sigui e de xoc el ctric i de danys personals pot augmentar durant el proc s de desmuntatge i de servei d aquest producte El personal professional ha d estar ne assabentat i prendre les mesures convenients Lescaracter stiques de seguretat d algunes de les peces poden no ser bvies Per tant les caracteristiques dels recanvis hauran de ser id ntiques o equivalents a les de les peces originals Chinese Safety Information GE ALS A D JH MEN sk A 5i 5 D Bf Em PE Em ARS HD BUS Br fe
34. printer Repair Information 4 59 Tension Pulley Plate Assembly 1 of D 4 60 Remove the top cover see Top Cover Removal on page 4 61 Remove the belt tension spring 1 from the hook Remove the screw 2 Remove the carrier belt 3 Remove the tension pulley plate assembly 4 by sliding it toward the right rear view Top Cover Removal ON Turn the printer off Disconnect the power cord at the printer 23XX 001 Remove the paper advance knob 1 by pulling to the right If the tractor assembly is installed in the pull tractor position remove the tractor assembly see Pull Tractor Removal on page 4 50 Remove the front cover 2 and the ribbon access cover 3 Release the two latches 9 and then remove the rear cover 3 Set the paper select lever 4 to the cut sheet position Remove the two screws 8 Stand the printer on its side Insert a flat blade screwdriver into each of the five holes in the bottom cover and release the five latches that secure the top cover 5 to the bottom cover 6 Repair Information 4 61 Note The 2381 and 2391 have six cover latches that secure the top cover to the bottom cover 10 While lifting the top cover slightly disconnect the operator panel cable 7 from the sub logic board and then remove the top cover Reinstallation Note Be sure that the operator panel cable is cor
35. see Top Cover Removal on page 4 61 Remove the pull tractor actuator see Pull Tractor Removal on page 4 50 Remove the paper select lever see Paper Select Lever Removal on page 4 42 Remove the printhead see Printhead Removal on page 4 48 Remove the sub logic board see Sub Logic Board Removal on page 4 59 Remove the paper feed motor see Paper Guide Platen Assembly Removal on page 4 40 Remove the carrier see Carrier Removal on page 4 12 Remove the upper feed roller see Upper Feed Roller Removal on page 4 66 Remove the lower pinch roller see Lower Pinch Roller Removal on page 4 32 Remove the gears on the right side frame see Right Side Frame Gears Removal on page 4 58 Remove the print unit see Print Unit Removal on page 4 47 Remove the right side frame see Right Side Frame Removal on page 4 56 Remove the idler gear 1 then remove the left feed roller lower gear 2 Release the latch and then remove the left lower bushing 3 On wide carriage machines remove the ground strap from the center of the platen Release the notch on the left of the lower feed roller 4 from tab A on the left side frame and then remove the lower feed roller Be sure to perform the Printhead to Platen Gap Adjustment see Printhead to Platen Gap Adjustment on page 4 2 Repair Information 4 31
36. then on If the abnormal noise is gone look for a problem with the carrier motor or ribbon drive mechanism Paper Feed Disconnect the paper feed motor from CN10 Mechanism from the main logic board Perform the Print Test If the abnormal noise is gone look for the problem in the paper feed mechanism 2 14 Auto Sheet Feeder ASF Service Check Note Be sure the sheet feeder is enabled Refer to Setup Mode on page 1 6 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 Setup 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 Setup Menu the cut sheet paper drive reverses itself for a short distance during paper loading This reversal engages the clutch and thus engages the paper picker 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 th
37. very tight fit 238X 001 Be sure the head gap sensor is in the correct position while installing the paper feed motor plate Repair Information 4 57 Right Side Frame Gears Removal 1 Remove the top cover see Top Cover Removal on page 4 61 Set the paper select lever upward to the cut form position Release the latch 1 and then remove the ASF drive gear 23XX 003 Remove the two screws and remove the shaft support plate not shown Remove both E rings 2 3 and then remove the ASF idler gear and the shift gear from the right side together with their washer and spring To prevent the washer and spring from springing off hold them down while removing the E ring Remove the lower feed roller right gear 4 4 58 Sub Logic Board Removal 1 Remove the top cover see Top Cover Removal on page 4 61 2 Disconnect the short flexible cable 5 from connector CN3 on the main logic board Note Do not twist the flexible cable when you disconnect 3 Disconnect all of the cables connected to the sub logic board 2 Do not bend or twist the flat cables when you disconnect them from CN7 CN8 and 9 4 Disconnect the ground wire 1 5 Remove the screws 3 4 and then remove the sub logic board 2 Note 4 is a self tapping screw 6 To replace first connect the short flexible cable to the sub logic board at CN2 The contact side of the cable must face the center of the
38. 0 on the locker cam 6 Remove the locker cam 6 Release the latch 9 and then remove the lift gear 7 Auto Sheet Feeder Pick up Roller Removal Remove the covers and the cut sheet support Remove the idler gear and pick up gear see Auto Sheet Feeder Gears Removal on page 4 8 Remove the left roller bushing 1 as shown Remove the right roller bushing 2 Move the pick up roller 3 to both ends of the shaft and then remove them Repair Information 4 9 Bottom Cover Removal 1 2 4 10 Remove the tractor assembly see Push Tractor Assembly Removal on page 4 53 Remove the top cover see Top Cover Removal on page 4 61 Remove the main logic board see Main Logic Board Removal on page 4 33 Remove the power supply unit see Power Supply Removal on page 4 46 Remove the print unit see Print Unit Removal on page 4 47 Remove the rubber board support 5 2380 amp 2390 Release the two latches 1 and then remove the Main Logic Board ground plate 2 by sliding it toward you 2381 amp 2391 Remove the two screws securing the Main Logic Board ground plate 2 to the bottom cover Release the two latches 1 and then remove the Main Logic Board ground plate from the bottom cover by sliding it toward you Release the two latches 1 then remove the power supply ground plate 4 by sliding
39. 26 Ribbon Access Cover Unit 2381 001 amp 2391 001 1 1333151 Ribbon Access Cover Unit 2380 002 003 2390 002 003 1 1333156 Ribbon Access Cover Unit 2381 002 003 2391 002 003 2 79F4782 Paper Stand 3 79F4781 Rear Cover 23XX 001 002 3 11A3304 Rear Cover 23XX 003 4 79F4856 Top Cover U S Canada and AFE LV 2380 001 4 79F4857 Top Cover U S Canada and AFE LV 2381 001 4 79F4858 Top Cover U S Canada and AFE LV 2390 001 4 79F4859 Top Cover U S Canada and AFE LV 2391 001 4 1180844 Top Cover 2390 PS 1 4 79F4852 Top Cover EMEA and AFE HV 2380 001 4 79F4853 Top Cover EMEA and AFE HV 2381 001 4 79F4854 Top Cover EMEA and AFE HV 2390 001 4 79 4855 Top Cover EMEA and AFE 2391 001 4 11A3305 Top Cover with logo kit 2380 002 003 2390 002 003 4 11A3306 Top Cover with logo kit 2381 002 003 2391 002 003 5 79F4778 Front Cover Unit 2380 001 amp 2390 001 5 79F4824 Front Cover Unit 2381 001 amp 2391 001 5 1333150 Front Cover Unit 2380 002 003 amp 2390 002 003 5 1333155 Front Cover Unit 2381 002 003 amp 2391 002 003 6 79F4783 Paper Guide 23XX 001 6 1333152 L H Paper Guide 23XX 002 003 7 79F4779 Front Guide Cover 2380 amp 2390 7 79F4825 Front Guide Cover 2381 amp 2391 8 1180863 Paper Guide 23XX 001 8 1333167 R Paper Guide 23 002 003 Parts Catalog 7 7 Assembly 2 Covers Continued
40. 6 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 4 Diagnostic Information 2 41 3 Beeps and Tractor 2 LED blinks 3 times Tractor 2 selected from operator panel but printer does not detect Tractor 2 or detects that the Tractor 2 mechanism is not installed FRU Action 1 Tractor 2 Check the Tractor 2 in place sensor or the Board Cable Asm cable connection The in place 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 in place 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 4 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 2 42 Paper Feed Problems FRU Action 1 Tractor 2 On the printer make sure the gear that drives Tractor 2 turns freely when the lever is not pressed but remain still when the lever is p
41. 675 Idler Gear 238 001 002 18 95F3676 Idler Gear 239X 001 002 18 11A3274 Idler Gear 238X 003 18 11A3275 Idler Gear 239X 003 19 1333238 Frame Support Shaft 2380 002 003 2390 002 003 19 1333239 Frame Support Shaft 2381 002 003 2391 002 003 20 1333240 Top of Form Sensor 2380 002 003 2390 002 003 20 1333241 Top of Form Sensor 2381 002 003 2391 002 003 Parts Catalog 7 17 Assembly 5 Electronics 7 18 Asm Part Index Number Description 5 1 79 4755 Power Supply Unit 100 127 V ac 23 001 1 1333242 Power Supply Unit 100 127 V ac 23 002 003 1 79F4756 Power Supply Unit 200 240 V ac 23 001 1 1333243 Power Supply Unit 200 240 V ac 23XX 002 003 NS 1368071 Fuse Kit Power Supply all LVPS NS 1333268 Fuse Kit Power Supply HVPS 23 001 NS 1333269 Fuse Kit Power Supply HVPS 23XX 002 003 2 79F4815 Power Supply Cable 2380 amp 2390 2 79 4850 Power Supply Cable 2381 amp 2391 3 79F4776 Base 2380 001 LV 3 79F5217 Base 2380 001 HV 3 79F4777 Base 2381 001 LV 3 79F5218 Base 2381 001 HV 3 79F4822 Base 2390 001 LV 3 79F4844 Base 2390 001 HV 3 79F4823 Base 2391 001 LV 3 79F5245 Base 2391 001 HV 3 1333206 Base 2380 002 003 2390 002 003 3 1333207 Base 2381 002 003 2391 002 003 3 1180962 Base 2390 PS 1 4 1180968 Main Logic Board W EPROM 2380 001 LV 4 1180
42. 969 Main Logic Board W EPROM 2380 001 HV 4 1333252 Main Logic Board W EPROM 2380 002 LV 4 1333256 Main Logic Board W EPROM 2380 002 HV 4 1180970 Main Logic Board W EPROM 2381 001 LV 4 1180971 Main Logic Board W EPROM 2381 001 HV 4 1333254 Main Logic Board W EPROM 2381 002 LV 4 1333258 Main Logic Board W EPROM 2381 002 HV 4 1180991 Main Logic Board W EPROM 2390 001 LV 2390 PS 1 4 1180992 Main Logic Board W EPROM 2390 001 HV Parts Catalog 7 19 Assembly 5 Electronics Continued 7 20 Part Index Number Description 5 4 1333260 Main Logic Board W EPROM 2390 002 LV 4 1333264 Main Logic Board W EPROM 2390 002 HV 4 1180993 Main Logic Board W EPROM 2391 001 LV 4 1180994 Main Logic Board W EPROM 2391 001 HV 4 1333262 Main Logic Board W EPROM 2391 002 LV 4 1333266 Main Logic Board W EPROM 2391 002 HV 4 1368012 Main Logic Board W EPROM Variable Forms Length 2380 001 LV 4 1368013 Main Logic Board W EPROM Variable Forms Length 2380 001 HV 4 1368014 Main Logic Board W EPROM Variable Forms Length 2381 001 LV 4 1368015 Main Logic Board W EPROM Variable Forms Length 2381 001 HV 4 1368007 Main Logic Board W EPROM Variable Forms Length 2390 001 LV 4 1368008 Main Logic Board W EPROM Variable Forms Length 2390 001 HV 4 1368016 Main Logic Board W EPROM Variable Forms Length 2391 001 LV 4 1368017 Ma
43. D 20 70 Diagnostic Aids 3 5 Serial Interface Adapter Print Test 3 6 The serial interface adapter has a switch that enables a test of the connection between the serial interface adapter and the printer main logic board This generates a short test print containing the serial interface adapter code level and switch settings and the printer character set To run the serial interface test print 1 Turn the printer off 2 Turn on serial interface Switch 10 3 Turn the printer on If the printer does not generate a printout there is a problem with the serial interface adapter or its connection to the printer Check the switch settings and be sure the serial interface adapter is correctly installed When the test is complete turn off Switch 10 4 Repair Information This chapter contains adjustments and removal procedures Whenever parts are replaced make sure that all adjustments are correct by running diagnostics procedures and checking adjustments as needed Handling ESD Sensitive Parts Many electronic products use parts that are known to be sensitive to electrostatic discharge ESD To prevent damage to ESD sensitive parts follow the instructions below in addition to all the usual precautions such as turning off power before removing logic boards Keep the ESD sensitive part in its original shipping container a special ESD bag until you are ready to install the part into the machine Mak
44. EDD Pin 3 SWO Pin 32 SWO Pin 32 SWO Pin 4 SW LTCH Pin 31 SW LTCH Pin 31 SW LTCH Pin 5 3SW Pin 30 3SW Pin 30 3SW Pin 6 PUL CSF Pin 29 PUL CSF Pin 29 PUL CSF Pin 7 HP Pin 28 HP Pin 28 HP Pin 8 ASF Pin 27 Not Used Pin 27 Not Used Pin 9 THRMO Pin 26 Not Used Pin 26 THRMO Pin 10 HDCOM Pin 25 Not Used Pin 25 HDCOM Pin 11 HD8 Pin 24 HD8 Pin 24 HD8 Pin 12 HD6 Pin 23 HD6 Pin 23 HD6 Pin 13 HD4 Pin 22 HD4 Pin 22 HD4 Pin 14 HD2 Pin 21 HD2 Pin 21 HD2 Pin 15 HD1 Pin 20 HD1 Pin 20 HD1 Pin 16 HD3 Pin 19 HD3 Pin 19 HD3 Pin 17 HD5 Pin 18 HD5 Pin 18 HD5 Pin 18 HD7 Pin 17 HD7 Pin 17 HD7 Pin 19 HD9 Pin 16 HD9 Pin 16 HD9 Pin 20 HD11 Pin 15 HD11 Pin 15 HD11 Pin 21 HD13 Pin 14 HD13 Pin 14 HD13 Pin 22 HD15 Pin 13 HD15 Pin 13 HD15 Pin 23 HD17 Pin 12 HD17 Pin 12 HD17 Pin 24 HD19 Pin 11 Not Used Pin 11 HD19 Pin 25 HD21 Pin 10 HD21 Pin 10 HD21 Pin 26 HD23 Pin 9 Not Used Pin 9 HD23 Pin 27 HD24 Pin 8 Not Used Pin 8 HD24 Pin 28 HD22 Pin 7 Not Used Pin 7 HD22 Pin 29 HD20 Pin 6 Not Used Pin 6 HD20 Pin 30 HD18 Pin 5 HD18 Pin 5 HD18 Pin 31 HD16 Pin 4 HD16 Pin 4 HD16 Pin 32 HD14 Pin 3 HD14 Pin 3 HD14 Pin 33 HD12 Pin 2 HD12 Pin 2 HD12 Pin 34 HD10 Pin 1 HD10 Pin 1 HD10 Connector Locations 5 13 Main Logic Board lt gt Sub Logic Board Model 002 003 23XX 002 003 238X 002 003 239X 002 003 Main Logic Board Sub Logic Board Sub Logic Board CN3 CN2 CN2 Pin 1 SCLK Pin 28 SCLK Pin 34 SCLK Pin 2 LEDD
45. GEST PAGE A Ag AE RG 1889466789 ss TAABCDEFGHITKGMNOPGESTL Bratt t 7 TARCDEFGMI IKLMNOPGRST aye i DO OC 1 3 lt 7A BC DEE GA Gothic 01224565789 5 gt 79ABCDEFBHI JELMMOPORST sayz O00e3aa4ac fee 11 125454789 s lt gt 7OABCDEF GH JELMNOPGRSTU Print Test Sample 24 wire 3 4 070 1332983 Copyright Lexmark 1 1 19 14 15 18 47 18 004454 agiis ti9ecoav 1 amp rept kk i 004 Xmf TES gt lt rte y GA Je ls 32 11 ABCDEFGHTJKLMMOPQRSTUVWXYZabedef 96 11 ABCDEFGHISKLMNOP GRSTUVWXYZabedefc 160 11 ABCDEFGHTIIKLMNOPQRSTUVWEY 160 12 ABCDEFGHISKLMNOPORSTUYYXYZabcdef 160 36 ABCDEFGHIJKLMNOPQRSTUVWXYZabcdef 160 25 ARCDEFGHIJKLMNOPQRS TUVWXYZabcdef 160 5 ABCDEFGHIJKLMNOPQRS TUVWXY ZABCDEF Hex Dump Mode The hex dump mode can help the user test and troubleshoot programs You can use the hex dump procedure to get a hexadecimal printout of the data stream sent to the printer All data including both control and character data print in hexadecimal instead of ASCII To activate hex dump mode 1 Press and hold Alt and then turn the printer on 2 After a few seconds release Alt 3 Start your application pro
46. Guide Platen Assembly Removal 4 40 Paper Select Lever Removal 4 42 Paper Select Sensor Removal 4 43 Paper Separator Removal 4 44 Power Supply 4 46 Print Unit Removal 3333939 dr PRESE EG p RR 4 47 Printhead Removal ada sima ob 4 48 Printhead Cables Removal 4 49 Pull Tractor Removal 4 50 Pull Tractor Actuator Removal 4 51 Pull Tractor Sensor Removal 4 52 vi Service Manual Push Tractor Assembly Removal 4 53 Ribbon Drive Rack Gear Removal 4 54 Right Side Frame Removal 4 56 Right Side Frame Gears Removal 4 58 Sub Logic Board 4 59 Tension Pulley Plate Assembly 4 60 Top Cover 4 61 Top of Form Sensor Sensor Flag And Spring Removal 4 64 Upper Feed Roller Removal 4 66 Connector Locations s ow tena 5 1 Front VIBW eed ede wars 5 2 A Sani ae died ae 5 3 Tractor 2 Cable Connectors 5 4 su es aoe Se wed 5 5 Block 238 001 4 2 2 22
47. NK Tractor 2 Home Position Error Alt OFF Others OFF If Tractor 2 is installed remove it to determine whether the problem is with the carrier home sensor or the Tractor 2 home sensor Refer to the Tractor 2 Service Check on page 2 40 None Home Position Error Without Alarm Go to Power Service Check on page 2 32 Diagnostic Information 2 3 Indication Alarm Action None Logical Error LED Status Turn the machine off and then back on E Gel If you get the same error during p y BLINK power up replace the main logic board aper and readjust the bidirectional print oe adjustment If the printer completes Alt BLINK POST successfully and eventually gets the same error check go to Intermittent Others OFF Problem Service Check on page 2 20 None Hardware Drive Error LED Status Power ON The printhead or the printhead cables Ready BLINK can cause this error Go to Printhead Paper BLINK Service Check on page 2 36 Turn the machine off and then back Alt BLINK If you get the same error replace the Others OFF main logic board and readjust the Bidirectional Print Adjustment on page 4 5 If the printer completes POST successfully and eventually gets the same error go to Intermittent Problem Service Check on page 2 20 If the problem still exists remove the new main logic board install the old main logic b
48. NO 6NO ZNO LINO YNO ENZ 91607 LNO 81489 1 910N LNO Aiddns INO 142 peeujuud OcNO 0240 Ido 649 INO DND geno pieog 21601 416 9N9 ENZ SNO 549 9d9 949 Josueg 401504 208095 129 95 Josueg peer ldo Connector Locations 5 5 10sueg aiqeo 1814 QE Block Diagram 239X 001 JOO 181189 idee JOJO 4 LNO 142 12 0 OINO 640 ZNO LENO 20240 Lido tan 6849 LNO E een ZNO 10SU8S 109811 5 DJeog 21601 016 249 1492 SNO pueog 91607 9 9 SNO 549 Josueg uonisod uondo Josuag
49. Press Form Feed and time how long the gear train rotates With the paper select lever in the cut sheet position sensor open the gear train should rotate for less than 2 seconds With the lever in the continuous forms position sensor closed the gear train should rotate for more than 3 seconds If the printer does not do this inspect the sensor to make sure it is being opened and closed by the paper separator Disconnect CN5 from the sub logic board and measure the paper selector sensor resistance from CP5 1 to CP5 2 Replace the sensor if the resistance does not change from zero to infinite as the paper select lever is moved Pull Tractor Sensor If the pull tractor sensor has failed to close Park Load and Auto Tear Off will not work when using push tractors If the sensor has failed to open Park Load will try to park paper when using pull tractors but the paper will feed all the way out of the tractors and cannot reload Refer to the Pull Tractor Sensor Service Check on page 2 38 Main Logic Board If no other problem is found replace the main logic board Reset the Bidirectional Print Adjustment on page 4 5 Diagnostic Information 2 29 Paper Select Sensor Service Check If form feed length is off by about 1 inch 25 mm enter Setup Mode and verify that the form length setting is correct See the Setup Mode and Switch Settings section FRU Action Paper Select
50. ate is removed the idler gear 3 may come off simultaneously 4 Remove the head gap sensor 2 Repair Information 4 23 Head Gap Sensor Removal 23XX 002 003 1 2 Remove the top cover see Top Cover Removal on page 4 61 Remove the sub logic board see Sub Logic Board Removal on page 4 59 Remove the paper feed motor and the paper feed motor plate see Paper Guide Platen Assembly Removal on page 4 40 Move the forms thickness lever to position 7 Remove the screw 1 and remove the head gap sensor assembly 2 When you re install the sensor be sure the rear of the head gap sensor assembly is held in place by the paper feed motor plate 4 24 Home Position Sensor Removal 1 Remove the top cover see Top Cover Removal on page 4 61 2 Disconnect the home position sensor cable from the sub logic board 3 Remove the screw 1 and then remove the home position sensor from the left side frame The sensor is attached to the left side support plate on newer models Repair Information 4 25 Label Jam Removal When a pressure sensitive label that separates from its protective backing has jammed and stuck to the paper separator and or below the carrier plate the following procedure should be used to remove the jammed label 1 2 4 26 Remove the top cover see Top Cover Removal on page 4 61 Remove the tractor assembly see Push Tract
51. atus Power F to POST Service Check on page Ready 331 Paper Font ON Pitch ON Alt ON Others None RAM ROM Timer Interrupt Controller LED Status Error Power Ready ON Turn the machine off and then on If you Paper ON get the same error during power up Font ON replace the main logic board and Pitch ON readjust the bidirectional print Alt ON adjustment If the printer completes Others OFF POST successfully and eventually gets the same error go to Intermittent Problem Service Check on page 2 20 2 2 Indication Alarm Action LED Switch Scan Test Error Power ON Go to Operator Panel Service Check Ready BLINK on page 2 24 Paper BLINK Font OFF Pitch BLINK Alt OFF Others OFF None NVRAM Read Write Error LED Status Power Turn the machine off and then back on Ready If you get the same error during power Paper BLINK up replace the main logic board and Font BLINK readjust the bidirectional print Pitch OFF adjustment If the printer completes Alt OFF POST successfully and eventually gets Others OFF the same error go to Intermittent Problem Service Check on page 2 20 Beeps Home Position Error LED Status 10 Power ON times Go to Carrier Drive Home Position Ready Sensor Ribbon Feed Service Check on Paper page 2 17 Font BLINK 2 Pitch BLI
52. between the printhead and the right end of the platen before you turn the printer on Perform the printhead to platen gap adjustment after replacing or disassembling any of the following parts Carrier e Platen e Pinch Roller Lower Ribbon Drive Rack Gear Side Frame Left Side Frame Right Paper Separator Feed Roller Lower Paper Guide Note Make sure the top cover is installed Turn the printer off Remove the ribbon access cover Remove the ribbon cartridge and paper Set the form thickness lever to position 1 Move the carrier so that it is just to the left of the left upper feed roller approximately 50 mm 2 0 in from the left side frame 6 Using feeler gauges 1 of 0 35 mm and 0 40 mm 0 014 in and 0 016 in move the left carrier bushing 2 forward or backward until the gap between the printhead 3 and platen 4 is between 0 35 mm 0 40 mm 0 014 in 0 016 in aor D Note The gap should be wide enough for the 0 35 mm 0 014 in feeler gauge to slide in smoothly without catching but too narrow to insert the 0 40 mm 0 016 in feeler gauge E Repair Information 4 3 7 Move the carrier so that it is just to the right of the right upper feed roller approximately 50 mm 2 0 in from the right side frame Using feeler gauges 1 of 0 35 mm and 0 40 mm 0 014 in and 0 016 in mov
53. bly 6 ASF Roller Support 7 26 Assembly 7 ASF Side Frame Covers 7 28 Assembly 8 Tractor 2 Option 7 30 Service Manual Notices and Safety Information Safety Notices 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 The safety features of some parts may not always be obvious Therefore replacement parts must have the identical or equivalent characteristics as the original parts Sicherheitshinweise Die Wartungsinformationen f r dieses Produkt sind ausschlieBlich f r die Verwendung durch einen Wartungsfachmann bestimmt Wahrend des Auseinandernehmens und der Wartung des Gerats besteht ein zusatzliches Risiko eines elektrischen Schlags und k rperlicher Verletzung Das zustandige Fachpersonal sollte entsprechende VorsichtsmaBnahmen treffen Ersatzteile m ssen gleiche oder gleichwertige Merkmale wie die Originalteile aufweisen da nicht immer offensichtlich ist welche Teile des Gerats Sicherheitsmerkmale aufweisen Consignes de S curit Les consignes d entretien et de r paration de ce produit s adressent uniquement un personnel de maintenance qualifi
54. c Board lt gt Top of Form Sensor 23XX 002 CN8 Pint TOFP Pin2 TOF Pin3 SIGNALGND Connector Locations 5 15 Main Logic Board lt gt Carrier Motor CN9 Pin 1 CAD Pin 2 CAC Pin 3 CAB Pin 4 CAA Pin 5 CACOMB Pin 6 CACOMA Main Logic Board lt gt Paper Feed Motor CN10 Pin 1 LFD Pin 2 LFC Pin 3 LFB Pin 4 LFA Pin 5 LFCOMB Pin 6 LFCOMA Not used on Model 003 Pin 7 Not Used Sub Logic Board 238X 001 lt gt Head Gap Sensor CN3 Pin 1 Aid Port Pin 2 Gap 5 16 Sub Logic Board 238X 002 003 lt gt Head Gap Pos 1 to 2 CN3 Pin 1 SIGNAL GND Pin 2 GS2 Sub Logic Board 238X 002 003 lt gt Head Gap Pos 3 to 4 CN4 Pin 1 5 V Pin 2 951 Sub Logic Board lt gt Paper Select Sensor CNS Pin 1 F T Pin 2 SIGNAL GND Sub Logic Board lt gt Home Position Sensor CN6 Pint HP Pin2 SIGNALGND Connector Locations 5 17 Sub Logic Board lt gt Operator Panel 23 001 Sub Logic Board Operator Panel CN7 239X 8 238 CN1 Pin 1 SIGNAL GND Pin 9 SIGNAL GND Pin2 SIGNAL GND Pin 8 SIGNAL GND Pin 3 5 V Pin 7 5 V Pin 4 LEDD Pin 6 LEDD Pin 5 SW LTCH Pin 5 SW LTCH Pin 6 SWD Pin 4 SWD Pin 7 SIGNAL GND Pin 3 SIGNAL GND Pin 8 SCLK Pin 2 SCLK Pin 9 5 V Pin 1 5 V Sub Logic Board lt gt Operato
55. c Information 2 19 Intermittent Problem Service Check FRU Symptom Action The machine sometimes fails before POST is complete Check for the following 1 Loose connectors Reconnect all connectors to the main and sub logic boards 2 Electrical noise or static discharge Check the following items Power supply ground Machine frame ground Printer interface cable is grounded and shielded If the upper feed roll shaft does not have a ground spring install P N 1368036 3 Intermittently low voltages Check for ac and all dc voltages and short circuits on the main and sub logic boards a Check the customer s outlet 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 CN1 on the sub logic board Turn the printer power on and check all dc output voltages at CP11 and CP1 Ensure the output voltages are CP11 1 26 V dc 10 amp CP11 2 GND CP11 3 5 V dc 596 amp CP11 4 Signal GND CP 1 1 26 V dc 10 amp CP1 2 GND 1 3 5 V dc 5 amp CP1 4 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 reset the bidirectional print adjustment Refer to Bidirectional Print Adjustment on
56. cated carrier shaft Idler pulley not binding Ribbon drive rack gear teeth not damaged If the carrier still binds Remove the belt and move the carrier again If the bind is gone replace the carrier motor If the bind still exists replace the carrier 2 Home Position Sensor Sub Logic Board Short Flexible Cable If the carrier moves manually without binding but the Home Position Error still occurs verify that the main logic board is receiving 26 V dc on pin CP11 1 Check that the 5 V dc home position sensor signal is getting to the main logic board Check CP3 7 on the main logic board Check CP6 1 on the sub logic board Replace the sensor the sub logic board or the short flexible cable as necessary 2 18 FRU Action Carrier Motor If the home position sensor is OK refer to the table and make sure the resistance of the carrier motor windings are from 1 to 5 ohms for all printers 238X 001 002 003 239X 002 003 239X 001 CP9 1 amp CP9 5 CP9 1 amp CP9 6 CP9 2 amp CP9 6 CP9 2 amp CP9 5 CP9 3 amp CP9 5 CP9 3 amp CP9 6 CP9 4 amp CP9 6 CP9 4 amp CP9 5 Main Logic Board If all parts appear OK but the Home Position Error still occurs replace the main logic board After replacing the main logic board or any parts affecting the carrier perform the bidirectional print adjustment See Bidirectional Print Adjustment on page 4 5 Diagnosti
57. cts the slider disengaging the Tractor 2 gear drive and reengaging the printer tractors 2 40 10 Beeps and Blinking Ready Paper Font and Pitch LEDs Tractor 2 home sensor never made after turning the printer off and then on or made at the wrong time The same error indication is used for carrier home failure FRU Action 1 Tractor 2 Remove the Tractor 2 and turn the printer off Home Sensor and then on again to determine if the fault is in the printer or Tractor 2 If the gear teeth chatter just before the beeps replace the home sensor 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 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 5V dc on CN1 5 If not check the cable connection and the voltages at main logic board CN6 1 The upper right pin at CN6 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 Check the resistances of the Tractor 2 motor Board Cable Asm windings there should be 101 5 ohms between pins 1 and 5 3 and 5 2 and 6 and 4 and
58. determines the top of form setting For top of forms problems on 23XX 001 printers refer to the Paper Empty Sensor Service Check on page 2 26 23XX 002 and 23XX 003 machines have two sensors The left sensor is paper empty The right sensor is top of form FRU Action 1 Top of Form Sensor Check that the top of form sensor and its flag are properly installed and are undamaged 2 Main Logic Board Remove the paper and set the paper select lever to the cut sheet position and turn the power on Measure the voltage between main logic board CN8 2 TOF signal and CN8 3 GND When there is paper in the printer the voltage should be 0 V dc When there is no paper in the printer the voltage should be 5 V dc Replace the sensor if the voltage is incorrect Replace the main logic board if the voltage is correct and there is still a problem Reset the Bidirectional Print Adjustment on page 4 5 Diagnostic Information 2 39 Tractor 2 Service Check Note This option can be used only on 23XX 003 printers The Tractor 2 in place 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 retra
59. dications Symptom Action 7 or more lights turn on but do not turn off The Power light is on but POST will not run 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 31 Abnormal Noise Problems Symptom Action During POST abnormal noise comes from the carrier Check the ribbon cartridge for binds or damage Go to the Carrier Drive Home Position Sensor Ribbon Feed Service Check on page 2 17 During idling abnormal noise comes from the printer When feeding paper abnormal noise is created During printing or POST abnormal noise is created Go to Abnormal Noise Service Check on page 2 14 2 6 Abnormal Print Operation Problems Symptom Action Printer will not print or become Ready Abnormal operation incorrect characters or incorrect line width Printer is ready but will not print from the computer correctly Undefined or incorrect character s Be sure the interface cable is connected properly If the serial interface adapter is installed be sure it and its power interface cable are installed correctly Some adapters do not have a separate power cable Go to the No Print or Abnormal Print Service Check on page 2 23 Slow printing
60. e Be sure the printhead cables are correctly aligned and secured They must be flat with no twists Repair Information 4 49 Pull Tractor Removal 1 Press the tractor assembly locking levers 1 down tilt the tractor assembly in the direction indicated by the arrow and remove it from the printer 4 50 Pull Tractor Actuator Removal 1 If the tractor is installed in the pull tractor position remove the tractor assembly see Pull Tractor Removal on page 4 50 2 Remove the top cover see Top Cover Removal on page 4 61 3 Remove the left pull tractor actuator 1 4 Remove the right pull tractor actuator 2 Note If the pull tractor actuator is difficult to remove or is accidentally dropped inside the printer remove the top cover Repair Information 4 51 Pull Tractor Sensor Removal 1 Remove the top cover see Top Cover Removal on page 4 61 2 Disconnect the pull tractor sensor cable from connector CN4 on the main logic board 3 Use a 1 Phillips screwdriver held in the position shown to remove the screw then remove the pull tractor sensor 4 52 Push Tractor Assembly Removal 1 Open the front cover 1 2 Press both tractor assembly locking levers 2 down then pull the tractor assembly 3 straight out of the printer Repair Information 4 53 Ribbon Drive Rack Gear Removal 4 54 1 Remove the top cover see Top Cover Removal on page 4 61 Move the
61. e lower pinch roller see Lower Pinch Roller Removal on page 4 32 Remove the print unit see Print Unit Removal on page 4 47 Remove the home position sensor see Home Position Sensor Removal on page 4 25 Remove the pull tractor sensor see Tractor Sensor Removal on page 4 52 238X 001 Remove the head gap sensor see Head Gap Sensor Removal 238X 001 on page 4 23 23XX 002 003 Remove the head gap sensor assembly see Head Gap Sensor Removal 23XX 002 003 on page 4 24 Remove the large idler gear 7 by inserting a small blade screwdriver between the gear and the side frame and twisting 23XX 002 003 Remove the screw 8 that was covered by the gear and remove the metal support plate Remove the platen bar screw 8 that was covered by the support plate 23XX 001 printers have only one screw to remove 238X XXX Remove the idler gear 1 Remove the lower left feed roller gear 2 Release the latch and then remove the left lower bushing 3 20 21 22 23 Remove the screw 4 Release the two latches 5 Remove the left side frame Be sure to perform the Printhead to Platen Gap Adjustment after you re assemble the printer see Printhead to Platen Gap Adjustment on page 4 2 Repair Information 4 29 Lower Feed Roller Removal 4 30 1 2 Remove the tractor assembly see Push Tractor Assembly Removal on page 4 53 Remove the top cover
62. e the least possible movements with your body to prevent an increase of static electricity from clothing fibers carpets and furniture Put the ESD wrist strap on your wrist Connect the wrist band to the system ground point This discharges any static electricity in your body to the machine Hold the ESD sensitive part by its edge connector shroud cover do not touch its pins If you are removing a pluggable module use the correct tool Do not place the ESD sensitive part on the machine cover or on a metal table if you need to put down the ESD sensitive part for any reason first put it into its special bag Machine covers and metal tables are electrical grounds They increase the risk of damage because they make a discharge path from your body through the ESD sensitive part Large metal objects can be discharge paths without being grounded Prevent ESD sensitive parts from touching other personnel Install machine covers when not working on the machine and do not put unprotected ESD sensitive parts on a table Keep all ESD sensitive parts in a grounded metal cabinet case Low humidity increases static electricity during cold weather Repair Information 4 1 Adjustments CAUTION Be sure to unplug the power cord whenever you are working on the printer with one of the covers removed Printhead to Platen Gap Adjustment 4 2 WARNING To prevent damage to the printhead when this adjust ment is made be sure a gap exists
63. e the paper load lever is in the correct position 2 16 Carrier Drive Home Position Sensor Ribbon Feed Service Check 23XX 001 only If the carrier stops but the print wires continue to fire printing one vertical column of dots or if the carrier does not move after turning the printer off and then on inspect the area of the main logic board that is below the paperfeed motor If this area is damaged or cracked replace the main logic board Also check the continuity of soldered on fuse FU1 located on the main logic board near the paper empty sensor If this fuse is open replace the main logic board Turn the printer off and then on The carrier should move to the left contact the home position sensor on the left side frame and immediately move slightly away from the sensor A Home Position Error occurs when The sensor is not closed The sensor is not quickly opened The sensor is closed any time other than when the printer is turned off and then on Diagnostic Information 2 17 FRU Action 1 Carrier If there is no Home Position Error check the carrier belt and the ribbon cartridge for wear or damage Check the belt and pulley engagement Manually move the carrier the full length of the carriage to check for binds and to make sure the ribbon advances when the carriage moves in either direction If the carrier binds check the following Correct printhead to platen gap Clean and lubri
64. e the right carrier bushing 2 forward or backward until the gap between the printhead 3 and platen 4 is between 0 35 mm 0 40 mm 0 014 in 0 016 in Note The gap should be wide enough for the 0 35 mm 0 014 in feeler gauge to slide in smoothly without catching but too narrow to insert the 0 40 mm 0 016 in feeler gauge 12 13 14 4 4 Repeat Steps 5 and 6 and readjust the gap if necessary 10 11 Repeat Steps 7 and 8 and readjust the gap if necessary Set the form thickness lever to suit the paper thickness you are using Install the ribbon cartridge and paper Install the ribbon access cover Run the self test and check the density of the printing Repeat procedure if necessary Bidirectional Print Adjustment After replacing any mechanical part which affects the operation of the main logic board or the carrier perform the following procedure to adjust the bidirectional print Note This adjustment cannot be completed if the printer runs out of paper so be sure to use continuous forms 1 Be sure the ribbon cartridge and continuous forms are installed 2 Turn the printer on 3 Press Alt and then press MicroT The printer enters Setup Mode 4 Press the Control Options button Button varies with model 5 Press the Bidirectional Alignment button Button varies with model 6 Press Font The printer prints out the pattern shown below The first and third l
65. em 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 On 23XX 001 printers check for equal gap between the lower feed rollers and lower pinch rollers If the gap is smaller on the left install Shim Kit P N 1368067 If the paper does not stop in the correct location refer to the Paper Empty Sensor Service Check on page 2 26 and the Top of Forms Problem Service Check on page 2 39 FRU Symptom Action 1 Auto Sheet Feeder If the Auto Sheet Feeder is installed remove it Enter the Setup Menu and reset ASF to off Verify that the machine works correctly without the ASF installed If the printer fails only with the Auto Sheet Feeder installed refer to the Auto Sheet Feeder ASF Service Check on page 2 15 2 Gear Train Remove all paper from the machine Press Form Feed several times and examine all rotating parts to find the problem For better visibility remove the covers and reconnect the operator panel to the sub 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 on a 23XX 002 or 23XX 003 turn the right end of the lower feed roller shaft with a 6 mm wrench Diagnostic Information 2 27 FRU Sy
66. ever is in the correct position Go to the Paper Select Sensor Service Check on page 2 30 2 8 Symptom Action Paper feeds but Auto Loading does not work Be sure the paper select lever is in the cut sheet position Be sure Auto Loading is enabled in the Setup Mode Go to the Paper Select Sensor Service Check on page 2 30 Alt Park Load functions when the pull tractor is installed With Paper Out blinking Form Feed does not operate until paper is located at first print line Be sure the paper select lever is in the tractor position Go to the Pull Tractor Sensor Service Check on page 2 38 Lower feed roll shaft rotates but paper does not feed Pressing Form Feed does not feed paper Abnormal noise created while feeding Paper jams skews or creases Incorrect or no line spacing wider narrower or overlapping lines Push Pull Tractor does not work Be sure the paper select lever is in the correct position Go to the Paper Feed Service Check on page 2 27 Incorrect Top of Form positioning Go to the Top of Forms Problem Service Check on page 2 39 Diagnostic Information 2 9 Operator Panel Problems Symptom Action Start Stop does not Turn the printer off and then on function but no error is indicated Go to the Operator Panel Service Check on page 2 24 Only the Power light turns on
67. fer to Bidirectional Print Adjustment on page 4 5 2 Interface Cable Check the connection and continuity of the interface cable 3 Emulation Mode Enter the Setup Menu and make sure the printer is in the correct emulation mode for the computer either IBM or Epson 4 Serial Interface If the serial interface adapter is installed make Adapter sure the dip switches match the computer settings Make sure the serial adapter power cable if present is securely connected to the printer power connector CN5 On newer models make sure the serial interface adapter s power LED is on when printer power is on Run the Serial Interface Adapter Print Test on page 3 6 If the test is not successful replace the serial interface adapter If no defect is found the printer and serial interface adapter are working correctly The problem may be with the interface cable the computer the printer driver or the specific job being sent Diagnostic Information 2 23 Operator Panel Service Check Note If the Op Panel Asm is locked only the Start Stop Form Feed Alt Tear Off and Alt Park Load buttons are active Model 2 and 3 printers have a Lock LED to indicate that the operator panel is locked To unlock the operator panel turn the printer off and then on while pressing Micro and Micro FRU Action 1 Op Panel Cable Sub Logic Board Check the connections from
68. gram Be sure the printout is similar to the hex dump sample shown Two hexadecimal digits followed by a space are printed for each byte of data sent to the printer 4 The printer continues to print in hexadecimal until you turn the printer off Hex Dump Mode Sample 20 20 30 20 20 en DO 20 eo EO 20 F0 91 20 20 Al 20 20 BI 29 en 20 62 7e en en 23 20 20 33 43 20 03 20 90 20 80 e0 94 20 A4 20 Ra 5 20 20 65 75 20 OR 26 36 20 06 20 20 ES 20 20 97 go 20 A7 eo eo 2 58 20 58 00 en 78 00 OA OA 29 20 eo 39 eo 00 C9 20 09 20 ED 94 00 AA 20 en 00 58 20 20 29 UD DA ec eo 3C CC eo DC 20 en 09 80 90 en OA OE 20 20 20 GE 20 20 SE 20 6E 20 CE 20 DE 20 20 20 20 FE OD DA eo 00 eo 20 20 AF 20 20 BF 20 CF en DF eo 0 20 20 20 90 80 71 80 81 eo eo 42 20 eo se 20 80 20 80 F2 00 20 20 20 B3 20 20 64 80 74 84 20 Ou 35 20 20 45 20 20 05 29 20 ES 20 20 FS 00 20 20 46 20 20 86 20 20 20 67 80 20 77 20 80 87 28 20 38 20 48 25 90 08 20 20 20 20 99 80 eo 20 20 B9 20 20 20 6A 20 80 74 29 20 OA 2B 20 eo 3B 20 48 3 20 80 20 20 20 eo 9C 20 20 AC 20 eo BC 50 20 6
69. he left after turning the printer off and then on do the following Make sure the line cord voltage to the power supply is correct Make sure the power supply outputs are 5 V de at CN1 2 and 26 V at CN1 4 If the voltage is incorrect check the internal fuses before replacing the power supply Generally if F3 is blown it is due to a short in the printhead replace the printhead and the fuse before powering on again Check for 5 V at main logic board CN11 3 and sub logic board CN1 3 and for 26 V dc at main logic board CN11 1 and sub logic board CN1 1 Make sure the short flexible cable is undamaged and correctly installed 2 Sub Logic Board If the carrier moves to the left after turning the printer off and then on do the following Move the carrier to the right and turn power on The carrier should move to the left The power LED should be on steady whenever the printer is on If the carrier moves to the left during after turning the printer off and then on but the power LED is not on steady Make sure the sub logic board is receiving voltage by checking for 5 V dc at sub logic board CN1 3 f no voltage or power cable problem is found make sure there is 5 V on pins 3 and 9 of the sub logic board connector for the operator panel cable If the voltage is incorrect replace the sub logic board 2 32 FRU Action Op Panel If there is still a power LED problem check the
70. he printer and disconnect the power cord at both ends Remove the top cover see Top Cover Removal on page 4 61 Remove the ground wire screw 1 Do not lose the star washer 2 if present located between the ground wire and the shield plate Disconnect the power supply cable 3 Remove the four mounting screws 4 Remove the power supply Reassembly Note The platen ground leg 5 goes on top of the power supply cover The ground spring on top of the power supply goes behind the frame support shaft and in front of the upper feed roller shaft 4 46 Print Unit Removal 1 2 CON Remove the tractor assembly see Push Tractor Assembly Removal on page 4 53 Remove the top cover see Top Cover Removal on page 4 61 Disconnect all cables connected to the main logic board Do not bend or twist the flexible cable when disconnecting it from CN3 Disconnect the power supply cable from connector CN1 on the sub logic board Disconnect the ground wire from the sub logic board plate Remove the screw 1 Remove two screws 2 and then remove the inserts Do the following for the left and right side frames Insert a screwdriver between the bottom front of the side frame and the bottom cover Raise the screwdriver gently to release the latch while sliding the print unit toward you Slide the print unit toward you until it stops then lift to separate the print unit from the botto
71. ieves appropriate without incurring any obligation to you Lexmark is a trademark of Lexmark International Inc Copyright Lexmark International Inc 1996 2000 All rights reserved UNITED STATES GOVERNMENT RESTRICTED RIGHTS This software and documentation are provided with RESTRICTED RIGHTS Use duplication or disclosure by the Government is subject to restrictions as set forth in subparagraph c 1 ii of the Rights in Technical Data and Computer Software clause at DFARS 252 227 7013 and in applicable FAR provisions Lexmark International Inc Greenwich CT 06836 Contents Notices and Safety Information ix Solely udis REG se eh ote eee Sees ix cecus SE CHER d xiii General Information 1 1 DESCIPICM EE EH 1 1 SPSCICAIONS RE e bae bs 1 3 Recommended Machine Usage 1 3 ncc ER 1 4 EE 1 4 ADBrevialtiOtiS he b ROL e TEE 1 5 Soup SOC DE ipe qur i dede 1 6 How To Change The Printer Functions 1 6 Serial Interface Adapters 1 7 Serial Interface Switches 1 8 Function Switch Setting EE 1 8 Diagnostic Information 2 1 ETATEN SEETI EEIT EAEE ETTE EESTE TEET S E TE 2 1 V
72. in Logic Board W EPROM Variable Forms Length 2391 001 HV 4 11A3322 Main Logic Board W O EPROM 2380 003 LV 4 11A3324 Main Logic Board W O EPROM 2380 003 HV 4 11A3323 Main Logic Board W O EPROM 2381 003 LV 4 11A3325 Main Logic Board W O EPROM 2381 003 HV 4 11A3326 Main Logic Board W O EPROM 2390 003 LV 4 11A3328 Main Logic Board W O EPROM 2390 003 HV 4 11A3327 Main Logic Board W O EPROM 2391 003 LV 4 11A3329 Main Logic Board W O EPROM 2391 003 HV NS 11A3330 EPROM 238X 003 NS 11A3331 EPROM 239X 003 Parts Catalog 7 21 Assembly 5 Electronics Continued 7 22 Asm Part Index Number Description 5 5 1180725 32Kb NVRAM Memory Module Option 5 1180727 32Kb Memory Module US Option 5 1180960 Extended NLS Module EMEA Option 238X 001 5 1180961 Extended NLS Module EMEA Option 239X 001 5 1332985 Extended NLS Module Turkish Greek Option 238X 002 5 1332986 Extended NLS Module Eastern Countries Option 238X 002 5 1332987 Extended NLS Module Middle East Countries Option 238X 002 5 1332988 Extended NLS Module Turkish Greek Option 239X 002 5 1332989 Extended NLS Module Eastern Countries Option 239X 002 5 1332990 Extended NLS Module Middle East Countries Option 239X 002 5 11A3285 Extended NLS Module Eastern Europe Option 238X 003 5 11A3286 Extended NLS Module Eastern Europe Optio
73. ines are printed from left to right The second and fourth lines are printed from right to left Repair Information 4 5 4 6 7 Align the second and fourth lines to the first and third lines Each time Micro is pressed the second and fourth lines shift toward the left Each time Micro 415 pressed the second and fourth lines shift toward the right 8 Continue adjusting the bidirectional alignment by repeating step 7 until your printout resembles the one shown HB ETAT 9 When the bidirectional alignment is satisfactory press Start Stop to exit the bidirectional alignment mode Removal Procedures Use the following procedures to remove and replace individual FRUs The procedures in this section are mainly for the 2380 and 2390 printers When a procedure for the 2381 and 2391 printers differ the procedure for the 2381 and 2391 is described under Wide Carriage CAUTION Be sure to unplug the power cord whenever you are working on the printer with one of the covers removed Repair Information 4 7 Auto Sheet Feeder Gears Removal 4 8 O1 BB Remove the right cover Release the latch A and then remove the joint gear 1 Remove the idler gear 2 Release the latch A and then remove the idler gear 3 Release the latch 8 and then remove the pick up gear 4 Release the latch A and then remove the combination lock mechanism 5 Remove the tension plate 1
74. inthead resistance according to the following table Make sure no pins have continuity to the printhead housing 2 36 FRU Action Printhead Continuity Table The correct resistance is 2 8 to 3 8 ohms 238X or 7 to 15 ohms 239X 238X 9 10 amp CP9 12 Dott CP9 6 amp CP9 4 Dot2 CP9 17 amp CP9 14 Dot3 9 7 CP9 3 CP9 15 amp 9 11 Dot5 CP9 1 amp CP9 5 Dot CP9 18 amp CP9 13 Dot7 CP9 2 amp CP9 8 Dot8 CP9 16 amp CP9 9 Dot9 239X CP8 10 amp CP8 13 CP8 8 amp CP8 7 CP8 12 amp CP8 13 CP8 6 amp CP8 7 CP8 14 amp CP8 11 CP8 4 amp CP8 7 CP8 16 amp CP8 11 CP8 2 amp CP8 9 CP8 18 amp CP8 11 CP8 1 amp CP8 9 CP8 17 amp CP9 10 CP8 3 amp CP8 9 CP8 15 amp CP9 10 CP8 5 amp CP9 8 CP9 16 amp CP9 12 CP9 4 amp CP9 8 CP9 17 amp CP9 12 CP9 2 amp CP9 8 CP9 15 amp CP9 12 CP9 1 amp CP9 6 CP9 13 amp CP9 14 CP9 3 amp CP9 6 CP9 11 amp CP9 14 CP9 5 amp CP9 6 Dot1 Dot2 Dot3 Dot4 Dot5 Dot6 Dot7 Dot8 Dot9 Dot10 Dot11 Dot12 Dot13 Dot14 Dot15 Dot16 Dot17 Dot18 Dot19 Dot20 Dot21 Dot22 Dot23 Dot24 E E E md mie ie reme uh em A If the problem is not missing or extra dots or lines do the following Make sure the printhead is securely installed in the carrier Perform the Printhead to Platen Gap adjustment Diagnos
75. is disengages the clutch and the picker 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 picker rollers continue to turn as the paper is fed their drive is disengaged and they are actually being turned by the paper FRU Action 1 Paper Select With the paper select lever in the cut sheet Sensor position do the following Try to load a sheet with Alt Park Load This button should not work Ifthe paper loads go to the Paper Select Sensor Service Check on page 2 30 Diagnostic Information 2 15 FRU Action Paper Feed 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 27 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 Combination Lock Mechanism Install the ASF and press Form Feed If the picker drive shaft does not rotate replace the combination lock mechanism Left and Right Hoppers If the ASF picker rollers rotate but a single sheet is not picked inspect the springs and corner separators on the left and right hoppers Make sur
76. ith the font forms thickness setting and printhead temperature Graphics output may print slowly due to data throughput limitations Thermal sensing is built into the printhead on 239X printers and protects the printhead from overheating Depending on the job content thermal slowdown may occur after 5 to 10 minutes of continuous operation on 239X 001 printers and after 10 to 20 minutes on 239X 002 003 printers Print slowdown modes are as follows Thermal Forms Thickness Slowdown Slowdown 238X 001 No 26 speed reduction at Forms Thickness 7 Head Gap Sensor contains one switch 239X 001 Yes No Forms Thickness speed reduction No Head Gap Sensor 238X 002 No Reduced print wire force at Forms 238X 003 Thickness 1 23 speed reduction at Forms Thickness 4 through 7 Head Gap Sensor Assembly contains two switches 239X 002 Yes Reduced print wire force at Forms 239X 003 Thickness 1 20 speed reductions at Forms Thickness 4 through 7 Head Gap Sensor Assembly contains two switches 2 34 FRU Action Head Gap Sensor Check the function of the head gap sensor by 23XX 001 moving the forms thickness lever from 6 to 7 and back while printing the Demo Page Alt Demo Print speed is reset at the beginning of each line listen for the printer to slow down in position 7 Disconnect the head gap sensor from connector CN3 on the sub logic board Check the resistance of the sensor while
77. ler spring center Pinch roller spring right Paper separator Specified Lubricants Oil P N 1280443 Approved equivalents Mobil DTE27 Shell Tellus 100 Fuchs Renolin MR30 Grease P N 6934659 Approved equivalent Mobil 28 Preventive Maintenance 6 1 Lubrication Points Oil Lubricate the following contact positions Grease 6 2 Oil Felt carrier block Tractor Shaft Lubricate the following contact positions Side Frame Left and Pull Tractor Idler Gear Side Frame Left and Gear B Side Frame Left and Idler Gear Side Frame Right and Shift Gear Side Frame Right and ASF Idler Gear Side Frame Right and ASF Drive Gear Pinch Roller Lower and Pinch Roller Spring Left Pinch Roller Lower and Pinch Roller Spring Center Pinch Roller Lower and Pinch Roller Spring Right Pinch Roller Lower and Paper Separator ASF Side Frame Right and Joint Gear ASF Side Frame Right and Idler Gear ASF Side Frame Right and Idler Gear ASF Side Frame Right and Combination Lock Mechanism I I lt lt gt ASF Side Frame Right and Feed Roll Gear Lower ASF Side Frame Right and Feed Roll Gear Upper ASF Side Frame Left and Upper Feed Roll Shaft ASF Pick up Roller Shaft and Roller Bushing Left ASF Pick up Roller Shaft and Roller Bushing Right Lubrication Points Oil The oil felt 1 in the carrier block The tractor shaft 1 Preventive Maintenance 6 3
78. m cover Repair Information 4 47 Printhead Removal Turn the printer off Disconnect the power cord at the printer e Let the printhead cool for 15 minutes before touching it e sure to avoid getting your finger stuck between the carrier and ribbon drive rack gear while moving the carrier Firmly grip the latch for the ribbon cartridge to move the carrier Before you remove the printhead set the form thickness lever to position 7 Remove the ribbon access cover Remove the ribbon cartridge Release the two latches 1 and then lift the printhead up and remove If necessary gently pry the printhead upward with a screwdriver inserted under it from the right side Disconnect the printhead cables 2 from the printhead connector Reassembly Note Be sure the printhead cables are correctly aligned and secured Be sure to perform the Printhead to Platen Gap Adjustment procedure see Bidirectional Print Adjustment on page 4 5 4 48 Printhead Cables Removal Note Be careful not to damage the printhead cables as they are secured with double sided adhesive tape 1 Remove the top cover see Top Cover Removal on page 4 61 2 Remove the printhead see Printhead Removal on page 4 48 3 Release the printhead cables from the flexible cable holders 4 Disconnect the printhead cables 1 from connector CN8 and CN9 239X or CNY 238 on the sub logic board 2 Reassembly Not
79. mally 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 that 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 Diagnostic Information 2 1 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 Check Table on page 2 6 Indication Alarm Action None Post Error LED St
80. moving the forms thickness lever Resistance should be 0 ohms at forms thickness position 7 and infinite at positions 1 through 6 Head Gap Sensor Check the function of the head gap sensor by 23XX 002 turning the power on with the Alt Macro 23XX 003 buttons pressed With the forms thickness lever at 1 Macro LED 1 will light With the forms thickness lever at 2 and 3 Macro LED 2 will light With the forms thickness lever at 4 through 7 Macro LED 3 will light Disconnect the head gap sensor asm from connector on the sub logic board Check the resistance of the sensor while moving the forms thickness lever Resistance should be 0 ohms at position 1 and infinite at positions 2 through 7 Disconnect the head gap sensor asm from connector CN4 on the sub logic board Check the resistance of the sensor while moving the forms thickness lever Resistance should be 0 ohms at positions 1 through 3 and infinite at positions 4 through 7 Diagnostic Information 2 35 Printhead Service Check FRU Action Printhead Cables Printhead If the problem is missing or extra dots or lines do the following Check the continuity and connection of the printhead cables and the short flexible cable Make sure the voltages to the sub logic board are correct If dots are missing Perform the print test to determine which wire is not firing Remove the printhead and check the pr
81. mptom Action Paper Selector Lever Make sure the selector lever alternately engages and disengages the tractor gear and the ASF drive gear Check the operation of the following parts as you move the paper select lever The tractor gear engages correctly in the continuous forms position The tractor belts are in good condition and rotate correctly The pinch roller shafts move downward as the lever moves to the cut sheet position The paper separator moves upward as the lever moves to the cut sheet position Operator Panel If paper does not move at all verify that the Form Feed button is working as follows With the tractor in the push position power off power on then press Alt Load The carrier should move to the center of the platen If it does not go to the Operator Panel Service Check on page 2 24 Paper Feed Motor Disconnect the paper feed motor cable CN10 from the main logic board No pin should have continuity to ground The resistances should be as follows 23XX 001 002 21 to 24 ohms CP10 1 to CP10 5 10 1 to CP10 6 CP10 2 to CP10 5 CP10 2 to CP10 6 CP10 3 to CP10 5 CP10 3 to CP10 6 CP10 4 to CP10 5 CP10 4 to CP10 6 23XX 003 8 to 9 ohms CP10 1 to CP10 5 CP10 2 to CP10 5 CP10 3 to CP10 5 CP10 4 to CP10 5 2 28 FRU Symptom Action Paper Select Sensor Remove all paper from the printer and place the tractor in the push position
82. n Description The Lexmark 238X and 239X XXX printers are small versatile tabletop printers suitable for use in the home or small business They are especially well suited for applications that use continuous or multipart forms The 2381 and 2391 are wide carriage versions of the 2380 and 2390 The 23XX Plus 23XX 002 printers are enhanced versions of the basic 23XX 001 printers These printers have the following additional features Forms macro and smooth paper scrolling capability available from the operator panel Option slot Resident bar code Quiet mode Higher print speed 239X The 23XX Forms Printers 23XX 003 in addition to the features of the 23XX 002 printers are 996 9 wire machines or 2896 24 wire machines faster in fast draft mode They also support the Tractor 2 Options There is also a PS 1 version of the 2390 001 which has a distinctive PS 1 logo but is otherwise identical to the 2390 001 General Information 1 1 The following table summarizes the differences between the printers in the 23XX family US Logo WTC Logo Mach Type Model e Width Knob Wires PPSII 2380 2380 2380 001 9 Narrow Yes PPSII 2381 2381 2381 001 9 Wide Yes PPSII 2390 2390 2390 001 24 Narrow Yes PPSII 2391 2391 2391 001 24 Wide Yes PS 1 N A 2390 PS1 24 Narrow Yes 2380 Plus 2380 Plus 2380 002 9 Narrow No 2381 Pl
83. n 239X 003 5 11A3287 Extended NLS Module Middle East Countries Option 238X 003 5 11A3288 Extended NLS Module Middle East Countries Option 239X 003 6 79F4860 Screw Washer and Clip Kit 23XX 001 6 1333219 Screw Washer and Clip Kit 23XX 002 6 11A3344 Screw Washer and Clip Kit 23XX 003 7 79F4811 Spring Kit 23XX 001 2381 002 2391 002 7 1333228 Spring Kit 2380 002 amp 2390 002 7 11A3308 Spring Kit 2380 003 amp 2390 003 7 11A3309 Spring Kit 2381 003 amp 2391 003 8 1368019 Rubber Board Support Parts Catalog 7 23 Assembly 6 ASF Roller Support 7 24 Asm Part Index Number Description 6 1 95F6884 Paper Guide 23XX 001 002 2380 003 2390 003 2 95F6883 Cut Sheet Support 2380 amp 2390 2 95F6895 Cut Sheet Support 2381 001 002 amp 2391 001 002 2A 11A3334 Cut Sheet Support WI Guides 2381 003 2391 003 3 95F6886 Feed Roller Upper 2380 amp 2390 3 95F6896 Feed Roller Upper 2381 amp 2391 4 95F6887 Feed Roller Lower 2380 amp 2390 4 95F6897 Feed Roller Lower 2381 amp 2391 5 1333275 Pick up Roller L amp R 2381 003 2391 003 5 95F6885 Pick up Roller All others 6 95F6889 Hopper R 7 1333278 Paper Support R 2381 003 2391 003 7 95F6879 Paper Support R All others 8 95F6880 Paper Support C 2381 amp 2391 9 95F6878 Paper Support L 10 1333280 Hopper L 2381 003 2391 003
84. n Pulley Plate Assembly 23XX 003 1143186 Carrier Motor Assembly 238X 001 1333221 Carrier Motor Assembly 238X 002 79F4817 Carrier Motor Assembly 239X 001 1333222 Carrier Motor Assembly 239X 002 1143313 Carrier Motor Assembly 23XX 003 79F4754 Sub Logic Board Assembly 238X 001 1333223 Sub Logic Board Assembly 238X 002 003 79F4764 Sub Logic Board Assembly 239X 001 1333224 Sub Logic Board Assembly 239X 002 003 NN NN OO P P Go D ch Parts Catalog 7 11 Assembly 3 Carrier Continued Asm Part Index Number Description 3 9 79F4795 Home Position Sensor 23XX 001 9 1333236 Home Position Sensor 23XX 002 003 10 1180988 Form Thickness Lever 23XX 001 10 1333168 Form Thickness Lever 23XX 002 003 11 79F4789 Paper Feed Motor 23XX 001 002 11 11A3307 Paper Feed Motor 23 003 12 1333225 Short Flexible Cable 238X 002 003 12 95F5315 Short Flexible Cable All others 13 79F4810 Gear and Bushing Kit 238X 001 002 13 79F4806 Gear and Bushing Kit 239X 001 002 13 11A3272 Gear and Bushing Kit 238X 003 13 11A3273 Gear and Bushing Kit 239X 003 14 79F4811 Spring Kit 23XX 001 2381 002 2391 002 14 1333228 Spring Kit 2380 002 amp 2390 002 14 11A3308 Spring Kit 2380 003 amp 2390 003 14 11A3309 Spring Kit 2381 003 amp 2391 003 15 79F4860 Screw Washer
85. nding on which serial interface unit is installed Snap On and Gray Units Protocol Switch 9 Snap On Gray Off XON XOFF DTR Pacing RS232 only On pacing RS232 only XON XOFF Black Units Switch 4 Switch 9 Protocol Off On XON XOFF Off Off pacing RS232 only On Off DTR XON XOFF Off On Robust XON XOFF Note protocol is for RS 232C only Switch 10 Print Test All Units Selects the print test for the serial interface adapter Refer to Serial Interface Adapter Print Test on page 3 6 Switch 10 Print Test Off Normal mode On Test mode General Information 1 11 Switch 11 Polarity For RS 422 Serial Interface All Units NOR REV reverses the polarity of the receive and transmit data line for the RS 422 serial interface Switch 11 Mode Off Normal On Reverse Switch 12 Serial Interface Mode Select All Units Switch 232 422 sets the serial interface in either RS 232C or RS 422 mode Switch 12 Mode Off RS 232C On RS 422 2 Diagnostic Information Start Make a quick visual check for defects loose or broken parts unplugged connectors paper jams and so on 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 nor
86. ng and leave Setup Mode press Start Stop until out of the menu 1 6 Serial Interface Adapters The 23XX printer product line uses three different serial adapters e 23XX 001 Snaps on back of the printer and plugs into the parallel port Power lead plugs into the printer s 5 V port e Switch settings are for Snap On e 23XX 002 In line gray box with a short cable to the parallel port Some units have a separate power lead to the 5 V port Units without the power cord will not work on the 23XX 001 Switch settings are for Gray e 23XX 003 Similar to the 23XX 002 but different switch definitions e All units have a power lead Switch settings are for Black Notes Except as noted all adapters work with all printers Some adapters may be installed on printers other than what is listed Only the Black adapter is available as a FRU Changes to switch settings are valid only after printer power is turned off and then on again e Contact Lexmark Technical Support for questions about serial adapters General Information 1 7 Serial Interface Switches The serial interface has 12 function switches which determine how the printer receives data from the computer or terminal Set the switches according to your particular equipment requirements Function Switch Setting Switches 1 To 4 Speed Define the serial interface speed in bits per second bps Snap On and Gray Se
87. oard then replace the sub logic board None Power Failure LED Status Power OFF Check the continuity of the power cord Ready OFF and the voltage of the user s outlet If Paper OFF they are correct go to Power Service Font OFF Check on page 2 32 Pitch OFF Alt OFF Others OFF 2 4 Indication Alarm Action None Operator Panel Failure LED Status Power ON Go to Operator Panel Service Check Ready OFF on page 2 24 Paper OFF Font OFF Pitch OFF Alt OFF Others OFF If other LED None Go to POST Service Check on page combinations 2 31 along with the Power LED are on Any LED on but None Go to Operator Panel Service Check the Power LED off on page 2 24 If the Power LED None Go to Power Service Check on page blinks or changes 2 32 intensity Any Beeps Optional Serial Interface Adapter 7 installed times Turn the printer off and check the connection from the serial interface adapter to the printer Turn the printer off and then on If you get the same error replace the serial interface adapter e If turning the printer off and then on is successful run the Serial Interface Adapter Print Test on page 3 6 Diagnostic Information 2 5 Symptom Check Table 1 Select the symptom that best describes the problem 2 Perform the appropriate action before you go to the indicated service check Abnormal In
88. oltage Ground And Continuity Readings 2 1 Error Indieation Table tages 2 2 symptom Check Table casses e tmm 2 6 Irrecoverable Operator Errors 2 13 Service CHECKS xa desee de ie ew d dA e dep qu 2 14 Abnormal Noise Service 2 14 Auto Sheet Feeder ASF Service Check 2 15 Carrier Drive Home Position Sensor Ribbon Feed Service CHECK ope d RS Eb 2 17 Intermittent Problem Service Check 2 20 No Print or Abnormal Print Service Check 2 23 Operator Panel Service Check 2 24 Paper Empty Sensor Service Check 2 26 Paper Feed Service Check 2 27 Paper Select Sensor Service Check 2 30 POST Service 2 31 Power Service 2 32 Print Speed Service Check 2 34 Printhead Service Check 2 36 Pull Tractor Sensor Service Check 2 38 Top of Forms Problem Service Check 2 39 Tractor 2 Service Checks iad ance medias enter 2 40 Contents Diagnostic EE 3 1 Power On Self Test POST e oe bebe baad 3 2 PADL P diio 3 3 Hex Dump MOMS x desto tet 3 5 Serial Interface Adapter Print Te
89. or Assembly Removal on page 4 53 Remove the print unit see Print Unit Removal on page 4 47 Remove the paper separator see Paper Separator Removal on page 4 44 Carefully remove the jammed label from the mylar strip on the paper separator If the mylar strip is damaged replace the paper separator If the label is jammed below the carrier plate or on the lower plastic portion of the paper guide platen assembly carefully remove the jammed label without scratching either surface or damaging the mylar strips that rest on the lower feed rollers This Page Intentionally Blank Repair Information 4 27 Left Side Frame Removal 1 2 17 18 19 4 28 Remove the tractor assembly see Push Tractor Assembly Removal on page 4 53 Remove the top cover see Top Cover Removal on page 4 61 Remove the pull tractor actuator see Pull Tractor Actuator Removal on page 4 51 Remove the printhead see Printhead Removal on page 4 48 Remove the sub logic board see Sub Logic Board Removal on page 4 59 Remove the paper feed motor and paper feed motor plate see Paper Guide Platen Assembly Removal on page 4 40 Remove the carrier motor assembly see Carrier Motor Assembly Removal on page 4 16 Remove the carrier see Carrier Removal on page 4 12 Remove the upper feed roller see Upper Feed Roller Removal on page 4 66 Remove th
90. page 4 5 2 20 FRU Symptom Action Machine power sometimes turns off 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 customer s outlet 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 CP11 and CP1 Be sure the output voltages are as follows CP11 1 26 V dc 10 amp CP11 2 GND CP11 3 5 V dc 596 amp CP11 4 Signal GND CP 1 1 26 V dc 10 amp CP1 2 GND CP 1 3 5 V dc 596 amp CP1 4 Signal GND If one of the voltages is 0 go to the Power Service Check on page 2 32 If the voltages are not 0 but are incorrect replace the power supply unit 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 Ifthe ribbon end of life has been reached have the customer replace the ribbon cartridge Diagnostic Information 2 21 FRU Symptom Action If the prior suggestions have not corrected the problem The service check has not defined the failure
91. parts packet Parts Catalog 7 1 Assembly 1 Major Components 7 2 Asm Part Index Number Description 1 1 79F4784 Paper Advance Knob 23XX 001 and 2390 PS 1 2 79F4757 Linecord U S Canada AFE LV Saudi Arabia LV Central and South America Mexico 2 1339519 Linecord United Kingdom Malaysia and Singapore 2 1339520 Linecord Germany France Spain Norway Finland The Netherlands Austria Belgium Brazil Greece Luxembourg Portugal Sweden Turkey Saudi Arabia HV Indonesia 2 1339525 Linecord Denmark 2 1339524 Linecord Italy and Chile 2 1339521 Linecord Israel 2 1339523 Linecord South Africa 2 1339522 Linecord Switzerland 2 1339518 Linecord Australia New Zealand Argentina Paraguay 2 1339517 Linecord Peru 3 79F4791 Tractor Unit 2380 001 amp 2390 001 3 79F4827 Tractor Unit 2381 001 amp 2391 001 3 1333153 Tractor Unit 2380 002 003 2390 002 003 3 1333157 Tractor Unit 2381 002 003 2391 002 003 4 79F4851 Operator Panel Overlay Pack 238X 001 4 79F4846 Operator Panel Overlay Pack 239X 001 4 1333212 Operator Panel Overlay Pack 238X 002 4 1333213 Operator Panel Overlay Pack 239X 002 4 11A3300 Operator Panel Overlay Pack 238X 003 4 11A3301 Operator Panel Overlay Pack 239X 003 5 79F4785 Operator Panel Asm with English Overlay 238X 001 5 79F4816 Operator Panel Asm with English Overlay 239X 001
92. position 1 and run the print test Go to the Carrier Drive Home Position Sensor Ribbon Feed Service Check on page 2 17 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 Carrier Drive Home Position Sensor Ribbon Feed Service Check on page 2 17 Diagnostic Information 2 11 Symptom Action Wavy vertical lines uneven left margin or character width is reduced Clean and lubricate the carrier shaft If the carrier drive belt is worn or broken replace the carrier unit Go to the Carrier Drive Home Position Sensor Ribbon Feed Service Check on page 2 17 Ribbon Feed Problems Symptom Action Ribbon comes off becomes loose or folded or jams Ribbon feeds correctly but is noisy Check the ribbon cartridge for binds or damage Go to the Carrier Drive Home Position Sensor Ribbon Feed Service Check on page 2 17 2 12 Irrecoverable Operator Errors Alt and Paper Out lights blink to indicate an operator error If this indication cannot be recovered the problem may be the paper empty sensor or the paper select sensor Check the following in the order listed and if the printer does not work correctly go to the indicated service check Paper
93. power cord at the printer The Download Module and the Print Buffer Module are options Remove the rear cover Remove the paper support Insert a small flat screwdriver 1 under each end of the module and lift up gently On 23XX 002 003 printers only one end of the module is accessible Do not insert the screwdriver too deep or the main logic board may be damaged On Note Be careful not to bend the pins when you re install the module 23XX 001 7 e 9 23XX 002 003 ty Repair Information 4 21 Form Thickness Lever Removal 1 2 Remove the top cover see Top Cover Removal on page 4 61 Remove the sub logic board see Sub Logic Board Removal on page 4 59 Remove the paper feed motor and the paper feed motor plate see Paper Guide Platen Assembly Removal on page 4 40 Remove the lever stop bracket from the carrier motor bracket not present on all machines Remove the screw and washer 3 Release the latch 4 and remove the form thickness lever 5 4 22 Head Gap Sensor Removal 238X 001 1 Remove the top cover see Top Cover Removal on page 4 61 2 Remove the sub logic board see Sub Logic Board Removal on page 4 59 3 Remove the paper feed motor and the paper feed motor plate see Paper Guide Platen Assembly Removal on page 4 40 When the paper feed motor pl
94. pty Sensor Service Check Note 23XX 001 machines have a single paper sensor that serves as a paper empty sensor and also determines the top of form setting 23XX 002 and 23XX 003 machines have two sensors The left sensor is paper empty The right sensor is Top of Form FRU Action 1 Paper Empty Sensor With no paper in the printer the tractor in the push position and the paper select lever set to continuous forms press Alt Park Load the gear train should turn forward to try to load paper Activate the paper empty sensor with a screwdriver and press Alt Park Load again the gear train should turn backward to try to park paper Measure the voltage between CN7 2 paper empty signal and CN7 3 GND on the main logic board There should be 0 V dc when there is paper in the printer and 5 V dc when there is no paper in the printer Make sure the sensor and its actuator are properly installed and undamaged Correct the problem or replace the sensor 2 Main Logic Board If the ASF is being used it is normal for the Paper Out LED not to blink when there is no paper in the printer Do the following Enter the Setup Menu Make sure the ASF setting is off unless the ASF is installed If the sensor and the ASF setting are OK replace the main logic board Reset the Bidirectional Print Adjustment on page 4 5 2 26 Paper Feed Service Check Note If the probl
95. r Panel 23XX 002 Sub Logic Board Operator Panel CN7 239X CN8 238X CN1 Pin 1 SIGNAL GND Pin 10 SIGNAL GND Pin 2 SIGNAL GND Pin 9 SIGNAL GND Pin 3 5 V Pin 8 5 Pin 4 LEDD Pin 7 LEDD Pin 5 SW LTCH Pin 6 SW LTCH Pin 6 SWD Pin 5 SWD Pin 7 SIGNAL GND Pin 4 SIGNAL GND Pin 8 SCLK Pin 3 SCLK Pin 9 5 V Pin 2 5 Pin 10 MSW Pin 1 MSW 5 18 003 Sub Logic Board 238 lt gt Printhead CN3 Printhead Pin 1 HDU6 Pin 2 HDU8 Pin 3 HDD4 Pin 4 HDD2 Pin 5 HDD6 Pin 6 HDU2 Pin 7 HDU4 Pin 8 HDD8 Pin 9 HDD9 Pin 10 HDU1 Pin 11 HDD5 Pin 12 HDD1 Pin 13 HDD7 Pin 14 HDD3 Pin 15 HDU5 Pin 16 HDU9 Pin 17 HDU3 Pin 18 HDU7 1 18 Sub Logic Board 239X lt gt Printhead CN8 CN9 Printhead Pin 1 HDP10 Pin 1 HDP20 Pin 2 HDP8 Pin 2 HDP18 Pin 3 HDP12 Pin 3 HDP22 Pin 4 HDP6 Pin 4 HDP16 Pin 5 HDP14 Pin 5 HDP24 Pin 6 HDP4 Pin 6 COM Pin 7 COM Pin 7 THRMO Pin 8 HDP2 Pin 8 COM Pin 9 COM Pin 9 THRMO Pin 10 HDP1 Pin 10 COM Pin 11 COM Pin 11 HDP23 Pin 12 HDP3 Pin 12 COM Pin 13 COM Pin 13 HDP21 Pin 14 HDP5 Pin 14 COM Pin 15 HDP13 Pin 15 HDP19 Pin 16 HDP7 Pin 16 HDP15 Pin 17 HDP11 Pin 17 HDP17 Pin 18 HDP9 Connector Locations 5 19 Connector Locations Main Logic Board 23XX 001 CN11 CN10 7 CN9 k 6 gt 2
96. r sensor can cause Sensor Alt Park Load not to function With the tractor in the push position press Alt Park Load several times while alternately holding down and releasing the left pull tractor actuator The paper should not park or load when the pull tractor actuator is held down If it does go to the Pull Tractor Sensor Service Check on page 2 38 POST Service Check FRU Action 1 Power LED If the power LED is not on go to the Power Service Check on page 2 32 2 Cables A faulty interface cable can cause POST errors Disconnect the interface cable from the printer and turn the printer off and then on Check the connections of the short flexible cable and the power cable to the main logic board and sub logic board Check the condition and continuity of the operator panel cable 3 Operator Panel If no problem is found the problem may be in either the operator panel or the main logic board Replace the operator panel and retest the printer 4 Main Logic Board Replace the main logic board if necessary Reset the bidirectional print adjustment refer to Bidirectional Print Adjustment on page 4 5 Diagnostic Information 2 31 Power Service Check If the symptom is that the Power light varies in intensity make sure the upper feed roll shaft has the ground spring If it does not install ESD Kit P N 1368036 FRU Action 1 Power Supply If the carrier does not move to t
97. rectly aligned and inserted securely WARNING Damage to the operator panel cable may cause failure of other electrical components of the printer Be sure not to crimp or pinch this cable while reinstalling the top cover 4 62 This Page Intentionally Blank Repair Information 4 63 Top of Form Sensor Sensor Flag And Spring Removal 4 64 1 2 Remove the tractor assembly see Push Tractor Assembly Removal on page 4 53 Remove the top cover see Top Cover Removal on page 4 61 Remove the print unit and position the print unit on its front see Print Unit Removal on page 4 47 Remove the screw 1 and the leaf spring 2 Push the sensor 8 to the right to unsnap and remove it To Replace The Sensor Flag Unless necessary do not replace the sensor flag when replacing the sensor 1 2 With diagonal pliers cut the post and two tabs 5 off as flush as possible Unsnap both ends of the sensor flag from the paper guide Carefully remove the sensor flag spring 4 from the bottom end of the sensor flag Pivot the upper tip of the sensor flag downward through the open area just to the right of the center feed roll and lift the lower end of the flag until it becomes free The sensor flag spring hooks over the lower arm of the flag Be sure the point of the sensor flag is kept in the paper path by the spring force Be sure the leaf spring 2 is in contact with
98. ressed Remove Tractor 2 from the printer and remove all paper With the paper select lever in the continuous forms position press Line Feed the tractors should rotate Press the sub slider cam lever below the ASF Tractor 2 drive gear and press Line Feed 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 in place 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 4 Diagnostic Information 2 43 2 44 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 Print Test Hex Dump Mode a computer or terminal i
99. rial Adapters Switch 1 Switch 2 Switch 3 Switch 4 Speed bps On On Off Off 150 On Off On Off 300 On Off Off Off 600 Off On On Off 1 200 Off On Off Off 2 400 Off Off On Off 4 800 Off Off Off Off 9 600 On On On Off 19 200 Off Off Off On 38 400 RS 422 only 1 8 Black Serial Adapter Switch 1 Switch 2 Switch 3 Speed bps N A N A N A 150 On Off On 300 On Off Off 600 Off On On 1 200 Off On Off 2 400 Off Off On 4 800 Off Off Off 9 600 On On On 19 200 On On Off 38 400 RS 422 Only Switch 5 Data Bits Selects the number of data bits 7 or 8 in each data frame Switch 5 Data Bits Off 8 On 7 General Information 1 9 Switches 6 and 7 Parity Select the interface parity Switch 6 Switch 7 Parity Off Off No Off On Ignore On Off Odd On On Even Note When setting the Ignore for parity the printer ignores the received parity and transmits using even parity For all other parity settings the transmitted parity matches the received parity Switch 8 Stop Bits Snap On Switch 8 Stop Bits Off 1 Stop Bit On 2 Stop Bits Switch 8 Buffer Size Gray and Black Selects the buffer size Switch 8 Buffer Size Off Normal 2048 bytes On Minimum 2 bytes Switch 9 Protocol Selects the type of protocol Differs depe
100. roller see Upper Feed Roller Removal on page 4 66 Remove the lower pinch roller see Lower Pinch Roller Removal on page 4 32 Remove the gears on the side frame right see Right Side Frame Gears Removal on page 4 58 Remove the print unit see Print Unit Removal on page 4 47 Remove the right side frame see Right Side Frame Removal on page 4 56 Remove the lower feed roller see Lower Feed Roller Removal on page 4 30 Release the two latches 1 on the left side of the paper guide 2 and then remove the assembly from the left side frame Perform the Printhead to Platen Gap adjustment see Printhead to Platen Gap Adjustment on page 4 2 Repair Information 4 41 Paper Select Lever Removal 1 Remove the top cover see Top Cover Removal on page 4 61 2 Release the latch 2 and then remove the paper select lever 1 from the right side frame 4 42 Paper Select Sensor Removal 1 Remove the top cover see Top Cover Removal on page 4 61 2 Remove the print unit see Print Unit Removal on page 4 47 3 Using diagonal pliers cut 4 mm off the ends of the last two ribs on the paper guide to allow better screwdriver access If necessary also remove the molded hook on the paper guide 4 Use a 1 Phillips screwdriver to remove the screw 1 and the sensor 2 Disconnect the sensor connector from the sub logic board Repair Information
101. s needed Serial Interface Adapter Print Test The following are special machine modes that run when the printer is turned off and then back on Turn the printer on while Does This Pressing Line Feed Print test with sample fonts Alt Sets printer in Hex Dump mode Microf amp Disables Enables Operator Panel Lockout Mode Alt Tear Off with Resets to World Trade default paper printhead at extreme left sizes Alt Setup with printhead Resets to US default paper sizes at extreme left Alt Macro Head Gap Sensor Test Macro LEDs 23XX 002 003 indicate sensor position Diagnostic Aids 3 1 Power On Self Test POST 3 2 The following tests are automatically performed when the printer is turned on LEDs Test Checks that the LEDs on the operator panel work The LEDs turn on and off after the printer is turned on then all LEDs turn on for a few seconds RAM Test Checks that the CPU can write read the RAM Font ROM Microcode Sum Test Checks that the ROM data is correct Timer Interrupt Controller Test Checks that this function works NVRAM Test Checks that the NVRAM data is correct Switch Scan Test Checks the buttons on operator panel Carrier Initialization Carrier moves to the left to activate the home position sensor then moves to the first print position Feed Initialization Form feed motor rotates forward then backward If any errors occur during the POST tests a combina
102. shing on the right end of the carrier shaft Raise the right pinch roller spring and slide the black retainer toward the center of the shaft Remove the spring from the right side frame Remove the gears on the right side frame see Right Side Frame Gears Removal on page 4 58 Remove the paper separator spring 2 and the slider cam 4 and for 23XX 003 the sub slider cam and its spring Remove the feed roll bushings 1 from the right side frame Remove the two screws 5 holding the right side frame to the carrier plate 23XX 002 003 Remove the screw 5 holding the right side frame to the support shaft 7 Lift the right end of the carrier plate up and slightly forward Release the two latches 6 and remove the right side frame Be sure to perform the Printhead to Platen Gap Adjustment see Printhead to Platen Gap Adjustment on page 4 2 Notes On Replacement Take care not to break the two latches 6 on the side frame that latch to the paper guide Be sure both ends of the paper separator are correctly in the mounting holes Use the new slider cam if one is included with the new side frame the old slider cam will not work properly although it may seem to fit The hub side of all gears goes toward the side frame While installing the large idler gear the slider should be in the outer position The conical side of the gear goes toward the side frame The lower feed roll gear may be a
103. speed Go to the Print Speed Service Check on page 2 34 Auto Sheet Feeder Problems Symptom Action Auto sheet feeder will not feed paper Auto sheet feeder double feeds Auto sheet feeder has intermittent feed problems Be sure Sheet Feed is enabled in the Setup Mode Be sure the paper select lever is in the cut sheet position Go to the Auto Sheet Feeder ASF Service Check on page 2 15 Diagnostic Information 2 7 Error Indications Symptom Action Ready and Paper Out lights blink to indicate a Hardware Error Turn the printer off and then on Go to Abnormal Indications on page 2 6 Paper Out and Alt lights blink to indicate an operator error Turn the printer off and then on Go to Irrecoverable Operator Errors on page 2 13 Paper Feed Problems Symptom Action Paper Out is Go to the Paper Empty Sensor Service Check on blinking with paper in page 2 26 the printer Paper Out does not blink when no paper is in the printer and ASF is not installed Print operation starts without paper Be sure the paper empty sensor is not blocked Go to the Paper Empty Sensor Service Check on page 2 26 Alt Park Load does not function when the push tractor is installed Form feed length is not correct Alt Park Load functions with cut sheets in use Be sure the paper select l
104. st 3 6 4 1 Handling ESD Sensitive Parts 4 1 ABIUSITIBEN S ides SARS 4 2 Printhead to Platen Gap Adjustment 4 2 Bidirectional Print Adjustment 4 5 Removal Procedures 00h deb ee sad ces 4 7 Auto Sheet Feeder Gears Removal 4 8 Auto Sheet Feeder Pick up Roller Removal 4 9 Bottom Gover Removal traverses 4 10 Carter Removal 255253959429 n 9 EROR 4 12 Carrier Motor Assembly Removal 4 16 Carrier Plate 4 18 Download or Print Buffer Module Removal 4 21 Form Thickness Lever Removal 4 22 Head Gap Sensor Removal 238 001 4 23 Head Gap Sensor Removal 23XX 002 003 4 24 Home Position Sensor Removal 4 25 Label Jam Removal 4 26 Left Side Frame Removal 4 28 Lower Feed Roller Removal 4 30 Lower Pinch Roller Removal 4 32 Main Logic Board 4 33 Operator Panel Assembly Removal 4 34 Paper Empty Sensor And Spring Removal 4 36 Paper Feed Motor Removal 4 38 Paper Guide Removal Left And Right 4 39 Paper
105. t Feeder ASF 32Kb Memory Module Volatile 32Kb Memory Module Non volatile Serial Interface Attachment RS232 RS422 Extended National Language Support modules World Trade only Acoustics Option Extended Cut sheet Paper Guides Tractor 2 23XX 003 Only Tools 1 4 The basic tools needed are Basic CE tool kit 1 Phillips screwdriver 2 Phillips screwdriver Feeler gauges 0 35 mm 0 014 in 0 4 mm 0 016 in Analog or digital volt ohmmeter Abbreviations ASIC Application Specific Integrated Circuit CSU Customer Setup DRAM Dynamic Random Access Memory EPROM Erasable Programmable Read Only Memory ESD Electrostatic Discharge FRU Field Replaceable Unit HVPS High Voltage Power Supply LAN Local Area Network LCD Liquid Crystal Display LED Light Emitting Diode LVPS Low Voltage Power Supply NVRAM Nonvolatile Random Access Memory OEM Original Equipment Manufacturer POR Power On Reset POST Power On Self Test PQET Print Quality Enhancement Technology ROS Read Only Storage SRAM Static Random Access Memory UPR Used Parts Replacement V ac Volts alternating current V dc Volts direct current General Information 1 5 Setup Mode How To Change The Printer Functions 1 Make sure continuous forms are in the printer 2 Press Alt and then press Setup to enter Setup Mode The printer prints out the Main Menu 3 To select a function press the buttons listed on the printout 4 To save the setti
106. the lower feed roll shaft OPEN Repair Information 4 65 Upper Feed Roller Removal 4 66 Te 2 Remove the top cover see Top Cover Removal on page 4 61 Disconnect the power supply cable from CN1 on the sub logic board Remove the self tapping screw that holds the sub logic board and the paper feed motor plate to the left side frame Remove the tractor idler gear 1 by inserting a small blade screwdriver between the tractor idler gear and the left side frame and twisting Bend the paper feed motor plate slightly to the left to remove the gear Release the latch and move the upper feed roller gear 3 to the left until it touches the paper feed motor plate It will stay on the feed roller shaft Release the latch and remove the upper bushings 2 Move the left bushing to the left it will stay on the feed roller shaft Release tab A and then remove the upper feed roller 4 in the direction indicated by the arrow The upper feed roll gear and the left upper bushing will come off the feed roller as it is being removed 5 Connector Locations This chapter shows the locations of specific parts of the printer Reference Part Name Form Thickness Lever Paper Select Lever Carrier Motor Paper Feed Motor Parallel Interface Connector Main Logic Board Sub Logic Board I O
107. the operator panel to the sub logic board and from the sub logic board to the main logic board Disconnect the operator panel from its cable and make sure 5 V dc is present on the following pins on the cable 23XX 001 23 002 003 1 1 1 2 1 7 1 8 If there is a voltage problem make sure the sub logic board is receiving 5 V dc on CN1 3 Replace the operator panel cable the sub logic board or the power cable as necessary 2 24 FRU Action Short Flexible Cable Disconnect the short flexible cable from the main logic board Check the continuity of the operator panel signal lines between the end of the short flexible cable and the operator panel connector on the sub logic board 238X 001 238X 002 003 CP3 4 amp CN8 5 CP3 4 amp CN8 2 CP3 3 amp CN8 6 CP3 3 amp CN8 4 CP3 2 amp CN8 4 CP3 2 amp CN8 8 CP3 1 amp CN8 8 CP3 1 amp CN8 6 239X 001 239X 002 003 CP3 4 amp CN7 5 CP3 4 amp 7 2 CP3 3 amp CN7 6 CP3 3 amp CN7 4 CP3 2 amp CN7 4 CP3 2 amp CN7 8 CP3 1 amp CN7 8 CP3 1 amp CN7 6 Replace the short flexible cable or the sub logic board as necessary If there is still a problem replace the operator panel If that does not fix the problem re install the old operator panel and replace the main logic board If you replace the main logic board reset the Bidirectional Print Adjustment on page 4 5 Diagnostic Information 2 25 Paper Em
108. tic Information 2 37 FRU Action 2 Carrier Shaft Carrier Unit Platen Assembly Printhead Nose Ribbon Guide Check and replace worn or damaged parts Pull Tractor Sensor Service Check Note The pull tractor sensor detects the tractor in the pull position and disables park load and auto tear off A failed sensor may prevent park load from functioning with the tractor in the push position FRU Action 1 Pull Tractor Sensor With the tractor in the push position press Alt Park Load several times while alternately holding down and releasing the left pull tractor actuator The paper should park and load when the actuator is not held down and should not park or load when the pull tractor actuator is held down If the paper does not move correctly e Disconnect CNA from the main logic board There should be 0 ohms from CP4 1 to CP4 2 when the left pull tractor actuator is pressed and infinite resistance when the actuator is not pressed Replace the sensor if necessary If the sensor is good but the paper still does not move correctly Replace the main logic board Reset the Bidirectional Alignment see Bidirectional Print Adjustment on page 4 5 2 38 Top of Forms Problem Service Check Note This service check applies to the 23 002 and 23XX 003 printers only 23XX 001 machines have a single paper sensor that serves as a paper empty sensor and also
109. tion of blinking LEDs will indicate which test failed See Start on page 2 1 Print Test The print test can help you test and troubleshoot the printer To start the print test do the following 1 2 3 4 5 Paper must be at the print position test does not print if paper is parked Press and hold Line Feed and then turn the printer on Release Line Feed when the printing starts To interrupt the printer test Press Start Stop The test stops after a complete line of characters has printed Press Start Stop to continue the test sample To stop the printer test turn the printer off The printout should be similar to the print test samples shown on page 3 4 If the printout is not like the sample go to Start on page 2 1 Note that the short horizontal lines at the top of the sample are a test of each printhead wire numbered in sequence from top to bottom Service Notes Before starting the 2380 and 2390 print test be sure letter size paper is loaded in the machine Before starting the 2381 and 2391 print test be sure wide paper is loaded in the machine and that the right margin is set to 13 6 inches After you complete any repairs run the print test several times to be sure the printer is operating correctly Diagnostic Aids 3 3 Print Test Sample 9 wire AD DYTE 31183207 Copyright Lexmark 1 27 53 5 Fastiira Tu DANS OU rpad THABCDEFGHIT KL HMD
110. us 2381 Plus 2381 002 9 Wide No 2390 Plus 2390 Plus 2390 002 24 Narrow No 2391 Plus 2391 Plus 2391 002 24 Wide No Forms Forms 2380 003 9 Narrow No Printer Printer 2380 Plus 2380 Plus Forms Forms 2381 003 9 Wide No Printer Printer 2381 Plus 2381 Plus Forms Forms 2390 003 24 Narrow No Printer Printer 2390 Plus 2390 Plus Forms Forms 2391 003 24 Wide No Printer Printer 2391 Plus 2391 Plus 1 2 Specifications Printhead life 140 Million Characters Ribbon Life 4 Million Characters Printer Life 5 Years BTU 409 Maximum 51 Idle Per Hour Power Consumption 120 Watts Maximum 15 Watts Idle Recommended Machine Usage 23XX 001 10 million characters per year e 23XX 002 003 12 million characters per year The character usage per day is calculated by dividing the yearly usage rating by 1300 characters per page divided by 12 months per year by 22 working days per month To reduce the probability of reliability service problems field data has shown printer usage should not exceed twice the daily page usage Notes All numbers are average or estimates Performance of individual printers may vary Lexmark does not represent or warrant that printers will achieve these results See the applicable statement of Limited Warranty for all warranty information General Information 1 3 Options The following options may be installed 238X 239X printers Auto Shee
111. y come loose It is held in place by the paper feed motor plate 238X 001 Be sure the head gap sensor is positioned correctly before installing the paper feed motor plate 4 38 Paper Guide Removal Left And Right 1 Remove the front cover and place it front down on a flat surface 2 Press down the paper guide 1 release the two latches and remove the paper guide Repair Information 4 39 Paper Guide Platen Assembly Removal 4 40 Te 2 Remove the tractor assembly see Push Tractor Assembly Removal on page 4 53 Remove the top cover see Top Cover Removal on page 4 61 Remove the pull tractor actuator see Pull Tractor Actuator Removal on page 4 51 Remove the paper select lever see Paper Select Lever Removal on page 4 42 Remove the printhead see Printhead Removal on page 4 48 Remove the sub logic board see Sub Logic Board Removal on page 4 59 Remove the paper feed motor see Paper Feed Motor Removal on page 4 38 Remove the carrier see Carrier Removal on page 4 12 Remove the tractor idler gear 23XX 001 Remove the platen bar screw that was covered by the gear 23XX 002 003 Remove the rear support plate mounting screw that was covered by the gear Remove the metal support plate mounting screw and the support plate Remove the platen bar screw that was covered by the support plate Remove the upper feed

Lexmark Dot Matrix 23XX - Printer Parts Exchange

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