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Forms Printer 2400 Series Service Manual

1. 6L 8NO ENO oo oo L E pNO 6 002NO Bes ILL e rg 19 eg ene 81 LENO NECI LLL fe LII O pieog SIM ve pJeog SIM 6 5 8 Service Manual 24XX 200 Logic board USB cable 9w amp 24w Connector Pin Signal 1 45 V dc CN201 S G 3 DPLS 4 Signal Gnd Logic board DC power 9w amp 24w Connector Pin Signal CN12 1 40 V dc 40 V dc Power Gnd Power Gnd Signal Gnd 5 V dc NIOJ oO AJ o M Power Save Mode Locations and connectors 5 9 24XX 200 Logic board 9w amp 24w LNO SNO 9NO CN OLNO E z oz 6L 8NO ENO oo oo L E pNO 6 002NO 0 9 EE LOcNO gh LENO Gz b i oll I pJeog SIM 6 NO alu pJe0g SIM ve 5 10 Service Manual 24XX 200 Logic board Printhead 9w Connector Pin Signal 1 H4 2 H6C
2. NO alu pJe0g SIM ve 5 20 Service Manual 24XX 200 Logic board Carrier motor 9w amp 24w Connector Pin Signal 1 CAD CN2 2 CAC 3 CAB 4 CAA Logic board Paper feed motor 9w amp 24w Connector Pin Signal 1 LFD 2 LFC CN1 3 LFB 4 LFA 5 NC Locations and connectors 5 21 24XX 200 Logic board 9w amp 24w LNO SNO 9NO CN OLNO E z oz 6L 8NO ENO oo oo L E pNO 6 002NO 0 9 EE LOcNO gh LENO Gz b i oll I pJeog SIM 6 NO alu pJe0g SIM ve 5 22 Service Manual 24XX 200 Logic board Operator panel 9w amp 24w Connector Pin Signal 1 5 V dc 2 SLATCH CN13 3 5 V dc Logic board 4 TXD 5 Signal Gnd 6 RXD 7 Signal Gnd 8 SCLK 9 SG Connector Pin Signal 1 5 V dc 2 SLATCH 3 5 V dc CN1 4 TXD Operator panel 5 Signal Gnd 6 RXD 7 Signal Gnd 8 SCLK 9 SG Locations and connectors 5 23 24XX 200 Logic board 9w amp
3. 2 13 Auto Sheet Feeder ASF service check 2 14 Carrier service CHECK lt lt lt lt 40 sem ra Rx nmt dn 2 16 Intermittent problem service 00 2 18 No print or abnormal print service check 2 21 Operator panel service check aaa aaa aaa 2 21 Paper Present sensor service check 2 22 Paper feed service GDeCK ec sums rh x Rx Ra eRe ee RU 2 23 Paper Select sensor service check 2 26 POST Semice Chi eK 2 27 Power service CHECK coca csc 2 28 Print speed service Check 2 29 Printhead service aaa Rr Rh RR tk 2 30 Pull Tractor sensor service Check mamar asma RR 2 32 Top of forms service check sea 0 6 2 6 eee eee eee 2 33 Tractor 2 service Check sexo ums cux GRO 2 34 24XX 200 Diagnostic aids 3 1 Power On Self Test POST cscs 3 2 Phn IOSU uio dee est Sond cote ada oka 3 3 ex Trace mode 3 4 Printer default Seting serium 3 5 3 5 World Trade detduli8 2i 3 5 Sela oslo ccs rec 3 6 Out sheet aS 3 6 Continuous OMS ANS a 3 6 Repair information c ess rr haa 4 1 Handling ESD sensitive paris cs rr Ie 4 1 PONS IO ERE pO AERE EN DEA Rd 4 2 Printhead to platen gap adjustment x x e e x 4 2 Bidirectional print adjustment uu sums 4 4 Removal procedures 4
4. Be sure the voltages to the logic board are correct If dots are missing Perform the print test to determine which wire is not firing Remove the printhead and verify that no pins on the printhead are broken or missing If pin s are missing replace the printhead Check the printhead resistance according to Printhead impedance tables on page 2 31 Be sure no pins have continuity to the printhead housing If the printout does not contain missing or extra dots or lines be sure the printhead is securely installed in the carrier and perform the Printhead to platen gap adjustment on page 4 2 2 Carrier shaft Carrier unit Platen assembly Printhead nose Ribbon guide Check and replace worn or damaged parts 2 30 Service Manual 24XX 200 Printhead impedance tables 2480 2490 approximately 5 ohms Dot Connector CN400 13 amp CN400 4 CN400 9 amp CN400 6 CN400 15 amp CN400 18 CN400 1 amp CN400 7 CN400 17 amp CN400 20 CN400 5 amp CN400 2 CN400 19 amp CN400 16 CN400 8 amp CN400 3 CN400 10 amp CN400 14 o CO N DO oO A O nv 2481 2491 approximately 8 to 16 ohms Dot Connector Dot Connector 1 CN300 1 amp CN301 9 13 CN300 1 amp CN300 9 2 CN300 1 amp CN301 11 14 CN300 1 amp CN300 11 3 CN300 1 8 CN301 7 15 CN300 1 amp CN300 2 4 CN300 1 amp CN301 13
5. Print speed service check The speed of the 24xx printers varies with 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 249x printers and protects the printhead from overheating FRU Action 1 Head Gap sensor Check the function of the Head Gap sensor by turning the printer on while pressing the Macro button Open the operator panel to the second level and do the following With the Forms Thickness lever at 1 Macro LED 1 lights With the Forms Thickness lever at 2 and 3 Macro LED 2 lights With the Forms Thickness lever at 4 through 7 Macro LED 3 lights Disconnect the Head Gap sensor from connector CN4 on the logic board Place the Forms Thickness lever in position 1 and verify continuity at the following pin locations CN4 1 and CN4 2 CN4 2 and CN4 3 Place the Forms Thickness lever in positions 2 and 3 and verify continuity at the following pin location CN4 1 and CN4 2 Verify that there is no continuity at Forms Thickness lever positions 4 through 7 Diagnostic information 2 29 24XX 200 Printhead service check FRU Action 1 Printhead cables Printhead If the printout contains missing or extra dots or lines do the following Check the continuity and connection of the printhead cables and the short flexible cable
6. Paper handling removals Paper Select lever removal 1 Remove the top cover Go to Covers top removal on page 4 8 2 Release the latch and remove the Paper Select lever from the right side frame Paper feed motor removal 1 Remove the top cover Go to Covers top removal on page 4 8 2 Remove the two screws A from the paper feed motor diis 3 Remove the motor 4 Disconnect the paper feed motor cable from the logic board 4 22 Service Manual 24XX 200 Forms Thickness lever removal 1 Remove the top cover Go to Covers top removal on page 4 8 2 Remove the screw A from the lever and then remove the Forms Thickness lever Repair information 4 23 24XX 200 Print handling removals Platen removal 1 Remove the top cover Go to Covers top removal on page 4 8 2 Remove the two platen screws A from each end of the platen 3 Remove the platen from the paper tray 4 Perform the printhead to platen gap adjustment Go to Printhead to platen gap adjustment on page 4 2 4 24 Service Manual 24XX 200 Printhead removal A 1 Turn the printer off 7 Disconnect the power cord at the printer and allow the printhead to cool for 15 minutes before you handle it Set the Forms Thickness lever to position 7 Remove the ribbon access cover Go to Covers ribbon access removal on page 4 6 Remove the ribbon cartridge Squeeze the printhead latches
7. Be sure the power supply cable from the power supply to the logic board is not damaged and is correctly installed 2 Operator panel Operator panel cable If there is still a Power LED problem check the operator panel cable continuity and replace the cable or the operator panel 3 Carrier motor Disconnect the carrier motor from logic board CN2 and turn the printer off and then back on If the Power LED lights correctly only with the carrier motor disconnected replace the carrier motor 4 Paper feed motor Disconnect the paper feed motor from logic board CN1 and turn the printer off and then back on If the Power LED lights correctly only with the paper feed motor disconnected replace the paper feed motor 5 Printhead Printhead cables Disconnect the printhead cable from the logic board and turn the printer on If the Power LED lights correctly only with the printhead cables disconnected from the logic board there is a short circuit in the printhead or printhead cables Disconnect the printhead cable from the logic board and be sure none of the leads on the cable are shorted to ground 2 28 Service Manual 24XX 200 FRU Action A 6 Logic board If no problem is found with the other components but the power problem still remains replace the logic board and reset the bidirectional print adjustment Go to Bidirectional print adjustment on page 4 4
8. Diagnostic aids contains tests and checks used to locate or repeat symptoms of MFP problems Repair information provides instructions for making MFP adjustments and removing and installing FRUs Connector locations uses illustrations to identify the connector locations and test points on the printer Preventive maintenance contains the lubrication specifications and recommendations to prevent problems Parts catalog contains illustrations and part numbers for individual FRUs Definitions Note A note provides additional information Warning A warning identifies something that might damage the product hardware or software CAUTION A caution identifies something that might cause a servicer harm CAUTION When you see this symbol there is a danger from T hazardous voltage in the area of the product where you are working Unplug the product before you begin or use caution if the product must receive power in order to perform the task Xii Service Manual 24XX 200 1 General information Printer description The Lexmark Forms Printer 248X 200 and 249X 200 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 multi part forms The 2481 and 2491 are wide carriage versions of the 2480 and 2490 Printer specifications Printhead life 300 million characters e Standard ribbon life 4 million characters
9. High yield ribbon life 8 million characters Printer life 5 years Power consumption 47 watts maximum 7 watts idler Model 9 Wire 24 Wire Short carriage Long carriage 2480 200 X X 2481 200 X X 2490 200 X X 2491 200 X X General information 1 1 24XX 200 Printer speeds 9 Wire 24 Wire 10 cpi 12 cpi 10 cpi 12 cpi Fast draft 438 cps 510 cps 409 cps 465 cps Draft 309 cps 304 cps 274 cps 328 cps NLQ Near 77 5 cps 77 5 cps 91 7 cps 109 cps Letter Quality cpi characters per inch CDS characters per second Setup mode Entering Setup mode 1 Open the operator panel cover to access layer two 2 Press Setup to put the printer in Setup mode and print the Main Menu 3 Press LineFeed to print a list of all the available options 4 Select any option from the Main Menu by pressing the corresponding button A new menu prints each time you press a button displaying new selections 5 After making a selection the printer prints a page with the changes shown Exiting Setup mode 1 Press Set TOF until the printer returns to the Main Menu or press Pitch from any menu containing a Return to Main Menu selection 2 Press Set TOF again to exit Setup mode New settings are saved only when the printer exits Setup mode Note If the printer runs out of paper while in Setup mode load more paper into the tractor pins and press Setup to con
10. 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 CUIDADO Quando vir este s mbolo existe a poss vel presen a de uma potencial tens o perigosa na zona do produto em que est a trabalhar Antes de come ar desligue o produto da tomada el ctrica ou seja cuidadoso caso o produto tenha de estar ligado corrente el ctrica para realizar a tarefa necess ria 24XX 200 Informaci de Seguretat La seguretat d aquest producte es basa en l avaluaci i aprovaci del disseny original i els components espec fics El fabricant no es fa responsable de les questions de Seguretat si s utilitzen peces de recanvi no autoritzades e La informaci pel manteniment d aquest producte est orientada exclusivament a professionals i no est destinada a ning que no ho sigui e El risc 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 PRECAUCIO aquest simbol indica que el voltatge de la part de l equip amb la qual esteu treballant s perill s Abans de comengar desendolleu l equip o extremeu les p
11. 1 Phillips screwdriver e 2 Phillips screwdriver e Feeler gauges 0 33 mm 0 013 in 0 37 mm 0 015 in Analog or digital volt ohmmeter Abbreviations ASF Automatic Sheet Feeder CSU Customer Setup EPROM Erasable Programmable Read Only Memory ESD Electrostatic Discharge FRU Field Replaceable Unit HV High Voltage LAN Local Area Network LED Light Emitting Diode LV Low Voltage POR Power On Reset POST Power On Self Test Vac Volts alternating current V dc Volts direct current 1 6 Service Manual 24XX 200 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 normally when a voltage measurement is performed When a line voltage measurement is to be performed the voltage on United States and Canada printers should be between 100 V ac and 127 V ac On World Trade printers the voltage is according to each country s specification Ground checks A 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
12. 3 H8C 4 H1C 5 H6 6 H2C 7 H4C 8 H8 CN400 3 He 10 H9 11 HDTHERMO 12 5 V dc 13 H1 14 H9C 15 H3 16 H7C 17 H5 18 H3C 19 H7 20 HSC Locations and connectors 5 11 24XX 200 Logic board 9w amp 24w LNO SNO 9NO CN OLNO E z oz 6L 8NO ENO oo oo L E pNO 6 002NO 0 9 EE LOcNO gh LENO Gz b i oll I pJeog SIM 6 NO alu pJe0g SIM ve 5 12 Service Manual 24XX 200 Logic board Printhead 24w Connector Pin Signal 1 440 V dc 2 R15 3 40 V dc 4 R21 5 40 V dc 6 R23 7 440 V dc 8 L24 CN300 9 R13 10 L22 11 L14 12 L20 13 40 V dc 14 L18 15 40 V dc 16 L16 17 440 V dc Locations and connectors 5 13 24XX 200 Logic board 9w amp 24w LNO SNO 9NO CN OLNO E z oz 6L 6NO L LINO 8NO ENO oo oo L L Y
13. Locations and connectors 5 17 24XX 200 Logic board 9w amp 24w LNO SNO 9NO CN OLNO E z oz 6L 8NO ENO oo oo L E pNO 6 002NO 0 9 EE LOcNO gh LENO Gz b i oll I pJeog SIM 6 NO alu pJe0g SIM ve 5 18 Service Manual 24XX 200 Logic board Paper Select sensor 9w amp 24w Connector Pin Signal 1 TR FR N ons 2 Signal Gnd Logic board Pull Tractor sensor 9w amp 24w Connector Pin Signal 1 PLTR CN3 2 Signal Gnd Logic board Top of form sensor 9w amp 24w Connector Pin Signal 1 Signal Gnd CN6 2 PE2P 3 PE2 Locations and connectors 5 19 24XX 200 Logic board 9w amp 24w LNO SNO 9NO CN OLNO E z oz 6L 8NO ENO oo oo L E pNO 6 002NO 0 9 EE LOcNO gh LENO Gz b i oll I pJeog SIM 6
14. Paper Select lever to the continuous forms position and pressing Start Stop 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 right side frame of the printer 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 this disengages the clutch and the picker rollers The sheet is then fed to the print line by the upper and lower feed rollers ofthe ASF and the lower feed rollers of the printer Although the ASF picker rollers continue to turn as the paper is fed their drive is disengaged and they are actually turned by the paper 2 14 Service Manual 24XX 200 FRU Action 1 Paper Select With the Paper Select lever in the cut sheet sensor position do the following Try to load a cut sheet with the Load Unload button This button should not work If paper loads go to Paper Select sensor service check on page 2 26 2 Paper feed If the paper does not feed do the following Remove the ASF Be sure the base printer f
15. and reengages the printer tractors 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 back 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 34 Service Manual 24XX 200 FRU Action 2 Logic board Remove Tractor 2 from the printer but leave the cable connected Be sure the slider the black plastic piece just above the right cover moves after turning the printer off and then back on If the slider does not move after turning the printer off and then back on Be sure the slider and gear train are properly connected and move freely with the power off Be sure the Tractor 2 board is receiving 40 V dc on CN1 1 and 5 V dc on CN1 5 If the slider does move check the cable connection and the voltages at logic board CN10 1 The upper right pin at CN10 is pin 1 40 V dc and the pin just beneath it is pin 5 5 V dc If these voltages are not present replace the logic board 3 Tractor 2 motor Check the resistances of the Tractor 2 motor board cable windings at CN5 on the Tractor 2 board There assembly should be 101 5 ohms bet
16. on page 4 26 4 Disconnect the power supply cable A 5 Remove the five screws B securing the power supply to the bottom cover Take care not to lose the ground clips which must be replaced between the ground plate and the board 6 Remove the two ground wire screws C 7 Remove the power supply Repair information 4 13 24XX 200 Carrier removals Carrier removal 1 Remove the top cover Go to Covers top removal on page 4 8 2 Remove the printhead from the carrier Go to Printhead removal on page 4 25 3 Loosen the carrier belt 1 Loosen the tension screw A 2 Remove tension from the belt by pulling up on the belt 3 Tighten the tension screw Loosening the screw tightens the belt 4 14 Service Manual 24XX 200 4 Remove the retaining wire B from the left side of the carrier shaft ELI n Repair information 4 15 24XX 200 5 Remove the screw C from the forms thickness lever and then remove the lever 4 16 Service Manual 24XX 200 6 Remove the lower carrier motor mount screw D 7 Remove the two screws E from the carrier shaft bushing bracket on the left end of the carrier shaft and then remove the bracket Do a Qe A S p ly 8 Remove the E clip from the right side of the carrier shaft Repair information 4 17 24XX 200 9 Push the carrier shaft F from the right side so it goes out of the left side of the printer 10 R
17. on page 4 8 2 Remove the screw from the print cable shield and then remove the shield 3 Remove the gear from the left end of the upper feed roller as shown 4 34 Service Manual 24XX 200 4 Remove the two screws A from the right upper feed roller bracket One screw also retains the upper feed roller ground clip 5 Pull the upper feed roller from the left bracket and then out of the printer 6 Be sure to perform the Printhead to platen gap adjustment Go to Printhead to platen gap adjustment on page 4 2 Repair information 4 35 24XX 200 Roller lower pinch removal 1 Remove the top cover Go to Covers top removal on page 4 8 2 Slide the carrier to the far left of the printer 3 Remove the four screws A from the paper feed motor NJ B B 4 Remove the screw from the top of the serial interface card bracket 5 Disconnect the paper feed motor cable from the logic board and then remove the paper feed motor and bracket from the printer 6 Slide the carrier to the left side of the printer 4 36 Service Manual 24XX 200 7 Unhook the spring clip B from the right end of the lower pinch roller shaft and then push it off the gray slotted spring block C toward the back of the printer as shown C B 8 Slide the carrier to the right side of the printer Repair information 4 37 24XX 200 9 Unhook the spring clip D from the left end of the lower pinch roller shaft and t
18. 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 either of the above Inspect the sensor to be sure it opens and closes by the paper separator Replace the sensor if the resistance does not change from zero to infinite as the Paper Select lever is moved 7 Pull Tractor sensor If the pull tractor sensor fails to close Load Unload and Auto Tear Off do not work when using push tractors The sensor fails to open The Load Unload button tries to park paper when using the pull tractors but instead the paper feeds all of the way out of the tractors and cannot be reloaded See Pull Tractor sensor service check on page 2 32 2 24 Service Manual 24XX 200 FRU symptom Action 8 Logic board If no other problem is found replace the logic board and reset the Bidirectional print adjustment on page 4 4 Diagnostic information 2 25 24XX 200 Paper Select sensor service check If the form feed length is off by about 1 inch 25 mm enter Setup mode and verify that the form length setting is correct Go to Setup mode on page 1 2 FRU Action 1 Paper Select Remove all paper from the printer and do the sensor following Place the tractor in the push position and be sure the Auto Sheet Fee
19. 16 CN300 1 amp CN300 16 5 CN300 1 amp CN301 5 17 CN300 1 amp CN301 4 6 CN300 1 amp CN301 15 18 CN300 1 amp CN300 14 7 CN300 1 8 CN301 3 19 CN300 1 amp CN301 6 8 CN300 1 amp CN301 17 20 CN300 1 amp CN300 12 9 CN300 1 amp CN301 1 21 CN300 1 amp CN300 4 10 CN300 1 amp CN301 18 22 CN300 1 amp CN300 10 11 CN300 1 amp CN301 2 23 CN300 1 amp CN300 6 12 CN300 1 amp CN301 16 24 CN300 1 amp CN300 8 Diagnostic information 2 31 24XX 200 Pull Tractor sensor service check The Pull Tractor sensor detects the tractor in the pull position and disables the load unload and auto tear off functions A failed sensor may prevent load unload from functioning with the tractor in the push position FRU Action 1 Pull Tractor sensor With the tractor in the push position press Load Unload several times while alternately holding down and releasing the left pull tractor actuator The paper should load and unload when the actuator is not held down and should not load or unload when the pull tractor actuator is held down If the paper does not move correctly disconnect CN3 from the logic board There should be continuity from CN3 1 and CN3 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 logic board an
20. 3 Unsnap the Home Position sensor A from the frame d 4 44 Service Manual 24XX 200 Options removals Auto Sheet Feeder gears removal 1 Remove the right cover 2 Release the joint gear latch A and remove the joint gear A Release the idler gear latch and remove the idler gear Release the pick up gear latch and remove the pick up gear Release the combination lock mechanism latch OOA o Remove the tension plate on the locker cam and remove the cam 7 Release the lift gear latch and remove the gear Repair information 4 45 24XX 200 Auto Sheet Feeder pick up roller removal 1 Remove the covers and the cut sheet support 2 Release the joint gear latch A and remove the joint gear idler gear and pick up gear A 3 Remove the left and right roller bushings 4 Move the pick up rollers to the ends of the shaft and then remove them 4 46 Service Manual 24XX 200 B Locations and connectors This chapter identifies the locations of specific parts of the printer Tension Paper Ribbon Ribbon Forms Carrier pulley select cartridge drive thickness motor plate lever rack lever assembly On Off Printhead Carrier Printhead cable s switch Code Tractor 2 Parallel Paper feed module option interface motor connector connector Power Logic USB Serial interface supply board connector cover plate Locations and connectors 5 1 24XX 200 Signal connections Power suppl
21. 3 5 World Trade 3 5 Diagnostic aids 3 1 E Entering Setup mode 1 2 Error codes 2 2 Error indication table 2 2 ESD sensitive parts 4 1 Exiting Setup mode 1 2 G General information 1 1 H Hex Trace mode 3 4 Interface Menu options 1 3 Irrecoverable operator errors Paper Empty sensor 2 12 Paper Present sensor 2 11 Paper Select sensor 2 12 L Lubrication 6 1 Menu Interface Menu options 1 3 Setup Menu options 1 3 O Operator errors Irrecoverable 2 11 Options 1 6 P Paper jams Clearing continuous forms 3 6 Clearing cut sheet 3 6 Parts ASF Roller support 7 16 Side Frame covers 7 18 Carrier paper feed left side 7 10 12 Carrier paper feed right side 7 6 fet 1 8 7 9 Covers 7 2 Electronics 7 14 Tractor 2 option 7 20 1 1 24XX 200 Parts catalog Howtouse 7 1 POST 3 2 Preventive maintenance Lubrication 6 1 Lubrication points 6 2 Specified lubricants 6 1 Print test 3 3 Printer Description 1 1 Options 1 6 Settings 1 4 Specifications 1 1 Speeds 1 2 Printer default settings 3 5 R Removals 4 4 ASF Gears 4 45 Pick up roller 4 46 Carrier 4 14 Carrier motor assembly 4 19 Covers Bottom 4 11 Front 4 6 Operator panel 4 10 Option 4 7 Ribbon access 4 6 Top 4 8 Covers illustration 4 5 Electronics EPROM 4 11 Logic board 4 12 Power supply 4 13 Forms Thickness lever 4 23 Gears Left side 4 29 Right side 4 32 Operator panel 4 10 Paper feed motor 4 22 Paper Select lever 4 22 Plate
22. Cover ASF right 4 40X2892 ASF screws parts packet 5 40X3011 Frame ASF side right NS 40X2937 Stand paper Parts catalog 7 19 24XX 200 Assembly 7 Tractor 2 option 7 20 Service Manual 24XX 200 Assembly 7 Tractor 2 option Asm Part Index number 7 1 40X3018 Table Tractor 2 paper with guides 2480 2490 2 40X2881 Guide Tractor 2 paper 3 40X3009 Tractor and frame assembly Tractor 2 2480 2490 4 40X2918 Kit tractors left and right 5 40X2960 Board assembly with cable and ferrite Tractor 2 Description 2480 2490 5 40X2961 Board assembly with cable and ferrite Tractor 2 2481 2491 6 40X2880 Motor Tractor 2 7 40X2882 Parts packet Tractor 2 8 40X2923 Cover Tractor 2 right 9 40X2958 Shaft Tractor 2 support 2480 2490 9 40X2959 Shaft Tractor 2 support 2481 2491 Parts catalog 7 21 24XX 200 7 22 Service Manual 24XX 200 Index A Abbreviations 1 6 Adjustments 4 2 Bidirectional print 4 4 Printhead to platen gap 4 2 ASF Principles of operation 2 14 C Connections Logic Board Printhead 9w 5 11 Logic board Carrier motor 5 21 DC power 5 9 Gap Set sensor 5 17 Home Position sensor 5 17 Paper feed motor 5 21 Paper Present sensor 5 17 Parallel interface cable 5 5 Pull Tractor sensor 5 19 Serial board 5 7 Top of form sensor 5 19 Power supply 5 2 Serial board Serial cable 5 26 Tractor 2 5 27 D Defaults U S
23. contact positions Oil felt carrier block Tractor shaft Grease Lubricate the following contact positions e Side frame left and gears Side frame right and ASF gears Pinch roller pinch roller springs and paper separator e ASF side frames gears and combination lock mechanism e ASF side frame left and upper feed roll shaft e ASF pick up roller shaft and roller bushings 6 2 Service Manual 24XX 200 Lubrication points oil The oil felt 1 in the carrier block The tractor shaft 1 Preventive maintenance 6 3 24XX 200 Lubrication points grease Gear mounting studs on the right side frame 2 6 4 Service Manual 24XX 200 Lubrication points grease cont Gear mounting studs on the left side frame 2 Preventive maintenance 6 5 24XX 200 Lubrication points grease cont Gear mounting studs on the left ASF side frame 2 6 6 Service Manual 24XX 200 T Parts catalog How to use this parts catalog Similar Assemblies If two assemblies contain a majority of identical parts they are shown on the same list Common parts are shown by one index number Parts peculiar to one or the other of the assemblies are listed separately and identified by description NS Not shown in the Asm Index column indicates that the part is procurable but is not pictured in the illustration Note Graphic artwork depicting FRU assemblies is designed using the 2480 200 9 wi
24. or reset the printer to the U S factory defaults Code page 437 Character Set 1 form length 11 inch 1 Make sure paper and the ribbon cartridge are installed 2 Turn the printer off 3 4 Move the printhead toward the operator panel side of the printer Open the ribbon access cover until it stops Close the ribbon access cover Press and hold Tear Off and Load Unload while you turn the printer on Continue holding these buttons until the carrier moves The operator panel lights blink several times Once the carrier moves your settings have been reset to factory defaults World Trade defaults To initialize or reset the printer to the World Trade defaults Code page 858 Character Set 2 form length 12 inch 1 Make sure paper and the ribbon cartridge are installed 2 Turn the printer off 3 4 Move the printhead toward the operator panel side of the printer Open the ribbon access cover until it stops Close the ribbon access cover Press and hold Tear Off and Tractor while you turn the printer on Continue holding these buttons until the carrier moves The operator panel lights blink several times Once the carrier moves your settings have been reset to factory defaults Diagnostic aids 3 5 24XX 200 Clearing paper jams Cut sheet jams To clear cut form paper jams 1 2 3 Turn the printer off Set the Forms Thickness lever to position 7 Push the Paper
25. page 4 4 If the printer completes POST successfully and eventually gets the same error go to Intermittent problem service check on page 2 18 2 2 Service Manual 24XX 200 LED Status Alarm Action Power ON Beeps Home Position Error Ready Blinking 10 m i i Paper Out Blinking times s id se a service check Panel Lock Blinking pag Font Lock Blinking Tractor 2 Home Position Error If Tractor 2 is installed remove it to determine whether the problem is with the Carrier Home Position sensor or the Tractor 2 Home Position sensor See the Tractor 2 service check on page 2 34 None Home Position Error Without Alarm Go to Power service check on page 2 28 Power ON None Timer Error id 2 inde Turn the printer off and then back Paper Out Binking IE E Font Lock Blinking board and readjust the bidirectional print adjustment Go to Bidirectional print adjustment on page 4 4 Power ON None Hardware Drive Error Ready Blinking The printhead or the printhead Tractor 2 Blinking uc cable s can cause this error Go Paper Out Blinking to Printhead servi heck Font Lock Blinking servise Cnoc on page 2 30 Turn the printer off and then back on If you get the same error replace the logic board and readjust the bidirectional print adjustment Go to Bidirectional print adjustment on page 4 4 If the printer completes POST successfully and eventually gets the same error go t
26. print unit Go to Print unit removal on page 4 26 Electronics removals EPROM removal 1 Remove the options cover A by pulling it outward and then up and out of the printer A 2 Remove the EPROM module Note When replacing the EPROM module be sure the notch on the module is toward the front of the printer Repair information 4 11 24XX 200 Logic board removal 1 Remove the top cover Go to Covers top removal on page 4 8 2 Disconnect all cables connected to the logic board Go to Logic board 9w amp 24w on page 5 3 for connector location details Note Do not twist the flexible cable when disconnecting the printhead cable s 3 Remove the top screw A from the serial interface card bracket 4 Remove the three screws B securing the logic board to the bottom cover Take care not to lose the ground clips which must be replaced between the ground plate and the board 5 Remove the ground clip screw C from the bottom cover 6 Remove the logic board Note Be sure to perform the bidirectional print adjustment after installing the logic board Go to Bidirectional print adjustment on page 4 4 4 12 Service Manual 24XX 200 Power supply removal CAUTION The power supply may be hot 1 Turn off the printer and disconnect the power cord at both ends 2 Remove the top cover Go to Covers top removal on page 4 8 3 Remove the print unit Go to Print unit removal
27. pulley assembly Roller upper feed 2480 2490 Roller upper feed 2481 2491 Sub frame right side Roller lower feed 2480 2490 Kit ESD ground 2480 2481 Kit ESD ground 2490 2491 Roller ASF pick up left and right 2480 2490 Roller ASF pick up left and right 2481 2491 Gear ribbon drive rack 2480 2490 Gear ribbon drive rack 2481 2491 Shaft carrier 2480 2490 Shaft carrier 2481 2491 Cover top 2480 2490 Cover top 2481 2491 Cover assembly front unit 2480 2490 Cover assembly front unit 2481 2491 Cover front guide 2480 2490 Cover front guide 2481 2491 Overlay pack operator panel 248X Overlay pack operator panel 249X Printhead assembly 2480 2481 Printhead assembly 2490 2491 Shaft set tractor 2481 2491 Shaft set tractor 2481 2491 Tractor unit 2480 2490 Tractor unit 2481 2491 Hopper ASF right 2481 2491 Cover bottom 2480 2490 Cover bottom 2481 2491 Plate frame support 2480 2490 Plate frame support 2481 2491 24XX 200 7 7 7 7 7 5 7 5 7 15 7 17 7 11 7 11 7 7 7 11 7 11 7 7 7 11 7 11 7 11 7 11 7 11 7 11 7 9 7 9 7 7 7 7 7 15 7 15 7 17 7 17 7 11 7 11 7 9 7 9 7 3 7 3 7 3 7 3 7 5 7 5 7 5 7 5 7 7 7 7 7 5 7 5 7 5 7 17 7 5 7 11 7 11 24XX 200 40X3009 40X3010 40X3011 40X3013 40X3014 40X3015 40X3016 40X3017 40X3018 40X3019 40X3020 40X3021 40X3022 40X3023 40X3024 40X30
28. when the pull tractor actuator is held down f the paper does park or load with the pull tractor actuator held down go to Pull Tractor sensor service check on page 2 32 POST service check FRU Action 1 Cables A faulty interface cable can cause a POST error Disconnect the interface cable from the printer and turn the printer off and then back on Check the connections of the power cable to the logic board Check the condition and continuity of the operator panel cable 2 Code module Turn the printer off and then back on If you get the same error during power up verify that the code module on the logic board is correctly installed 3 Logic board Replace the logic board if necessary and reset the bidirectional print adjustment Go to Bidirectional print adjustment on page 4 4 Diagnostic information 2 27 24XX 200 Power service check FRU Action A 1 Power supply If the carrier does not move to the left after turning the printer off and then back on be sure the line cord voltage to the power supply is correct and the power supply outputs are 40 V dc at CN12 1 40 V dc at CN12 2 and 5 V dc at CN12 6 If the voltages are incorrect Check the internal fuse before replacing the power supply Generally if F1 is blown it is due to a short circuit in the printhead replace the printhead and the fuse before turning the power on again
29. 12 Service Manual 24XX 200 Service checks Abnormal noise service check Check the entire printer for loose parts FRU Action 1 Ribbon cartridge Remove and reinstall the ribbon cartridge 2 Printhead Disconnect the printhead cable s Run the print test do not fold or damage the cables during the test Go to Print test on page 3 3 Replace the printhead if the noise is gone 3 Carrier motor Disconnect the carrier motor connector CN2 ribbon drive from the logic board Turn the printer off and mechanism then back on If the abnormal noise is gone look for a problem with the carrier motor or ribbon drive mechanism Go to Carrier service check on page 2 16 4 Paper feed Disconnect the paper feed motor CN1 from the mechanism logic board Perform the Print Test Go to Print test on page 3 3 If the abnormal noise is gone look for the problem in the paper feed mechanism Diagnostic information 2 13 24XX 200 Auto Sheet Feeder ASF service check Note Be sure the sheet feeder is enabled in the Setup mode Go to Setup mode on page 1 2 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 the cut sheet position The Auto Sheet Feeder must be selected in the Setup Menu Continuous forms can be used with the ASF installed by moving the
30. 2490 20 40X2979 Roller upper feed 2481 2491 Parts catalog 7 9 24XX 200 Assembly 3 Carrier paper feed left side 7 10 Service Manual 24XX 200 Assembly 3 Carrier paper feed left side 3 1 40X2910 Gears and bushings parts packet 248X 2 40X2926 Screws washers and clips parts packet 3 40X2931 Kit pull tractor actuator 4 40X2966 Frame left side 2480 2481 4 40X2967 Frame left side 2490 2491 5 40X2938 Sensor Pull Tractor 6 40X3007 Plate frame support 2480 2490 6 40X3008 Plate frame support 2481 2491 7 40X2921 Holder lower pinch roller shaft left 8 40X2906 Springs parts packet 9 40X2939 Sensor Paper Select 10 40X2908 Holder platen 11 40X2893 Sensor Head Gap 12 40X2969 Guide paper assembly 2480 2490 12 40X2970 Guide paper assembly 2481 2491 13 40X2973 Platen 2480 2490 13 40X2974 Platen 2481 2491 14 40X2895 Guide ASF DTR left 15 40X2919 Sensor Top of form 16 40X2972 Sensor Paper Present 17 40X2986 Gear ribbon drive rack 2480 2490 17 40X2987 Gear ribbon drive rack 2481 2491 18 40X2977 Plate tension pulley assembly 19 40X3021 Plate carrier assembly 2480 2490 19 40X3022 Plate carrier assembly 2481 2491 20 40X2975 Separator paper 2480 2490 20 40X2976 Separator paper 2481 2491 21 40X2901 Motor carrier with BKT 22 40X2920 Sensor Home Position Parts
31. 24w LNO SNO 9NO CN OLNO E z oz 6L 8NO ENO oo oo L E pNO 6 002NO 0 9 EE LOcNO gh LENO Gz b i oll I pJeog SIM 6 NO alu pJe0g SIM ve 5 24 Service Manual 24XX 200 Logic board Dual tractor cable 9w amp 24w Connector Pin Signal 1 440 V dc 2 440 V dc 3 Power Gnd 4 Power Gnd 5 5 V dc CN10 6 COCOM 7 D SET 8 Signal Gnd 9 COA 10 COB 11 JAM 12 D H P 13 D POS Locations and connectors 5 25 24XX 200 Serial board Serial cable 9w amp 24w OO OO CN2 m Connector Pin Signal Pin Signal 1 Chassis Gnd 13 NC 2 TXD 14 NC 3 RXD 15 NC 4 RTS 16 NC 5 CTS 17 NC CN2 6 DSR 18 NC 7 Signal Gnd 19 NC 8 NC 20 DTR 9 NC 21 NC 10 NC 22 NC 11 NC 23 NC 12 NC 24 NC 25 NC 5 26 Service Manual 24XX 200 Tractor 2 cable connectors The Tractor 2 cable is soldered to the Tractor 2 board at CN1 there is no connector Connector Mode CN1 1 426 V dc CN1 2
32. 25 40X3026 40X3028 40X3029 40X3030 40X3032 40X3034 40X3035 40X3136 40X3141 Tractor and frame assembly Tractor 2 2480 2490 Holder lower pinch roller shaft right Frame ASF side right Ribbon access cover unit 2480 Ribbon access cover unit 2481 Cable power supply 2480 2490 Cable power supply 2481 2491 Support ASF cut sheet with guides 2481 2491 Table Tractor 2 paper with guides 2480 2490 Roller lower pinch 2480 2490 Roller lower pinch 2481 2491 Plate carrier assembly 2480 2490 Plate carrier assembly 2481 2491 Roller ASF upper feed 2481 2491 Roller ASF lower feed 2481 2491 Ribbon access cover unit 2490 Ribbon access cover unit 2491 Narrow auto feeder assembly 2480 2490 Narrow dual tractor assembly 2480 2490 Module EPROM 248X Memory 249X no PNP EPROM Wide auto feeder assembly 2481 2491 Wide dual tractor assembly 2481 2491 ASF gears and bushings parts packet 7 21 7 7 7 19 7 3 7 15 7 15 7 17 7 21 7 7 7 7 7 11 7 11 7 17 7 17 7 3 7 3 7 7 7 7 7 15 7 15 7 7 7 7 7 17 Power cord Austria Belgium Brazil Germany Greece Finland France Indonesia Luxembourg Portugal Norway Saudi Arabia HV Spain Sweden Netherlands Turkey I 8 Service Manual 7 3
33. 26 V dc CN1 3 Frame GND CN1 4 Not used CN1 5 45 V dc CN1 6 Motor common CN1 7 D Set signal for Tractor 2 plugged in CN1 8 Signal GND CN1 9 Motor phase A 0 V dc except when Tractor 2 motor is on CN1 10 Motor phase B 5 V dc when Tractor 2 not in use 0 V dc when Tractor 2 is in use CN1 11 Not used CN1 12 Slider home sensor 5 V dc when open 0 V dc when closed CN1 13 Tractor 2 in place sensor 5 V dc when open 0 V dc when closed Locations and connectors 5 27 24XX 200 5 28 Service Manual 24XX 200 6 Preventive maintenance This chapter describes procedures for preventive maintenance for the printer Following these recommendations can help prevent problems and maintain optimum performance Lubrication Warning Petroleum based lubricants can attack polycarbonate parts causing premature failure Use only mineral oil based lubricants The following parts should be lubricated when replaced Oil felt carrier block Tractor unit e Side frame left Side frame right e Pinch roller lower e Pinch roller spring left e Pinch roller spring center e Pinch roller spring right Paper separator Specified lubricants s Oil P N 1280443 e Approved equivalents Mobil DTE27 Shell Tellus 100 Fuchs Renolin MR30 e Grease P N 6934659 Approved equivalent Mobil 28 Preventive maintenance 6 1 24XX 200 Lubrication points Cil Lubricate the following
34. 4 aoo Scan aw dog 4 5 Covers front removal co 4 6 Covers ribbon access removal 2 aaa cece eee eee eee 4 6 Covers option YVelioValas 4 7 Covers OETA 4 8 Covers operator panel assembly removal 4 10 Covere bottom removal uuu acra seme sca praem E ER A RE S ai 4 11 4 11 EPRONTSITBVdl ss esc sso E g s sz s e k d t al ENTE 4 11 Logis board removal co 4 12 Power Supply qsmpovalsss 4 13 Garner Teliovalls 43 9 4 14 4 14 Carrier motor assembly removal 22 essence 4 19 4 22 Paper Select lever removal c e x x e x x e e K K e nee 4 22 Paper feed motor removal 4 22 Forms Thickness lever removal sse 4 23 Pant banding rembovals 4 24 Paten TEMOVAl 4 24 4 25 Printhead cables removal lt s s sag raas 668 96 060 R R Lee 4 25 Phabulitremauval cc 4 26 Ribbon drive rack gear removal ace sce a rn 4 28 iV Service Manual 24XX 200 4 29 Lett side gears removal assesses 4 29 Right side gears sub frame removal 4 32 Roles 4 34 Roller upper feed removal 4 34 Roller lower pinch removal sesso E X R R NR RR TER 4 36 Roller lower feed removal eere 4 39 SOOT ENV 4 41 Sens
35. 9 Logic board Top of form sensor QW amp 24w 5 19 Logic board Carrier motor QW amp 24W ss 5 21 Logic board Paper feed motor QW amp 24W 5 21 Logic board Operator panel 9w amp 24W 5 23 Logic board Dual tractor cable 9w amp 24W 5 25 Serial board Serial cable QW amp 24W LL 5 26 Tractor 2 cable connectors 22 aa aaa K w R isa 5 27 24XX 200 Preventive maintenance eee eee eee eee 6 1 LUDNES amp NOM m PC MITT 6 1 LUDNCAION PONS 6 2 Be gers DONIS Oll ausa a E cu E x Res are wid Er 6 3 Lubri aton ports grea56 0 6679 6 a rr tidas er RR g 6 4 Parts Catalog 2 202 seregenn Rg 7 1 How to use this parts Catalog 7 1 Assembly eT 7 2 Assembly 2 Carrier paper feed right side 7 6 Assembly 3 Carrier paper feed left side 7 10 ESC oS 7 14 Assembly 5 ASF Roller support e x e rers 7 16 Assembly 6 ASF Side 7 18 Assembly 7 Tractor 2 ODUOH cius 7 20 NCC cee 1 1 Part number ind 1 5 vi Service Manual 24XX 200 Safety information The safety of this product is based on testing and approvals of the original design and specific components The manufacturer is not responsible for safety in the
36. Edition July 2006 st Lexmark Forms Printer 2400 Series 24XX 200 Service Manual e Table of contents e Start diagnostics Safety and notices e Trademarks e Index LEXMARK 24XX 200 Edition July 13 2006 The following paragraph does not apply to 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 Improvements or changes in the products or the programs described may be made at any time Comments may be addressed to Lexmark International Inc Department D22A 032 2 740 West New Circle Road Lexington Kentucky 40550 U S A or e mail at ServicelnfoAndTraining Lexmark com Lexmark may use or distribute any of the information you supply in any way it believes appropriate without incurring any obligation to you Lexmark and Lexmark with diamond design are trademarks of Lexmark International Inc registered in the United States and or other countries Al
37. NO oo ooo L L NO p 9 i LL Almi pJeog aM 6 pJe0g SIM ve 5 14 Service Manual 24XX 200 Logic board Printhead 24w Connector Pin Signal 1 R9 2 R11 3 R7 4 R17 5 R5 6 R19 7 R3 8 HDTHERMO CN301 9 R1 10 5 V dc 11 L2 12 40 V dc 13 L4 14 40 V dc 15 L6 16 L12 17 L8 18 L10 Locations and connectors 5 15 24XX 200 Logic board 9w amp 24w LNO SNO 9NO CN OLNO E z oz 6L 8NO ENO oo oo L E pNO 6 002NO 0 9 EE LOcNO gh LENO Gz b i oll I pJeog SIM 6 NO alu pJe0g SIM ve 5 16 Service Manual 24XX 200 Logic board Gap Set sensor 9w amp 24w Connector Pin Signal 1 GAP1 CN4 2 Signal Gnd 3 GAP2 Logic board Home Position sensor 9w amp 24w Connector Pin Signal 1 HPSW CN9 2 Signal Gnd Logic board Paper Present sensor 9w amp 24w Connector Pin Signal 1 PE1P 3 Signal Gnd
38. Position sensor and then moves to the first print position Feed Initialization Form feed motor rotates forward and then backward If any errors occur during the POST tests a combination of blinking LEDs indicates which test failed See Start on page 2 1 3 2 Service Manual 24XX 200 Print test The Print test helps you test and troubleshoot the printer To start the Print test 1 Paper must be at the print position the test does not print if paper is parked 2 Press and hold Line Feed and turn the printer on Release Line Feed when the printing starts 4 To interrupt the printer test a Press Start Stop The test stops after a complete line of characters prints b Press Start Stop to continue the test sample 5 To stop the printer test turn the printer off If the Print test fails go to Start on page 2 1 Note The short horizontal lines at the top of the sample are a test of each printhead wire numbered in sequence from top to bottom Diagnostic aids 3 3 24XX 200 Hex Trace mode The Hex Trace mode helps the user test and troubleshoot programs Use the Hex Trace 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 Trace mode 1 Press and hold Tractor and then turn the printer on 2 After a few seconds release Tractor and the lights go out 3
39. Select lever down to the continuous forms position Gently pull out the sheet of paper from the front of the printer Remove the ribbon access cover to clear any torn pieces of paper Set the Paper Select lever to the cut forms position Set the Forms Thickness lever to the proper setting for the type of paper you are using Refer to the 24xx User s Guide Continuous forms jams SON ZU Turn the printer off Detach any continuous forms already printed Set the forms thickness lever to position 7 Tear the continuous forms off at the perforation line before the forms enter the printer If you are using the tractor in the push position open the front cover Skip this step if you are using the optional Tractor 2 Feeder Open the left and right tractor doors Lift the paper from tractor pins Carefully pull out the paper Remove the ribbon access cover to clear any torn paper Remove any torn perforation strips or bits of paper from the paper path 3 6 Service Manual 24XX 200 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 sens
40. Startyour application program Be sure the printout is similarto the hex trace 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 trace mode sample 20 ev 20 30 280 20 u 20 20 DO 20 29 EO 29 20 FH 71 20 en Al 80 PQ El en 2D 20 62 20 20 72 20 29 JA 23 ev 20 33 20 eu 43 CJ 20 03 29 et EJ on En 20 94 20 20 AY 20 20 R4 55 20 20 65 80 80 75 29 OA OA 26 20 20 36 CO 20 C 20 20 D 20 20 ES 20 ey eo 97 go ev A7 eo eo 29 58 20 20 68 20 en 78 UD VA OA 29 20 20 39 29 C9 e0 70 09 e9 en ES BA 20 20 9A en 20 AA 20 29 20 58 20 20 6B 280 80 FR OD oA NA eC eo 20 3C 20 en CC 20 20 DC 20 en cy BD 20 20 9D 20 eo AD GE 29 20 SE 20 20 6E 20 eD FE OD OA DA eF eo 20 BF 20 80 CF 20 20 DF 29 AD 20 20 BD 80 20 Co en 29 80 71 20 80 81 20 29 eo 3e en eo 4e eo en Se 20 O0 Ee 20 80 FE 00 0A 20 A3 20 20 B3 20 20 C3 64 20 20 74 20 20 84 20 20 20 35 20 80 45 20 20 DS e 20 ES 80 80 FS 00 20 20 Ab 20 2D BS 20 20 20 67 80 20 77 80 80 87 88 20 20 38 ov 20 48 en 20 08 20 20 EB en 80 F8 99 20 20 A9 20 20 B9 EL 20 20 68 20 80 7A 80 20 OR EB 20 eo 3B 20 20 4B 3 20 20 DB 20 20 EB 20 20 20 9C 20 20 ac eo eo BC SD 20 80 6D 20 20 70 e OA OA CE ov 80 3E 20 20 CE 20 20 DE 20 20 EE 20 20 ev 9F 20 20 AF ev eo 3 4 Service Manual 24XX 200 Printer default settings U S defaults To initialize
41. The Load Unload button functions when the pull tractor is installed The Paper Out lights blinks and the FormFeed button does not operate until paper is located at first print line Be sure the Paper Select lever is in the tractor position Go to Pull Tractor sensor service check on page 2 32 2 8 Service Manual 24XX 200 Symptom Action Lower feed roll shaft Be sure the Paper Select lever is in the correct rotates but paper position does not feed Go to Paper feed service check on page 2 23 Pressing FormFeed does not feed paper Abnormal noise created while printer is feeding Paper jams skews or creases Incorrect or no line spacing wider narrower or overlapping lines Push Pull Tractor does not work Incorrect Top of Go to Top of forms service check on form positioning page 2 33 Power problems Symptom Action T When the power Check the continuity of the power cord and the Switch is on the voltage of the user s outlet Power light does not turn on or the printer does not start Go to Power service check on page 2 28 The Power light blinks or changes intensity Diagnostic information 2 9 24XX 200 Print quality problems Symptom Action No print but the carrier moves as if printing Adjust the Forms Thickness lever to a lower number Be sure the printhead cables are not loose or dama
42. able printhead 2481 40X2954 Cable printhead 2490 40X2955 Cable printhead 2491 40X2931 Kit pull tractor actuator 40X2906 Springs parts packet 40X2983 Kit ESD ground 2490 2491 40X2982 Kit ESD ground 2480 2481 40X2926 Screws washers and clips parts packet 9 40X2922 Kit Head Gap adjustment 10 40X2910 Gears and bushings parts packet 248X 11 40X2980 Sub frame right side 12 40X2956 Gear idler 2480 2481 12 40X2957 Gear idler 2490 2491 13 40X2907 Paper Select lever 14 40X2968 Frame right side 15 40X3010 Holder lower pinch roller shaft right 16 40X2896 Guide ASF DTR right 17 40X2971 Roller lower feed 2481 2491 17 40X2981 Roller lower feed 2480 2490 18 40X3019 Roller lower pinch 2480 2490 18 40X3020 Roller lower pinch 2481 2491 NS 40X3028 Narrow auto feeder assembly 2480 2490 NS 40X3029 Narrow dual tractor assembly 2480 2490 NS 40X3034 Wide auto feeder assembly 2481 2491 NS 40X3035 Wide dual tractor assembly 2481 2491 Description o JH OC CI HP A A WW WWD LD Parts catalog 7 7 24XX 200 Assembly 2 cont Carrier paper feed right side 7 8 Service Manual 24XX 200 Assembly 2 cont Carrier paper feed right side RE eL Description 2 191 40X2988 Shaft carrier 2480 2490 19 40X2989 Shaft carrier 2481 2491 20 40X2978 Roller upper feed 2480
43. ata 5 25 Signal Gnd 8 Data 6 26 Signal Gnd CN11 9 Data 7 27 Signal Gnd 10 Acknlg 28 Signal Gnd 11 Busy 29 Signal Gnd 12 PE 30 Signal Gnd 13 Select 31 INIT 14 AUTFED 32 ERROR 15 NC 33 Signal Gnd 16 Signal Gnd 34 NC 17 Chassis Gnd 35 5 V dc 18 45 V dc 36 SELIN Locations and connectors 5 5 24XX 200 Logic board 9w amp 24w LNO SNO 9NO CN OLNO E z oz 6L 8NO ENO oo oo L E pNO 6 002NO Bes ILL e rg 19 eg ene 81 LENO NECI LLL fe LII O pieog SIM ve pJeog SIM 6 5 6 Service Manual 24XX 200 Logic board Serial board 9w amp 24w Connector Pin Signal 1 45 V dc 2 45 V dc 3 CTS 4 DTS CN200 5 RXD 6 RTS 7 DSR 8 TXD 9 Signal Gnd 10 SBSET Connector Pin Signal 10 45 V dc 9 45 V dc 8 CTS 7 DTS CN1 6 RXD 5 RTS 4 DSR 3 TXD 2 Signal Gnd 1 SBSET Locations and connectors 5 7 24XX 200 Logic board 9w amp 24w LNO SNO 9NO CN OLNO E z oz
44. ation 2 17 24XX 200 Intermittent problem service check FRU Symptom Action A 1 The printer sometimes fails before POST is complete Check for the following 1 Loose connectors Reconnect all connectors to the logic board 2 Electrical noise or static discharge Check the following Power supply ground Printer frame ground Printer interface cable is grounded and shielded 3 Intermittently low voltages Check for ac and all dc voltages and short circuits on the logic board a Check the user 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 connector CN12 on the logic board Turn the printer power on and check all dc output voltages at CN12 1 CN12 2 and CN12 6 Verify the following output voltages CN12 1 40 V dc 1109 CN12 2 40 V dc 10 CN12 3 GND CN12 4 GND CN12 5 Signal GND CN12 6 5 V dc 2590 CN12 7 Power Save Mode f the voltages are incorrect replace the power supply If the failure remains replace the logic board Note When replacing the logic board always reset the bidirectional print adjustment See Bidirectional print adjustment on page 4 4 2 18 Service Manual 24XX 200 FRU Symptom Action A 2 Printer power The cause of this problem may be that the sometimes turns power circuit is failing or the wiring is o
45. ator panel 7 5 40X2915 Plate serial interface card 7 15 40X2916 Frame left side tractor 7 5 24XX 200 40X2917 Frame right side tractor 7 5 40X2918 Kit tractors left and right 7 21 40X2918 Tractors left and right 7 5 40X2919 Sensor Top of form 7 11 40X2920 Sensor home position 7 11 40X2921 Holder lower pinch roller shaft left 7 11 40X2922 Kit Head Gap adjustment 7 7 7 13 40X2923 Cover Tractor 2 right 7 21 40X2924 Frame ASF side left 7 17 40X2926 Screws washers and clips parts packet 7 7 7 11 7 15 40X2927 Support ASF paper right 7 17 40X2928 Support ASF paper left 7 17 40X2929 Hopper ASF left 7 17 40X2930 Card serial interface card with plate 7 15 40X2931 Kit pull tractor actuator 7 7 7 11 40X2932 Lever ASF paper load 7 17 40X2933 Link ASF paper load 7 17 40X2934 Serial interface cable 7 15 40X2935 Cover ASF left 7 17 40X2936 Cover ASF right 7 19 40X2937 Stand paper 7 5 7 19 40X2938 Sensor Pull Tractor 7 11 40X2939 Sensor Paper Select 7 11 40X2940 Board logic without EPROM 2480 LV 7 15 40X2941 Board logic without EPROM 2480 HV 7 15 40X2942 Board logic without EPROM 2481 LV 7 15 40X2943 Board logic without EPROM 2481 HV 7 15 40X2944 Board logic without EPROM 2490 LV 7 15 40X2945 Board logic without EPROM 2490 HV 7 15 40X2946 Board logic without EPROM 2491 LV 7 15 40X2947 Board logic without EPROM 2491 HV 7 15 40X2948 Carrier unit 2480 7 7 40X2949 Carrier unit 2481 7 7 40X2950 Carr
46. cartridge for binds or damage becomes loose or Go to Carrier service check on page 2 16 folded or jams Ribbon feeds correctly but is noisy Irrecoverable operator errors Paper Out and Font lights blink If this indication occurs the problem may be with the Paper Present 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 Present sensor Action Check Remove all paper The Paper Out light blinks when paper is not from the printer loaded Turn the power on The Paper Out light turns off when paper is loaded Go to Paper Present sensor service check on page 2 22 Diagnostic information 2 11 24XX 200 Paper Select sensor Action Check Turn the power off Install the Push Tractor Set the Paper Select lever to the tractor position and load continuous forms Turn the power on The Load Unload button functions correctly Go to Paper Select sensor service check on page 2 26 Remove the continuous forms Set the Paper Select lever to the cut sheet position and insert a cut sheet When Auto Ready Cut Sheet is enabled paper feeds automatically When Auto Ready Cut Sheet is disabled press FormFeed to load a cut sheet Verify that the Load Unload button does not function Go to Paper Select sensor service check on page 2 26 2
47. catalog 7 11 24XX 200 Assembly 3 cont Carrier paper feed left side 7 12 Service Manual 24XX 200 Assembly 3 cont Carrier paper feed left side sud MG Description 3 23 40X2922 Kit Head Gap adjustment 24 40X2894 Lever Forms Thickness 25 40X2902 Motor paper feed with BKT 26 40X2956 Gear idler 248X 26 40X2957 Gear idler 249X Parts catalog 7 13 24XX 200 Assembly 4 Electronics 7 14 Service Manual 24XX 200 Assembly 4 Electronics pete Ban Description Index number 4 1 40X2926 Screws washers and clips parts packet 2 40X2983 Kit ESD ground 2490 2491 2 40X2982 Kit ESD ground 2480 2481 3 40X2886 Power supply unit LV 3 40X2885 Power supply unit HV 4 40X3030 Module EPROM 248X 4 40X2964 Module EPROM 249X 5 40X2940 Board logic without EPROM 2480 LV 5 40X2941 Board logic without EPROM 2480 HV 5 40X2942 Board logic without EPROM 2481 LV 5 40X2943 Board logic without EPROM 2481 HV 5 40X2944 Board logic without EPROM 2490 LV 5 40X2945 Board logic without EPROM 2490 HV 5 40X2946 Board logic without EPROM 2491 LV 5 40X2947 Board logic without EPROM 2491 HV 6 40X2903 Bracket serial interface card 7 40X2915 Plate serial interface card 8 40X3015 Cable power supply 2480 2490 8 40X3016 Cable power supply 2481 2491 NS 40X2909 Kit fuse LV NS 40X2930 Card ser
48. d ASF is set to off in Setup mode Press FormFeed 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 gear train does not rotate for more than 3 seconds Inspect the sensor to be sure it opens and closes by the paper separator Replace the paper select 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 Paper Select 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 CN8 on the logic board Check the continuity between CN8 2 paper select sensor and GND while activating the Paper Select lever If the resistance is incorrect replace the logic board and reset the bidirectional print adjustment Go to Bidirectional print adjustment on page 4 4 2 26 Service Manual 24XX 200 FRU Action 2 Pull Tractor A failed Pull Tractor sensor can cause the sensor Load Unload button to malfunction With the tractor in the push position Press Load Unload several times while alternately holding down and releasing the left pull tractor actuator The paper should not park or load
49. d reset the bidirectional print adjustment Go to Bidirectional print adjustment on page 4 4 2 32 Service Manual 24XX 200 Top of forms service check FRU Action 1 Top of form sensor Check that the Top of form sensor and its flag are properly installed and are not damaged 2 Logic board Remove the paper and set the Paper Select lever to the cut sheet position and turn the printer on Measure the voltage between logic board connector CN6 2 TOF signal and CN6 1 GND You should receive the following voltage readings 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 Top of form sensor if the voltage is incorrect Replace the logic board if the voltage is correct and reset the bidirectional print adjustment Go to Bidirectional print adjustment on page 4 4 Diagnostic information 2 33 24XX 200 Tractor 2 service check The Tractor 2 in place sensor opens during installation when its actuator touches the printer cover The Tractor 2 Home sensor detects the position of the slider When Tractor 2 is selected the motor driven Tractor 2 slider pushes the printer sub slider cam lever to engage the printer gear train which drives the Tractor 2 tractors When the Tractor 2 is deselected the motor retracts the slider disengages the Tractor 2 gear drive
50. dom 7 3 40X0274 Power cord Switzerland 7 3 40X0275 Power cord lsrael 7 3 40X0276 Power cord South Africa 7 3 40X0287 Power cord Chile Italy 7 3 40X0294 Power cord Denmark 7 3 40X0296 Power cord Australia New Zealand 7 3 40X0297 Power cord U S AFE LV Canada Central and South America Mexico Saudi Arabia LV 7 3 40X1766 Power cord Peru 7 3 40X2880 Motor Tractor 2 7 21 40X2881 Guide Tractor 2 paper 7 21 40X2882 Parts packet Tractor 2 7 21 40X2885 Power supply unit HV 7 15 40X2886 Power supply unit LV 7 15 40X2887 Carrier roller set 7 7 40X2888 Roller ASF upper feed 2480 2490 7 17 40X2889 Roller ASF lower feed 2480 2490 7 17 40X2890 ASF gears and bushings parts packet 7 19 40X2891 ASF springs parts packet 7 17 7 19 40X2892 ASF screws parts packet 7 17 7 19 40X2893 Sensor head gap 7 11 40X2894 Lever Forms Thickness 7 13 40X2895 Guide ASF DTR left 7 11 40X2896 Guide ASF DTR right 7 7 40X2897 Cover operator panel front with overlay packs 7 5 40X2901 Motor carrier with BKT 7 11 40X2902 Motor paper feed with BKT 7 13 40X2903 Bracket serial interface card 7 15 40X2905 Support tractor paper 7 5 40X2906 Springs parts packet 7 7 7 11 40X2907 Paper Select lever 7 7 40X2908 Holder platen 7 11 40X2909 Kit fuse LV 7 15 40X2910 Gears and bushings parts packet 248X 7 7 7 11 40X2911 Cover rear 2481 2491 7 3 40X2912 Guide left paper 7 3 40X2913 Guide right paper 7 3 40X2914 Cable oper
51. e entsprechende VorsichtsmaBnahmen treffen ACHTUNG Dieses Symbol weist auf eine gef hrliche elektrische Spannung hin die in diesem Bereich des Produkts auftreten kann Ziehen Sie vor den Arbeiten am Ger t den Netzstecker des Ger ts bzw arbeiten Sie mit groBer Vorsicht wenn das Produkt f r die Ausf hrung der Arbeiten an den Strom angeschlossen sein muB viii Service Manual 24XX 200 Pautas de Seguridad La seguridad de este producto se basa en pruebas y aprobaciones del dise o original y componentes espec ficos El fabricante no es responsable de la seguridad en caso de uso de piezas de repuesto no autorizadas 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 PRECAUCI N este s mbolo indica que el voltaje de la parte del equipo con la que est trabajando es peligroso Antes de empezar desenchufe el equipo o tenga cuidado si para trabajar con l debe conectarlo Informa es de Seguran a A seguran a deste produto baseia se em testes e aprova es do modelo original e de componentes espec ficos O fabricante n o respons vel pela segunran a no caso de uso de pe as de substitui o n o autorizadas As informa
52. e four holes B in the bottom cover releasing the top cover from the bottom cover 10 Turn the printer right side up and insert a flat blade screwdriver into each of the two holes C in the back of the top cover C 11 Lift the top cover up and over the print unit assembly Note When replacing the top cover be sure the operator panel cable is correctly aligned and inserted securely into the logic board Damage to the operator panel cable may cause failure of other electrical components in the printer Repair information 4 9 24XX 200 Covers operator panel assembly removal 1 Remove the top cover Go to Covers top removal on page 4 8 2 Disconnect the operator panel cable from the operator panel card on the inside of the top cover 3 Push down on the two latches A at the top of the operator panel on the inside of the top cover as shown A 4 While holding the latches down push the operator panel out of the top cover toward the bottom of the cover Note During replacement be sure the operator panel cable is correctly inserted into both the operator panel card and the logic board 4 10 Service Manual 24XX 200 Covers bottom removal 1 Remove the top cover Go to Covers top removal on page 4 8 2 Remove the logic board Go to Logic board removal on page 4 12 3 Remove the power supply unit Go to Power supply removal on page 4 13 4 Remove the
53. e sure the gear on the printer that drives Tractor 2 turns freely when the lever is not pressed but remains still when the lever is pressed Remove the Tractor 2 unit from the printer and remove all paper With the Paper Select lever in the continuous forms position press FormFeed the tractors should rotate Press the sub slider cam lever below the ASF Tractor 2 drive gear and press FormFeed again the tractors should not rotate but the drive gear should Check the condition of the pin feed belts With the printer off make sure that the slider does not bind Verify that 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 2 Tractor 2 cover Remove the Tractor 2 cover and reinstall the Tractor 2 unit 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 When the cover is removed it tends 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 go to Tractor 2 cable connectors on page 5 27 Diagnostic information 2 37 24XX 200 2 38 Service Manual 24XX 200 3 Diagnostic aids The printer contains self tests to
54. eeds paper correctly If the base printer does not feed paper correctly go to Paper feed service check on page 2 23 3 Geartrain Be sure the ASF drive gear on the inside right side frame of the printer rotates Inspect the right side gear train for damage or debris Remove the ASF right cover and ensure that all the gears are in good condition 4 Combination lock Install the ASF and press FormFeed mechanism If the picker drive shaft does not rotate replace the combination lock mechanism 5 Left and right If the ASF picker rollers rotate but a single hoppers sheet is not picked inspect the springs and corner separators on the left and right hoppers Be sure the Paper Load lever is in the correct position Diagnostic information 2 15 24XX 200 Carrier service check Note The carrier service check includes the carrier drive Home Position sensor and ribbon feed FRU Action 1 Carrier Verify the carrier motor connector is connected to the logic board at CN2 If the carrier motor connector is connected properly 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 be sure the ribbon advances when the carriage moves in either direction If the carrier binds check the following Correct printhead to platen gap Go to Print
55. emove the carrier from the printer Note Following replacement perform the printhead to platen gap adjustment Go to Printhead to platen gap adjustment on page 4 2 4 18 Service Manual 24XX 200 Carrier motor assembly removal 1 Remove the top cover Go to Covers top removal on page 4 8 2 Loosen the carrier belt 1 Loosen the tension screw A 2 Remove tension from the carrier belt by pulling up on the belt 3 Tighten the tension screw Loosening the screw tightens the belt A 3 Slip the belt off the carrier motor pulley Repair information 4 19 24XX 200 4 Remove the screw B from the forms thickness lever and then remove the lever 4 20 Service Manual 24XX 200 5 Remove the screw C securing the carrier motor bracket to the bottom cover D E D back 10 11 Disconnect the printhead cable from the logic board and move it back and out of the way as shown Remove the five screws D securing the carrier motor bracket to the print unit Remove the Home Position sensor E from the top of the carrier motor bracket by pinching the clips underneath the bracket Remove the carrier motor bracket from the print unit by pulling up and out on the rubber grommet F between the motor bracket and the bottom cover Disconnect the carrier motor cable from the logic board Remove the carrier motor from the motor bracket Repair information 4 21 24XX 200
56. event of use of unauthorized replacement parts The maintenance information for this product has been prepared for use by a professional service person and is not intended to be used by others There may be an increased risk of electric shock and personal injury during disassembly and servicing of this product Professional service personnel should understand this and take necessary precautions CAUTION When you see this symbol there is a danger from hazardous voltage in the area of the product where you are working Unplug the product before you begin or use caution if the product must receive power in order to perform the task Consignes de s curit La s curit de ce produit repose sur des tests et des agr ations portant sur sa conception d origine et sur des composants particuliers Le fabricant n assume aucune responsabilit concernant la s curit en cas d utilisation de pi ces de rechange non agr es Les consignes d entretien et de r paration de ce produit s adressent uniquement un personnel de maintenance qualifi 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 ATTENTION Ce symbole indigue la pr sence dune tension dangereuse dans la partie du produit sur laguelle vous travaillez D branchez le produit avant de commencer ou faites preuve de vigilance si l ex cuti
57. f or if it runs out of paper when the printer is in Pull Tractor mode Press Start Stop to set the printer online Setting Top of form cut forms envelopes Top of form can range from minus 1 to plus 22 inches from the top of cut sheet paper To set and save Top of form 1 N Turn the printer on The Paper Out light blinks if no paper is loaded If the Paper Out light is off tear off excess forms and press Load Unload If an individual form is loaded press FormFeed to clear the paper path Move the paper select lever up to the cut forms position Load a cut sheet of paper or envelope through the manual feed door The printer moves the paper or envelope to the current Top of form if Auto Cut Sheet is set to on If not press FormFeed when the Paper Out light goes off Open the operator panel cover to access layer two Press any paper movement button LineFeed Micro or Micro J to align the horizontal lines located on the platen with the Top of form you want Press Set TOF to set and save Top of form Close the operator panel cover Press Start Stop to set the printer online General information 1 5 24XX 200 Options The 24xx printers support the following options e Automatic Sheet Feeder ASF Internal serial interface RS232 OKI emulation 9 wire only Tractor 2 sheet feeder Tools The basic tools necessary to service the 24xx 200 printers are Basic CE tool kit e
58. ff intermittently open Check the following in sequence 1 Check the user 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 connector CN12 on the logic board Turn the printer power on and check all dc output voltages at CN12 1 CN12 2 and CN12 6 Verify the following output voltages CN12 1 40 V dc 10 CN12 2 40 V dc 10 CN12 3 GND CN12 4 GND CN12 5 Signal GND CN12 6 5 V dc 25 If one of the voltages is 0 go to Power service check on page 2 28 If the voltages are not 0 but are incorrect replace the power supply unit 3 Intermittent poor print quality Remove paper jams from the paper path Clean all feed roller surfaces Clean the ribbon shield and printhead Clean the platen surface Install the ribbon cartridge correctly If the ribbon has reached its end of life have the user replace the ribbon cartridge Diagnostic information 2 19 24XX 200 FRU Symptom Action A 4 The previous suggestions have not corrected the problem The following may cause undefined or intermittent failures Loose connector pins that fail to contact Check the following Reconnect the connectors of all FRUs and printer interface cables Check the continuity of the line cord Electrical noise Check the following Power supply ground Printer f
59. g Go to Abnormal noise service check on abnormal noise page 2 13 comes from the printer Abnormal noise when feeding paper Abnormal noise during printing or POST Diagnostic information 2 5 24XX 200 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 Go to No print or abnormal print service check on page 2 21 Slow printing speed Go to Print speed service check on page 2 29 Auto Sheet Feeder problems Symptom Action Auto Sheet Feeder does 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 Auto Sheet Feeder ASF service check on page 2 14 2 6 Service Manual 24XX 200 Error indications Symptom Action Ready and Paper Out lights blink Turn the printer off and then back on Go to Abnormal indications on page 2 5 Paper Out and Font lights blink Turn the printer off and then on Go to Irrecoverable operator errors on page 2 11 Operator panel proble
60. ged Be sure the interface cable is connected properly Check the ribbon cartridge for binds or damage Go to Print speed service check on page 2 29 Print density is light Turn the ribbon advance knob on the print cartridge from 1 to 2 to increase the darkness of print If the ribbon has reached its end of life or is worn replace the ribbon cartridge Go to Carrier service check on page 2 16 Uneven print density across the print line Specific dots missing Extra dots or lines printing Turn the ribbon advance knob on the print cartridge from 1 to 2 to increase the darkness of print Be sure the printhead cables are connected correctly to the printhead Clean the printhead Set the Forms Thickness lever to position 1 and run the print test Go to Carrier service check on page 2 16 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 replace the ribbon cartridge Go to Carrier service check on page 2 16 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 Carrier service check on page 2 16 2 10 Service Manual 24XX 200 Ribbon feed problems Symptom Action Ribbon comes off Check the ribbon
61. he Paper Present sensor 2 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 Be sure the ASF setting is off unless the ASF is installed f the Paper Present sensor is good and the ASF setting is on replace the logic board and reset the bidirectional print adjustment Go to Bidirectional print adjustment on page 4 4 2 22 Service Manual 24XX 200 Paper feed service check Note If paper creases or jams frequently verify that the paper is neither too thick nor thin If necessary refer the user to the User s Guide for specifications of acceptable papers If the paper does not stop in the correct location see Paper Present sensor service check on page 2 22 and the Top of forms service check on page 2 33 FRU symptom Action 1 Auto Sheet If the Auto Sheet Feeder is installed remove it Feeder Enter the Setup Menu and reset ASF to off Verify that the printer works correctly without the ASF installed If the printer fails only with the Auto Sheet Feeder installed go to Auto Sheet Feeder ASF service check on page 2 14 2 Geartrain Remove all paper from the printer Press FormFeed several times and examine all rotating parts to find the problem The feed rollers and pinch roller should all be clean and in good condition and should all rotate when p
62. he rubber on the platen and using a feeler gauge 1 slowly adjust the right gap adjust bushing 2 clockwise until a gap of within 0 33 and 0 37 mm exists between the printhead 3 and the platen ITTTTTTT HEH 1 10 After adjusting both left and right Gap Adjust bushings push the printhead to the center of the platen and verify that a gap of within 0 33 and 0 37 mm exists between the printhead and the platen Note For maximum print quality adjust the head gap on both the left and right sides of the printer to within 0 01mm If the gap value exceeds the specified range return to step 4 and re adjust both left and right Gap Adjust bushings Repair information 4 3 24XX 200 11 After confirming that the head gap is within the specified range for all printhead positions left right and center apply Lock Tite on both bushings Bidirectional print adjustment After replacing any mechanical part which affects the operation of the logic board or the carrier perform the following procedure to adjust the bidirectional print This adjustment cannot be completed if the printer runs out of paper so be sure to use continuous forms 1 10 11 Through the Setup Menu be sure the default macro is set to disabled Turn the printer off Open the operator panel cover to access layer tvvo Press and hold the Pitch key while turning the printer on The d
63. head to platen gap adjustment on page 4 2 Clean and lubricated 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 e If the bind is gone replace the carrier motor e If the bind remains replace the carrier After replacing the logic board or any parts affecting the carrier perform the bidirectional print adjustment See Bidirectional print adjustment on page 4 4 2 Home Position sensor If the carrier moves manually without binding but the Home Position Error still occurs verify that the logic board is receiving 40 V dc on pin CN12 1 Check that the 5 V dc Home Position sensor signal is reaching the logic board Replace the sensor or the short flexible cable as necessary 2 16 Service Manual 24XX 200 FRU Action 3 Carrier motor If the Home Position sensor is okay verify that the resistance of the carrier motor windings are approximately 2 ohms for all printers Check the resistance at the following pin locations CN2 1 and CN2 3 CN2 2 and CN2 4 4 Logic board If all parts appear okay but the Home Position Error still occurs replace the logic board After replacing the logic board or any parts affecting the carrier perform the bidirectional print adjustment See Bidirectional print adjustment on page 4 4 Diagnostic inform
64. help find and solve problems You do not need to connect the printer to a computer or terminal to run these tests Types of self tests are e Power on self test POST e Print test Hex Trace mode a computer or terminal is necessary The following are special machine modes that run when the printer is turned off and then back on Turn printer on while pressing Result LineFeed Prints print test with sample fonts Tractor Sets printer in Hex Trace mode Load Unload and Tractor Disables enables Operator Panel Lockout mode Tearoff and Tractor with the Resets the printer to the World Trade printhead at the left limit defaults Tearoff amp Load Unload with the Resets the printer to the U S defaults printhead at the left limit Diagnostic aids 3 1 24XX 200 Power On Self Test POST The following tests are automatically performed when the printer is turned on LEDs Test Checks operation of LEDs on the operator panel The LEDs turn on and off after the printer is turned on and 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
65. hen push it off the gray slotted spring block B toward the back of the printer as shown F 10 Slide the carrier to the center of the printer 11 Slide the gray slotted spring blocks E on each end toward the center of the roller shaft taking care that the blocks remain with the shaft during removal 12 Slide the carrier to the right side of the printer 13 While holding the lower pinch roller shaft by the gear F move the shaft to the left approximately one half inch Lift the shaft up and to the back of the printer and then carefully remove the lower pinch roller and shaft 14 Be sure to perform the printhead to platen gap adjustment Go to Printhead to platen gap adjustment on page 4 2 4 38 Service Manual 24XX 200 Roller lower feed removal 1 Remove the top cover Go to Covers top removal on page 4 8 Remove the print unit Go to Print unit removal on page 4 26 Remove the carrier Go to Carrier removal on page 4 14 Remove the two screws securing the black bracket to the inside of the right side frame Remove the right side sub frame and the right side gears Go to Right side gears sub frame removal on page 4 32 Remove the left side gears Go to Left side gears removal on page 4 29 Remove the gears and C clip from both ends of the lower feed roller Remove the upper feed roller Go to Roller upper feed removal on page 4 34 Repair informat
66. ial interface card with plate NS 40X2934 Serial interface cable NS 40X3032 Memory 249X no PNP EPROM Parts catalog 7 15 24XX 200 Assembly 5 ASF Roller support 7 16 Service Manual 24XX 200 Assembly 5 ASF Roller support Asm Part Index number Description 5 1 40X2965 Support ASF cut sheet with guides 2480 2490 1 40X3017 Support ASF cut sheet with guides 2481 2491 2 40X2888 Roller ASF upper feed 2480 2490 2 403023 Roller ASF upper feed 2481 2491 3 40X2889 Roller ASF lower feed 2480 2490 3 40X3024 Roller ASF lower feed 2481 2491 4 40X2984 Roller ASF pick up left and right 2480 2490 4 40X2985 Roller ASF pick up left and right 2481 2491 5 40X3004 Hopper ASF right 2481 2491 6 40X2927 Support ASF paper right 7 40X2928 Support ASF paper left 8 40X2929 Hopper ASF left 9 40X2891 ASF springs parts packet 10 40X2924 Frame ASF side left 11 40X2892 ASF screws parts packet 12 40X2932 Lever ASF paper load 13 40X2933 Link ASF paper load 14 40X3136 ASF gears and bushings parts packet 15 40X2935 Cover ASF left Parts catalog 7 17 24XX 200 Assembly 6 ASF Side frame covers 7 18 Service Manual 24XX 200 Assembly 6 ASF Side frame covers Asm Part Index number Description 6 1 40X2891 ASF Springs parts packet 2 40X2890 ASF gears and bushings parts packet 3 40X2936
67. idity increases static electricity during cold weather 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 Perform the printhead to platen gap adjustment after replacing the carrier platen lower pinch roller ribbon drive rack gear left side frame right side frame paper separator lower feed roller or paper guide 1 Turn the printer off and remove all covers with the exception of the bottom cover See Covers removals on page 4 5 2 Remove the ribbon cartridge and paper 3 Remove the Lock Tite red from the Gap Adjust bushings on both the left and right side of the printer 4 Set the Forms Thickness lever to position 1 by pushing it toward the back of the printer as far as it will go 5 Move the printhead to the left edge of the rubber on the platen 6 Shift the left Gap Adjust bushing clockwise as far as it will go 7 Shift the right Gap Adjust bushing counterclockwise as far as it will go Note At this time the nose of the printhead should be touching the platen 4 2 Service Manual 24XX 200 8 Using a feeler gauge 1 slowly adjust the left Gap Adjust bushing 2 counterclockwise until a gap of within 0 33 and 0 37 mm exists between the printhead 3 and the platen mi 1 x t 4 i REL gx 3 9 Move the printhead to the right edge of t
68. ier unit 2490 7 7 40X2951 Carrier unit 2491 7 7 40X2952 Cable printhead 2480 7 7 40X2953 Cable printhead 2481 7 7 40X2954 Cable printhead 2490 7 7 40X2955 Cable printhead 2491 7 7 40X2956 Gear idler 2480 2481 7 7 40X2956 Gear idler 248X 7 13 40X2957 Gear idler 2490 2491 7 7 40X2957 Gear idler 249X 7 13 40X2958 Shaft Tractor 2 support 2480 2490 7 21 40X2959 Shaft Tractor 2 support 2481 2491 7 21 40X2960 Board assembly with cable and ferrite Tractor 2 7 21 40X2961 Board assembly with cable and ferrite Tractor 2 7 21 I 6 Service Manual 40X2962 40X2963 40X2964 40X2965 40X2966 40X2967 40X2968 40X2969 40X2970 40X2971 40X2972 40X2973 40X2974 40X2975 40X2976 40X2977 40X2978 40X2979 40X2980 40X2981 40X2982 40X2983 40X2984 40X2985 40X2986 40X2987 40X2988 40X2989 40X2990 40X2991 40X2992 40X2993 40X2994 40X2995 40X2996 40X2997 40X2998 40X2999 40X3000 40X3001 40X3002 40X3003 40X3004 40X3005 40X3006 40X3007 40X3008 Operator panel assembly 248X Operator panel assembly 249X Module EPROM 249X Support ASF cut sheet with guides 2480 2490 Frame left side 2480 2481 Frame left side 2490 2491 Frame right side Guide paper assembly 2480 2490 Guide paper assembly 2481 2491 Roller lower feed 2481 2491 Sensor Paper Present Platen 2480 2490 Platen 2481 2491 Separator paper 2480 2490 Separator paper 2481 2491 Plate tension
69. ion 4 39 24XX 200 9 Remove the two screws A securing the platen to the side frames 10 Remove the carrier motor bracket Go to Carrier motor assembly removal on page 4 19 11 Remove the five screws securing the left side frame and then remove the frame 12 Remove the four screws from the right side frame and then remove the bottom frame assembly 13 Remove the five screws from the frame support plate and then remove the lower feed roller 14 Be sure to perform the printhead to platen gap adjustment Go to Printhead to platen gap adjustment on page 4 2 4 40 Service Manual 24XX 200 Sensors removals Head Gap Paper Select Sensor E P i i P Pr Pull Tractor Top Of Form Paper Present Sensor Sensor Sensor Repair information 4 41 24XX 200 Sensor Pull Tractor removal 1 Remove the top cover Go to Covers top removal on page 4 8 2 Remove the small screw securing the Pull Tractor sensor to the inside of the left frame Go to Sensors removals on page 4 41 3 Disconnect the pull tractor sensor from the logic board Sensor Head Gap removal 1 Remove the top cover Go to Covers top removal on page 4 8 2 Remove the screw from the Forms Thickness lever and then remove the lever 3 Remove the screw from the Head Gap sensor and then remove the sensor 4 Disconnect the Head Gap sensor cable from the logic board Go to Sensors removals on page 4 41 Sensor To
70. itive 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 printer Make as few movements as possible 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 printer 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 printer cover or ona metal table if you need to put down the ESD sensitive part for any reason first put it into its special bag Printer 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 Repair information 4 1 24XX 200 e Prevent ESD sensitive parts from being accidently touched by other personnel Install printer covers when not working on the printer and do not put unprotected ESD sensitive parts on a table Keep all ESD sensitive parts in a grounded metal cabinet case Low hum
71. l other trademarks are the property of their respective owners 2000 2006 Lexmark International Inc All rights reserved UNITED STATES GOVERNMENT RIGHTS This software and any accompanying documentation provided under this agreement are commercial computer software and documentation developed exclusively at private expense U S A P N 12G9624 24XX 200 Table of contents Safety information cesses 1 vii PEACE cc acc e 1 xii General information e e sss sss 1 1 Printer specifications 6 x cess 1 1 Printerspeeds san R RRR REER ences 1 2 Setup MODE SCR RR ie RU RR 1 2 Entering Setup mode os seas 1 2 Exiting Setup mode c asse s 8 68 R 9 0 66 xu 1 2 Setup menu OPTIONS iere uiu Rr 1 3 Interface menu options 2c 1 3 Setting the tear off position se ccc 1 4 Setting Top of form continuous pull mode 1 5 Setting Top of form cut forms envelopes 1 5 BIOS s ERU 1 6 Diagnostic information eese 2 1 otal 2 1 Voltage ground and continuity readings esee 2 1 Errorindicatlon fable ssec RR hh hr 2 2 Symptom check Table a eis ska RR RR nS in 2 5 Irrecoverable operator errorS sss assess ee 2 11 Service ChECKS a 2 13 Abnormal noise Service 0 0
72. ms Symptom Action The Start Stop button does not function but no error is indicated Only the Power light turns on One or more buttons do not function One or more lights do not function Turn the printer off and then on Go to Operator panel service check on page 2 21 Paper feed problems Symptom Action The Paper Out light is blinking when there is paper in the printer Go to Paper Present sensor service check on page 2 22 The Paper Out light does not blink when there is no paper is in the printer and the ASF is not installed Print operation starts without paper Be sure the paper present sensor is not blocked Go to Paper Present sensor service check on page 2 22 Diagnostic information 2 7 24XX 200 Symptom Action The Load Unload button does not function when the push tractor is installed Form feed length is not correct The Load Unload button functions when cut sheets are being used Be sure the Paper Select lever is in the correct position Go to Paper Select sensor service check on page 2 26 Continuous forms feed but cut sheets fail to load Be sure the Paper Select lever is in the cut sheet position Verify that continuous forms have been parked using the Load Unload button Be sure Auto Cut Sheet is enabled in the Setup mode Go to Paper Select sensor service check on page 2 26
73. n 4 24 Print unit 4 26 Printhead 4 25 Printhead cables 4 25 I 2 Service Manual Ribbon drive rack gear 4 28 Right side sub frame 4 32 Rollers Lower feed 4 39 Upper feed 4 34 Upper pinch 4 36 Sensors Head Gap 4 42 Home Position 4 44 Paper Present 4 43 Paper Present flag 4 43 Paper Select 4 43 Pull Tractor 4 42 Top of form 4 42 Repair information 4 1 S Safety information 1 vii Service checks 2 13 Abnormal noise 2 13 Abnormal print 2 21 Auto Sheet Feeder 2 14 Carrier 2 16 Intermittent problem 2 18 No print 2 21 Operator panel 2 21 Paper feed 2 23 Paper Present sensor 2 22 Paper Select sensor 2 26 POST 2 27 Power 2 28 Printhead 2 30 Printhead continuity tables 2 31 Pull Tractor sensor 2 32 Top of forms 2 33 Tractor 2 2 34 Settings Tear off position 1 4 Top of form continuous 1 5 Top of form cut forms 1 5 Top of form envelopes 1 5 Setup Menu options 1 3 Setup mode 1 2 Entering 1 2 Exiting 1 2 Signal connections 5 2 24XX 200 Specific printer parts 5 1 Specifications 1 1 Start 2 1 Symptom checks 2 5 Abnormal indications 2 5 Abnormal noise problems 2 5 ASF problems 2 6 Error indications 2 7 Operator panel problems 2 7 Paper feed problems 2 7 power problems 2 9 Print quality problems 2 10 T Tools 1 6 V Voltage ground and continuity 2 1 24XX 200 I 4 Service Manual 24XX 200 Part number index P N Description Page 40X0271 Power cord Malaysia Singapore United King
74. n either side of the ribbon access cover up toward the front of the printer A 2 Lift the ribbon access cover up and out of the printer Note When replacing the ribbon access cover be sure to hook the front hinge points on either side of the ribbon access cover first and then lower the cover into place Be sure that both gray spring loaded ribbon access cover latches snap and lock 4 6 Service Manual 24XX 200 Covers option removal 1 From the bottom pull the option cover A outward and up removing it from the printer Repair information 4 7 24XX 200 Covers top removal A 1 Turn the printer off and disconnect the power cord at the printer 2 Remove the tractor assembly if it is installed in the pull tractor position by pressing the locking levers and pulling the tractor assembly out of the printer 3 Remove the ribbon access cover Go to Covers ribbon access removal on page 4 6 4 Remove the front cover Go to Covers front removal on page 4 6 5 Remove the option cover Go to Covers option removal on page 4 7 Note With the option cover removed you can see the operator panel cable attached to the logic board 6 Disconnect the operator panel cable from the logic board 7 Remove the two screws A from each side of the front cover area 4 8 Service Manual 24XX 200 8 Turn the printer upside down 9 Insert a flat blade screwdriver into each of th
75. o Intermittent problem service check on page 2 18 Diagnostic information 2 3 24XX 200 LED Status Alarm Action All LEDs OFF None Power Failure Check the continuity of the power cord and the voltage of the user s outlet If they are correct go to Power service check on page 2 28 Power ON None Operator Panel Failure na ae ehe Go to Operator panel service Paper oul CEE check on page 2 21 Panel Lock OFF i Font Lock OFF Any LED None Go to Operator panel service on and check on page 2 21 Power LED off The Power None Go to Power service check LED blinks on page 2 28 or changes intensity 2 4 Service Manual 24XX 200 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 indications Symptom Action 7 or more lights turn Disconnect the interface cable from the printer and on but do not turn turn the printer off and then back on If POST now off runs correctly the problem is in the computer or The Power light is interface cable on but POST will Go to POST service check on page 2 27 not run Abnormal noise problems Symptom Action During POST Check the ribbon cartridge for binds or damage abnormal noise comes hor ife Go to Carrier service check on page 2 16 carrier During idlin
76. o the printer after advancing to the Top of form The print buffer has not received data for one second If you have already set Top of Form and now want to change the tear off bar position follow these steps E G M Press Start Stop to take the printer offline Press and hold Tear Off until the printer beeps Open the operator panel cover to access layer two Press Micro or Micro to move the paper to the correct position on the tear off bar Close the operator panel cover The printer beeps twice The paper rolls backward then goes to the new tear off position The Reagy light is on The paper remains at the current tear off position until you send another job to the printer The paper moves from the tear off position to the Top of form and begins printing 1 4 Service Manual 24XX 200 Setting Top of form continuous pull mode 1 N 9 Turn the printer on The Paper Out light blinks if no paper is loaded Move the Paper Select lever down to the continuous forms position Load continuous form paper on the pull tractor feed pins Open the operator panel cover to access layer two Press any paper movement button LineFeed Micro or Micro J to move the paper to the Top of form position Use the second sheet of continuous forms to set Top of form Press Set TOF to set and save Top of form Close the operator panel cover Top of form is not saved if the printer is turned of
77. on de la t che exige que le produit reste sous tension vii 24XX 200 Norme di sicurezza La sicurezza del prodotto si basa sui test e sull approvazione del progetto originale e dei componenti specifici II produttore non responsabile per la sicurezza in caso di sostituzione non autorizzata delle parti 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 II personale di assistenza autorizzato deve quindi adottare le precauzioni necessarie ATTENZIONE Questo simbolo indica la presenza di tensione pericolosa nell area del prodotto Scollegare il prodotto prima di iniziare o usare cautela se il prodotto deve essere alimentato per eseguire l intervento Sicherheitshinweise Die Sicherheit dieses Produkts basiert auf Tests und Zulassungen des urspr nglichen Modells und bestimmter Bauteile Bei Verwendung nicht genehmigter Ersatzteile wird vom Hersteller keine Verantwortung oder Haftung f r die Sicherheit bernommen Die Wartungsinformationen f r dieses Produkt sind ausschlieBlich f r die Verwendung durch einen Wartungsfachmann bestimmt W hrend des Auseinandernehmens und der Wartung des Ger ts besteht ein zus tzliches Risiko eines elektrischen Schlags und k rperlicher Verletzung Das zust ndige Fachpersonal sollt
78. or Pull Tractor removal sc 9 4 42 Sensor Head Gap removal sicions skok rm RR R RE mrs 4 42 Sensor Top of form removal u e ne 4 42 Sensor Paper Select removal 4 43 Sensor Paper Present removal 4 43 Flags Paper Present Top of form removal 4 43 Sensor Home Position sensor removal 4 44 4 45 Auto Sheet Feeder gears removal 4 45 Auto Sheet Feeder pick up roller removal 4 46 Locations and Connectors xs s x essen 5 1 Signal connections ea R cuu uum RR mE saa en 5 2 Power supply QW amp 24W e a asa 5 2 Logic board Parallel interface cable 9w amp 24w 5 5 Logic board Serial board QW amp 24w LL eL 5 7 Logic board USB cable 9w amp 24w x s s s e x e cece eee eee 5 9 Logic board DC power 9w amp 24W e e e K eee 5 9 Logic board Printhead QW cess 5 11 Logic board Printhead 24W cese 5 13 Logic board Printhead 24W cesses 5 15 Logic board Gap Set sensor Ow amp 24w 5 17 Logic board Home Position sensor 9w amp 24w 5 17 Logic board Paper Present sensor 9w amp 24w 5 17 Logic board Paper Select sensor 9w amp 24w 5 19 Logic board Pull Tractor sensor QW amp 24W 5 1
79. p of form removal 1 Remove the top cover Go to Covers top removal on page 4 8 2 Remove the print unit Go to Print unit removal on page 4 26 3 Turn the print unit upside down 4 Unsnap the Top of form sensor from the platen Go to Sensors removals on page 4 41 4 42 Service Manual 24XX 200 Sensor Paper Select removal 1 Remove the top cover Go to Covers top removal on page 4 8 Remove the print unit Go to Print unit removal on page 4 26 Turn the print unit upside down Remove the four small screws securing the Paper Select sensor to the left side frame Go to Sensors removals on page 4 41 Sensor Paper Present removal il Remove the top cover Go to Covers top removal on page 4 8 Remove the print unit Go to Print unit removal on page 4 26 Turn the print unit upside down Remove the small screw securing the Paper Present sensor to the bottom frame Go to Sensors removals on page 4 41 Flags Paper Present Top of form removal 1 2 Remove the lower feed roller Go to Roller lower feed removal on page 4 39 Remove the Paper Present flag or the Top of form flag from the paper guide Go to Sensors removals on page 4 41 Repair information 4 43 24XX 200 Sensor Home Position sensor removal 1 Remove the top cover Go to Covers top removal on page 4 8 2 Disconnect the Home Position sensor cable from the logic board
80. r information 4 27 24XX 200 Ribbon drive rack gear removal 1 Remove the top cover Go to Covers top removal on page 4 8 2 Remove the carrier Go to Carrier removal on page 4 14 3 Unsnap the white plastic end stop A from the top left side of the print unit 4 Unlatch the left side of the rack from the top of the print unit 5 Slide the rack to the right and out of the print unit 4 28 Service Manual 24XX 200 Gears removals Left side gears removal 1 Remove the top cover Go to Covers top removal on page 4 8 2 Remove the three screws A from the serial interface card bracket Repair information 4 29 24XX 200 3 Remove the four screws B from the paper feed motor bracket assembly A C AN om ey 4 30 Service Manual 24XX 200 4 Remove the paper feed motor bracket assembly exposing the gears as shown Repair information 4 31 24XX 200 Right side gears sub frame removal 1 Remove the top cover Go to Covers top removal on page 4 8 2 Unhook the wire retainer A from the carrier shaft C A 3 Remove the two screws and washers B from the sub frame 4 Remove the Paper Select lever C 4 32 Service Manual 24XX 200 5 Remove the sub frame exposing the right side gears D as shown Repair information 4 33 24XX 200 Rollers removals Roller upper feed removal 1 Remove the top cover Go to Covers top removal
81. raft alignment bars print The current value is the number printed below the bars To set draft select the best alignment from the alignment bars in rows 01 11 Press Micro or Micro J to select the best alignment by number or keep the current value After selecting the printer prints a single row showing the current alignment setting Press Set TOF to save the selection The printer automatically prints the alignment bars for NLQ The current value is the number printed below the bars To set NLQ select the best alignment from the alignment bars in rows 01 11 The current value is the number printed below the bar Press Micro or Micro J to select the best alignment by number or keep the current value After selecting the printer prints a single row showing the current alignment setting Press Set TOF to save the selection Close the operator panel cover The printer returns to Ready Removal procedures f CAUTION Be sure to unplug the power cord whenever you are working on the printer with one of the covers removed 4 4 Service Manual 24XX 200 Covers removals Repair information 4 5 24XX 200 Covers front removal 1 Rotate the front cover out and up about three inches from the bottom of the printer 2 Push the front cover up and out of the printer Covers ribbon access removal 1 Pull the gray spring loaded ribbon access cover release latches A located o
82. rame ground Printer interface cable is grounded or shielded Undefined data in user applications Check the baud rate at the controller Check that the printer interface cable matches the printer 5 Problem occurs only in specific user applications Perform the Hex Trace Print hexadecimal printing by the following procedure and check the data streams Go to Hex Trace mode on page 3 4 Turn the printer off Press and hold Tractor and turn the printer on Have the user print the failing job To stop printing turn the power off If the failure still occurs replace the logic board Be sure to reset the bidirectional print adjustment See Bidirectional print adjustment on page 4 4 2 20 Service Manual 24XX 200 No print or abnormal print service check FRU Function Action 1 Logic board If the print test does not complete correctly replace the logic board and reset the bidirectional print adjustment See Bidirectional print adjustment on page 4 4 2 Interface cable Check the connection and continuity of the interface cable 3 Emulation mode Enter the Setup Menu and be sure the printer is in the correct emulation mode for the computer either IBM or Epson Go to Setup mode on page 1 2 Operator panel service check If the operator panel is locked only the Start Stop FormFeed Tear Off and Load UnLoad buttons are active 24
83. re model as reference Some of the artwork may not be completely representative of all models For example the 24 wire models are not depicted with two printhead cables and there is no artwork depicting the extended carriage models 2481 or 2491 Parts catalog 7 1 24XX 200 Assembly 1 Covers 7 2 Service Manual 24XX 200 Assembly 1 Covers ince ana Description 1 1 40X2912 Guide left paper 2 40X2992 Cover assembly front unit 2480 2490 2 40X2993 Cover assembly front unit 2481 2491 3 40X2913 Guide right paper 4 40X3013 Ribbon access cover unit 2480 4 40X3014 Ribbon access cover unit 2481 4 40X3025 Ribbon access cover unit 2490 4 40X3026 Ribbon access cover unit 2491 5 40X2990 Cover top 2480 2490 5 40X2991 Cover top 2481 2491 6 40X2911 Cover rear 2481 2491 7 40X0297 Power cord U S AFE LV Canada Central and South America Mexico Saudi Arabia LV 7 40X0271 Power cord Malaysia Singapore United Kingdom 7 40X3141 Power cord Austria Belgium Brazil Germany Greece Finland France Indonesia Luxembourg Portugal Norway Saudi Arabia HV Spain Sweden Netherlands Turkey 7 40X0294 Power cord Denmark 7 40X0287 Power cord Chile Italy 7 40X0275 Power cord Israel 7 40X0276 Power cord South Africa 7 40X0274 Power cord Switzerland 7 40X0296 Power cord Australia New Zealand 7 40X1766 Power cord Peru Part
84. recaucions si per treballar amb l equip l heu de connectar em n e EARE sop spo SY 24 Bo 09 s pas oy GEM esp aq egg Age y SHE SRANJA ers ep rq EAEAP PA 24 SYNE me AHA gj gos AAS YO ma ep WATE gut 4 GALIN e ENE SNS TL SHR BS PIA S33 g WU N ASUS U se MHA EAE 0 Ag SKE EE Sx gs spes spa FY 24 E YSU YA DIV RY SELE AGS que 4a mop BAS 2411 EYE 189 SAY Ha UY X Service Manual 24XX 200 ASP d RO zs E LA ROR ZT HS SE T fili JI 18 H ASP in ERE 2 am AIMA RR UE AE CIA IT XS AN e TE T 2577 RES fri ES RS A RISE ST SEA Mt HEN ZERERA Da SEG f TE EE Te MIR AE A RTI RD IT Br TA RUBE MP TE o Mic VER BUCS MY AS Re LSE TE e WEF R VETE TH WIP im De TSL A TE RU CIE in HU FLORE A EST m UH FR EE SES JM xi 24XX 200 Preface This manual contains maintenance procedures for service personnel It is divided into the following chapters 1 General information contains a general description of the MFP and the maintenance approach used to repair it Special tools and test equipment are listed as well as general environmental and safety instructions Diagnostic information contains an error indicator table symptom tables and service checks used to isolate failing field replaceable units FRUs
85. ressing FormFeed 3 Paper Select lever Be 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 Diagnostic information 2 23 24XX 200 FRU symptom Action 4 Operator panel If paper does not move at all verify that the Load Unload button is working as follows With the tractor in the push position turn the power off and then back on and then press Load Unload The carrier should move to the center of the platen If it does not go to Operator panel service check on page 2 21 5 Paper feed motor Disconnect the paper feed motor cable CN1 from the logic board No pin should have continuity to ground The resistance should be between 8 to 9 ohms between CN10 1 and CN10 5 CN10 2 and CN10 5 CN10 3 and CN10 5 CN10 4 and CN10 5 6 Paper Select sensor Remove all paper from the printer and place the tractor in the push position Press FormFeed and time how long the gear train rotates With the Paper Select lever in the cut sheet
86. s catalog 7 3 24XX 200 Assembly 1 cont Covers 7 4 Service Manual 24XX 200 Assembly 1 cont Covers Asm Part Index number 1 8 40X3005 Cover bottom 2480 2490 8 40X3006 Cover bottom 2481 2491 9 40X3002 Tractor unit 2480 2490 9 40X3003 Tractor unit 2481 2491 9A 40X2917 Frame right side tractor 9B 40X2918 Tractors left and right 9C 40X2905 Support tractor paper 9D 40X3000 Shaft set tractor 2480 2490 9D 40X3001 Shaft set tractor 2481 2491 9E 40X2916 Frame left side tractor 10 40X2962 Operator panel assembly 248X 10 40X2963 Operator panel assembly 249X 11 40X2914 Cable operator panel 12 40X2994 Cover front guide 2480 2490 12 40X2995 Cover front guide 2481 2491 NS 40X2897 Cover operator panel front with overlay packs NS 40X2996 Overlay pack operator panel 248X NS 40X2997 Overlay pack operator panel 249X NS 40X2937 Stand paper Description Parts catalog 7 5 24XX 200 Assembly 2 Carrier paper feed right side 7 6 Service Manual 24XX 200 Assembly 2 Carrier paper feed right side Asm Part Index number 2 1 40X2887 Carrier roller set 40X2998 Printhead assembly 2480 2481 40X2999 Printhead assembly 2490 2491 40X2948 Carrier unit 2480 40X2949 Carrier unit 2481 40X2950 Carrier unit 2490 40X2951 Carrier unit 2491 40X2952 Cable printhead 2480 40X2953 C
87. tinue 1 2 Service Manual 24XX 200 Setup menu options Menu Function Forms Macro options Customize macros to print a variety of forms Data options Define how information is processed Control options Define how the printer performs basic tasks Emulation options Determine how the printer interacts with software applications Interface options Define how information is transferred from a computer to the printer Interface menu options Menu Function Interface Automatically select the printer interface Use the parallel cable Use the USB cable Use the serial cable only appears if optional serial adapter is installed Honor init Enable honors the init signal on the parallel port Disable ignores the init signal on the parallel port Data speed 300 bps 600 bps 1200 bps 2400 bps 4800 bps 9600 bps 19200 bps Data bits 7 8 Parity No Ignore Odd Even Stop bits 1 2 Protocol XON XOFF MultiXON XOFF DTR Pacing General information 1 3 24XX 200 Printer settings Setting the tear off position When Auto Tear Off is on or set to One Second it moves the top perforation of a continuous form to the tear off position when all of the following are true The printer has finished printing The paper has advanced to the Top of form on the next page No data printer control codes or escape codes have been sent t
88. to measure to a known good ground using the lowest ohms scale and check for zero ohms WARNING 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 Diagnostic information 2 1 24XX 200 circuit will read infinity A circuit with correct continuity will read zero ohms 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 5 LED Status Alarm Action Power ON None POST Ready ON RAM ROM Controller Error Tractor 2 ON Paper Out ON Go to POST service check on Panel Lock ON page 2 27 Font Lock ON Power ON None Switch Scan Test Error Ready Blinking Paper Out Blinking Panel Lock Blinking Go to Operator panel service check on page 2 21 Power ON None NVRAM Read Write Error Ready Blinking Paper Out Blinking Font Lock Blinking Turn the printer off and then back on If you get the same error during power up replace the logic board and readjust the bidirectional print adjustment Go to Bidirectional print adjustment on
89. together while pulling the printhead up and out of the printer Disconnect the printhead cable s from the printhead Reassembly Note Be sure the printhead cables are correctly aligned and secured Be sure to perform the printhead to platen Gap adjustment Go to Printhead to platen gap adjustment on page 4 2 Printhead cables removal WARNING Be careful not to damage the printhead cable s as they are secured with double sided adhesive tape b 3 4 Remove the top cover Go to Covers top removal on page 4 8 Remove the printhead Go to Printhead removal on page 4 25 Release the printhead cables from the flexible cable holders Disconnect the printhead cables from the logic board Note Be sure the printhead cables are correctly aligned and secured They must be flat with no twists Repair information 4 25 24XX 200 Print unit removal 1 Remove the top cover Go to Covers top removal on page 4 8 2 Disconnect all cables from the logic board except the power supply cable 3 Remove the screw from the Forms Thickness lever and then remove the lever 4 Remove the two grommet anchored screws A from the left side of the print unit Pa 4 26 Service Manual 24XX 200 5 Remove the two grommet anchored screws B from the right side of the print unit 6 Remove the print unit from the bottom cover by pulling up forcefully on both sides of the print unit Repai
90. ween pins CN5 1 and CN5 4 CN5 1 and CN5 6 CN5 2 and CN5 3 CN5 2 and CN5 5 If the motor is good replace the board cable assembly For information on the Tractor 2 cable connectors see Tractor 2 cable connectors on page 5 27 Diagnostic information 2 35 24XX 200 3 beeps and Tractor 2 LED blinks 3 times Tractor 2 is selected from the operator panel but the 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 cable connection assembly 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 be 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 when it is closed Replace the Tractor 2 board cable assembly if the sensor signal is wrong For information on the Tractor 2 cable connectors see Tractor 2 cable connectors on page 5 27 2 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 logic board 2 36 Service Manual 24XX 200 Tractor 2 paper feed problems FRU Action 1 Tractor 2 B
91. xx printers have a Padlock LED to indicate that the operator panel is locked To lock or unlock the operator panel turn the printer off and while holding the Load Unload and Tractor buttons turn the printer on FRU Action 1 Operator panel cable Disconnect the operator panel cable from the operator panel and the logic board and verify the continuity of the operator panel cable Connect the operator panel to the logic board and be sure 5 V dc is present at connectors CN13 1 and CN13 3 Replace the operator panel cable or the power cable as necessary 2 Operator panel If the problem remains replace the operator panel Diagnostic information 2 21 24XX 200 Paper Present sensor service check FRU Action 1 Paper Present sensor With no paper in the printer the tractor in the push position and the Paper Select lever set to continuous forms press Load Unload the gear train should turn forward to load paper Activate the Paper Present sensor with a screwdriver and press Load Unload again the gear train should turn backward to park paper Measure the voltage between CN5 2 paper present signal and CN5 3 GND on the 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 Be sure the Paper Present sensor and its actuator are properly installed and not damaged e If the problem remains replace t
92. y 9w amp 24w Switch Connector Pin Signal 1 440 V dc 2 40 V dc CN1 3 Power Gnd 4 Power Gnd 5 Signal Gnd 6 5 V dc 7 Power Save Mode Connector Signal F1 Fuse 5 2 Service Manual 24XX 200 Logic board 9w amp 24w z 00YNO oz LNO CNO L 6L L L yNO 9N9 600 NO BNO es sss 29ND 01 EE 19 LOZN e FEM ba ENS L LENS A E JUL T LL preog aM 6 gt M ve Locations and connectors 5 3 24XX 200 Connector Signal F1 Fuse Connector Pin Signal 1 40 V dc 2 40 V dc 3 Power Gnd CN1 a 4 Povver Gnd 5 Signal Gnd 6 5 V dc 7 Power Save Mode Connector Signal F1 Fuse 5 4 Service Manual 24XX 200 Logic board Parallel interface cable 9w amp 24w Connector Pin Signal Pin Signal 1 Strobe 19 Signal Gnd 2 Data 0 20 Signal Gnd 3 Data 1 21 Signal Gnd 4 Data 2 22 Signal Gnd 5 Data 3 23 Signal Gnd 6 Data 4 24 Signal Gnd 7 D

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