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Oki 2400 Printer User Manual

1. Diagnostic Information 2 19 24xx FRU Symptom Action 4 If the prior suggestions have not corrected the problem The following may cause undefined or intermittent failures 1 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 2 Electrical noise Check the following Power supply ground Printer frame ground Printer interface cable is grounded or shielded 3 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 1 Turn the printer off 2 Press and hold Tractor and turn the printer on 3 Have the user print the failing job 4 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 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
2. 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 Informa es de Seguran a e Este produto foi concebido testado e aprovado para satisfazer os padr es globais de seguran a na utiliza o de componentes espec ficos da Lexmark As fun es de seguran a de alguns dos componentes podem n o ser sempre bvias A Lexmark n o respons vel pela utiliza o de outros componentes de substitui o As informa es de seguran a relativas a este produto destinam se a profissionais destes servi os e n o devem ser utilizadas por outras pessoas e 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 24xx Informacio de Seguretat Aquest producte est dissenyat comprovat i aprovat per tal d acomplir les estrictes normes de seguretat globals amb la utililitzaci de components espec fics de Lexmark Les caracter stiques de seguretat d algunes peces pot ser que no sempre siguin bvies Lexmark no es responsabilitza de l us d altres peces de recanvi e La informaci pel manteniment d aquest producte esta orientada exclusivament a professionals i no est destinada a ning que no ho sigui Elrisc de xoc el ctric i de danys personals pot augmentar dura
3. l YNO ooo L E E amp 6NO L LLNO 1 preog aM 6 ROS SUN M ve Connector Locations 5 5 24xx Logic Board Serial Board 9w amp 24w Connector Pin Signal 5 V dc 5 V dc CTS CN200 DTS RXD RTS DSR TXD 0 J oO a AJ OJN Signal Gnd A SBSET Connector Pin Signal CN1 A 5 V dc 5 V dc CTS DTS RXD RTS DSR TXD oo BND Signal Gnd SBSET 5 6 Service Manual 24xx Logic Board 9 amp 24w z 00YNO oz LNO ZNO 1 Sr L L L 9NO 6 002NO anai UNO oz EE io LOZ AA LENO 1 preog aM 6 9JIM ve Connector Locations 5 7 24xx Logic Board USB Cable 9w amp 24w Connector Pin Signal 1 5 V dc CN201 2 DMNS 3 DPLS 4 Signal Gnd Logic Board DC Power 9w amp 24w Connector Pin Signal CN12 1 40 V dc 40 V
4. 2 Pull Tractor Sensor A failed pull tractor sensor can cause Load Unload 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 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 31 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 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 on If you get the same error during power up verify the code module on the logic board is correctly installed 3 Logic Board Replace the logic board if necessary and reset Bidirectional Print Adjustment on page 4 4 2 26 Service Manual 24xx Power Service Check FRU Action 1 Power Supply If the carrier does not move to the left after turning the printer off and then 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
5. Bidirectional Print Adjustment on page 4 4 2 Interface Cable 3 Emulation Mode Check the connection and continuity of the interface cable 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 24xx 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 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 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
6. Check the internal fuse before replacing the power supply Generally if F1 is blown it is due to a short in the printhead replace the printhead and the fuse before powering on again Be sure the power supply cable from the power supply to the logic board is not damaged and correctly installed 2 Operator Panel If there is still a power LED problem check the Operator Panel operator panel cable continuity and replace the Cable cable or the operator panel 3 Carrier Motor Disconnect the carrier motor from logic board CN and turn the printer off and then 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 on If the power LED lights correctly only with the paper feed motor disconnected replace the paper feed motor 5 Printhead Disconnect the printhead cable from the logic Printhead Cables 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 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 Diagnostic Information 2 27 24xx FRU Action 6 Logic Board If no problem is found with the other components but the
7. Types of self tests are e Power On Self Test POST 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 Results LineFeed Prints print test with sample fonts Tractor Sets printer in Hex Trace mode Load Unload amp Tractor Disables Enables Operator Panel Lockout Mode Tearoff amp 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 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 then all LEDs turn on for a few seconds RAM Test Checks that the CPU can write read the RAM Font ROM Microcode Sum Test Checks that the ROM data is correct Timer Interrupt Controller Test Checks that this function works NVRAM Test Checks that the NVRAM data is correct Switch Scan Test Checks the buttons on operator panel Carrier Initialization Carrier moves to the left to activate the home position sensor then moves to the first print position Feed Initialization Form feed motor rotates forward and t
8. Continuous Forms 3 6 Repair Information seil p Rx ERR AG eee 4 1 Handling ESD Sansitive Pans sean 1 STO 4 2 Printhead to Platen Gap Adjustment Bidirectional Print 4 4 Removal s Rae aca naa a 4 5 Covers Renmiovale Covers Front Removal 4 6 Covers Ribbon Access Removal 4 4 4 6 Covers Option Removal 2422222 4 7 Covers Tap Removal asus saca ice Covers Operator Panel Assembly Removal 4 11 Covers Bottom Removal 4 12 Electronics Removals randa aad EPROM Remgvgl ax aa gx ac aco hd Logic Board Removal se assassin 4 14 D ONT URES Carrier Removals chee Carrier Removal een a ui Carrier Motor Assembly Removal M 4 21 Paper Handling 4 24 Paper Select Lever Removal Paper Feed Motor Removal 4 24 Form Thickness Lever 4 25 4 26 Platen Removal 2 ese a s Printhead Removal iussu sunk x ck o c c SEE Printhead Cables Removal M 4 27 Prnt Unt Removal
9. Covers Top Removal on page 4 8 2 Remove the two screws A from the paper feed motor bracket g NO 3 Remove the motor 4 Disconnect the paper feed motor cable from the logic board 4 24 Service Manual 24xx Form 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 remove the form thickness lever Repair Information 4 25 24xx 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 26 Service Manual 24xx Printhead Removal 1 Turn the printer off Disconnect the power cord at the printer and allow the printhead to cool for 15 minutes prior to handling Set the form thickness lever to position 7 Remove the ribbon access cover Go to Covers Ribbon Access Removal on page 4 6 5 Remove the ribbon cartridge 6 Squeeze the printhead latches together while pulling the 7 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 t
10. exists between the printhead 3 and the platen 10 After adjusting both left and right gap adjust bushings push the printhead to the center of the platen and verify a gap of within 0 33 and 0 37 mm exists between the printhead and the platen Repair Information 4 3 24xx 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 11 After confirming the head gap is within the specified range for all left right and center printhead positions 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 Through the Setup Menu be sure the Default Macro is set to Disabled 2 Turn the printer off 3 Open the operator panel cover to access layer two 4 Press and hold the Pitch key while turning the printer on 10 11 The draft 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 MicroT
11. 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 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 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 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 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 select lever down to the continuous f
12. front hinge points on either side of the ribbon access cover first and lower the cover into place Be sure that both gray spring loaded ribbon access cover latches snap and lock 4 6 Service Manual 24xx 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 Covers Top Removal 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 8 Turn the printer upside down 9 Insert a flat blade screwdriver into each of the four holes A in the bottom cover releasing the top cover from the bottom cover Repair Information 4 9 24xx 10 Turn the printer right side up and insert a flat blade screwdriver into each of the two holes A in the back o
13. 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 Information 2 17 24xx Intermittent Problem Service Check FRU Symptom Action 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 10 CN12 2 40 V dc 10 CN12 3 GND CN12 4 GND CN12 5 Signal GND CN1
14. 00YNO oz LNO ZNO L 6L L L L 9NO g 002NO ER 29ND oz EE Vo LOZ AA LINO 1 preog aM 6 ROS SUN M ve Connector Locations 5 19 24xx 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 5 20 Service Manual 24xx Logic Board 9 amp 24w z 00YNO oz LNO ZNO 1 Sr L L L 9NO 6 002NO anai UNO oz EE io LOZ AA LENO 1 preog aM 6 9JIM ve Connector Locations 5 21 24xx Logic Board Operator Panel 9w amp 24w Connector Pin Signal CN13 Logic Board 5 V dc SLATCH 45 V dc TXD Signal Gnd RXD Signal Gnd SCLK c o NI oO ay RY
15. 2519 7 17 7 17 Index 5 24xx 6 Service Manual
16. Carrier Action 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 Printhead 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 If the bind is gone replace the carrier motor 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 FRU Action 3 Carrier Motor If the home position sensor is okay verify the
17. joint gear A Release the idler gear latch and remove the idler gear Release the pick up gear latch and remove the gear Release the combination lock mechanism latch 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 47 24xx 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 3 Remove the left and right roller bushings 4 Move the pick up rollers to the ends of the shaft and remove them 4 48 Service Manual 24xx 5 Connector Locations This chapter identifies the locations of specific parts of the printer Tension Paper Ribbon Ribbon Form Carrier Pulley Select Cartridge Drive Thickness Motor Plate Lever Rack Lever Assembly On Off Printhead Carrier Printhead Switch Cable s Code Tractor 2 Parallel Paper Feed Module Option Interface Motor Connector Connector Power Logic USB Serial Interface Supply Board Connector Cover Plate Connector Locations 5 1 24xx Signal Connections Power Supply 9w amp 24w Switch Connector Pin Signal 1 40 V 2 40 V CN1 3 Power Gnd 4 Power Gnd 5 S
18. power problem still remains replace the logic board and reset Bidirectional Print Adjustment on page 4 4 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 with the Macro button pressed 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 no continuity at forms thickness lever positions 4 through 7 2 28 Service Manual 24xx Printhead Service Check FRU Action 1 Printhead Cables Printhead If the printout contains missing or extra dots or lines do the following Ch
19. preog aM 6 ROS SUN M ve Connector Locations 5 15 24xx 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 CN 2 Signal Gnd Logic Board Paper Present Sensor 9w amp 24w Connector Pin Signal 1 PE1P CN5 2 PE1 3 Signal Gnd 5 16 Service Manual 24xx Logic Board 9 amp 24w z 00YNO oz LNO ZNO 1 Sr L L L 9NO e 002NO N9 oz EE io LOZ AA LENO 1 preog aM 6 9JIM ve Connector Locations 5 17 24xx Logic Board Paper Select Sensor 9w amp 24w Connector Pin Signal 1 TR FR CN8 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 5 18 Service Manual 24xx Logic Board 9 amp 24w z
20. 1 Speeds 1 1 Printer Default Settings 3 5 R Removals 4 5 ASF Gears 4 47 Pick up Roller Carrier 4 16 Carrier Motor Assembly 4 21 Covers Bottom 4 12 Front 4 6 Operator Panel Option 4 7 Ribbon Access 4 6 Top 4 8 4 28 4 48 4 11 2 Service Manual Covers Illustration 4 5 Electronics EPROM 4 13 Logic Board 4 14 Power Supply 4 15 Form Thickness Lever Gears Left Side 4 31 Right Side 4 34 Operator Panel 4 11 Paper Feed Motor 4 24 Paper Select Lever 4 24 Platen 4 26 Print Unit 4 28 Printhead 4 27 Printhead Cables 4 27 Ribbon Drive Rack Gear 4 30 Right Side Sub Frame 4 34 Rollers Lower Feed 4 41 Upper Feed 4 36 Upper Pinch 4 38 Sensors Head Gap 4 44 Home Position 4 46 Paper Present 4 45 Paper Present Flag 4 45 Paper Select 4 45 Pull Tractor 4 44 Top Of Form 4 44 Top Of Form Flag 4 45 Repair Information 4 1 4 25 24xx 5 Safety Information vii Tools 1 6 Service Checks 2 13 Abnormal Noise 2 13 V 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 25 POST 2 26 Power 2 27 Print Speed 2 28 Printhead 2 29 Printhead Continuity Tables 2 30 Pull Tractor Sensor 2 31 Top Of Forms 2 32 Tractor 2 2 33 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 Ent
21. 1 14 CN300 1 amp CN300 11 3 CN300 1 amp CN301 7 15 CN300 1 amp CN300 2 4 CN300 1 amp CN301 13 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 amp 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 2 30 Service Manual 24xx Pull Tractor Sensor Service Check The pull tractor sensor detects the tractor in the pull position and disables load unload and auto tear off A failed sensor may prevent load unload from functioning with the tractor in the push position FRU 1 Pull Tractor Sensor Action 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 necess
22. 12G3886 12G3887 12G3888 12G3889 12G3890 12G3891 Tu Js 7 7 7 7 pug 7 1 7 13 7 13 7 11 mi 7218 1 9 To 7 5 DS 7 8 7 01 7 5 7 5 7 5 7 5 7 3 7 3 7 15 7 15 7 3 7 3 7 3 7 3 7 3 7 3 7 2 7 5 7 3 7 3 7 5 7 5 7 8 TS 7 18 7 1 7515 7 7 iF 7 7 24xx 12G3892 12G3893 12G3894 12G3895 12G3896 12G3897 12G3898 12G3900 12G3901 12G3902 12G3903 12G3904 12G3905 12G3906 12G3907 12G3908 12G3909 12G3911 12G3912 12G3914 12G3915 12G3916 12G3918 12G3920 12G3921 12G3922 12G3923 12G3924 12G3926 12G3927 12G3928 12G3929 12G3930 12G3931 12G3932 12G3933 12G3934 12G3935 12G3936 12G3937 12G3938 12G3939 12G3940 12G3941 12G3942 12G3943 12G3944 3311 4 17 7 7 7 7 Te Te 7 7 7 7 7 7 4 7 i 4 18 7 15 565 1 Pu T 7 7 I 7515 7 17 7 11 7 17 7 17 4 17 ro 4 17 GAL 7 19 249 7 21 7 11 7 21 7 51 7 21 7 21 7 21 7 15 1 19 7 21 7 7 7 13 if ro 7 17 fll 7515 7 11 7 11 7 19 7511 Fel ff IA 4 4 7 17 12G3945 12G3946 12G3947 12G3948 12G3999 13A0296 13A0297 1333275 1339517 1339518 1339519 1339520 1339521 1339522 1339523 1339524 1339525 79F4757 79F4802 79 4830 79 4834 95F6885 95F6886 95F6887 95F6892 95F6893 95F6894 95F6896 95F6897 7 19 7 11 7 13 2 1 7511 7 5 7 22 7 82 1 17 7 3 7 3 7 3 7 3 7 3 7 3 7 3 7 11 7 8 7 11 TAr 7 17 7 17 17 r9 7 17 7 19 7517
23. 12G3888 Cable Printhead 2481 4 12G3891 Cable Printhead 2490 4 12G3890 Cable Printhead 2491 5 12G3942 Kit Pull Tractor Actuator 6 12G3896 Springs Parts Packet 7 12G3836 Kit ESD Ground 2490 2491 7 12G3887 Kit ESD Ground 2480 2481 8 12G3907 Screws Washers and Clips Parts Packet 9 12G3931 Kit Head Gap Adjustment 10 12G3884 Damper Frame Assembly 11 12G3905 Gears and Bushings Parts Packet 248 11 12G3906 Gears and Bushings Parts Packet 249 12 12G3834 Sub Frame Right Side 13 12G3898 Cam Release Slider and Sub Slider 14 11A3274 Gear Idler 2480 2481 14 11A3275 Gear Idler 2490 2491 15 12G3897 Lever Paper Select Lever 16 12G3819 Frame Right Side 17 12G3932 Holder Lower Pinch Roller Shaft Right 18 12G3949 Guide ASF DTR Right 19 12G3823 Roller Lower Feed 2480 2490 19 12G3822 Roller Lower Feed 2481 2491 20 12G3835 Roller Lower Pinch 2480 2490 20 12G3943 Roller Lower Pinch 2481 2491 21 12G3900 Shaft Carrier 2480 2490 21 12G3901 Shaft Carrier 2481 2491 Parts Catalog 7 7 24xx Assembly 2 Carrier Paper Feed Right Side 7 8 Service Manual 24xx Asm Part Index Number Description 2 22 12G3832 Roller Upper Feed 2480 2490 22 12G3833 Roller Upper Feed 2481 2491 Parts Catalog 7 9 24xx Assembly 3 Carrier Paper Feed Left Side 7 10 Servi
24. 2 6 5 V dc 5 CN12 7 Power Save Mode If 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 FRU Symptom Action 2 Printer power The cause of this problem may be that the sometimes turns power circuit is failing or the wiring is off 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 5 If one of the voltages is 0 go to Power Service Check on page 2 27 If the voltages are not 0 but are incorrect replace the power supply unit 3 Intermittently 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 end of life have the user replace the ribbon cartridge
25. 39517 Line Cord Peru Description 1 NO oOo 2 HP HP HR WD LD NNNNNN Parts Catalog 7 3 24xx Assembly 1 Covers 7 4 Service Manual 24xx Asm Part Index Number 1 8 12G3856 Cover Bottom 2480 2490 8 12G3857 Cover Bottom 2481 2491 9 12G3854 Tractor Unit 2480 2490 9 12G3855 Tractor Unit 2481 2491 9A 12G3850 Frame Right Side Tractor 9B 12G3853 Tractors Left and Right 9C 79F4830 Support Tractor Paper 9D 12G3851 Shaft Set Tractor 2480 2490 9D 12G3852 Shaft Set Tractor 2481 2491 9E 12G3849 Frame Left Side Tractor 10 12G3810 Operator Panel Assembly 248 10 12G3811 Operator Panel Assembly 249X 11 12G3883 Cable Operator Panel 12 12G3875 Cover Front Guide 2480 2490 12 12G3876 Cover Front Guide 2481 2491 NS 12G3999 Cover Operator Panel Front w Overlay Packs NS 12G3881 Overlay Pack Operator Panel 248 NS 12G3882 Overlay Pack Operator Panel 249 NS 12G3939 Stand Paper Description Parts Catalog 7 5 24xx Assembly 2 Carrier Paper Feed Right Side 7 6 Service Manual 24xx Asm Part Index Number Description 2 1 1263841 Carrier Roller Set 2 12G3894 Printhead Assembly 2480 2481 2 12G3895 Printhead Assembly 2490 2491 3 12G3838 Carrier Unit 2480 3 12G3837 Carrier Unit 2481 3 12G3840 Carrier Unit 2490 3 12G3839 Carrier Unit 2491 4 12G3889 Cable Printhead 2480 4
26. 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 out of the printer 6 Be sure to perform the Printhead to Platen Gap Adjustment procedure Go to Printhead to Platen Gap Adjustment on page 4 2 Repair Information 4 37 24xx 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 bracket 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 remove the paper feed motor and bracket from the printer 6 Slide the carrier to the left side of the printer 4 38 Service Manual 24xx 7 Unhook the spring clip A from the right end of the lower pinch roller shaft and push it off the gray slotted spring block B toward the back of the printer as shown 8 Slide the carrier to the right side of the printer Repair Information 4 39 24xx 9 Unhook the spring clip A from the left end of the lower pinch roller shaft and push it off the gray slotted spring block B toward the back of the printer as shown A B 10 Slide the carrier to the center of the printer 11 Slide the gray slotted spring blocks B on each end toward the cente
27. 4 28 Ribbon Drive Rack Gear Removal 4 30 Gears Removals 9 1 Left Side Gears Removal 4 31 iv Service Manual 24xx Preventive Maintenance 6 1 ua ac cst 6 1 uiia icd rios se 6 2 Reject slats Cll 6 3 Lubrication 6 4 Parts srs RIGEN E 7 1 How To Use This Parts Galalog 7 1 Assembly 7 2 Assembly 2 Carrier Paper Feed Right Side 7 6 Assembly 3 Carrier Paper Feed Left Side 7 10 Assembly 4 7 14 Assembly 5 ASF Roller 7 16 Assembly 6 ASF Side Frame Covers 7 18 Assembly 7 Tractor 2 7 20 7 22 lr a M 1 1 vi Service Manual 24xx Safety Information This product is designed tested and approved to meet strict global safety standards with the use of specific Lexmark components The safety features of some parts may not always be obvious Lexmark is not responsible for the use of other replacement parts The maintenance information for this product has been prepared for use by a professional service person and is not intended to be used by others There may be an increased risk of
28. 5 ASF Roller Support 7 16 Service Manual 24xx am NES Description 5 1 12G3814 Support ASF Cut Sheet W Guides 2480 2490 1 12G3908 Support ASF Cut Sheet W Guides 2481 2491 2 95F6886 Roller ASF Upper Feed 2480 2490 2 95F6896 Roller ASF Upper Feed 2481 2491 3 95F6887 Roller ASF Lower Feed 2480 2490 3 95F6897 Roller ASF Lower Feed 2481 2491 4 95F6885 Roller ASF Pick up Left and Right 2480 2490 4 1333275 Roller ASF Pick up Left and Right 2481 2491 5 12G3911 Hopper ASF Right 2480 2490 5 12G3893 Hopper ASF Right 2481 2491 6 12G3912 Support ASF Paper Right 7 12G3914 Support ASF Paper Center 2481 2491 8 12G3915 Support ASF Paper Left 9 12G3916 Hopper ASF Left 10 12G3933 Lever ASF Paper Load 11 12G3934 Link ASF Paper Load 12 12G3918 Cover ASF Left 13 95F6892 ASF Gears and Bushings Parts Packet 14 95F6893 ASF Springs Parts Packet 15 95F6894 ASF Screws Parts Packet 16 12G3944 Frame ASF Side Left Parts Catalog 7 17 24xx Assembly 6 ASF Side Frame Covers 7 18 Service Manual 24xx 6 1 95F6893 ASF Springs Parts Packet 2 95F6892 ASF Gears and Bushings Parts Packet 3 12G3920 Cover ASF Right 4 95F6894 ASF Screws Parts Packet 5 12G3921 Cover ASF TR2 Front 2480 2490 5 12G3930 Cover ASF TR2 Front 2481 2491 6 12G3945 Frame ASF Side Right NS 12G3939 Stand Paper Parts Catalog 7 19 24xx Assembly 7 Tractor 2 Op
29. Check on page 2 27 Power ON None Timer Error cored 2 Turn the printer off and then back Paper Out Blinking MUR DOSE 2 the logic 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 Blinking cable s can cause this error Go Font Lock Blinking to Printhead Service Check on page 2 29 Turn the printer off and then back on If you get the same error replace the logic board and readjust the Bidirectional Print Adjustment on 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 Diagnostic Information 2 3 24xx 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 27 Power ON None Operator Panel Failure POOR B Go to Operator Panel Service Panel Lock OFF Check on page 2 21 Font Lock OFF Any LED None Go to Operator Panel Service on and Check on page 2 21 Power LED off If the Power None Go to Power Service Check LED blinks on page 2 27 or changes intensity 2 4 Service Manual 24xx Sympto
30. 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 To check for a correct ground measure the voltage between the ground and a known good voltage source The voltage measurement must be the same as the source voltage to consider that the ground is correct Continuity measurements may be used to check grounds however be sure to measure to a known good ground using the lowest ohms scale and check for zero ohms CAUTION Always unplug the power cord before doing any continuity measurement Continuity Readings When measuring continuity be sure no back circuits affect the measurement If necessary unplug connectors to remove any back circuits Zero the ohm range on the lowest scale X1 An open circuit will read infinity A circuit with correct continuity will read zero ohms Diagnostic Information 2 1 24xx 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
31. NC Connector Locations 5 25 24xx 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 26 V de CN1 2 26 1 3 Frame GND CN1 4 Not used CN1 5 5 V de 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 5 26 Service Manual 24xx 6 Preventive Maintenance This chapter describes procedures for printer preventive maintenance Following these recommendations can help prevent problems and maintain optimum performance Lubrication Warning Petroleum based lubricants can attack polycarbonate parts causing premature failure Use only mineral oil based lubricants The following parts should be lubricated when replaced Oil felt carrier block Tractor unit Side frame left Side frame right Pinch roller lower Pinch roller spring left Pinch roller spring center Pinch roller spring right Paper separator Specified Lubricants Oil P N 1280443 Approved equivalents Mobil DTE27 Shell
32. 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 13 24xx 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 check the Bidirectional Print Adjustment after installing the logic board Go to Bidirectional Print Adjustment on page 4 4 4 14 Service Manual 24xx 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 on page 4 28 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 mu
33. SG Connector Pin Signal CN1 Operator Panel 5 V dc SLATCH 5 V dc TXD Signal Gnd RXD Signal Gnd SCLK 0 oOo oF AJ OJN SG 5 22 Service Manual 24xx Logic Board 9 amp 24w z 00YNO oz LNO ZNO L 6L L L L 9NO 6 002NO anai UNO oz EE io LOZ AA LENO 1 preog aM 6 9JIM ve Connector Locations 5 23 24xx Logic Board Dual Tractor Cable 9w amp 24w Connector Pin Signal CN10 40 V dc 40 V dc Power Gnd Power Gnd 45 V dc COCOM D SET Signal Gnd 0 J Do ay AJ OJN COA E a oa JAM D H P A wo D POS 5 24 Service Manual 24xx Serial Board Serial Cable 9 amp 24w OO OO CN2 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 21 10 NC 22 NC 11 NC 23 NC 12 NC 24 NC 25
34. Tellus 100 Fuchs Renolin MR30 Grease P N 6934659 Approved equivalent Mobil 28 Preventive Maintenance 6 1 24xx Lubrication Points Oil Oil Felt carrier block e Tractor Shaft Grease Side Frame Left and Gears Side Frame Right and ASF Gears e 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 Lubrication Points Oil The oil felt 1 in the carrier block The tractor shaft 1 Preventive Maintenance 6 3 24xx Lubrication Points Grease Gear mounting studs on the right side frame 2 6 4 Service Manual 24xx Lubrication Points Grease Continued Gear mounting studs on the left side frame 2 Preventive Maintenance 6 5 24xx Lubrication Points Grease Continued Gear mounting studs on the left ASF side frame 2 Gear mounting studs on the right ASF side frame 2 6 6 Service Manual 24xx 7 Parts Catalog How To Use This Parts Catalog SIMILAR ASSEMBLIES If two assemblies contain a majority of identical parts they are shown on the same list Common parts are shown by one index number Parts peculiar to one or the other of the assemblies are listed separately and identified by description NS Not Shown the Asm Index column indicates that the part i
35. Top Of Forms Service Check on page 2 32 Power Problems Symptom Action When the power switch is on the Power light does not turn on or the printer does not start The Power light blinks or changes intensity Check continuity of the power cord and the voltage of the user s outlet Go to Power Service Check on page 2 27 Diagnostic Information 2 9 24xx Print Quality Problems Symptom Action No print but carrier moves as if printing Adjust the form thickness lever to a lower number Be sure the printhead cables are not loose or damaged Be sure the interface cable is connected properly Check the ribbon cartridge for binds or damage Go to Print Speed Service Check on page 2 28 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 form thickness lever to position 1 and run the print test Go to Carrier Service Check on p
36. actor 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 and be sure the slider does not bind Verify When the slider is to the rear the white gear drives the tractors When the slider is to the front the gear and tractors are not connected 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 With the cover 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 Signal Connections on page 5 2 2 36 Service Manual 24xx 3 Diagnostic Aids The printer contains self tests to help find and solve problems You do not need to connect the printer to a computer or terminal to run these tests
37. ad 24w Connector Pin Signal 1 40 V 2 R15 3 40 V de 4 R21 5 40 V de 6 R23 7 40 V 8 L24 CN300 9 R13 10 L22 11 L14 12 L20 13 40 V de 14 L18 15 40 V de 16 L16 17 40 V 5 12 Service Manual 24xx Logic Board 9 amp 24w z 00YNO oz LNO ZNO L 6L L L L 9NO g 002NO ER 29ND oz EE Vo LOZ AA LINO 1 preog aM 6 ROS SUN M ve Connector Locations 5 13 24xx 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 5 14 Service Manual 24xx Logic Board 9 amp 24w z 00YNO oz LNO ZNO I ex L L L 9NO g 002NO ER 29ND oz EE Vo LOZ AA LINO 1
38. age 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 Ribbon Feed Problems Symptom Action Ribbon comes off Check the ribbon cartridge for binds or damage becomes loose or folded or jams Ribbon feeds correctly but is noisy Go to Carrier Service Check on page 2 16 Diagnostic Information 2 11 24xx 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 Paper Out blinks when paper does not exist printer Paper Out turns off when paper exists PRETO Go to Paper Present Sensor Service Check on page 2 22 Paper Select Sensor Action Check Turn the power off Load Unloa
39. aper 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 Micro7 or Micro to align with 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 Options The 24xx printers support the following options Auto 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 100 printers are Basic CE tool kit e 1 Phillips screwdriver 2 Phillips screwdriver Feeler gauges 0 33 mm 0 013 0 37 mm 0 015 in e Analog or digital volt ohmmeter Abbreviations 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 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
40. ark with diamond design are trademarks of Lexmark International Inc registered in the United States and or other countries Other trademarks are the property of their respective owners Copyright Lexmark International Inc 2000 All rights reserved UNITED STATES GOVERNMENT RESTRICTED RIGHTS This software and documentation are provided with RESTRICTED RIGHTS Use duplication or disclosure by the Government is subject to restrictions as set forth in subparagraph c 1 ii of the Rights in Technical Data and Computer Software clause at DFARS 252 227 7013 and in applicable FAR provisions Lexmark International Inc Lexington KY 40550 U S A P N 12G3662 24xx Table of Contents vii d o owe xii General Information 1 1 SHECIIGANONG 1 1 Gig 1 1 SHU MOO 1 2 Entering Setup MOUS uaa eius ama eaa ca doe don aca eas aie d 1 2 Exiting Setup 1 2 1 3 Intertace Menu ODUODE 1 3 Setting The Tear Off POST 1 4 Setting Top Of Form Continuous Pull Mode 1 5 Setting Top Of Form Cut Forms Envelopes 1 5 CUD e eas ege Ma E ce 1 6 Diagnostic Information 2 1 vrl e 2 1 Voltage Ground And Continuity Readings 2 1 Emor Indication Table Jussu ice
41. ary If the sensor is good but the paper still does not move correctly replace the logic board and reset the Bidirectional Print Adjustment on page 4 4 Diagnostic Information 2 31 24xx 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 on page 4 4 2 32 Service Manual 24xx Tractor 2 Service Check The Tractor 2 in place sensor opens during installation when its actuator touches the printer cover The home sensor detects the position of the slider When Tractor 2 is selected the motor driven Tractor 2 slider pushes the printer sub slider cam lever to engage the printer gear train which drives the Tractor 2 tractors When the Tractor 2 is deselected the motor retracts the slider disengages the Tractor 2 gear drive and
42. at 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 Gear Train 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 pressing FormFeed 3 Paper Selector 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 FRU Symptom Action 4 Operator Panel If paper does not move at all verify the Load Unload button is working as follows With the tractor in the push position power off power 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
43. ce Manual 24xx 3 1 12G3905 Gears and Bushings Parts Packet 248X 1 12G3906 Gears and Bushings Parts Packet 249X 2 12G3907 Screws Washers and Clips Parts Packet 3 12G3942 Kit Pull Tractor Actuator 4 12G3817 Frame Left Side 2480 2481 4 12G3818 Frame Left Side 2490 2491 5 12G3940 Sensor Pull Tractor 6 12G3922 Plate Frame Support 2480 2490 6 12G3844 Plate Frame Support 2481 2491 7 12G3935 Holder Lower Pinch Roller Shaft Left 8 12G3896 Springs Parts Packet 9 12G3941 Sensor Paper Select 10 12G3902 Holder Platen 11 12G3884 Damper Frame Assembly 12 12G3946 Sensor Head Gap 13 12G3821 Guide Paper Assembly 2480 2490 13 12G3820 Guide Paper Assembly 2481 2491 14 12G3826 Platen 2480 2490 14 12G3825 Platen 2481 2491 15 12G3948 Guide ASF DTR Left 16 12G3909 Sensor Top Of Form 17 12G3824 Sensor Paper Present 18 79F4802 Gear Ribbon Drive Rack 2480 2490 18 79F4834 Gear Ribbon Drive Rack 2481 2491 19 12G3831 Plate Tension Pulley Assembly 20 12G3937 Plate Carrier Assembly 2480 2490 20 12G3938 Plate Carrier Assembly 2481 2491 21 12G3828 Separator Paper 2480 2490 21 12G3827 Separator Paper 2481 2491 22 12G3846 Motor Carrier 23 12G3892 Bracket Carrier Motor 24 12G3845 Sensor Home Position Parts Catalog 7 11 24xx Assembly 3 Carrier Paper Feed Left Side 7 12 Serv
44. d 5 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 26 2 34 Service Manual 24xx 3 Beeps and Tractor 2 LED blinks 3 times Tractor 2 selected from operator panel but printer does not detect Tractor 2 or detects that the Tractor 2 mechanism is not installed FRU Action 1 Tractor 2 Check the Tractor 2 in place sensor or the Board Cable Asm cable connection The in place sensor actuator extends through the Tractor 2 cover and rests on the printer cover when Tractor 2 is installed Remove the Tractor 2 cover and 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 with it 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 26 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 Diagnostic Information 2 35 24xx Tractor 2 Paper Feed Problems FRU Action 1 Tractor 2 Be sure the gear on the printer that drives Tr
45. d function correctly Install the Push Go to Paper Select Sensor Service Check on Tractor page 2 25 Set the paper select lever to the tractor position and load continuous forms Turn the power on Remove the When Auto Ready Cut Sheet is enabled paper continuous forms feeds automatically Set the paper select When Auto Ready Cut Sheet is disabled press lever to the cut sheet FormFeed to load a cut sheet position and insert a Verify Load Unload does not function cut sneer Go to Paper Select Sensor Service Check on page 2 25 2 12 Service Manual 24xx 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 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
46. d ox kei RR 2 2 Symon 2 5 Irrecoverable Operator Errors 2 12 CHECKS 2 13 Abnormal Noise Service 2 13 Auto Sheet Feeder ASF Service Check 2 14 Camer Serice Che0k s cate 2 16 Intermittent Problem Service Check 2 18 No Print or Abnormal Print Service 2 21 Operator Panel Service 2 21 Paper Present Sensor Service 2 22 Paper Feed Service Check 2 23 Paper Select Sensor Service 2 25 POST 2 26 Power Service CBOK xd bed 2 27 Print Speed Service Check 2 28 Printhead 2 29 Pull Tractor Sensor Service Check 2 31 Top OFForms Service Check 2 32 Tractor eV a sa cx quo ERR xe ad pud d e gui e E 2 33 24xx Diagnosi 3 1 Power On Self Test POST de EN Hex Trace Mod Rm x C REPROCA CR RC 3 4 Printer Settings IS World Trade Delaulls wea 3 5 vacas decina 3 6 Lut 1 Jai Sac ioco ravi d da
47. dc Power Gnd Power Gnd Signal Gnd 5 V dc 2 3 4 5 6 7 Power Save Mode 5 8 Service Manual 24xx Logic Board 9 amp 24w LNO ZNO 9NO OLNO Pee z 00YNO oz 6L l YNO ooo L E E amp 6NO L LLNO 1 preog aM 6 ROS SUN M ve Connector Locations 5 9 24xx Logic Board Printhead 9w Connector Pin Signal 1 H4 2 H6C 3 H8C 4 5 H6 6 H2C 7 H4C 8 H8 CN400 9 H2 10 H9 11 HDTHERMO 12 5 V dc 13 H1 14 H9C 15 H3 16 H7C 17 H5 18 H3C 19 H7 20 HSC 5 10 Service Manual 24xx Logic Board 9 amp 24w z 00YNO oz LNO ZNO I ex L L L 9NO g 002NO ER 29ND oz EE Vo LOZ AA LINO 1 preog aM 6 ROS SUN M ve Connector Locations 5 11 24xx Logic Board Printhe
48. e Lexmark Forms Printer 2400 Series 24XX 100 Service Manual e Table of Contents e Start Diagnostics e Safety and Notices e Trademarks Index LEXMARK 24xx Edition November 2000 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 You can purchase additional copies of publications related to this product by calling 1 800 553 9727 In other countries contact your point of purchase Lexmark and Lexm
49. eck the continuity and connection of the printhead cables and the short flexible cable 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 30 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 Diagnostic Information 2 29 24xx Printhead Impedance Tables 2480 2490 Approximately 5 ohms Dot Connector i 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 o N aj A wT N CN400 10 amp CN400 14 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 1
50. electric shock and personal injury during disassembly and servicing of this product Professional service personnel should understand this and take necessary precautions Consignes de S curit Ce produit a t concu test et approuv pour respecter les normes strictes de s curit globale lors de l utilisation de composants Lexmark sp cifiques Les caract ristiques de s curit de certains l ments ne sont pas toujours videntes Lexmark ne peut tre tenu responsable de l utilisation d autres pi ces de rechange 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 vii 24xx Norme di sicurezza prodotto stato progettato testato e approvato conformit severi standard di sicurezza e per l utilizzo con componenti Lexmark specifici Le caratteristiche di sicurezza di alcune parti non sempre sono di immediata comprensione Lexmark non responsabile per l utilizzo di parti di ricambio di altri produttori Le informazioni riguardanti la manutenzione di questo prodotto sono indirizzate soltanto al personale di assistenza autorizzato Durante lo smontaggio e la manutenzione di questo prodotto il rischio di subire scosse elettriche e danni alla pe
51. ensor from the platen Go to Sensors Removals on page 4 43 4 44 Service Manual 24xx 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 28 Turn the print unit upside down Remove the 4 small screws securing the paper select sensor to the left side frame Go to Sensors Removals on page 4 43 Sensor Paper Present 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 28 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 43 Flags Paper Present Top Of Form Removal 1 Remove the lower feed roller Go to Roller Lower Feed Removal on page 4 41 2 Remove the paper present flag or the top of form flag from the paper guide Go to Sensors Removals on page 4 43 Repair Information 4 45 24xx 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 3 Unsnap the home position sensor A from the frame 4 46 Service Manual 24xx Options Removals Auto Sheet Feeder Gears Removal 1 Remove the right cover 2 Release the joint gear latch A and remove the
52. er 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 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 Load Unload This button should not work f paper loads go to Paper Select Sensor Service Check on page 2 25 2 Paper Feed If the paper does not feed do the following Remove the ASF Be sure the base printer feeds paper correctly If the base printer does not feed paper correctly go to Paper Feed Service Check on page 2 23 3 Gear Train 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 Ea 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 Carrier Service Check Note The Carrier Service Check includes the carrier drive home position sensor and ribbon feed FRU 1
53. ering 1 2 Exiting 1 2 Signal Connections 5 2 Specific Printer Parts 5 1 Specifications 1 1 Start 2 1 Symptom Checks 2 5 Abnormal Indications 2 5 Abnormal Noise Problems 2 5 Abnormal Print Problems 2 6 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 Ribbon Feed Problems 2 11 Voltage Ground and Continuity 2 1 Index 1 3 24xx Part Numbers 11A3274 11A3275 11A3283 11A3284 11A3335 11A3336 11A3337 11A3338 11A3341 11A6109 12G3704 12G3705 12G3709 12G3800 12G3801 12G3802 12G3803 12G3804 12G3805 12G3806 12G3807 12G3808 12G3809 12G3810 12G3811 12G3812 12G3813 12G3814 12G3817 12G3818 12G3819 12G3820 12G3821 12G3822 12G3823 12G3824 12G3825 12G3826 12G3827 12G3828 12G3831 12G3832 12G3833 12G3834 12G3835 4 Service Manual 7 4 1 13 Tet TS 7 21 2 21 7 21 7 21 fel 7 21 7 21 7 22 eee 4 22 2 22 Falls 7 18 7 15 7 18 1518 7 18 1 18 4 15 1515 TAS 7 0 ee 7 18 TAS 7 17 7 11 7 11 7 7 7 11 7517 7 11 7 9 7 9 27 727 1263836 1203837 1263838 1263839 1203840 1263841 1203842 1263843 1203844 12093845 1203846 1203848 12093849 1263850 1263851 12613852 1263853 1203854 1263855 1263856 1203857 1263858 1263859 1263860 1263861 1263868 1263869 1263870 1263871 12093872 1263873 1203874 1293875 12093876 1203877 1203878 1263881 12G3882 12G3883 12G3884 12G3885
54. f the top cover 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 4 10 Service Manual 24xx 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 4 While holding the latches down push the operator panel out of the top cover toward the bottom of the cover Note Be sure the operator panel cable is correctly inserted during replacement into both the operator panel card and the logic board Repair Information 4 11 24xx 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 14 3 Remove the power supply unit Go to Power Supply Removal on page 4 15 4 Remove the print unit Go to Print Unit Removal on page 4 28 4 12 Service Manual 24xx Electronics Removals EPROM Removal 1 Remove the options cover A by pulling it outward up and out of the printer A 2
55. 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 20 00 40 00 20 DO 20 80 EO 20 91 00 en At 200020 Bi en eo 20 62 20 20 72 20 0A 23 ev 20 33 20 eu 43 29 03 20 et 20 80 20 94 20 A4 20 20 R4 65 20 20 65 80 75 g9 OA OA 26 36 CO 20 C 20 20 06 20 20 ES 20 ey eo 97 go 20 eo 20 20 58 20 20 68 20 en 78 00 VA OA 29 20 20 39 29 C9 20 20 09 20 20 EF 20 20 94 20 20 AA eO 00 00 58 20 20 280 80 oA DA eC eo 20 3C 09 20 CC 20 DC 20 en cy 8D 20 20 9D 20 eo AD GE 20 20 SE 20 6E 20 eD FE OD OA DA eo 20 80 CF 20 29 DF 29 AD 20 20 BD 20 20 eo 20 80 71 20 20 81 20 29 20 3e 20 eo ae 20 eo se 20 O0 20 F2 00 0A 20 20 20 20 C3 64 20 20 74 20 20 84 20 20 80 35 20 45 05 20 80 ES 80 80 FS 00 00 20 Ab 20 2D BE 20 20 67 20 20 77 20 80 87 28 38 20 48 ev 20 08 20 eo F8 99 20 80 9 20 B9 20 29 20 80 7A 80 20 OR 2B 20 eo 3B 20 4B 3 20 DB 20 20 20 20 20 9C 20 eo eo eo BC 50 20 20 60 20 20 70 20 OA OE 20 80 20 20 20 20 DE 20 20 EE 20 9F eo 20 20 eo 3 4 Service Manual 24xx Printer Default Settings U S Defaults To initialize or reset the printer to the U S
56. formation 2 7 24xx Symptom Action Load Unload does not function when the push tractor is installed Form feed length is not correct Load Unload functions with cut sheets in use Be sure the paper select lever is in the correct position Go to Paper Select Sensor Service Check on page 2 25 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 25 Load Unload functions when the pull tractor is installed With Paper Out blinking FormFeed 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 31 2 8 Service Manual 24xx Symptom Action Lower feed roll shaft rotates but paper does not feed Pressing FormFeed does not feed paper Abnormal noise created while feeding Paper jams skews or creases Incorrect or no line spacing wider narrower or overlapping lines Push Pull Tractor does not work Be sure the paper select lever is in the correct position Go to Paper Feed Service Check on page 2 23 Incorrect Top of Form positioning Go to
57. ge 2 28 Auto Sheet Feeder Problems Symptom Action Auto sheet feeder Be sure Sheet Feed is enabled in the Setup Mode winot EER paper Be sure the paper select lever is in the cut sheet Auto sheet feeder position COUDE feeds Go to Auto Sheet Feeder ASF Service Auto sheet feeder Check on page 2 14 has intermittent feed problems 2 6 Service Manual 24xx Error Indications Symptom Action Ready and Paper Out lights blink Turn the printer off and then on Go to Abnormal Indications on page 2 5 Paper Out and Font lights blink page 2 12 Turn the printer off and then on Go to Irrecoverable Operator Errors on Operator Panel Problems Symptom Turn the printer off and then on Start Stop does not function but no error is indicated Only the Power light turns on One or more buttons do not function One or more lights do not function Paper Feed Problems Action Go to Operator Panel Service Check on page 2 21 Symptom Action Paper Out is Go to Paper Present Sensor Service Check blinking with paper in on page 2 22 the printer Paper Out does not blink when no paper is in the printer and ASF is not installed Print operation starts without paper Be sure the paper present sensor is not blocked Go to Paper Present Sensor Service Check on page 2 22 Diagnostic In
58. gone look for the problem in the paper feed mechanism Diagnostic Information 2 13 24xx 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 cut sheet The Auto Sheet Feeder must be selected in the Setup menu Continuous forms can be used with the ASF installed by moving the paper select lever to continuous forms and pressing Start 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 of the ASF and the lower feed rollers of the printer Although the ASF pick
59. h 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 1 Paper Select Sensor Action Remove all paper from the printer and do the following Place the tractor in the push position and be sure the Auto Sheet Feed 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 actuating the paper select lever If the resistance is incorrect replace the logic board and reset the Bidirectional Print Adjustment on page 4 4 Diagnostic Information 2 25 24xx FRU Action
60. hen 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 Print Test The print test helps you test and troubleshoot the printer To start the print test 1 2 3 4 5 Paper must be at the print position test does not print if paper is parked Press and hold Line Feed and turn the printer on Release Line Feed when the printing starts 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 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 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 Start your application program Be sure the printout is similar to the hex trace sample shown Two hexadecimal digits
61. ice Manual 24xx Asm Part Index Number Description 3 25 12G3931 Kit Head Gap Adjustment 26 12G3947 Lever Form Thickness 27 12G3842 Motor Paper Feed 28 12G3843 Bracket Paper Feed Motor Assembly 29 11A3274 Gear Idle 248 29 11A3275 Gear Idle 249 Parts Catalog 7 13 24xx Assembly 4 Electronics 7 14 Service Manual 24xx meres ipart Description Index Number 4 1 12G3907 Screws Washers and Clips Parts Packet 2 12G3836 Kit ESD Ground 2490 2491 2 12G3887 Kit ESD Ground 2480 2481 3 12G3801 Power Supply Unit LV 3 12G3800 Power Supply Unit HV 4 12G3812 Module EPROM 248 4 12G3813 Module EPROM 249 4 12G3848 Module EPROM Okidata MICROLINE 5 12G3802 Board Logic W O EPROM 2480 LV 5 12G3806 Board Logic W O EPROM 2480 HV 5 12G3803 Board Logic W O EPROM 2481 LV 5 12G3807 Board Logic W O EPROM 2481 HV 5 12G3804 Board Logic W O EPROM 2490 LV 5 12G3808 Board Logic W O EPROM 2490 HV 5 12G3805 Board Logic W O EPROM 2491 LV 5 12G3809 Board Logic W O EPROM 2491 HV 6 12G3886 Bracket Serial Interface Card 7 12G3885 Plate Serial Interface Card 8 12G3861 Cable Power Supply 2480 2490 8 12G3860 Cable Power Supply 2481 2491 NS 1203903 Kit Fuse LV NS 12G3904 Kit Fuse HV NS 12G3929 Card Serial Interface Card with Plate NS 12G3936 Cable Serial Interface Cable Parts Catalog 7 15 24xx Assembly
62. ignal Gnd 6 5 V dc 7 Power Save Mode Connector Signal F1 Fuse 5 2 Service Manual 24xx Logic Board 9 amp 24w LNO ZNO 9NO OLNO Pee z 00YNO oz 6L l YNO ooo L E E amp 6NO L LLNO 1 preog aM 6 ROS SUN M ve Connector Locations 5 3 24xx Logic Board Parallel Interface Cable 9 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 Data 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 5 V dc 36 SELIN 5 4 Service Manual 24xx Logic Board 9 amp 24w LNO ZNO 9NO OLNO Pee z 00YNO oz 6L
63. ive screws securing the left side frame and remove the frame 12 Remove the four screws from the right side frame and remove the bottom frame assembly 13 Remove the five screws from the frame support plate and remove the lower feed roller 14 Be sure to perform the Printhead to Platen Gap Adjustment procedure Go to Printhead to Platen Gap Adjustment on page 4 2 4 42 Service Manual 24xx Sensors Removals Head Gap Sensor Paper Select Sensor Pull Tractor Top Of Form Paper Present Sensor Sensor Sensor Repair Information 4 43 24xx 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 43 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 remove the lever 3 Remove the screw from the head gap sensor and remove the sensor 4 Disconnect the head gap sensor cable from the logic board Go to Sensors Removals on page 4 43 Sensor Top 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 28 3 Turn the print unit upside down 4 Unsnap the Top Of Form s
64. le 5 24 Gap Set Sensor 5 16 Home Position Sensor 5 16 Operator Panel 5 22 Paper Feed Motor 5 20 Paper Present Sensor 5 16 Paper Select Sensor 5 18 Parallel Interface Cable 5 4 Printhead 24w 5 12 Printhead 9w 5 10 Pull Tractor Sensor 5 18 Serial Board 5 6 Top of Form Sensor 5 18 USB Cable 5 8 Power Supply 5 2 Serial Board Serial Cable 5 25 Tractor 2 5 26 Connector Locations 5 1 D Defaults U S 3 5 World Trade 3 5 Diagnostic Aids 3 1 Diagnostic Information 2 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 3 4 Interface Menu Options 1 3 Irrecoverable Operator Errors Paper Empty Sensor 2 12 Paper Present Sensor 2 12 Paper Select Sensor 2 12 L Lubrication 6 1 Menu Interface Menu Options 1 3 Setup Menu Options 1 3 Operator Errors Irrecoverable 2 12 Options 1 6 Index 1 1 24xx 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 7 12 Carrier Paper Feed Right Side 7 6 7 8 Coax Twinax Adapter Covers 7 2 Electronics 7 14 Tractor 2 Option 7 20 Parts Catalog How to use 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
65. m 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 on If POST now runs off 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 26 not run Abnormal Noise Problems Symptom Action During POST Check the ribbon cartridge for binds or damage abnormal noise com s from tho Go to Carrier Service Check on page 2 16 carrier During idling Go to Abnormal Noise Service Check on abnormal noise page 2 13 comes from the printer When feeding paper abnormal noise is created During printing or POST abnormal noise is created Diagnostic Information 2 5 24xx Abnormal Print Operation Problems Symptom Action Printer will not print Be sure the interface cable is connected properly or become ready Abnormal operation Go to No Print or Abnormal Print Service incorrect characters Check on page 2 21 or incorrect line width Printer is ready but will not print from the computer correctly Undefined or incorrect character s Slow printing speed Go to Print Speed Service Check on pa
66. n provides instructions for making printer adjustments and removing and installing FRUs Connector Locations uses illustrations to identify the major components and test points on the printer Preventive Maintenance contains lubrication specifications and maintenance information to prevent problems and maintain optimum performance Parts Catalog contains illustrations and part numbers for individual FRUs xii Service Manual 24xx 1 General Information Printer Description The Lexmark Forms Printer 248X 100 and 249X 100 are small versatile tabletop printers suitable for use in the home or small business They are especially well suited for applications that use continuous or multipart forms The 2481 and 2491 are wide carriage versions of the 2480 and 2490 Printer Specifications Printhead life 300 million characters Standard ribbon life 4 million characters High yield ribbon life 8 million characters Printer life 5 Years Power consumption 47 watts maximum 7 watts idle 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 cps characters per second General Information 1 1 24xx Setup Mode Entering Setup Mode 1 Open the operator panel cover to access layer t
67. nt el proc s de desmuntatge i de servei d aquest producte personal professional ha d estar ne assabentat i prendre les mesures convenients X Service Manual 24xx RE 0 SiR AMERA Lexmark At HERI WARME ALES EA A TYE BT BEAR Su TTA At ERE EA Lexmark A An BO ERS A REH SEED RE WE Ha A AS hh Sm RIS AYALA FRU MH E OX 2 09 op 2 TH Did r A Lexmark TH VAL Af Soll 910 AA st EFA HEE HA ASST 9 0 At So HAAS stat HAs Lexmark wal SEO chest E 0 x zo no Cn 50 L e HES HASH Mule AS AIA Se WALL SHS elm Ho s SLICE Me All ol ANS Hest Ex HES ni xi 24xx Preface This manual is divided into the following chapters General Information contains a general description of the printer and the maintenance approach used to repair it Special tools and test equipment are listed in this chapter as well as general environmental and safety instructions Diagnostic Information contains error code table symptom table and service checks used to isolate failing field replaceable units FRUs Diagnostic Aids contains tests and checks used to locate or repeat symptoms of printer problems Repair Informatio
68. o Platen Gap Adjustment procedure 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 1 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 27 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 27 24xx 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 form thickness lever and remove the lever 4 Remove the two grommet anchored screws A from the left side of the print unit 4 28 Service Manual 24xx 5 Remove the two grommet anchored screws A 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 Repair Information 4 29 24xx 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 16 3 Unsnap the white plastic end stop A from the t
69. ons 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 the least possible movements with your body to prevent an increase of static electricity from clothing fibers carpets and furniture Put the ESD wrist strap on your wrist Connect the wrist band to the system ground point This discharges any static electricity in your body to the 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 on a 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 Prevent ESD sensitive parts from touching 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 humidity increases static electricity during cold weather Repair Information 4 1 24xx Adjustments CAUTION Be sure to unplug the power c
70. op 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 30 Service Manual 24xx 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 31 24xx 3 Remove the four screws A from the paper feed motor bracket assembly 4 m li 1 YN A J NR EA 5 EP amp E p e 75 4 32 Service Manual 24xx 4 Remove the paper feed motor bracket assembly exposing the gears as shown Repair Information 4 33 24xx 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 3 Remove the two screws and washers B from the sub frame 4 Remove the paper select lever C 4 34 Service Manual 24xx 5 Remove the sub frame exposing the right side gears A as shown Repair Information 4 35 24xx Rollers Removals Roller Upper Feed Removal 1 Remove the top cover Go to Covers Top Removal on page 4 8 2 Remove the screw from the print cable shield and remove the shield 3 Remove the gear from the left end of the upper feed roller as shown 4 36 Service Manual 24xx
71. 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 MicroT 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 4 4 Service Manual 24xx Removal Procedures CAUTION Be sure to unplug the power cord whenever you are working on the printer with one of the covers removed Removals Covers Repair Information 4 5 24xx 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 both gray spring loaded ribbon access cover release latches A on either side of the ribbon access cover up toward the front of the printer 2 Lift the ribbon access cover up and out of the printer Note When replacing the ribbon access cover be sure to hook the
72. ord 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 Remove the ribbon cartridge and paper Remove the Lock Tite red from the gap adjust bushings on both the left and right side of the printer Set the form 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 Shift the left gap adjust bushing clockwise as far as it will go Shift the right gap adjust bushing counterclockwise as far as it will go Note Atthis time the nose of the printhead should be touching the platen 4 2 Service Manual 24xx 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 9 Move the printhead to the right edge of the 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
73. orms 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 AOUN e 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 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 4 Repair Information This chapter contains adjustments and removal procedures Whenever parts are replaced make sure that all adjustments are correct by running diagnostics procedures and checking adjustments as needed Handling ESD Sensitive Parts Many electronic products use parts that are known to be sensitive to electrostatic discharge ESD To prevent damage to ESD sensitive parts follow the instructions below in addition to all the usual precauti
74. 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 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 If the problem remains replace the 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 If the paper present sensor is good and the ASF setting is on replace the logic board and reset the Bidirectional Print Adjustment on page 4 4 2 22 Service Manual 24xx Paper Feed Service Check Note If paper creases or jams frequently verify 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 32 FRU Symptom Action 1 Auto Sheet Feeder If the Auto Sheet Feeder is installed remove it Enter the Setup Menu and reset ASF to off Verify th
75. pter 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 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 to 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 Py 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 Micro7 or Micro J 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 Ready light is on The paper remains at the curren
76. r 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 C move the shaft to the left approximately one half inch Lift the shaft up and to the back of the printer and carefully remove the lower pinch roller and shaft 14 Be sure to perform the Printhead to Platen Gap Adjustment procedure Go to Printhead to Platen Gap Adjustment on page 4 2 4 40 Service Manual 24xx 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 28 Remove the carrier Go to Carrier Removal on page 4 16 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 34 Remove the left side gears Go to Left Side Gears Removal on page 4 31 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 36 Repair Information 4 41 24xx 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 21 11 Remove the f
77. 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 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 Diagnostic Information 2 33 24xx 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 on If the slider does not move after turning the printer off and then 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 not 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 Board Cable Asm Check the resistances of the Tractor 2 motor windings at CN5 on the Tractor 2 board There should be 101 5 ohms between pins 5 1 an
78. rsona pi elevato personale di assistenza autorizzato deve quindi adottare le precauzioni necessarie Sicherheitshinweise Dieses Produkt und die zugeh rigen Komponenten wurden entworfen und getestet um beim Einsatz die weltweit g ltigen Sicherheitsanforderungen zu erf llen Die sicherheitsrelevanten Funktionen der Bauteile und Optionen sind nicht immer offensichtlich Sofern Teile eingesetzt werden die nicht von Lexmark sind wird von Lexmark keinerlei Verantwortung oder Haftung f r dieses Produkt bernommen Die Wartungsinformationen f r dieses Produkt sind ausschlieBlich f r die Verwendung durch einen Wartungsfachmann bestimmt e W hrend des Auseinandernehmens und der Wartung des Ger ts besteht ein zus tzliches Risiko eines elektrischen Schlags und k rperlicher Verletzung Das zustandige Fachpersonal sollte entsprechende VorsichtsmaBnahmen treffen viil Service Manual 24xx Pautas de Seguridad e Este producto se ha dise ado verificado y aprobado para cumplir los m s estrictos est ndares de seguridad global usando los componentes espec ficos de Lexmark Puede que las caracter sticas de seguridad de algunas piezas no sean siempre evidentes Lexmark no se hace responsable del uso de otras piezas de recambio e 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
79. s procurable but is not pictured in the illustration Note Graphic artwork depicting FRU assemblies is designed using the 2480 100 9 wire 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 Assembly 1 Covers 7 2 Service Manual 24xx Asm Part Index Number 12G3877 Guide Left Paper 12G3873 Cover Front Unit 2480 2490 12G3874 Cover Front Unit 2481 2491 12G3878 Guide Right Paper 12G3858 Cover Ribbon Access Unit 2480 12G3859 Cover Ribbon Access Unit 2481 12G3868 Cover Ribbon Access Unit 2490 12G3869 Cover Ribbon Access Cover 2491 12G3871 Cover Top 2480 2490 12G3872 Cover Top 2481 2491 12G3870 Cover Option 79F4757 Line Cord U S AFE LV Canada Central and South America Mexico Saudi Arabia LV 7 1339519 Line Cord Malaysia and Singapore United Kingdom 7 1339520 Line Cord Austria Belgium Brazil Germany Greece Finland France Indonesia Luxembourg Portugal Norway Saudi Arabia HV Spain Sweden The Netherlands Turkey 1339525 Line Cord Denmark 1339524 Line Cord Chile Italy 1339521 Line Cord Israel 1339523 Line Cord South Africa 1339522 Line Cord Switzerland 1339518 Line Cord Argentina Australia New Zealand Paraguay 7 13
80. st 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 15 24xx 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 27 3 Loosen the carrier belt a Loosen the tension screw A b Remove tension from the belt by pulling up on the belt C Tighten the tension screw Loosening the screw tightens the belt 4 16 Service Manual 24xx 4 Remove the retaining wire A from the left side of the carrier shaft Repair Information 4 17 24xx 5 Remove the screw A from the forms thickness lever and remove the lever 4 18 Service Manual 24xx 6 Remove the lower carrier motor mount screw 7 Remove the two screws B from the carrier shaft bushing bracket on the left end of the carrier shaft and remove the bracket 8 Remove the E clip from the right side of the carrier shaft Repair Information 4 19 24xx 9 Push the carrier shaft A from the right side and out the left side of the printer 10 Remove 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 20 Service Manual 24xx Carrier Motor Assembly Removal 1 Remove the
81. t 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 Setting Top Of Form Continuous Pull Mode 1 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 MicroT or Micro 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 off or 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 T 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 p
82. 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 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 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 If the sensor fails to open Load Unload tries to park paper when using pull tractors but the paper feeds all the way out of the tractors and cannot reload See Pull Tractor Sensor Service Check on page 2 31 8 Logic Board If no other problem is found replace the logic board and reset the Bidirectional Print Adjustment on page 4 4 2 24 Service Manual 24xx Paper Select Sensor Service Check If form feed lengt
83. tion 7 20 Service Manual 24xx 7 1 12G3923 Table Tractor 2 Paper W Guides 2480 2490 1 12G3924 Table Tractor 2 Paper W Guides 2481 2491 2 11A3338 Guide Tractor 2 Paper 3 12G3926 Tractor and Frame Assembly Tractor 2 2480 2490 3 12G3927 Tractor and Frame Assembly Tractor 2 2481 2491 4 12G3853 Kit Tractors Left and Right 5 11A3335 Board Assembly W Cable and Ferrite Tractor 2 2480 2490 5 11A3336 Board Assembly W Cable and Ferrite Tractor 2 2481 2491 6 11A3337 Motor Tractor 2 7 11A3341 Parts Packet Tractor 2 8 12G3928 Cover Tractor 2 Right 9 12G3921 Cover ASF Tractor 2 Front 2480 2490 9 12G3930 Cover ASF Tractor 2 Front 2481 2491 10 11A3283 Shaft Tractor 2 Support 2480 2490 10 11A3284 Shaft Tractor 2 Support 2481 2491 Parts Catalog 7 21 24xx Coax Twinax Adapter oe E Description NS 12G3704 Adapter Coax Power Cable and Adapter NS 1263705 Adapter Twinax Power Cable and Adapter NS 12G3709 Bracket Adapter Bracket Only NS 13A0297 Cable Coax Cable Only NS 13A0296 Cable Twinax Cable Only NS 11A6109 Cable Socket Power Coax Twinax Socket Power Cable Only 7 22 Service Manual 24xx 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 Carrier Motor 5 20 DC Power 5 8 Dual Tractor Cab
84. top cover Go to Covers Top Removal on page 4 8 2 Loosen the carrier belt a Loosen the tension screw A b Remove tension from the carrier belt by pulling up on the belt C Tighten the tension screw Loosening the screw tightens the belt 3 Slip the belt off the carrier motor pulley Repair Information 4 21 24xx 4 Remove the screw A from the forms thickness lever and remove the lever 4 22 Service Manual 24xx 5 Remove the screw A securing the carrier motor bracket to the bottom cover B 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 B securing the carrier motor bracket to the print unit Remove the home position sensor C 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 D 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 23 24xx 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
85. wo 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 your 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 using Setup mode load more paper into the tractor pins and press Setup to continue 1 2 Service Manual 24xx Setup Menu Options Menus Function Forms Macro options Customize macros to print a variety of forms Data options Defines how information is processed Control options Defines how the printer performs basic tasks Emulation options Determines how the printer interacts with software applications Interface options Defines how information is transferred from computer to the printer Interface Menu Options Menus Function Interface Automatically select the printer interface Use the parallel cable Use the USB cable Use the serial cable only appears if optional serial ada
86. 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 Go to POST Service Check on Paper Out ON aae 2 26 Panel Lock ON pag Font Lock ON Power ON None Switch Scan Test Error Ready Blinking Go to Operator Panel Service Paper Out Blinking Check on page 2 21 Panel Lock Blinking 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 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 LED Status Alarm Action Power ON Beeps Home Position Error Ready Blinking 10 Paper Out Blinking times mE sered Sorice 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 33 None Home Position Error Without Alarm Go to Power Service

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