Lexmark 2390, 2381-001, 2390-PS1, 2380-002, 2381-002 Service Manual

23XX-XXX

Lexmark 23XX Series

Lexmark and Lexmark with diamond
design are trademarks of Lex m ark
International , I nc., registered in the
United States and/or other countries.

• Table of Contents

•Index

• Safety and Notices

• Trademarks

•Start Diagnostics

• Manuals Menu

Edition: April 2000

THE FOLLOWING PARAGRAPH DOES NOT APPLY TO THE UNITED
KINGDOM OR ANY COUNTRY WHERE SUCH PROVISIONS ARE
INCONSISTENT WITH LOCAL LAW: LEXMARK INTERNATIONAL, INC.

PROVIDES THIS PUBLICATION “AS IS” WITHOUT WARRANTY OF ANY
KIND, EITHER EXPRESS OR IMPLIED, INCLUDI NG, BUT NOT LIMITED TO,
THE IMPLIED WARRANTI ES OF MERCHANTABILITY OR FITNESS FOR A
PARTICULAR PURPOSE. Some states do not allo w disclaimer of express or
implied warranties in certain transactions; therefore, this statement may not
apply to you .

This publ ication could include technical inaccura cies or typogr aphical errors .
Changes are peri odically made to the informati on herein; t hese changes wi ll be
incorporated in later editi ons of t he publ icat ion. I mpro vemen ts or changes in the
products or the programs described in this publication may be made at any
time. Publications are not stocked at the address given below; requests for
publications should be made to your point of purchase.

A form for reader’s comments is provided at the back of this publication. If the
form has been removed, comments may be addressed to Lexmark
International, In c., Department F95/032-2, 740 New Circle Road NW,
Lexingt on, Kent ucky 40511, U.S. A. Lexmark may use or distribute any of the
information you supply in any way it believes appropriate without incurring any
obliga ti on to you.

Lexmark is a trademark of Lex ma rk Internati onal, Inc.

 Copyright Lexmark International, Inc. 1996, 2000

All rights res erved.

UNITED STATES GOVERNMENT RESTRICTED RIGHTS

This software and documentation are provided with RESTRICTED RIGHTS.
Use, duplication or disclosure by the Go vernment is subject to restrictions as
set fo rth in subparag r aph (c) (1)(ii ) of t he Right s in Technical Data and Co mpute r
Software clause at DFARS 252.227-7013 and in applicab le F AR provision s:
Lexmark International, Inc., Greenwich, CT 06836.

Contents v

Contents

Notices and Safety Information. . . . . . . . . . . . . . . . . . . . . . . . . . .ix

Safety Notices. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ix

Preface. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .xiii

General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

Recommended Machine Usage. . . . . . . . . . . . . . . . . . . . 1-3

Options. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

Tools. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5

Setup Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6

How To Change The Printer Functions . . . . . . . . . . . . . . 1-6

Serial Interface Adapters . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7

Serial Interface Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8

Function Switch Setting . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8

Diagnostic Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1

Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

Voltage, Ground, And Continuity Readings . . . . . . . . . . . 2-1

Error Indication Table. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

Symptom/Check Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6

Irrecoverable Operator Errors. . . . . . . . . . . . . . . . . . . . . . . . 2-13

Service Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14

Abnormal Noise Service Check . . . . . . . . . . . . . . . . . . . 2-14

Auto Sheet Feeder (ASF) Service Check. . . . . . . . . . . . 2-15

Carrier Drive, Home Position Sensor, Ribbon Feed Service

Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17

Intermittent Problem Service Check . . . . . . . . . . . . . . . 2-20

No Print or Abnormal Print Service Check. . . . . . . . . . . 2-23

Operator Panel Service Check. . . . . . . . . . . . . . . . . . . . 2-24

Paper Empty Sensor Service Check . . . . . . . . . . . . . . . 2-26

Paper Feed Service Check . . . . . . . . . . . . . . . . . . . . . . 2-27

Paper Select Sensor Service Check . . . . . . . . . . . . . . . 2-30

POST Service Check. . . . . . . . . . . . . . . . . . . . . . . . . . . 2-31

Power Service Check . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-32

Print Speed Service Check . . . . . . . . . . . . . . . . . . . . . . 2-34

Printhead Service Check . . . . . . . . . . . . . . . . . . . . . . . . 2-36

Pull Tractor Sensor Service Check . . . . . . . . . . . . . . . . 2-38

Top of Forms Problem Service Check. . . . . . . . . . . . . . 2-39

Tractor 2 Service Check. . . . . . . . . . . . . . . . . . . . . . . . . 2-40

vi Service Ma nual

Diagnostic Aids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

Power-On Self Test (POST) . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

Print Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

Hex Dump Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5

Serial Interface Adapter Print Test. . . . . . . . . . . . . . . . . . . . . 3-6

Repair Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-1

Handling ESD-Sensitive Parts . . . . . . . . . . . . . . . . . . . . . . . . 4-1

Adjustments. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

Printhead-to-Platen Gap Adjustment. . . . . . . . . . . . . . . . 4-2

Bidirectional Print Adjustment . . . . . . . . . . . . . . . . . . . . . 4-5

Removal Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7

Auto Sheet Feeder Gears Removal . . . . . . . . . . . . . . . . 4-8

Auto Sheet Feeder Pick-up Roller Removal . . . . . . . . . . 4-9

Bottom Cove r Removal. . . . . . . . . . . . . . . . . . . . . . . . . 4-10

Carrier Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12

Carrier Motor Assembly Removal . . . . . . . . . . . . . . . . . 4-16

Carrier Plate Removal. . . . . . . . . . . . . . . . . . . . . . . . . . 4-18

Download or Print Buffer Module Removal . . . . . . . . . . 4-21

Form Thickne ss Lever Re mova l . . . . . . . . . . . . . . . . . . 4-22

Head Gap Sensor Removal (238X-001) . . . . . . . . . . . . 4-23

Head Gap Sensor Removal (23XX-002 , 003) . . . . . . . . 4-24

Home Positi o n Senso r Removal . . . . . . . . . . . . . . . . . . 4-25

Label Jam Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-26

Left Side Frame Removal . . . . . . . . . . . . . . . . . . . . . . . 4-28

Lower Feed Rolle r Remov al . . . . . . . . . . . . . . . . . . . . . 4-30

Lower Pinch Roller Removal. . . . . . . . . . . . . . . . . . . . . 4-32

Main Logic Board Removal . . . . . . . . . . . . . . . . . . . . . . 4-33

Operator Panel Assembly Removal . . . . . . . . . . . . . . . 4-34

Paper Empty Sensor And Spring Removal . . . . . . . . . . 4-36

Paper Feed Motor Removal . . . . . . . . . . . . . . . . . . . . . 4-38

Paper Guide Removal (Left And Right). . . . . . . . . . . . . 4-39

Paper Guide / Platen Assembly Removal . . . . . . . . . . . 4-40

Paper Select Lever Removal. . . . . . . . . . . . . . . . . . . . . 4-42

Paper Select Sensor Removal . . . . . . . . . . . . . . . . . . . 4-43

Paper Separator Removal. . . . . . . . . . . . . . . . . . . . . . . 4-44

Power Supply Re mova l. . . . . . . . . . . . . . . . . . . . . . . . . 4-46

Print Unit Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-47

Printhead Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-48

Printhead Cables Removal . . . . . . . . . . . . . . . . . . . . . . 4-49

Pull Tractor Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . 4-50

Pull Tractor Actuator Removal. . . . . . . . . . . . . . . . . . . . 4-51

Pull Tractor Sensor Removal. . . . . . . . . . . . . . . . . . . . . 4-52

Contents vii

Push Tractor Assembly Removal . . . . . . . . . . . . . . . . . . 4-53

Ribbon Drive Rack Gear Removal. . . . . . . . . . . . . . . . . 4-54

Right Side Frame Removal . . . . . . . . . . . . . . . . . . . . . . 4-56

Right Side Frame Gears Removal. . . . . . . . . . . . . . . . . 4-58

Sub Logic Board Removal . . . . . . . . . . . . . . . . . . . . . . . 4-59

Tension Pulley Plate Assembly . . . . . . . . . . . . . . . . . . . 4-60

Top Cover Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-61

Top of Form Sensor, Sensor Flag And Spring Removal 4-64

Upper Feed Roller Removal. . . . . . . . . . . . . . . . . . . . . . 4-66

Connector Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1

Front View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2

Rear View. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3

Tractor 2 Cable Connectors. . . . . . . . . . . . . . . . . . . . . . . 5-4

Wiring Diagrams. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5

Block Diagram 238X-001 . . . . . . . . . . . . . . . . . . . . . . . . . 5-5

Block Diagram 239X-001 . . . . . . . . . . . . . . . . . . . . . . . . . 5-6

Block Diagram 238X-002 . . . . . . . . . . . . . . . . . . . . . . . . . 5-7

Block Diagram 239X-002 . . . . . . . . . . . . . . . . . . . . . . . . . 5-8

Block Diagram 238X-003 . . . . . . . . . . . . . . . . . . . . . . . . . 5-9

Block Diagram 239X-003 . . . . . . . . . . . . . . . . . . . . . . . . 5-10

Signal Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11

Connector Locations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-20

Main Logic Board 23XX-001 . . . . . . . . . . . . . . . . . . . . . 5-20

Main Logic Board 23XX-002 . . . . . . . . . . . . . . . . . . . . . 5-21

Main Logic Board 23XX-003 . . . . . . . . . . . . . . . . . . . . . 5-22

Sub Logic Boards. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-23

Power Supply. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-25

Operator Panel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-26

Preventive Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-1

Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

Specified Lubricants. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

Lubrication Points. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2

Lubrication Points (Oil). . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3

Lubrication Points (Grease) . . . . . . . . . . . . . . . . . . . . . . . 6-4

viii Service Manual

Parts Catalog . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

How To Use This Parts Catalog. . . . . . . . . . . . . . . . . . . . . . . 7-1

Assembly 1: Major Components . . . . . . . . . . . . . . . . . . . . . . 7-2

Assembly 2: Covers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6

Assembl y 3: Carr i e r . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10

Assembly 4: Paper Guide / Platen / Feed Roller . . . . . . . . . 7-16

Assembly 5: Electronics. . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-20

Assembly 6: ASF - Roller / Support . . . . . . . . . . . . . . . . . . . 7-26

Assembly 7: ASF - Side Frame / Covers. . . . . . . . . . . . . . . 7-28

Assembly 8:Tractor 2 Option . . . . . . . . . . . . . . . . . . . . . . . . 7-30

Notices and Safety Information ix

Notices and Safety Information

Safety Notices

•

The maintenance information for this product has been
prepared for use by a professional service person and is not
intended to be used by others.

• There may be an increased risk of electric shock and personal

injury during disassembly and servicing of this product.
Professional service personnel should understand this and take
necessary precaut ions.

• The safety features of some part s may not always be obvious.

Therefore, replacement parts must have the identical or
equivalent characteristics as the original parts.

Sicherheitshinweise

• Die Wartungsinformationen für dieses Produkt sind

ausschließlich für die Verwendung durch einen
Wartungsfachmann bestimmt.

• Während des Auseinander nehm ens und der War tung des

Geräts besteht ein zusätzliches Risiko eines elektrischen
Schlags und kör perlicher Verletzung. Das zuständige
Fachpersonal sollte entsprechende Vorsichtsmaßnahmen
treffen.

• Ersatz t e ile müssen gleiche oder gleichwer t ige Merk m ale wie

die Originalteile aufweisen, da nicht immer offensichtlich ist,
welche Teile des Geräts Sicherheitsmerk m ale aufweisen.

Consignes de Sécurité

• Les consignes d'entretien et de réparation de ce produit

s'adressent uniquement à un personnel de mainten anc e
qualifié.

• Le démontage et l'entretien de ce produit pouvant présenter

certains risques électriques, le personnel d'entretien qualifié
devra prendre toutes les précautions nécessaires.

• Les normes de sécurité de certaines pièces n'étant pas toujours

explicites, le s pièces de rechange doivent être identique s ou
conformes aux caractéristique s des pièces d'ori gine.

x

Norme di sicurezza

• Le informazioni riguardanti la manutenzione di questo prodotto

sono indirizzate soltanto al personale di assistenza autorizzato.

• Durante lo smontaggio e la manutenzione di questo prodotto, il

rischio di subire scosse elettrich e e danni alla persona è più
elevato. Il personale di assistenza autorizzato, deve, quindi,
adottare le precauzioni necessarie.

• Poiché non tutti i pezzi di ricambio garantiscono la stessa

sicurezza, questi devono avere caratteristiche identiche o
equivalenti a quelle dei pezzi originali.

Pautas de Seguridad

• La in formación sobre el mantenimiento de este producto está

dirigida exclusivamente al personal cualificado de
mantenimiento.

• Existe mayor riesgo de descarga eléctri ca y de daños

personales durante el desmontaje y la reparación de la
máquina. El personal cualificado debe ser conscien te de este
peligro y tomar las precauciones necesarias.

• Los dispositivos de seguridad de algunas piezas no siempre

pueden reconocerse a simple vista. Por lo tanto, los recambios
deben poseer características idénticas o equivalentes a las de
las piezas originales.

Informações de Segurança

• As informações de segurança relativas a este produto

destinam-se a profissionais destes ser v iços e não devem ser
utilizadas por outras pessoas.

• Risco de choques eléctricos e ferimentos graves durante a

desmontagem e manutenção deste produto. Os profissionais
destes serviços devem estar avisados deste facto e tomar os
cuidados necess ári os.

• Os dispositivos de segurança de algumas peças poderão não

ser sempre suficientemente evidentes. Assim, as peças
sobressalentes devem possuir características idênticas ou
equivalentes às peças or iginais.

Notices and Safety Information xi

Informació de Seguretat

• La informació pel manteniment d’aquest producte està

orientada exclusivament a professionals i no està destinada a
ningú que no ho sigui.

• El risc de xoc elèctric i de danys personals pot augmentar

durant el procés de desmuntatge i de servei d’aquest producte.
El personal professional ha d’estar-ne assabentat i prendre les
mesures convenients.

• Les característiques de seguretat d’algunes de les peces poden

no ser òbvies. Pe r tant, les ca racterístiques dels recanvis
hauran de ser idèntiques o equivalents a les de les peces
originals.

Chinese Safety Information

xii

Korean Safety Information

Preface xii i

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 f ailing field replaceable
units (FRUs).

• “Diagnostic Aids” contains tests and checks used to locate or

repeat symptoms of printer problems.

• “Repair Information” provides instructions for making printer

adjustments and removing and installing FRUs.

• “Connector Locations” uses illustrations to identify the major

components and test points on the printer.

• “Preventive Maintenance” contains lubrication specifications,

and maintenance information to prevent problems and maintain
optimum performance.

• “Parts Ca talog ” contains illustrations and part numbers for

individual FRUs.

xiv

General Informat ion 1-1

1. General Information

Description

The Lexma rk 238X and 23 9X - XXX printe rs ar e smal l versatile
tabletop printers suitable for use in the home or small business. They
are especially well-suited for applications that use continuous or
multipar t forms. The 2381 and 2391 are wide-carriage versions of
the 2380 and 2390.

The 23XX Plus (23XX-002) printers are enhanced versions of the
basic 23XX-001 printers. These printers have the follo wing
additional features:

• Forms macro and smooth paper scrolling capab ilit y, available

from the operator panel.

• Option sl ot.

• Resident bar code.

• Quiet mode.

• Higher print speed (239X).

The 23XX Forms Printers (23XX-003), in addition to the features of
the 23XX-002 printers are 9% (9-wire machines) or 28% (24-wire
machines) faster in fast draft mode. They also suppor t the Tracto r 2
Options.

There is also a PS/1 v ersion of the 2390-001, which has a distinctiv e
PS/1 logo but is otherwise identical to the 2390-001.

1-2

The following table summarizes the differences between the printers
in the 23 XX family :

US Logo
Name

WTC Logo
Name

Mach Type
Model #

No. of
Print
Wires

Paper
Width

Paper
Knob

PPSII 2380 2380 2380-001 9 Narrow Yes
PPSII 2381 2381 2381-001 9 Wide Yes
PPSII 2390 2390 2390-001 24 Narrow Yes
PPSII 2391 2391 2391-001 24 Wide Yes
PS/1 N/A 2390-PS1 24 Nar row Yes
2380 Plus 2380 Plus 2380-002 9 Narrow No
2381 Plus 2381 Plus 2381-002 9 Wide No
2390 Plus 2390 Plus 2390-002 24 Nar row No
2391 Plus 2391 Plus 2391-002 24 Wide No
Forms

Printer
2380 Plus

Forms
Printer
2380 Plus

2380-003 9 Narrow No

Forms
Printer
2381 Plus

Forms
Printer
2381 Plus

2381-003 9 Wide No

Forms
Printer
2390 Plus

Forms
Printer
2390 Plus

2390-003 24 Narrow No

Forms
Printer
2391 Plus

Forms
Printer
2391 Plus

2391-003 24 Wide No

General Informat ion 1-3

Specifications

• Printhe ad life: 140 Million Cha racter s

• Ribbon Life: 4 Million Characters

• Printer Life: 5 Years

• BTU: 409-Maximum/51 Idle (Per Hour)

• Power Consumption: 120 Watts-Maximum/15 Watts Idle

Recommend ed Mac hin e Usa ge

• 23XX-001 - 10 million characters per year.

• 23XX-002, 003 - 12 million characters per year.

The character usage per day is calculated by dividing the yearly
usage rating by 1300 characters per page, divided by 12 months per
year , by 22 working days per month. T o reduce the probability of
reliability/service problems, field data has shown printer usage
should not exceed twice the daily page usage.

Notes:

• All numbers are average or estimates.

• Performance of individual printers may vary.

• Lexmark does not represent or warrant that printers wi ll achieve

these results. (See the applicable statement of Limited Warranty
for all warranty information).

1-4

Options

The following options may be installed on 238X/239X printers:

• Auto Sheet Feeder (ASF)

• 32Kb Memory Module, Volatile

• 32K b Me mor y Module, No n- volat ile

• Serial Interface Attachment (RS232/RS422).

• Extended National Language Support modules (World Trade

only)

• Acoustics Option

• Extended Cut-sheet Paper Guides

• Tractor 2 (23XX-003 Only)

Tools

The basic tools needed are:

• Basic CE tool kit

• #1 Phillips screwdriver

• #2 Phillips screwdriver

• Feeler gauges 0.35 mm (0.014 in.) 0.4 mm (0.016 in.)

• Analog or digital volt-ohmmeter

General Informat ion 1-5

Abbreviations

ASIC Application-Specific Integrated Circuit
CSU Customer Setup
DR AM Dynam ic Rand o m Access M emory
EPROM Erasable Programmable Read-Only Memory
ESD Electrostatic Discharge
FRU Field Replaceable Unit
HVPS High Voltage Power Supply
LAN Local Area Network
LCD Liquid Crystal Display
LED L ight-Emitting Diode
LVP S Low Vol tage Power Supply
NVRAM Nonvolatil e Random Access Memory
OEM Original Equipment Manufacturer
POR Power-On Reset
POST Power-On Self Test
PQET Print Quality Enhancement Technology
ROS Read-Only Storage
SRAM Static Random Access Memory
UPR Used Parts Replacement
V ac Volts alternating current
V dc Volts direct current

1-6

Setup Mode

How To Chang e The Print er Func tion s

1. Make sure continuous forms are in the printer.

2. Press Alt and then press Setup to enter Setup Mode.The
printer prints out the Main Menu.

3. To select a function, press the buttons listed on the printout.

4. To save the setting and leave Setup Mode, press Start/Stop
until out of the menu.

General Informat ion 1-7

Serial Interface Adapters

The 23XX printer product line uses three different serial adapters.

• 23XX-001:

• Snaps on back of the printer and plugs into the parallel port.

• Power lead plugs into the printer’s +5 V port.

• Switch settings are for “Snap-On”.

• 23XX-002:

• In-line gray box with a shor t cable to the parallel port.

• Some units have a separate power lead to the +5 V port.

• Units without the power cord will not work on the 23XX-001.

• Switch settings are for “Gray”.

• 23XX-003:

• Similar to the 23XX-002, but different switch definitions.

• All units have a power lead.

• Switch settings are for “Black”.

Notes:

• Except as noted, all adapters work with all printers.

• Some adapters may be installed on printers other than what is

listed.

• Only the “Black” adapter is available as a FRU.

• Changes to switch settings are valid only after printer power is

turned off and then on again.

• Contact Lexmark Technical Support for questions about serial

adapters.

1-8

Serial Interface Switches

The serial interface has 12 function switches which determ ine how
the printer receives data from the computer or terminal. Set the
switches according to your par ticular equipment requirement s.

Function Sw itch Setting

Switches 1 To 4 - Speed:

Define the serial interface speed in bits per second (bps).

Snap-On and Gray Serial Adapters

Switch 1 Sw itch 2 Switch 3 Switch 4 Speed (bps)

On On Off Off 150
On O ff On Off 300
On Off Off Off 600
Off On On Off 1,200
Off On Off Off 2,400
Off Off On Off 4,800
Off Off Off Off 9,600
On On On Off 19,200
Off Off Off On 38,400

(RS-422 only)

General Informat ion 1-9

Black Serial Adapter

Switch 5 - Data Bits:

Selects the number of data bits (7 or 8) in each data frame.

Switch 1 Switch 2 Switch 3 Speed (bps)

N/A N/A N/A 150

On Off On 300
On Off Off 600
Off On On 1,200
Off On Off 2,400
Off Off O n 4,800
Off Off O ff 9,600
On On On 19,200
On On Off 38,400

(RS-422 Only)

Switch 5 Data Bits

Off 8
On 7

1-10

Switches 6 and 7 - Parity:

Select the interface parity.

Note: When setting the “Ignore” for parity, the printer ignores the
received parity and transmits using even parity. For all other parity
settings, the transmitted parity matches the received parity.

Switch 8 - Stop Bits (Snap-On):.

Switch 8 - Buffer Size (Gray and Black):

Selects the buffer si ze.

Switch 6 Switch 7 Parity

Off Off No
Off On Ignore
On Off Odd
On On Even

Switc h 8 Stop Bits

Off 1 Stop Bit
On 2 Stop Bits

Switch 8 Buffer Size

Off N ormal (2 048 bytes)
On Minimum (2 bytes)

General Information 1-11

Switch 9 - Protocol:

Selects the type of protocol. Differs depending on which ser ial
interface unit is installed.

Snap - On and Gr ay Units

Black Units

Note: DTR protocol is for RS-232C only.
Switch 10 - Print Te st (All Units):

Selects the print test for the serial interface adapter. Refer to “Serial
Interface Adapter Print Test” on page 3-6.

Switch 9

Protocol

Snap-On Gray

Off XON/XOFF DTR P acing (RS2 32 only)
On DTR pacing (RS232 only) XON/XOFF

Switch 4 Switch 9 Protocol

Off On XON/XOFF
Off Off DTR pacing (RS2 32 only)
On Off DTR + XON/XOFF
Off On Robust XO N/XOFF

Switch 10 Print Test

Off Normal mode
On Test mode

1-12

Switch 11- Polarity For RS-422 Serial Interface (All Units):

NOR/REV reverses the polarity of the receive and transmit data line
for the RS-422 serial interface.

Switch 12 - Serial Interface Mode Select: (All Units)
Switch 232/422 sets the serial interface in either
RS-232C or RS-422 mode.

Switch 11 Mode

Off Normal
On Reverse

Switch 12 Mode

Off RS-232C
On RS-422

Diagnostic Information 2-1

2. Diagnostic Information

Start

Make a quick visual check for defects (loose or broken parts,
unplugged connectors, paper jams, and so on).

Voltage, Ground, And Continuity Readings

Vo ltag e Reading s

All DC voltages must be within +5% through -10% of the values to
be considered correct. Unless stated otherwise, all connectors
should be connected norm al ly when a voltage measurement is
done.

When a “Line Voltage” measurement is to be done, the voltage on
United States and Canada machines should be between 100 V ac
and 127 V ac. On World Trade machines, the voltage is according to
each country’s specification.

Ground Checks

To check for a correct ground, measure the voltage between the
ground and a known good voltage source. The voltage
measurement must be the same as the source voltage to consider
that the ground is correct. Continuity measurements may be used to
check grounds, however, be sure to measure to a known good
ground using the lowest ohms scale and check for zero ohms.

Note: Always unplug the power cord before doing any continuity
measurement.

Continuity Readings

When measurin g continuity, be sure no back circuits affect the
measurement. If necessar y, unplug connectors to remove any back
circuits. Zero the ohm range on the lowest scale (X1). An open
circuit will read inf ini ty. A circuit with correct continuit y wi ll read zero
ohms.

2-2

Error Indication Table

The following t able describes the service check entries f or the printer
error indication codes.

When an error indication changes after you have entered a service
check, you have an intermittent problem. If this occurs, leave the
service check and go to “Symptom/Check Table” on page 2-6.

Indication Al arm Action

None Post Error

Go to “POST Service Check” on page

2-31.

None RAM, ROM, Timer I nterrupt Controll er

Error

Turn the machine off and then on. If you
get the same erro r during power-up,
replace the main logic board and
readjust the bidirectional print
adju st me n t. If the printer co m p l et e s
POST successfully and eventuall y gets
the same error, go to “Intermittent

Proble m Service Chec k” on page 2-20.

LED Status

Power
Ready
Paper
Font
Pitch
Alt
Others

ON
ON
ON
ON
ON
ON
ON

LED Status

Power
Ready
Paper
Font
Pitch
Alt
Others

ON
ON
ON
ON
ON
ON
OFF

Diagnostic Information 2-3

None Switch Scan Test Error

Go to “Operator Panel Service Check”

on page 2-24.

None NVRAM Read/Write Error

Turn the machine off and then back on.
If you get the same error during power­up, replace the main logic board and
readjust the bidirectional print
adjustment. If the pri nter completes
POST successfully and eventually gets
the same error, go to “Intermittent

Problem Service Check” on page 2-20.

Beeps
10
times

Home Position Error

Go to “Carrier Drive, Home Position

Sensor , Ribbon F eed Service Check ” on
page 2-17.

Tractor 2 Home Position Error

If Tractor 2 is installed, remove it to
determine whether the problem is with
the carrier home sensor or the Tractor 2
home sensor. Refer to the “Tractor 2

Serv i c e Check” on page 2-40.

None Home Position Error Wit hout Alarm

Go to “Power Service Check” on page

2-32.

Indication Alarm Action

LED Status

Power
Ready
Paper
Font
Pitch
Alt
Others

ON
BLINK
BLINK
OFF
BLINK
OFF
OFF

LED Status

Power
Ready
Paper
Font
Pitch
Alt
Others

ON
BLINK
BLINK
BLINK
OFF
OFF
OFF

LED Status

Power
Ready
Paper
Font
Pitch
Alt
Others

ON
BLINK
BLINK
BLINK
BLINK
OFF
OFF

2-4

None Logical Error

Turn the machine off and then back on.
If you get the same error during
power-up, replace the main logic board
and readjust the bidirectional print
adju st me n t. If the printer co m p l et e s
POST successfully and eventuall y gets
the same er ror che c k, go t o “Intermittent

Proble m Service Chec k” on page 2-20.

None Hardwa re D rive Error

The printhead or the printhead cables
can cause this error. Go to “Printhead

Service Check” on page 2-36.

Turn the machine off and then back on.
If you get the same error, replace th e
main logic bo ard and readjust the
“Bidirectional Print Adjustment” on page
4-5. If the printer completes POST
successfully and eventually get s the
same error, go to “Intermittent Problem

Service Check” on page 2-20.

If the problem still exists, remove the
new main logic board, install the old
main logic board, then replace the sub
logic board.

None Power Failur e

Check the continuity of t he power cord
and the vol tage of the user’s outlet. If
they are correct, go to “Power Service

Check” on page 2-32.

Indication Al arm Action

LED Status

Power
Ready
Paper
Font
Pitch
Alt
Others

ON
BLINK
BLINK
BLINK
OFF
BLINK
OFF

LED Status

Power
Ready
Paper
Font
Pitch
Alt
Others

ON
BLINK
BLINK
OFF
BLINK
BLINK
OFF

LED Status

Power
Ready
Paper
Font
Pitch
Alt
Others

OFF
OFF
OFF
OFF
OFF
OFF
OFF

Diagnostic Information 2-5

None Operator Panel Failure

Go to “Operator Panel Service Check”

on page 2-24.

If other LED
combinations
along with the
Power L ED are on.

None Go to “POST Service Check” on page

2-31.

Any LED on but
the Power LED off .

None Go to “Operator Panel Service Check”

on page 2-24.

If the Power LED
bli nks or changes
intensity.

None Go to “Power Service Check” on page

2-32.

Any Beeps

7
times

(Optional Serial Int erface Adapter
installed)

• Turn the printer off and chec k the
connecti on from the serial interf ace
adapter to the printer.

• Turn the printer off and then on. If
you get t he same error, replace the
serial inter face adapter.

• If turning the printer off and then on
is success ful, run the “Serial
Interface Adapter Print T e st” on
page 3-6.

Indication Alarm Action

LED Status

Power
Ready
Paper
Font
Pitch
Alt
Others

ON
OFF
OFF
OFF
OFF
OFF
OFF

2-6

Symptom/Check Table

1. Select the symptom that best descr ibes the problem.

2. Perf orm the appropriate action before you go to the indicated
service check.

Abn o rma l Indic a tion s

Abnormal Noise Problems

Symptom Action

7 or more lights turn
on but do not turn
off.

The Power light is
on, but POST will
not run.

Disconnect the in terf ace c ab le from t he print er and
turn the printer off and then on. If POST now runs
correctly, the probl em is in the computer or
interface cable.

Go to th e “POST Service Check” on page 2-31.

Symptom Action

During POST,
abnormal noise
come s fr om the
carrier.

Check the ribb on cartridge for binds or damage.
Go to th e “Carrier Drive, Home Position Sensor,

Ribbon Feed Service Check” on page 2-17.

During idling,
abnormal noise
come s fr om the
printer.

When fee ding pap er,
abnormal noise is
created.

During printing or
POST, abnormal
noise is created.

Go to “Abnormal Noise Service Check” on page

2-14.

Diagnostic Information 2-7

Abnormal Print Operati on Problems

Auto Sheet Feeder Problems

Symptom Action

Printer will not print,
or become Ready.

Abnormal oper ation,
incorr ect characters,
or incorrect line
width.

Printer is ready but
will not print from the
computer correctly.

Undefined or
incorrect
character(s).

Be sure the interface cable is connected properly.
If the serial inter f ace adap ter is i nstalled , be sur e it

and its powe r in terface cable are inst alled
correct ly. (Some adapter s do not have a separate
power cable.)

Go to the “No Print or Abnormal Print Service

Check” on page 2-23.

Slow printing speed. Go to the “Print Speed Service Check” on page

2-34.

Symptom Action

Auto sheet feeder
will not feed paper.

Auto sheet feeder
double feeds.

Auto sheet feeder
has intermittent feed
problems.

Be sure Sheet F eed is enab led in the Set up Mode .
Be sure the paper select lever is in the cut sheet

position.
Go to the “Auto Sheet Feeder (ASF) Service

Check” on page 2-15.

2-8

Error Indica tion s

Paper Feed Problem s

Symptom Action
Ready and Paper

Out lights bl ink to

indicate a Hardware
Error.

Turn the printer off and then on.
Go to “Abnormal Indications” on page 2-6.

Paper Out and Alt
lights blink to
indicate an operator
error.

Turn the printer off and then on.
Go to “Irrecoverable Oper ator Errors” on page

2-13.

Symptom Action
Paper Out is

blinkin g with paper in
the printer.

Go to the “Paper Empty Sensor Service Check” on

page 2-26.

Paper Out does not
blin k w hen no pape r
is in the printer and
ASF is not installed.

Print operatio n starts
without paper.

Be sure the paper empty sen sor is not blocked.
Go to the “Paper Empty Sensor Service Check” on

page 2-26.

Alt + Park/Load
does not function
when the push
tra c tor is in s talled.

Form feed length is
not correct.

Alt + Park/Load
functions with cut
sheets i n use.

Be sure the paper select lever is in the correct
position.

Go to the “P aper Sel ect Sensor Service Chec k” on

page 2-30.

Diagnostic Information 2-9

Paper fee ds, but
Auto Loading does
not work.

Be sure the paper select lever is in the cut sheet
position.

Be sure Auto Loading is enab led in the Setup
Mode.

Go to the “Pap er Selec t Sens or Service Check” on

page 2-30.

Alt + Park/Load
functions when the
pull tractor is
installed.

With Paper Out
blinking, Form Feed
does not operate
until pap er is l ocated
at first print line.

Be sure the paper select lever is in the tractor
position.

Go to the “Pull Tractor Sensor Service Check” on

page 2-38.

Lower feed roll shaft
rotate s, but pape r
does not feed.

Pressing Form Feed
does not feed paper.

Abnormal noise
created while
feeding.

Paper jams, skews
or creases.

Incorr ect or no line
spacing: wider,
narrower, or
overlapping lines.

Push/Pull Tractor
does not work.

Be sure the paper select lever is in the correct
position.

Go to the “Paper Feed Service Check” on page

2-27.

Incorrect Top of
Form positioning.

Go to the “Top of Forms Problem Service Check ”

on page 2-39.

Symptom Action

2-10

Operator Panel Problems

Pow er P r oblems

Symptom Action
Start/Stop does not

function b ut no error
is indic at e d.

Only the Power light
turns on.

One or more b ut tons
do not function.

One or more lights
do not function.

Turn the printer off and then on.
Go to th e “Oper ator Panel Service Check” on page

2-24.

Symptom Action

When the power
switch is on, the
Power light does not
turn on or the printer
does not start.

The Power light
blink s or changes
intensity.

Check conti nui ty of t he p ow er cord and the voltage
of the user’s outlet.

Go to th e “Power Service Check” on page 2-32.

Diagnostic Information 2-11

Print Quality Problems

Symptom Action

No print, but carrier
moves a s i f print ing.

Adjust the form thickness lever to a lower number.
Be sure the printhead cables are not loose or

damaged.
Be sure the interface cable is connected properly.
Be sure the serial interface adapter is install ed

correct ly and the dip switches are set correctly.
Check the ribbon cartridge for binds or damage.
Go to the “Print Speed Service Check” on page

2-34.

Print density is light. Verify that the ribbon density control knob on the

ribbon cartridge is not set to 0.
If the ribbon has re ached its end of life or is worn,

the ribbon cartridge needs to be replaced.
Go to the “Carrier Drive, Home Position Sensor,

Ribbon Feed Ser vice Check” on page 2-17.

Unev en print densi ty
acr os s the pri n t li n e.

Specific dots
missing.

Extra dots or lines
printing.

Be sure the printhead cables are connected
correct ly t o the printhead and the sub logic board.

Clean the printhead .
Set the f orm thickn ess le v er to posi tio n “1” and run

the print test.
Go to the “Carrier Drive, Home Position Sensor,

Ribbon Feed Ser vice Check” on page 2-17.

Scattered ink
smearing, blurred
characters.

Fuzzy print.

Clean the printhead nose.
Clean the ribbon gui de and shield.
If the ribbon has re ached its end of life or is worn,

the ribbon cartridge needs to be replaced.
Go to the “Carrier Drive, Home Position Sensor,

Ribbon Feed Ser vice Check” on page 2-17.

2-12

Ribbon Fe ed Problems

Wavy vertical lines,
unev en left margin or
character width is
reduced.

Clean and lubricate the carrier shaft.
If the carrier drive belt is worn or broke n, replace

the carrier unit.
Go to th e “Carrier Drive, Home Position Sensor,

Ribbon Feed Service Check” on page 2-17.

Symptom Action

Ribbon comes off,
becomes loose or
folded, or jams.

Ribbon feeds
correctly but is noisy.

Check the ribb on cartridge for binds or damage.
Go to th e “Carrier Drive, Home Position Sensor,

Ribbon Feed Service Check” on page 2-17.

Symptom Action

Diagnostic Information 2-13

Irrecovera ble Operator Errors

Alt and Pa per Ou t lights blink to indicate an operator error. If this

indication cannot be recovered, the problem may be the paper
empty sensor or the paper select sensor . Check the following in the
order listed and if the printer does not work correctly, go to the
indicated ser v ice check.

Paper Empty Sensor

Paper Select Sensor

Action Check

Remove all paper
from the printer.

Turn the power on.

Paper Out blinks when paper does not exist.
Paper Out turns off when paper ex ist s.

Go to the “Paper Empty Sens or Se rvice Chec k” on

page 2-26.

Action Check

Turn the power off.
Install the Push

Tractor.
Set the paper select

le ver to the tractor
position an d load th e
continuous forms.

Turn the power on.

Alt + Park/Load function correctly.
Go to the “Pap er Selec t Sens or Service Check” on

page 2-30.

Remove the
continuous forms.

Set the paper select
le ve r to the c ut shee t
position and insert a
cut sheet.

When Aut o Loading is enable d, paper feeds
automatically.

When Auto Loading i s disabled, press Form Feed
to load a cut sheet. Check that Alt + Park/Load
does not function.

Go to the “Pap er Selec t Sens or Service Check” on

page 2-30.

2-14

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 cables.

Run the print test (do not fold or damage the
cables during the test).

Replace the printhead if the noise is gone.

3 Carrier Motor

Ribbon Drive
Mechanism

Disconnect the carrier motor connector CN9
from the main logic board, and turn the printer
off and then on.

If the abnormal noise is gone, look for a
probl em with the carrier motor or ribbon drive
mechanism.

4 Paper Feed

Mechanism

Disconnect the paper feed motor from CN10
from the main logic board.

Perform the Print Test.
If the abnormal noise is gone, look for the

problem in the paper feed mechanism.

Diagnostic Information 2-15

Auto Sheet Feeder (ASF) Service Check

Note: Be sure the sheet feeder is enabled. Refer to “Setup Mode”

on page 1-6.

Auto Sheet Feeder Principles of Operation

The auto-sheet feeder (ASF) feeds into the cut sheet paper entry
throat. To use the ASF:

• The paper select lever must be set to cut sheet.

• Auto Sheet Feeder must be selected in the Setup menu.

Continuous forms can be used with the ASF installed by moving the
paper select lever to continuous forms and pressing Start to feed the
continuous forms to the first print line.

The ASF contains no electri cal par t s. It is driven from the gear on
the inside of the printer’s right side frame.

The combination lock mechanism is a clutch that causes the ASF
pick rollers to feed only one sheet of paper at a time. When Auto
Sheet Feeder is selected on the Setup Menu, the cut sheet paper
drive reverses itself for a short distance during pape r 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 ASF’s upper and lower feed
rollers and the printer’s lower feed rollers. Although the ASF picker
rollers continue to turn as the paper is fed, their drive is disengaged
and they are actually being turned by the paper.

FRU Action

1 Paper Select

Sensor

With the paper select lever in the cut sheet
position, do t he following:

• Try to load a sheet with Alt+Park/Load.
(This button should not work)

• If the paper loads go to the “Paper Select

Sensor Service Check” on page 2-30.

2-16

2 Paper Fee d I f the paper does not feed, do the fol lowing:

• Remove the ASF.

• Be sure the base printer feeds paper

correctly.

• If it does not f eed paper correct ly, go to
the “Paper Feed Service Check” on page

2-27.

3 Gear Train Be sure the ASF driv e gear on the in side of t he

printer’s right frame rotates.
Inspect the right side gear train for damage or

debris.
Remove the ASF right cover and ensure that

all gears are in good conditi on.

4 Combination Lock

Mechanism

Install the ASF and press Form Feed.
If the p ick er dri ve sha ft does not r otate , repl ace

the combinat ion lock mechanism.

5 Left and Right

Hoppers

If the ASF pi cker ro lle r s ro ta t e but a si n gl e
sheet is not picked, inspect the springs and
corner separ ators on the left and right hoppe rs.

Make sure the pape r load le v er is in the corr ect
position.

FRU Action

Diagnostic Information 2-17

Carrier Drive, Home Position Sensor, Ribbon Feed
Service Check

23XX-001 only: If t he carrier stops but the print wires continue to fire

(printing one vertical column of dots), or if the carrier does not move
after turning the printer off and then on, inspect the area of the main
logic board that is below the paperfeed motor. If this area is
damaged or cracked, replace the main logic board. Also check the
continuity of soldered-on fuse FU1 located on the main logic board
near the paper empty sensor. If this fuse is open, replace the main
logic board. T urn the printer off and then on. The carrier should
move to the left, contact the home position sensor on the left side
frame, and immediately move slightly away from the sensor.

A Home Position Error occurs when:

• The sensor is not closed.

• The sensor is not quickly opened.

• The sensor is closed any time other than when the printer is

turned off and then on.

2-18

.

FRU Action

1 Carrier If there is no Home Position Error , check the

carrier belt and the ribbon cartridge for wear or
damage . Check the belt and pulley
engagement.

Manually move the carrier the full lengt h of the
carriage to check fo r bi nds and to make sure
the ribbon advances when the carri age m oves
in either di rection.

If the carrie r binds check the follo w ing:

• Correct print head-to-platen gap.

• Clean and lubricat ed carrier shaft.

• Idler pulley not binding.

• Ribbon drive rack gear teeth not

damaged.

If the carrie r still binds:
Remove the belt and move the carri er again. If

the bind is gone, replace the carrier motor. If
the bind still exists, replace the carrier.

2 Home Position

Sensor
Sub Logic Board
Short Flexible
Cable

If the carrie r moves manual ly without binding
but the Home Position Error still occurs, verify
that the main logic board is receiving +26 V dc
on pin CP11-1. Check that the 5 V dc home
position sensor signal i s getting to the main
logic boa rd. Check CP3-7 on the main logic
board. Chec k CP6-1 on the sub logic boar d.

Replace the sensor , the sub logic boar d, or the
short flexible cable as necessary.

Diagnostic Information 2-19

3 Carrier Motor If the home position sensor is OK, refer to the

table and make sure the resistance of the
carrier motor wi ndings ar e from 1 to 5 ohms for
all printers.

238X-001,002,003
239X-002,003 239X-001

CP9-1 & CP9-5 CP9-1 & CP9-6
CP9-2 & CP9-6 CP9-2 & CP9-5
CP9-3 & CP9-5 CP9-3 & CP9-6
CP9-4 & CP9-6 CP9-4 & CP9-5

4 Main Logic Board If all parts appear OK but the Home Position

Error still occurs, repl ace the main logic boar d.
After replaci ng the main logic boar d or any

parts affecting the carrier, perform the
bidirecti onal print adjustment. See
“Bidirectional Print Adjustment” on page 4-5.

FRU Action

2-20

Intermittent Problem Service Check

FRU/Symptom Action

1 The machine

sometimes fails
before POST is
complete.

Check for the f ollowing:

1. Loose connectors. Reconnect all

connectors to the main and sub logic
boards.

2. Electrical noise or static discharge.
Check the following items:

• Power supply ground.

• Machine fra me ground.

• Printer interface cable is grounded and

shielded.

• If the upper feed roll shaft does not ha ve a

ground spring, i nstall P/N 1368036.

3. Intermittently low volt ages. Ch eck f or ac and
all dc v olt ages and sho rt circui ts on t he main
and sub logic boards.

a. Check the customer’s outlet voltage and

ensure that it is wit hin tolerance .

b. Check the conti nuity of the pow er

cord.

c. Disconnec t t he power supply cable

from the connectors CN11 on the
main logic board and CN1 on the sub
logic board. Turn the printer po wer on
and check all dc output volt ages at
CP11 and CP1.

Ensure the outpu t voltages are :

CP11-1 (+26 V dc ±10%) & CP11-2 (GND)
CP11-3 (+5 V dc ±5%) & CP11-4 (Signal GND)
CP 1-1 (+26 V dc ±10%) & CP1-2 (GND)
CP 1-3 (+5 V dc ±5%) & CP1-4 (Signal GND)

If the voltages are not cor rect, replace the
Power Supply Unit.
If the failure remai ns, replace the main logic
board and sub logic board.

Note: When replacing the main logic board,
always reset the bidirectional print adjustment.
Refer to “Bidirectional Print Adjustment” on
page 4-5.

Diagnostic Information 2-21

2 Machine power

sometim es turns
off.

The cause of this problem may be that the
power circuit is failing, or the wiring is
intermittently open. Check the following in
sequence:

1. Check the customer’s outlet voltage and
be sur e it is within tolerance.

2. Check the contin uity of the power cord.

3. Disconnect the power supply cable from the

connectors CN11 on th e main logic board
and CN1 on the sub logic board. Turn the
printer powe r on and check all dc out put
voltag es at CP11 and CP1.
Be sure the output vol tages are as follows:

CP11-1 (+26 V dc ±10%) & CP11-2 (GND)
CP11-3 (+5 V dc ± 5%) & CP11-4 (Signal G ND)
CP 1-1 (+26 V dc ±10% & CP1-2 (GND)
CP 1-3 (+5 V dc ±5%) & CP1- 4 (Signal GND)

If one of the voltages is 0, go to the “Power

Service Check” on page 2-32. If the volt ages

are not 0 but are incorrect, replace the power
supply unit.

3 Intermittently poor

print quality.

Do the following:

• Remove paper jams fr om the paper path.

• Clean all feed roller surfaces.

• Clean the ribbon shield and print head.

• Clean the platen surface.

• Install the ribbon cartridge correctly.

• If the ribbon end of li fe has been reached ,

have the customer replace the ribbon
cartridge.

FRU/Symptom Action

2-22

4 If the prior

suggestions have
not corrected the
problem.

The service chec k has not defined the failure,
or the machin e is having inte rmitt ent fail ures.
The following may cause undef ined or
intermittent failures:

1. Customer’s outlet voltage. Be sure that it
is within the tolerance.

2. Loose connector pins or k eys that fail to

contact.
Check the following:

a.Reconnect the connectors of all FRUs

and printer interface cables.

b.Check the conti nuity of the line cor d.

3. Electrical noise.

Check the following:
a. Power supply ground.

b. Machine frame ground.
c. Printer interface cable is grounded

or shielded.

4. Undefined data in custome r appl ications.

Check the baud rate at the controller . Check
that the printe r interf ace cable match es the
printer.

5 Problem occurs

only in specific
customer
applications.

Perform the Trace Print (hexadecimal printing)
by the following procedure and check the data
streams.

1. Turn the power off.

2. Turn the power on while pressing and

holding Alt.

3. Have the customer print the failing job.

4. To stop printing, turn the power switch off.

If the failure still occurs, replace the main logic
board. Be sur e to res et the bidirectional print
adjustment , re fer to th e “Bidirectional Print
Adjustment” on page 4-5.

FRU/Symptom Action

Diagnostic Information 2-23

No Print or Abnormal Print Service Check

FRU/Function Action

1 Main Logic Board If the Print Test does not complete correctly,

do the following:

• Replace the main logic board.

• Reset the bidirectional print adjustment.

Refer to “Bidirectional Print Adjustment”
on page 4-5.

2 Interface Cable Check the connection and continuity of the

interface cabl e.

3 Emulation Mode Enter the Setup Men u and make sure the

printer is in the corr ect emulation mode for the
computer, either IBM or Epson.

4 Serial Interface

Adapter

If the serial interface ada pter is installed, make
sure the dip sw itches match the computer
settings.

• Make sure the s erial adapter po wer cab le ,
if present, is securely connected to the
printer power connector CN5.

• On newer models, make sure the serial
interface adapter’s power LED is on when
printer power i s on.

Run the “Serial Int erf a ce Adapter Print Test” on
page 3-6. If the tes t is not successful rep lace
the serial interface adapter.

If no def ect is found, the printer and serial
interface adapter are working correctl y. The
proble m may be with the inter face cable, the
computer, the printer driver, or the specific job
being sent.

2-24

Operator Panel Service Check

Note: If the Op-Panel Asm is locked, only the Start/Stop, Form
Feed, Alt + T ear Off and Alt + Park/Load buttons are active. Model

2 and 3 printers have a “Lock” LED to indicate that the operator
panel is locked. To unlock t he operator panel, turn the printer off and
then on while pressing Micro↑ and Micro↓.

FRU Action

1 Op-Panel Cab le

Sub Logic Board

Check t he c onnecti ons fr om the ope ra tor pan el
to the sub logic board and from the sub logic
board to the main logic board.

Disconnect the operator panel from its cable
and mak e sure +5 V dc is present on the
fol lowing pins on th e cable:

23XX-001 23XX-002,003
CP1-1 CP1-2
CP1-7 CP1-8

If there is a vol tage probl em mak e sure the s ub
logic boa rd i s receiving +5 V dc on CN1-3.
Replace t he oper at or pa nel cab l e, th e sub l ogic
board, or the power cable as necessary.

Diagnostic Information 2-25

2Short Flexible

Cable

Disconnect the short flexible cable fro m the
main logic board.

Check the cont inuity of the operator panel
signal lines between the end of the short
flex ibl e cabl e an d the oper at or panel connecto r
on the sub logic board.

238X-001 238X-002,003

CP3-4 & CN8-5 CP3-4 & CN8-2
CP3-3 & CN8-6 CP3-3 & CN8-4
CP3-2 & CN8-4 CP3-2 & CN8-8
CP3-1 & CN8-8 CP3-1 & CN8-6

239X-001 239X-002,003

CP3-4 & CN7-5 CP3-4 & CN7-2
CP3-3 & CN7-6 CP3-3 & CN7-4
CP3-2 & CN7-4 CP3-2 & CN7-8
CP3-1 & CN7-8 CP3-1 & CN7-6

Replace t he short f le xib le cabl e or t he sub log ic
board as necessary.

If there is still a problem, replace the operat or
panel. If th at does not fix t he prob lem, re-i nstal l
the old operator panel and replac e the main
logic board. If you replace the main logic
board, reset the “Bidirectional Print
Adjustment” on page 4-5.

FRU Action

2-26

Paper Empty Sensor Servi ce Check

Note: 23XX-001 machines have a single paper sensor that serves

as a paper empty sensor and also determines the top of form
setting.

23XX-002 and 23XX-003 machines have two sensors:

• The left sensor is paper empty.

• The right sensor is Top of Form.

FRU Action

1 Paper Empty

Sensor

With no paper in the pri nter, the tractor in t he
push position, and the paper select l ever set to
continuous forms, press Alt+Park/Load; the
gear tr ain should turn forward (to try to load
paper).

Activ ate the paper empty sensor with a
screwdriver and press Alt+Park/Load again;
the gear train should turn bac kward (to try to
park paper).

Measure the voltage between CN7-2 (paper
empty signal) and CN7-3 (GND) on the main
logic board. There should be 0 V dc when
there is paper in the printer, and +5 V dc when
there is no paper in the printer.

Make sure the sensor and its actuator are
properly installed and undamaged. Correct t he
problem or replace the sensor.

2 Main Logic Board If the ASF is being used, it is normal for the

Paper Out LED not to blink when there is no
paper in the printer. Do the following:

• Enter the Setup Menu.

• Make sure the ASF setting is off unless

the ASF is instal led.

• If the sensor and the ASF setting are OK ,
replace th e main logic board.

• Reset the “Bidirectional Print Adjustment”
on page 4-5.

Diagnostic Information 2-27

Paper Feed Service Check

Note: If the problem is frequent jams or paper creases, verify that

the paper is neither very thick nor very thin. If necessary refer the
customer to the User’s Guide for specifications of acceptable
papers. On 23XX-001 printers check for equal gap between the
lower feed rol lers and lo wer pi nch rollers . If the gap is smaller on the
left, install Shim Kit, P/N 1368067.

If the paper does not stop in the correct location, refer to the “Paper

Empty Sensor Service Check” on page 2-26 and the “Top of Forms
Problem Service Check” on page 2-39.

FRU / Symptom Action

1 Auto Sheet

Feeder

If the Auto Sheet F eeder is in stalled, remo ve it .
Enter the Setup Menu and reset “ASF” to off.
Verify tha t the machine works correctly without
the ASF installed.

If the printer fails only with the Auto Sheet
Feeder installed, refer to th e “A uto Sheet

Feeder (ASF) Service Check” on page 2-15.

2 Gear Train Remove all paper from the machine.

Press Form Feed several times and examine
all rotating parts to find the problem.

For better visibility, remove the covers and
reconnect t he operator panel t o the sub logic
board.

The upper and l ow er f eed rol lers and the uppe r
and lower pinch rollers sh ould all be clean and
in good condition, and should all rotate during
Form Feed.

To turn the gear train manually on a 23XX-002
or 23XX-003, turn the right end of the lo wer
feed roller shaft with a 6 mm wrench.

2-28

3 Paper Selector

Lever

Make sure the selector lever alternately
engages and disengages the tractor gear and
the ASF drive gear.

Check the operation of the follo wing parts as
you move the paper select lever:

• The tract or gear engages correctly in the
contin uous forms position.

• The tract or belts are in good conditi on and
rotate correctly.

• The pinch roll er shafts mov e down ward as
the lever moves to the cut sheet position.

• The paper separator moves upward as
the lever moves to the cut sheet position.

4 Operator Panel If paper does not mo ve at all, v eri fy t hat the

For m Fee d button is worki ng as fo ll o w s:
With the t ractor in the push position, power off,

pow er on, then press Alt/Load. The car rier
should move to the center of the platen. If it
does not, go to the “Operator Panel Service

Check” on page 2-24.

5 Paper Fee d Motor Disconnect th e paper feed motor cable CN10

from the main logic board. No pin should have
contin uity to ground. The resistances should
be as fo ll o w s :

23XX-001, 002 = 21 to 24 ohms.
CP10-1 to CP10-5 CP10-1 to CP10-6

CP10-2 to CP10-5 CP10-2 to CP10-6
CP10-3 to CP10-5 CP10-3 to CP10-6
CP10-4 to CP10-5 CP10-4 to CP10-6

23XX-003 = 8 to 9 ohms.
CP10-1 to CP10-5

CP10-2 to CP10-5
CP10-3 to CP10-5
CP10-4 to CP10-5

FRU / Sym p to m Act io n

Diagnostic Information 2-29

6 Paper Select

Sensor

Remov e all paper from the printer and place
the tractor in the push position.

Press Form Feed and time how long the gear
tra in rotat e s.

• With the paper select le ver in the cut
sheet position (sensor open) the gear
train should rotate fo r 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 doe s not do t his, inspect the
sensor to make sure it is being opened and
closed by t he paper separator.

Disconnect CN5 from the sub logic board and
measure the paper selector sens or resistance
from CP5-1 to CP5-2.

Replace the sens or if the resistance does not
change from z ero to infini te as t he pape r selec t
lever is moved.

7 P u ll Tracto r

Sensor

If the pull tractor sensor has failed t o close,
Park/Load and Auto Tear Off will not work
when using push tractors.

If the sensor has failed to open, Park/Load will
try to park paper when using pull tractors, but
the paper will feed all the way out of the
tractors and cannot reload. Refer to the “Pull

Tractor Sensor Service Check” on page 2-38.

8 Main Logic Board If no other problem is found replace the main

logic board. Reset the “Bidirectional Print
Adjustment” on page 4-5.

FRU / Symptom Action

2-30

Paper Select Sensor Service Check

If form feed length is off by about 1 inch (25 mm), enter Setup Mode
and verify that the form length setting is correct. See the Setup
Mode and Switch Settings section.

FRU Action

1 Paper Select

Sensor

Remove all paper from the printer and place
the tractor in the push position. Make sure the
A u to Shee t Feed (ASF) i s se t to OFF in th e
Setup Mode.

Press Form Feed and ti me how long the gear
train rotates.

With the paper select lever in the cut sheet
position (sensor open) the gear train shou ld
rotat e for less t han 2 seconds; with the lever in
the continuous forms position (sensor closed),
the gear train should rotate for more than 3
seconds. If the printer does not do this, inspect
the sensor to mak e sure it is being opened and
closed by the paper separ ator .

Disconnect CN5 from the sub logic boar d and
measure the paper selector sensor resistance
from CP5-1 to CP5-2.

Replace the sensor if the resistance does not
change fr om zero t o in finite a s the paper sel ect
lever is moved from cut sheet to cont inuous
forms.

If th e sensor is good b ut the gear tra in does not
run the right length of tim e, set the head gap to
position 1 and disconnect the short flexible
cable from CN3 on the main logic board.
Check the continuity bet ween CP3-6 (paper
select sensor) and GND while actuating the
paper select lever.

Cut Sheet Continuous Forms

23XX-001

23XX-002
1K ± 0.5K ohms 0K ± 0.5K ohms
12K ± 0.5K ohms 3.5K ± 0.5K ohms

If the resistance is correct, replace th e main
logic boa rd. If the resistance is incorrect,
replace the sub logic board.

Diagnostic Information 2-31

POST Service Check

2 P u ll Tracto r

Sensor

A failed pull tractor sensor can cause
Alt + Park/Load not to function. With the
tractor in the push position, press Alt+Park/
Load several ti me s whil e alternately holdi ng
down and releas ing the left pull tractor
actuator. The paper should not park or load
when the pul l t ractor actuator is h eld down. If it
does, go to the “Pull Tractor Senso r Service

Check” on page 2-38.

FRU Action

1 Power LE D If the power LED is not on, go to the “Power

Service Check” on page 2-32.

2 Cables A faulty in ter face cable can cause POST

errors . Disconnect the inter face cable from the
printer and turn the printer off and then on.

Check the connections of the short flexible
cable and th e power cabl e to the main logic
board and sub logic board.

Check the condition and continuity of the
operator panel cable.

3 Operator Panel If no problem is found, the problem may be in

either the operator panel or the main logic
board. Replace the operator panel and ret est
the printer.

4 Main Logic Board Replace the main l ogic board if necess ary.

Reset the bidirectional print adjustment; refer
to “Bidirectional Print Adjustment” on page 4-5.

FRU Action

2-32

Power Service Check

If the symptom is that the Power l ight varies in intensity, make sure
the upper feed roll shaft has the ground spring. If it does not, install
ESD Kit P/N 1368036.

FRU Action

1 Power Supply If the carrie r does not move to the lef t af te r

turning the printer of f and then on, do the
following:

• Make sure the line cord voltage to the

power suppl y is correct.

• Make sure the power supply out puts are

+5 V dc at CN1-2 and +26 V dc at CN1-4.
If the voltage is incorrect, check the
internal fuses before replacing the power
supply. Generally if F3 is bl own it is due to
a short in the printhead; replace the
printhead and the fus e before powering
on again.

• Check for +5 V dc at main logic board

CN11-3 and sub logic board CN1-3, and
for +26 V dc at main logic board CN11-1
and sub logic board CN1-1.

• Make sure the short flexi ble cable is

undamaged and correctly inst alled.

2 Sub Logic Board If the carrie r moves to the lef t after turning the

printer off and then on, do the following:

• Move the carrier to the right and turn

power on. The carrier should move to the
left. The power LED should be on steady
whenever the printer is on. If the carrier
moves t o th e lef t during afte r tu rni ng the
printer off and t hen o n, but the po wer LED
is not on steady: M ake sure the sub logi c
board is rece iving volt age by check ing for
+5 V dc at sub logic board CN1-3.

• If no voltage or power cable probl em is

found, make sure there is +5 V on pins 3
and 9 of the sub logic board connector for
the operator panel cable. If the vol tage is
incorrect replace the sub logic board.

Diagnostic Information 2-33

3Op-Panel

Op-Panel Cable

If there is sti ll a power LED problem, check the
operator panel c ab le cont inui ty and rep lace t he
cable or the operator panel.

4 Carrier Motor Disconn ect the carrier motor fr om main logic

board CN9 and turn the pri nter off and t hen on.
If the power LED lights correctly only with the
carrier motor di sconnected, repl ace the carrier
motor.

5 Paper Feed Motor Disconnect the paper feed motor from main

logic board CN10 and turn the printer off and
then on. If the power LED lights correctly only
with the paper feed motor disconnected,
replace the paper feed motor.

6 Printhead

Printhead Cables

Disconnect the pri nthead cable fr om the sub
logic board and t urn the printe r on. If the po wer
LED lights correc tly only with the printhead
cables di sconnected f rom the sub logic board,
there is a short in the printhead or printhead
cables.

Disconnect the pri nthead cable fr om the sub
logic board and make sure none of the leads
on the cable are shorted to ground.

7 Main Logic Board If no problem is found with other components

but the pr in t e r st ill h a s a power pr oble m ,
replace the main logic board.

Reset the bidirectional print adjustment; refer
to “Bidirectional Print Adjustment” on page 4-5.

FRU Action

2-34

Print Speed Service Check

Reduced speed while printing the top 2 inch (51 mm) of a job is
normal; for Model 003 printers, the slow down can be eliminated by
entering S et u p Mode and disabling TOF Read. The speed of the
23XX 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
239X printers and protects the printhead from overheating.
Depending on the job content, therm al slowdown may occur after 5
to 10 minutes of continuous operation on 239X-001 printers and
after 10 to 20 minutes on 239X-002, 003 printers.

Print slowdown modes are as follows:

Thermal
Slowdown

Forms Thickness Slowdown

238X-001 No 26% speed reduction at Forms

Thickness 7.
Head Gap Sensor contai ns one
switch.

239X-001 Yes No Forms Thickness speed

reduction.
No Head Gap Sensor.

238X-002
238X-003

No Reduced print wire forc e at Forms

Thickness 1.
23% speed reducti on at Forms
Thickness 4 through 7.
Head Gap Se nsor Assemb ly contai ns
two switches.

239X-002
239X-003

Yes Reduced print wire force at Forms

Thickness 1.
20% speed reductions at Forms
Thickness 4 through 7.
Head Gap Se nsor Assemb ly contai ns
two switches.

Diagnostic Information 2-35

FRU Action

1 Head Gap Sensor

23XX-001

Check the fun cti on of the head gap sensor by
moving the forms thickness lever from 6 to 7
and back while prin ting the Demo Page
Alt + Demo. Pri n t s p eed is reset a t the
beginning of each line; listen for the printer to
slow down in position 7.

Disconnect the head gap sensor from
connector CN3 on the sub logi c board. Check
the resistance of the sensor while moving the
forms thickness le ver. Resis tance should be 0
ohms at forms thickness position 7 and infinite
at positions 1 through 6.

2 Head Gap Sensor

23XX-002
23XX-003

Check the fun cti on of the head gap sensor by
turning the power on with the Alt + Macro
buttons pressed.

• With the forms th ick ness le ver at 1, Macro
LED 1 will light.

• With the forms thickness lever at 2 and 3,
Macro LED 2 will light.

• With the forms thickness lever at 4
through 7, Macro LED 3 will light.

Disconnect the head gap sensor asm from
connector CN3 on the sub logi c board. Check
the resistance of the sensor while moving the
forms thickness le ver. Resis tance should be 0
ohms at position 1 and infinite at positions 2
through 7.

Disconnect the head gap sensor asm from
connector CN4 on the sub logi c board. Check
the resistance of the sensor while moving the
forms thickness le ver. Resis tance should be 0
ohms at positions 1 through 3 and infinite at
positions 4 thr ough 7.

2-36

Printhead Service Check

FRU Action

1 Printhead Cables

Printhead

If the problem is missing or extra dots or lines,
do the following:

• Check the cont inuity and connection of
the printhead ca bl es and th e short fle xib le
cable.

• Make sure the voltages to the sub logic
board are correct.

If dots are missing:

• Perfo rm the print test to determine which
wire is not firing.

• Remove the printhead and check the
printhead resistance according to the
following table. Make sure no pins have
contin uity to the printhead housi ng.

Diagnostic Information 2-37

1 Printhead Continuity Table

The correct resistance is:

2.8 to 3 .8 ohms (238X) or 7 t o 15 ohms (239X).

238X

CP9-10 & CP9-12 (Dot1)
CP9- 6 & CP9- 4 (Dot2)
CP9-17 & CP9-14 (Dot3)
CP9- 7 & CP9- 3 (Dot4)
CP9-15 & CP9-11 (Dot5)
CP9- 1 & CP9- 5 (Dot6)
CP9-18 & CP9-13 (Dot7)
CP9- 2 & CP9- 8 (Dot8)
CP9-16 & CP9- 9 (Dot9)

239X

CP8-10 & CP8-13 (Dot1)
CP8- 8 & CP8- 7 (Dot2)
CP8-12 & CP8-13 (Dot3)
CP8- 6 & CP8- 7 (Dot4)
CP8-14 & CP8-11 (Dot5)
CP8- 4 & CP8- 7 (Dot6)
CP8-16 & CP8-11 (Dot7)
CP8- 2 & CP8- 9 (Dot8)
CP8-18 & CP8-11 (Dot9)
CP8- 1 & CP8- 9 (Dot10)
CP8-17 & CP9-10 (Dot11)
CP8- 3 & CP8- 9 (Dot12)
CP8-15 & CP9-10 (Dot13)
CP8- 5 & CP9- 8 (Dot14)
CP9-16 & CP9-12 (Dot15)
CP9- 4 & CP9- 8 (Dot16)
CP9-17 & CP9-12 (Dot17)
CP9- 2 & CP9- 8 (Dot18)
CP9-15 & CP9-12 (Dot19)
CP9- 1 & CP9- 6 (Dot20)
CP9-13 & CP9-14 (Dot21)
CP9- 3 & CP9- 6 (Dot22)
CP9-11 & CP9-14 (Dot23)
CP9- 5 & CP9- 6 (Dot24)

If the problem is not missing or extra dots or
lines, do the following:

• Make sure the printhead is securely
installed in the carrier .

• Perform the Printhead-to-Platen Gap
adjustment.

FRU Action

2-38

Pull Tractor Sensor Service Check

Note: The pull tractor sensor detects the tractor in the pull position

and disables park/load and auto tear-off. A failed sensor may
prevent park/load from functioning with the tractor in the push
position.

2 Carrier Shaft

Carrier Unit
Platen Assembly
Printhead Nose
Ribbon Guide

Check and replace worn or damaged parts.

FRU Action

1Pull Tractor

Sensor

With the tractor in the push position, press
Alt+Park/Load several times whi le al ternately
holdin g down and releasing the left pull tract or
actuato r . The paper shoul d park an d loa d wh en
the actuator is not held down, and should not
park or load when the pull tractor act uator is
hel d d ow n.

If the paper does not move cor rectly:

• Disconnect CN4 from the main logic
board.

• There should be 0 ohms from
CP4-1 to CP4-2 when the left pul l t ractor
actuator is pr essed, and infinite
resist ance when the actuator is not
pressed.

• Replace the sens or i f necessary.

If t he sensor is good b ut th e pa per st ill doe s no t
mov e correctly:

• Replace the main logic board.

• Reset the Bidir ectional Alignment, see
“Bidirectional Print Adjustment” on page

4-5.

FRU Action

Diagnostic Information 2-39

Top of Forms Problem Service Check

Note: This service check applies to the 23XX-002 and 23XX-003

pri nters only. 23XX-001 machines have a single paper sensor that
serves as a paper empty sensor and also determines the top of form
setting. For top of forms problems on 23XX-001 printers, refer to the

“P aper Empty Sensor Service Check” on page 2-26.

23XX-002 and 23XX-003 machines have two sensors:

• The left sensor is paper empty.

• The right sensor is top of form.

FRU Action

1 Top of Form

Sensor

Check that the top of form sensor and its flag
are properly installed and are undamaged.

2 Main Logic Board Remov e the paper and set the paper select

le ver t o th e cut sheet position and turn th e
power on.

Measure the v olta ge bet ween main l ogic boa rd
CN8-2 (TOF signal) and CN8-3 (GND).

• When there is paper in the printer the
voltag e should be 0 V dc.

• When there is no paper in the printer the
voltag e should be 5 V dc.

Replace the sens or i f the voltage is incorrect.
Replace the main logic board if the voltage is

correct and there is still a problem.
Reset the “Bidirectional Print Adjustment” on

page 4-5.

2-40

Tractor 2 Service Check

Note: This option can be used only on 23XX-003 printers.

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

• When Tractor 2 is selected the motor-driven Tractor 2 slider

pushes the printer sub slider cam lever to engage the printer
gear train which drives the Tractor 2 tractors.

• When the Tractor 2 is deselected, the motor retracts the slider,

disengaging the T ractor 2 gear drive and reengaging the printer
tractors.

Diagnostic Information 2-41

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

1Tractor 2

Home Sensor

Remov e the Tractor 2 and turn the printer off
and then on again to determine if the fault is in
the printer or Tractor 2.

If the gear teeth chatter just before the beeps,
replace the home sensor.

2 Main Logic Board Remove Tractor 2 fr om the pri nter b ut lea v e t he

cable connected. Make sure the slider (the
black plastic piece just above the right cover)
mov es after turning the printer off and then on.

If the slider does not move after turning the
printer off and then on:

• Make sure the slider and gear train are
properly connected and move freely with
the power off.

• Make sure the Tractor 2 board is
receiving:

+26 V dc on CN1-1 and
+ 5 V dc on CN1-5.

If not, check the cable connection and the
voltages at main logic board CN6-1.
The upper right pin at CN6 is pin 1 (+26 V dc)
and the pin just beneath it is pin 5 (+5 V dc).

If these voltages are not pre sent replace the
main logic board.

3 Tractor 2 Motor

Board /Cable Asm

Check the res istances of the Tractor 2 motor
windings: ther e should be 101 ± 5 ohms
between pins : 1 and 5, 3 and 5, 2 and 6 and
4 and 6. If the motor is good , rep lace the
board/cable assembly.

For information on the Tractor 2 cable
connectors, see “Tractor 2 Cable Connectors”
on page 5-4.

2-42

3 Beeps and Tractor 2 LED blinks 3 times

Tractor 2 selected from operator panel but printer does not detect Tracto r 2
or detects that the Tractor 2 mechanism is not installed.

FRU Action

1Tractor 2

Board/Cable Asm.

Check the Tractor 2 in-place sensor or the
cable connection.

The in-pla ce sensor actuator extends through
the Tractor 2 cover and rest s on the printer
cover when Tractor 2 is installed.

Remov e the Tracto r 2 cov er an d make sure the
in-place sensor opens when the Tractor 2 is
installed. The vol tage at Tractor 2 CN1-13
should be +5 V dc with the sens or open and 0
with it closed.

Replace the Tractor 2 board/cable asm if the
sensor si gnal is wrong.

For informati on on the Tractor 2 cable
connector s, see “Tractor 2 Cable Connectors”
on page 5-4.

2 Main Logic Board Check the cable connection from Tractor 2 to

the printer.
If poss ibl e, t ry the Tracto r 2 with ano the r printer

to determine if th e problem is the Tractor 2
board/cable assembly or the printer main logic
board.

Diagnostic Information 2-43

Paper Feed Probl em s

FRU Action

1 Tractor 2 On the printer, make sure the gear that drives

Tractor 2 turns freely when the lever is not
pressed, but remain stil l when the lever is
pressed.

Remove Tractor 2 from the printer and remove
all paper. With the paper select le ver in the
continuous forms posit ion, press Line Feed;
the tractors should rotat e.

Press the sub slider cam lever below the ASF/
T r actor 2 driv e gear and press Line F eed agai n;
the tractor s sho uld not rota te b ut the driv e ge ar
should.

Check the condi tion of the pin feed belts. Wi th
the power off, make sur e th e sli de r does not
bind.

Verify

:

• When the slider is to the rear, the white
gear drives the tractors;

• When the slider is to the front t he gear
and tractors are not connected.

Remov e the Tractor 2 cover and reinstall
Tractor 2 i n th e p rinter ( if neces sary remo v e the
printer covers also). Note that the small idl er
gear just belo w the sl i der is held i n place b y the
cover; with the cover removed it will tend to
mov e off the st ud. Also note that when
operating the Tractor 2 with the printer cover
removed, the Tractor 2 in-place sensor must be
held open.

Turn the printer on and look for mechanical
problems.

For information on the Tractor 2 cable
connectors, see “Tractor 2 Cable Connectors”
on page 5-4.

2-44

Diagnostic Aids 3-1

3. Diagnostic Aids

The printer contains self tests to help find and solve problems. You
need not connect the printer to a computer or terminal to run these
tests.

Types of self tests are as follows:

• Power-On Self Test (POST)

• Print Test

• Hex Dump Mode (a computer or terminal is needed)

• Serial Interface Adapter Print Test

The following are special machine modes that run when the printer
is turned off and then back on:

Turn the printer on while
Pressing:

Does This:

Line Feed Print test with sample fonts.
Alt Sets printer in Hex Dump mode.
Micro↑ & Micro↓ Disables/Enables Operator Panel

Lockout Mode.

Alt + Tear Off (with
printhead at extreme left)

Resets to World Trade default paper
sizes.

Alt + Setup (with printhead
at extreme left)

Resets to US default paper sizes.

Alt + Macro
(23XX-002, 003)

Head Gap Sensor Test: Macro LEDs
indicate sensor position.

3-2

Power-On Self Test (POST)

The following tests are automatically performed when the printer is
turned on.

• LEDs Test (Checks that the LEDs on the operator panel work.

The LEDs turn on and off after the printer is turned on then all
LEDs turn on for a few seconds.

• RAM Test (Checks that the CPU can write/read the RAM.)

• Font ROM/Microcode Sum Test (Checks that the ROM data is

correct.)

• Timer/Interrupt Controller Test (Checks t hat this function works.)

• NVRAM Test (Checks that the NVRAM data is correct.)

• Switch Scan Tes t (Checks the buttons on operator panel.)

• Carrier Initialization (Carrier moves to the left to activate the

home position sensor, then moves to the first print position.)

• Feed Initialization (Form feed motor rotates forward, then

backward.)

If any errors occur during the POST tests, a combination of blinking
LEDs will indicate which test failed. See “Start” on page 2-1.

Diagnostic Aids 3-3

Print Test

The print test can help you test and troubleshoot the printer. To start
the print test, do the following:

1. Paper must be at the print position; test does not print if paper is
parked.

2. Press and hold Line Feed and then turn the printer on.

3. Release Line Feed when the printing starts.

4. To interrupt the printer test:
– Press Start/Stop. The test stops after a complete line of

characters has printed.

– Press Start/Stop to continue the test sample.

5. To stop the printer test, turn the printer off.

The printout should be similar to the print test samples shown on
page 3-4.

If the printout is not like the sample, go to “Start” on page 2-1.
Note that the short horizontal lines at the top of the sample are a test

of each printhead wire numbered in sequence from top to bottom.

Service Notes

• Before starting the 2380 and 2390 print test, be sure letter size

paper is loaded in the machine.

• Before starting the 2381 and 2391 print test, be sure wide paper

is loaded in the machine, and that the right margin is set to 13.6
inches.

• After you complete any repairs, run the print test several times

to be sure the printer is operating correctly.

3-4

Print Test Sample (9 wire)

Print Test Sample (24 wire)

Diagnostic Aids 3-5

Hex Dump Mod e

The hex dump mode can help the user test and troubleshoot
programs. You can use the hex dump procedure to get a
hexadecimal printout of the data stream sent to the printer. All data,
including both control and character data, print in hexadecimal
instead of ASCII.

To activate hex dump mode:

1. Press and hold Alt and then turn the printer on.

2. After a few seconds, release Alt.

3. Start your application program. Be sure the printout is similar to
the hex dump sample shown. Two hexadecimal digits, followed
by a space, are printed for each byte of data sent to the printer.

4. The printer continues to print in hexadecimal until you turn the
printer off.

Hex Dump Mode Sample

3-6

Serial Interface Adapter Print Test

The serial interface adapter has a switch that enables a test of the
connection between the serial interface adapter and the printer main
logic board. This generates a short test print containing the serial
interface adapter code level and switch settings, and the printer
character set.

To run the serial interface test print:

1. Turn the print er off.

2. Tur n on serial interface Switch 10.

3. Turn the print er on .

If the printer does not generate a printout, there is a problem with th e
serial interface adapter or its connection to the printer. Check the
switch settings and be sure the serial interface adapter is correctly
installed.

When the test is complete, turn off Switch 10.

Repair Information 4-1

4. Repair Information

This chapter contains adjustments and rem oval 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 t o
electrostatic discharge (ESD). To prevent damage to ESD-sensitive
parts, follow the instructions below in addition to all the usual
precautions, such as turning off power before removing logic boards:

• Keep the ESD-sensitive part in its original shipping container (a

special “ESD bag”) until y ou are ready t o install the part into the
machine.

• 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 machine.

• Hold the ESD-sensitive part by its edge connector shroud

(cover); do not touch its pins. If you are removing a pluggable
module, use the correct tool.

• Do not place the ESD-sensitive part on the machine cover or on

a metal table; if you need to put down the ESD-sensitive part for
any reason, first put it into its special bag.

• Machine covers and metal tables are electrical grounds. They

increase the risk of damage because th ey 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 touchi ng other personn el.

Install machine covers when not working on the machine, and
do not put unprotected ESD-sensitive parts on a table.

• Keep all ESD-sensitive parts in a grounded metal cabinet

(case).

• Low humidity increases static electricity during cold-weather.

4-2

Adjustments

CAUTION: Be sure to unplug the power cord whenever you are

working on the printer with one of the covers removed.

Printhead-to-Platen Gap Adjustment

WARNING: To prevent damage to the printhead when this adjust-

ment is made, be sure a gap exists between the printhead and the
right end of the platen before you turn the printer on.

Perform the printhead-to-platen gap adjustment after replacing or
disassembling any of the following parts:

• Carrier

• Platen

• Pinch Roller (Lower)

• Ribbon Drive Rack Gear

• Side Frame (Left)

• Side Frame (Right)

• Paper Separator

• Feed Roller (Lower)

• Paper Guide.

Note: Make sure the top cover is installed.

Repair Information 4-3

1. Tur n the printe r off.

2. Remove the ribbon access cover.

3. Remove the ribbon cartridge and pape r.

4. Set the form thickness lever to position 1.

5. Move the carrier so that it is just to the left of the left upper feed
roller, approximately 50 mm (2.0 in.) from the left side frame.

6. Using feeler gauges [1] of 0.35 mm and 0.40 mm (0.014 in. and

0.016 in.), move the left carrier bushing [2] forward or backward
until the gap between the printhead [3] and platen [4] is between

0.35 mm - 0.40 mm (0.014 in. - 0.016 in.).

Note: The gap should be wide enough for the 0.35 mm (0.014 in.)
feeler gauge to slide in smoothly without catching, but too narrow to
insert the 0.40 mm (0.016 in.) feeler gauge.

4-4

7. Move the carrier so that it is just to the right of the right upper
feed roller, approximately 50 mm (2.0 in.) from the right side
frame.

8. Using feeler gauges [1] of 0.35 mm and 0.40 mm (0.014 in. and

0.016 in.), move the right carrier bushing [2] forward or
backward until the gap between the printhead [3] and platen [4]
is between 0.35 mm - 0.40 mm (0.014 in. - 0.016 in.).

Note: The gap should be wide enough for the 0.35 mm (0.014 in.)
feeler gauge to slide in smoothly without catching, but too narrow to
insert the 0.40 mm (0.016 in.) feeler gauge.

9. Repeat Steps 5 and 6 and readjust the gap if necessary.

10. Repeat Steps 7 and 8 and readjust the gap if necessary.

11. Set the form thickness lever to suit the paper thickness you are
using.

12. Install the ribbon cart ri dge and paper.

13. Install the ribbon access cover.

14. Run the self test and check the density of the printing. Repeat
procedure if necessar y.

Repair Information 4-5

Bidirectional Print Adjustment

After replacing any mechanical par t which affects the operation of
the main logic board or the carrier, perform the following procedure
to adjust the bidirectional print.

Note: This adjustment cannot be completed if the printer runs out of
paper, so be sure to use continuous forms.

1. Be sure the ribbon cartridge and continuous forms are installed.

2. Tur n the printe r on.

3. Press Alt and then press Micro↑ . The printer enters Setup
Mode.

4. Press the Control Options button. (Button varies with model.)

5. Press the Bidirectional Alignment button. (Button varies with
model.)

6. Press Font. The printer prints out the pattern shown below . The
first and third lines are printed from left to right. The second and
fourth lines are printed from right to left.

4-6

7. Align the second and fourth lines to the first and third lines.
Each time Micro↑ is pressed, the second and fourth lines shift
towa r d the l e ft. Ea c h ti me Micro ↓ is pressed, the second and
fourth lines shift toward the right.

8. Continue adjusting the bidirectional alignment by repeating step
7, until your printout resembles the one shown.

9. When the bidirectional alignment is satisfactory, press Start/
Stop to exit the bidirectional alignment mode.

Repair Information 4-7

Removal Procedures

Use the following procedures to remove and replace individual
FRUs. The procedures in this section are mainly for the 2380 and
2390 printers. When a procedure for the 2381 and 2391 printers
differ , the procedure for the 2381 and 2391 is described under “Wide
Carriage”.

CAUTION: Be sure to unplug the power cord whenever you are
working on the printer with one of the covers removed.

4-8

Auto Sheet Feeder Gears Removal

1. Remove the right cover.

2. Release the latch [A], and then remove the joint gear [1].

3. Remove the idler gear [2].

4. Release the latch [A], and then remove the idler gear [3].

5. Release the latch [8], and then remove the pick-up gear [4].

6. Release the latch [A], and then remove the combination lock
mechanism [5].

7. Remove the tension plate [10] on the locker cam [6].

8. Remo ve the l o cke r cam [6].

9. Release the latch [9], and then remove the lift gear [7].

Repair Information 4-9

Auto Sheet Feeder Pick-up Roller Removal

1. Remove the covers and the cut sheet support.

2. Remove the idler gear and pick-up gear
see “Auto Sheet Feeder Gears Removal” on page 4-8.

3. Remove the left roller bushing [1] as shown.

4. Remove the right roller bushing [2].

5. Move the pick-up roller [3] to both ends of the shaft, and then
remove them.

4-10

Bottom Cover Removal

1. Remove the tractor assembly
see “Push Tractor Assembly Removal” on page 4-53.

2. Remove the top cover
see “Top Cover Removal” on page 4-61.

3. Remove the main logic board
see “Main Logic Board Removal” on page 4-33.

4. Remove the power supply unit
see “Powe r S upply Re mo v al ” on page 4-46.

5. Remove the print unit see “Print Unit Removal” on page 4-47.

6. Remove the rubber board support [5].

7. 2380 & 2390 - Release the two latches [1] and then remove the
Main Logic Board ground plate [2] by sliding it toward you.

• 2381 & 2391 - Remove the two screws securing the Main

Logic Board ground plate [2] to the b o ttom co ve r. Re le ase
the two latches [1] and then remove the Main Logic Board
ground plate from the bottom cover by sliding it toward you.

8. Release the two latches [1] th en re m ove th e power su pply
ground plate [4] by slid ing it toward you.

Repair Information 4-11

4-12

Carrier Removal

1. Remove the top cover
see “Top Cover Removal” on page 4-61.

2. Remove the printhead
see “Printhead Removal” on page 4-48.

3. Remove the printhead cables from the carrier assembly
see “Printhead Cables Removal” on page 4-49.

4. Remove the sub logic board
see “Sub Logic Board Removal” on page 4-59.

5. Remove the paper feed motor and the paper feed motor plate
see “Paper Guide / Platen Assembly Removal” on page 4-40.

6. Move the carrier to the center of the printer.

7. Remove the belt tension spring [1] from the hook closest to the
tension pulley.

8. Loosen the screw [4] securing the tension pulley plate asm [2].

9. Remove the carrier belt [3] from the tension pulley.

Repair Information 4-13

10. Release the ground spring [11] from the end of the carrier shaft;
the spring need not be removed.

11. Rotate the left carrier bushing.

12. Remove the lever stop bracke t from the carrier motor
(bracket not present on all machines).

13. Release the latch [8] and slide the carrier shaft and forms
thickness lever to the left and remove them together from the
printer. Do not to lose the gap set collar [15] attached to th e
right end of the carrier shaft.

14. Lift the rear of the carrier [12] to disengage the carrier ribbon
drive gears, then remove the carrier. Do not to lose the oil felt
[14].

15. Be sure to get the carrier shaft correctly through the oil felt.

16. Perform the Printhead-to-Platen Gap Adjustm ent
see “Printhead-to-P laten Gap A djustmen t” on page 4-2.

4-14

Repair Information 4-15

This Page Intentionally Blank.

4-16

Carrier Motor Assembly Removal

1. Remove the top cover
see “Top Cover Removal” on page 4-61.

2. Remove the sub logic board
see “Sub Logic Board Removal” on page 4-59.

3. Move the carrier to the center of the printer.

4. Remove the belt tension spring [1] and loosen the screw [2].

5. Remove the carrier belt [3] from the tension pulley and the
carrier motor pulley.

Repair Information 4-17

6. Disconnect the carrier motor cable [4] from connector CN9 on
the main logic board.

7. Remove the screws [5] and [6] and then remove the carrier
motor assembly from the left side frame.

4-18

Carrier Plate Removal

1. Remove the tractor assembly
see “Push Tractor Assembly Removal” on page 4-53.

2. Remove the top cover
see “Top Cover Removal” on page 4-61.

3. Remove the paper select lever
see “Paper Select Lever Remov al” on page 4-42.

4. Remove the printhead
see “Printhead Removal” on page 4-48.

5. Remove the printhead cables
see “Printhead Cables Removal” on page 4-49.

6. Remove the sub logic board
see “Sub Logic Board Removal” on page 4-59.

7. Remove the paper feed motor
see “Paper Guide / Platen Assembly Removal” on page 4-40.

8. Remove the carrier motor assembly
see “Carrier Motor Assembly Removal” on page 4-16.

9. Remove the tension pulley plate assembly
see “Tension Pulley Plate Assembly” on page 4-60.

10. Remove the carrier see “Carrier Removal” on page 4-12.

11. 23XX-002, 003: Remove the tractor idler gear.

12. 23XX-002, 003: Remove the support plate.

13. Remove the lower pinch roller
see “Lower Pinch Roller Removal” on page 4-32.

14. Remove the gears on the right side frame
see “Right Side Fram e Gears Removal” on page 4-58.

15. Remove the ribbon drive rack gear
see “Ribbon Drive Rack Gear Removal” on page 4-54.

16. Remove the home position sensor
see “Home Position Sensor Removal” on page 4-25.

17. Remove the paper separator spring [2].

18. Remove the screw [3] from the paper separator.

19. 23XX-001, 002 - Release the latch, and then remove the
release slider cam [4] from the right side frame.
23XX-003 - Remove the slider cam screw and spring. Remove
the sub slider cam and the slider cam from the right side frame.

20. Remove the two screws [5] and the screw [6].

Repair Information 4-19

4-20

21. Gently bend both side frames outward to release tabs [7] from
the slots [8]. Lift and remove the carrier plate.

Repair Information 4-21

Download or Print Buffer Module Removal

Notes:

• Turn the printer Off and disconnect the power cord at the

printer.

• The Download Module and the Print Buffer Module are options.

1. Remove the rear cover .

2. Remove the paper support.

3. Insert a small flat scre wdrive r [1] under each end of the module
and lift up gently. (On 23XX-002, 003 printers only one end of
the module is accessible.) Do not insert the screwdriver too
deep, or the main logic board may be damaged.

Note: Be careful not to bend the pins when you re-install the
module.

4-22

Form Thickness Lever Removal

1. Remove the top cover
see “Top Cover Removal” on page 4-61.

2. Remove the sub logic board
see “Sub Logic Board Removal” on page 4-59.

3. Remove the paper feed motor and the paper feed motor plate
see “Paper Guide / Platen Assembly Removal” on page 4-40.

4. Remove the lever stop bracket from the carrier motor
(bracket not present on all machines).

5. Remove the screw and washer [3].

6. Release the latch [4] and remove the form thickness lever [5].

Repair Information 4-23

Head Gap Sensor Removal (238X-001 )

1. Remove the top cover
see “Top Cover Removal” on page 4-61.

2. Remove the sub logic board
see “Sub Logic Board Removal” on page 4-59.

3. Remove the paper feed motor and the paper feed motor plate
see “Paper Guide / Platen Assembly Removal” on page 4-40.
When the paper feed motor plate is removed, the idler gear [3]
may come off simultaneously.

4. Remove the head gap sensor [2].

4-24

Head Gap Sensor Removal (23XX-002, 003)

1. Remove the top cover
see “Top Cover Removal” on page 4-61.

2. Remove the sub logic board
see“Sub Logic Board Removal” on page 4-59.

3. Remove the paper feed motor and the paper feed motor plate
see “Paper Guide / Platen Assembly Removal” on page 4-40.

4. Move the forms thickness lev er to position 7.

5. Remove the screw [1] and remove the head gap sensor
ass embly [2].

6. When you re-install the sensor , be sure the rear of the head gap
sensor assembly is held in place by the paper feed motor plate.

Repair Information 4-25

Home Position Sensor Removal

1. Remove the top cover
see “Top Cover Removal” on page 4-61.

2. Disconnect the home position sensor cable from the sub logic
board.

3. Remove the screw [1], and then remove the home position
sensor from the left side frame. The sensor is attached to the
left side support plate on newer models.

4-26

Label Jam Removal

When a pressure-sensitive label that separates from its protective
backing has jammed and stuck to the paper separator and/or below
the carrier plate, the following procedure should be used to remove
the jammed label.

1. Remove the top cover
see “Top Cover Removal” on page 4-61.

2. Remove the tractor assembly
see “Push Tractor Assembly Removal” on page 4-53.

3. Remove the print unit see “Print Unit Removal” on page 4-47.

4. Remove the paper separator
see“Paper Separator Removal” on page 4-44.

5. Carefully remove the jammed label from the mylar strip on the
paper separator. If the mylar strip is damaged, replace the
paper separator. If the label is jammed below the carrier plate or
on the lower plastic portion of the paper guide/platen assembly,
carefully remove the jammed label without scratching either
surface or damaging the mylar strips that rest on the lower feed
rollers.