Lexmark 2391 Plus Service Manual

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Page 1

Lexmark 23XX Series

• Table of Content s

• Start Diagnostics

• Safety and Notices

• Trademarks

23XX-XXX

•Index

Lexmark and Lexmark with diamond design are trademarks of Lexmark International, Inc., registered in the United States and/or other countries.

Page 2

Edition: April 2000

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

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

This publication could include technical inaccuracies or typographical errors. Changes are periodically ma de to the information herein; these changes will be incorporated in later editi ons of the pub lic ation. Impro ve ments or ch anges in th e products or the programs described in this publication may be made at any time. Publications are not stocked at the address given below; requests for publications should be made to your point of purchase.

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

Lexmark is a trademark of Lexmark International, Inc.

 Copyright Lexmark International, Inc. 1996, 2000

UNITED STATES GOVERNMENT RESTRICTED RIGHTS

This software and documentation are provided with RESTRICTED RIGHTS. Use, duplication or disclosure by the Government is subject to restrictions as set forth in subparag raph (c)(1 )(ii) of the R ights in Technical Data and Compute r Software clause at DFARS 252.227-7013 and in applicable FAR provisions: Lexmark International, Inc., Greenwich, CT 06836.

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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

Contents v

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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 Cover 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 Thickness Lever Removal . . . . . . . . . . . . . . . . . . 4-22

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

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

Home Position Sensor Removal . . . . . . . . . . . . . . . . . . 4-25

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

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

Lower Feed Roller Removal . . . . . . . . . . . . . . . . . . . . . 4-30

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

Main Logic Board 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 Removal . . . . . . . . . . . . . . . . . . . . . . . . . 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

vi Service Manual

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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

Contents vii

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

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

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

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

Assembly 3: Carrier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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

viii Service Manual

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Notices and Safety Informatio n

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 necessar y pr ec autions.

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

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

Sicherheitshinweise

• Die Wartungsinformationen für diese s Produ kt si nd

ausschließlich für die Verwendung durch einen Wartungsfachmann bestimmt.

• Während des Auseinandernehmens und der Wartung des

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

• Ers atzteile müssen gleiche oder gleichwertige Merkmale wie

die Originalteile aufweisen, da nicht immer offensichtlich ist, welche Teile des Geräts Sicherheitsmerkmale aufweisen.

Consignes de Sécurité

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

s'adressent uniquement à un personnel de maintenance 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 n ormes de sécurité de certaines pièces n'étant pas toujours

explicites, les pièces de rechange doivent être identiques ou conformes aux caractéristiques des pièces d'origine.

Notices and Safety Information ix

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Norme di sicurezza

• Le informazioni riguardanti la manutenzione di questo prodotto

sono indirizzate soltanto al personale di assistenza autorizzato.

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

rischio di subire scosse elettriche e danni alla persona 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 información sobre el mantenimiento de este producto está

dirigida exclusivamente al personal cualificado de mantenimiento.

• Existe mayor riesgo de descarga eléctrica y de daños

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

• Los dispositivos de seguridad de algunas piezas no siempre

pueden reconocerse a simple vista. Por lo tanto, los recambios deben poseer 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 serviços 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 necessários.

• 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 originais.

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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 pr oc és de desmuntatge i de servei d’aquest producte. El personal professional ha d’estar-ne assabentat i prendre les mesures convenients.

• Les característiques de segu retat d ’algunes de les peces poden

no ser òbvies. P er tant, les característiques dels recanvis hauran de ser idèntiques o equivalents a les de les peces originals.

Chinese Safety Information

Notices and Safety Information xi

Page 10

Korean Saf e ty Information

xii

Page 11

Preface

This manual is divided into the following chapters:

• “General Information” contains a general description of the

printer and the maintenance approach used to repair it. Special tools and test equipment are listed in this chapter, as well as general environmental and safety instructions.

• “Diagnostic Information” contains error code table, symptom

table, and service checks used to isolate failing field replaceable units (FRUs).

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

repeat symptoms of printer problems.

• “Repair Information” provides instructions for making printer

adjustments and removing and installing FRUs.

• “Connector Locations” uses illustrations to identify the major

components and test points on the printer.

• “Preventive Maintenance” contains lubrication specifications,

and maintenance information to prevent problems and maintain optimum performance.

• “Parts Cat alog” contains illustrations and part numbers for

individual FRUs.

Preface xiii

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xiv

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1. General Information

Description

The Lexmark 238X and 239X - XXX printers are small versatile tabletop printers suitable for use in the home or small business. They are especially well-suited for applications that use continuous or multipart forms. The 2381 and 2391 are wide-carriage versions of the 2380 and 2390.

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

• Forms macro and smooth paper scrolling capability, available

from the operator panel.

• Option slot.

• Resident bar code.

• Quiet mode.

• Higher print speed (239X).

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

There is also a PS/1 version of the 2390-001, which has a distinctive PS/1 logo but is otherwise identical to the 2390-001.

General Information 1-1

Page 14

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

US Logo Name

WTC Logo Name

Mach T ype 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 Narrow 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 Narrow No 2391 Plus 2391 Plus 2391-002 24 Wide No Forms

Printer 2380 Plus

Forms Printer 2381 Plus

Forms Printer 2390 Plus

Forms Printer 2380 Plus

Forms Printer 2381 Plus

Forms Printer 2390 Plus

2380-003 9 Narrow No

2381-003 9 Wide No

2390-003 24 Narrow No

Forms Printer 2391 Plus

1-2

Forms Printer 2391 Plus

2391-003 24 Wide No

Page 15

Specifications

• Printhead life: 140 Million Characters

• Ribbon Life: 4 Million Characters

• Printer Life: 5 Years

• BTU: 409-Maximum/51 Idle (Per Hour)

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

Recommended Machine Usage

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

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

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

Notes:

• All numbers are average or estimates.

• Performance of individual printers may vary.

• Le xmark does not represent or warrant that printers will achieve

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

General Information 1-3

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Options

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

• Auto Sheet Feeder (ASF)

• 32Kb Memory Module, Volatile

• 32Kb Memory Module, Non-volatile

• Serial Interface Attachment (RS232/RS422).

• Extended National Language Support modules (World Trade

only)

• Acoustics Option

• Extended Cut-sheet Paper Guides

• Tractor 2 (23XX-003 Only)

Tools

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

1-4

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Abbreviations

ASIC Application-Specific Integrated Circuit CSU Customer Setup DRAM Dynamic Random Access Memory EPROM Erasable Programmable Read-Only Memory ESD Electrostatic Discharge FRU Field Replaceable Unit HVPS High Voltage Power Supply LAN Local Area Network LCD Liquid Crystal Display LED Light-Emitting Diode LVPS Low Voltage Power Supply NVRAM Nonvolatile Random Access Memory OEM Original Equipment Manufacturer POR Power-On Reset POST Power-On Self Test PQET Print Quality Enhancement Technology ROS Read-Only Storage SRAM Static Random Access Memory UPR Used Parts Replacement V ac Volts alternating current V dc Volts direct current

General Information 1-5

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Setup Mode

How To Change The Printer Functions

1. Make sure continuous forms are in the printer.

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

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

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

1-6

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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 short cable to the parallel port.

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

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

• Switch settings are for “Gray”.

• 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.

General Information 1-7

Page 20

Serial Interface Switches

The serial interface has 12 function switches which determine how the printer receives data from the computer or terminal. Set the switches according to your particular equipment requirements.

Function Switch Setting

Switches 1 To 4 - Speed:

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

Snap-On and Gray Serial Adapters

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

On On Off Off 150 On Off On Off 300 On Off Off Off 600 Off On On Off 1,200 Off On Off Off 2,400 Off Off On Off 4,800

1-8

Off Off Off Off 9,600 On On On Off 19,200 Off Off Off On 38,400

(RS-422 only)

Page 21

Black Serial Adapter

Switch 1 Switch 2 Switch 3 Speed (bps)

N/A N/A N/A 150

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

(RS-422 Only)

Switch 5 - Data Bits:

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

Switch 5 Data Bits

Off 8 On 7

General Information 1-9

Page 22

Switches 6 and 7 - Parity:

Select the interface parity.

Switch 6 Switch 7 Parity

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

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

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

Switch 8 Stop Bits

Off 1 Stop Bit On 2 Stop Bits

Switch 8 - Buffer Size (Gray and Black):

Selects the buffer size.

Switch 8 Buffer Size

Off Normal (2048 bytes) On Minimum (2 bytes)

1-10

Page 23

Switch 9 - Protoc ol:

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

Snap-On and Gray Units

Protocol

Switch 9

Snap-On Gray

Off XON/XOFF DTR Pacin g (RS232 only ) On DTR pacing (RS232 only) XON/XOFF

Black Units

Switch 4 Switch 9 Protocol

Off On XON/XOFF Off Off DTR pacing (RS232 only) On Off DTR + XON/XOFF Off On Robust XON/XOFF

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

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

Switch 10 Print Test

Off Normal mode On Test mode

General Information 1-11

Page 24

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

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

Switch 11 Mode

Off Normal On Reverse

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

Switch 12 Mode

Off RS-232C On RS-422

1-12

Page 25

2. Diagnostic Inf ormation

Start

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

Voltage, Ground, And Continuity Readings

Voltage Readings

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

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

Ground Checks

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

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

Continuity Readings

When measuring continuity , be sure no back circuits affect the measurement. If necessary, unplug connectors to remove any back circuits. Zero the ohm range on the lowest scale (X1). An open circuit will read infinity. A circuit with correct continuity will read zero ohms.

Diagnostic Information 2-1

Page 26

Error Indication Table

The following table describes the service check entries for the printer error indication codes.

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

Indication Alarm Action

LED Status

Power Ready Paper Font Pitch Alt Others

LED Status

Power Ready Paper Font Pitch Alt Others

ON ON ON ON ON ON ON

ON ON ON ON ON ON OFF

None Post Error

Go to “POST Service Check” on page

2-31.

None RAM, ROM, Timer Interrupt Controller

Error

Turn the machine off and then on. If you get the same error during power-up, replace th e main logic board and readjust t he bidirectional print adjustment. If the printer completes POST successfully and eventually gets the same error, go to “Intermittent

Problem Service Check” on page 2-20.

2-2

Page 27

Indication Alarm Action

LED Status

Power Ready Paper Font Pitch Alt Others

LED Status

Power Ready Paper Font Pitch Alt Others

LED Status

Power Ready Paper Font Pitch Alt Others

ON BLINK BLINK OFF BLINK OFF OFF

ON BLINK BLINK BLINK OFF OFF OFF

ON BLINK BLINK BLINK BLINK OFF OFF

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 printer 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 Feed 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 Tr actor 2 home sensor. Refer to the “Tractor 2

Service Check” on page 2-40.

None Home Position Error Without Alarm

Go to “Power Service Check” on page

2-32.

Diagnostic Information 2-3

Page 28

Indication Alarm Action

None Logical Error

LED Status

Power Ready Paper Font Pitch Alt Others

ON BLINK BLINK BLINK OFF BLINK OFF

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 adjustment. If the printer completes POST successfully and eventually gets the same error chec k, go to “Intermittent

Problem Service Check” on page 2-20.

LED Status

Power Ready Paper Font Pitch Alt Others

LED Status

Power Ready Paper Font Pitch Alt Others

ON BLINK BLINK OFF BLINK BLINK OFF

OFF OFF OFF OFF OFF OFF OFF

None Hardware Drive 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 the main logic board and readjust the “Bidirectional Print Adjustmen t” on pa ge 4-5. If the printer completes POST successfully and eventually gets the same error, go to “Intermittent Problem

Service Check” on page 2-20.

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

None Power Failure

Check the continuity of the power cord and the voltage of the user’s outlet. If they are corre ct, go to “Power Service

Check” on page 2-32.

2-4

Page 29

Indication Alarm Action

LED Status

Power Ready Paper Font Pitch Alt Others

If other LED combinations along with the Po we r LED are on.

Any LED on but the Po w e r LED off.

If the Power LED blinks or changes intensity.

Any Beeps

ON OFF OFF OFF OFF OFF OFF

None Operator Panel Failure

None Go to “POST Service Check” on page

None Go to “Operator Panel Service Check”

None Go to “Power Service Check” on page

7 times

Go to “Operator Panel Service Check”

on page 2-24.

2-31.

on page 2-24.

2-32.

(Optional Serial Interface Adapter installed)

• Turn the printer off and check the connection from the s erial interfac e adapter to the printer.

• Turn the printer off and then on. If you get the same error, replace the serial interface adapter.

• If turning the printer off and then on is successful, run the “Serial Interface Adapter Print Test” on page 3-6.

Diagnostic Information 2-5

Page 30

Symptom/Check Table

1. Select the symptom that best describes the problem.

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

Abnormal Indications

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 interf ace cabl e from the printer and turn the printer off and then on. If POST now runs correctly, the problem is in the computer or interface cable.

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

Abnormal Noise Problems

Symptom Action

During POST, abnormal noise comes from the carrier.

During idling, abnormal noise comes from the printer.

When feeding pa per, abnormal noise is created.

During printing or POST, abnormal noise is created.

Check the ribbon cartridge for binds or damage. Go to the “Carrier Drive, Home Position Sensor,

Ribbon Feed Service Check” on page 2-17.

Go to “Abnormal Noise Service Check” on page

2-14.

2-6

Page 31

Abnormal Print Operation Problems

Symptom Action

Printer will not print, or become Ready.

Abnormal operation, incorrect characters, or incorrect line width.

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

Undefined or incorrect character(s).

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

Be sure the interface cable is connected properly. If the serial interf ace adap ter is instal led, be sure i t

and its power interface cable are installed correctly. (Some adapters do not have a separate power cable.)

Go to the “No Print or Abnormal Print Service

Check” on page 2-23.

2-34.

Auto Sheet Feeder Problems

Symptom Action

Auto sheet feeder will not feed paper.

Auto sheet feeder double feeds.

Auto sheet feeder has intermittent f eed problems.

Be sure Sheet Feed is enable d in the Setup Mode . Be sure the paper select lever is in the cut sheet

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

Check” on page 2-15.

Diagnostic Information 2-7

Page 32

Error Indications

Symptom Action Ready and Paper

Out lights blink to

indicate a Hardware Error.

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

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

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

2-13.

Paper Feed Problems

Symptom Action Paper Out is

blinking with paper in the printer.

Paper Out does not blink when no paper is in the printer and ASF is not installed.

Print operation starts without paper.

Alt + Park/Load does not function when the push tractor is installed.

Form feed length is not correct.

Go to the “Paper Empty Sensor Service Check” on

page 2-26.

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

page 2-26.

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

Go to the “Paper Select Sensor Service Chec k” on

page 2-30.

Alt + Park/Load functions with cut sheets in use.

2-8

Page 33

Symptom Action

Paper feeds, but Auto Loading does not work.

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

With Paper Out blinking, Form Feed does not operate until paper is located at first print line.

Lower feed roll shaft rotates, but paper does not feed.

Pressing Form Feed does not feed paper.

Abnorm al noise created while feeding.

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

Be sure Auto Loading is enabled in the Setup Mode.

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

page 2-30.

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

Go to the “Pull Tractor Sensor Service Check” on

page 2-38.

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

Go to the “Paper Feed Service Check” on page

2-27.

Pap er jams, skews or creases.

Incorrect or no line spacing: wider, narrower, or overlapping lines.

Push/Pull Tractor does not work.

Incorrect Top of Form positioning.

Go to the “Top of Forms P roblem Ser v ice Check”

on page 2-39.

Diagnostic Information 2-9

Page 34

Operator Panel Problems

Symptom Action Start/Stop does not

function but no error is indicated.

Only the Power light turns on.

One or more b uttons do not function.

One or more lights do not function.

Turn the printer off and then on. Go to the “Operator Panel Service Check” on page

2-24.

Power Problems

Symptom Action

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

The Power light blinks or changes intensity.

Check contin uity of the pow er co rd and the vol tage of the user’s outlet.

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

2-10

Page 35

Print Quality Problems

Symptom Action

No print, but carrier moves as if printing.

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

Unev en print densi ty across the print line.

Specific dots missing.

Extra dots or lines printing.

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

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

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

2-34.

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

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

Ribbon Feed Service Check” on page 2-17.

Be sure the printhead cables are connected correctly to the printhead and the sub logic board.

Clean the printhead. Set the form thic kness le v er to pos ition “1” an d run

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

Ribbon Feed Service Check” on page 2-17.

Scattered ink smearing, blurred characters.

Fuzzy print.

Clean the printhead nose. Clean the ribbon guide and shield. If the ribbon has reached its end of life or is worn,

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

Ribbon Feed Service Check” on page 2-17.

Diagnostic Information 2-11

Page 36

Symptom Action

Wavy vertical lines, uneve n left margin or character width is reduced.

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

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

Ribbon Feed Service Check” on page 2-17.

Ribbon Feed Problems

Symptom Action

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

Ribbon feeds correctly but is noisy.

Check the ribbon cartridge for binds or damage. Go to the “Carrier Drive, Home Position Sensor,

Ribbon Feed Service Check” on page 2-17.

2-12

Page 37

Irrecoverable Operator Errors

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

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

Paper Empty Sensor

Action Check

Remove all paper from the printer.

Turn the power on.

Paper Out blinks when paper does not exist. Paper Out turns off when paper exists.

Go to the “P aper Empty Sen sor Service Check ” on

page 2-26.

Paper Select Sensor

Action Check

Turn the power off. Install the Push

Tractor. Set the paper select

lever to the tractor position and load the continuous forms.

Turn the power on. Remove the

continuous forms. Set the paper select

lever to the cut sheet position and insert a cut sheet.

Alt + Park/Load function correctly. Go to the “P aper Sel ect Sensor Service Chec k” on

page 2-30.

When Auto Loading is enabled, paper feeds automatically.

When Auto Loading is dis ab led, pres s Form Feed to load a cut sheet. Check that Alt + Park/Load does not function.

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

page 2-30.

Diagnostic Information 2-13

Page 38

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.

3Carrier Motor

Ribbon Drive Mechanism

4 Paper Feed

Mechanism

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

If the abn o rmal noise is gone, look for a problem with the carrier motor or ribbon drive mechanism.

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

Perf o rm the Print Test. If the abnormal noise is gone, look for the

problem in the paper feed mechanism.

2-14

Page 39

Auto Sheet Feeder (ASF) Service Check

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

on page 1-6.

Auto Sheet Feeder Principles of Operation

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

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

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

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

The ASF contains no electrical parts. It is driven from the gear on the inside of the printer’s right side frame.

The combination lock mechanism is a clutch that causes the ASF pick rollers to feed only one sheet of paper at a time. When Auto Sheet Feeder is selected on the Setup Menu, the cut sheet paper drive reverses itself for a short distance during paper loading. This reversal engages the clutch and thus engages the paper picker rollers, which feed the top sheet from the cut sheet paper stack. The sheet is fed about 5 inches (125 mm) and the paper path briefly reverses again; 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 the following:

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

• If the paper loads go to the “Paper Select

Sensor Service Check” on page 2-30.

Diagnostic Information 2-15

Page 40

FRU Action

2 Paper Feed If the paper does not feed, do the following:

• Remove the ASF.

• Be sure the base printer feeds paper

correctly.

• If it does not feed paper correctly, go to the “Paper Feed Service Check” on page

2-27.

3 Gear Tr ain Be sure the ASF drive gear on th e ins ide of the

4 Combination Lock

Mechanism

5 Left and Right

Hoppers

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

debris. Remove the ASF right cover and ensure that

all gears are in good condition. Install the ASF and press Form Feed.

If the picker driv e shaft do es not rotate , replace the combination lock mechanism.

If the ASF picker rollers rotate but a single sheet is not pick ed, insp e ct the sp rings and corner separators on t he lef t a nd right h opp ers.

Make sure the paper l oad l e v er is in the c orrect position.

2-16

Page 41

Carrier Drive, Home Position Sensor, Ribbon Feed Service Check

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

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

A Home Position Error occurs when:

• The sensor is not closed.

• The sensor is not quickly opened.

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

turned off and then on.

Diagnostic Information 2-17

Page 42

FRU Action

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

2 Home Position

Sensor Sub Logic Board Short Flexible Cable

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

Manually move the carrier the full length of the carriage to check for binds and to make sure the ribbon advances when the carriage moves in either direction.

If the carrier binds check the following:

• Correct prin the ad-to -pl ate n gap.

• Clean and lubricated carr ier shaft.

• Idler pulley not binding.

• Ribbon drive rack gear teeth not

damaged.

If the carrier still binds: Remove the bel t and move the carrier again. If

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

If the carrier moves manually without binding but the Home Position Error still occurs, verify that the main logic board is receiving +26 V dc on pin CP11-1. Check that the 5 V dc home position sensor signal is getting to the main logic board. Check CP3-7 on the main logic board. Check CP6-1 on the sub logic board.

2-18

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

Page 43

FRU Action

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

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

table and make sure the resistance of the carrier motor windings are from 1 to 5 ohms for all printers.

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

CP9-1 & 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

Error still occurs, repl ace the main l ogic board. After replacing the main logic board or any

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

Diagnostic Information 2-19

Page 44

Intermittent Problem Service Check

FRU/Symptom Action

1 The machine

sometimes fails before POST is complete.

Check for the following:

1. Loose connectors. Reconnect all

connectors to the main and sub logic boards.

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

• Power supply ground.

• Machine frame gro und .

• Printer interface cable is grounded and

shielded.

• If the upper fee d rol l sh aft do es not have a

ground spring, install P/N 1368036.

3. Intermittently low volt ages . C hec k f o r ac an d all dc voltages and short circuits on the main and sub logic boards.

a. Check the customer’s outlet voltage and

ensure that it is within tolerance.

b. Check the continuity of the power

cord.

c. Disconnect the power supply cable

from the connectors CN11 on the main logic board and CN1 on the s ub logic board. Turn the printer pow er on and check all dc output voltages at CP11 and CP1.

2-20

Ensure the output 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 correct, replace the Power Supply Unit. If the failure remains, replace the main logic board and sub logic board.

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

Page 45

FRU/Symptom Action

2 Machine power

sometimes turns off.

3 Intermittently poor

print quality.

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

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

2. Check the continuity of the power cord.

3. Disconnect the power supply cable from the

connectors CN11 on the main logic board and CN1 on the sub logic board. Turn the printer power on and check all dc output voltages at CP11 and CP1. Be sure the output voltages are as follows:

CP11-1 (+26 V dc ±10%) & 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 one of the voltages is 0, go to the “Power

Service Check” on page 2-32. If the voltages

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

Do the following:

• Remove paper jams from the paper path.

• Clean all feed roller surfaces.

• Clean the ribbon shield and printhead.

• Clean the platen surface.

• Install the ribbon cartridge correctly.

• If the ribbon end of life has been reached,

have the customer replace the ribbon cartridge.

Diagnostic Information 2-21

Page 46

FRU/Symptom Action

4If the prior

suggestions have not corrected the problem.

5 Problem occurs

only in specific customer applications.

The service check has not defined the failure, or the machine is having intermittent failures. The following may cause undefined or intermittent failures:

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

2. Loose connector pins or keys that fail to

contact. Check the following:

a.Reconnect the connectors of all FRUs

and printer interface cables.

b.Check the continuity of the line cord.

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 customer applications.

Check the baud rate at the controller. Check that the printer interface cable matches the printer.

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

1. Turn the power off.

2. Tur n 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.

2-22

If the failure still occurs, replace the main logic board. Be sure to reset the bidirectional print adjustment, refer to the “Bidirectional Print Adjustment” on page 4-5.

Page 47

No Print or Abnormal Print Service Check

FRU/Function Action

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

2 Interface Cable Check the connection and continuity of the

3 Emulation Mode Enter the Setup Menu and make sure the

4 Serial Interface

Adapter

do the following:

• Replace the main logic board.

• Reset the bidirectional print adjustment.

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

interface cable.

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

If the serial interf a ce ad apt er i s i ns tal led , m ake sure the dip switches match the computer settings.

• Mak e sur e the seri al adapte r pow er cab le , if present, is securely connected to the printer power connector CN5.

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

Run the “Serial Interface Adapter Print Test” on page 3-6. If the test is not successful replace the serial interface adapter.

If no defect is found, the printer and serial interface adapter are working correctly. The problem may be with the interface cable, the computer, the printer driver, or the specific job being sent.

Diagnostic Information 2-23

Page 48

Operator Panel Service Check

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

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

FRU Action

↑ and Micro↓.

1 Op-Panel Cable

Sub Logic Board

Check the connec tions fro m the ope rator pa nel to the sub logic board and from the sub logic board to the main logic board.

Disconnect the operator panel from its cable and make sure +5 V dc is present on the follow ing pins on the cable:

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

If there is a voltage prob lem mak e sure the sub logic board is receiving +5 V dc on CN1-3. Replace the operat or panel cab le, the s ub logic board, or the power cable as necessary.

2-24

Page 49

FRU Action

2 Short Flexible

Cable

Disconnect the short flexible cable from the main logic board.

Check the continuity of the operator panel signal lines between the end of the short flexible c able a nd the oper ator panel c onnector 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 the short flex ible ca ble or the sub logic board as necessary.

If there is still a problem, replac e the oper at or panel. If that does not fix the prob lem, re -install the old operator panel and replace the main logic board. If you replace the main logic board, reset the “Bidirectional Print Adjustment” on page 4-5.

Diagnostic Information 2-25

Page 50

Paper Empty Sensor Service Check

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

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

23XX-002 and 23XX-003 mach in es have two sensors:

• The left sensor is paper empty.

• The right sensor is Top of Form.

FRU Action

1 Paper Empty

Sensor

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

With no paper in the printer, the tractor in the push position, a nd the p ape r s el ect lever set to continuous forms, press Alt+Park/Load; the gear train should turn forward (to try to load paper).

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

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

Make sure the sensor and its actuator are properly installed a nd u nda ma ged. Correct the problem or replace the sensor.

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

• Enter the Setup Menu.

• Make sure the ASF setting is off unless

the ASF is installed.

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

• Reset th e “Bid irec ti ona l Print A dju stm en t” on page 4-5.

2-26

Page 51

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 rollers and lower pinch rollers. If the gap is smaller on the left, install Shim Kit, P/N 1368067.

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

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

FRU / Symptom Action

1 Auto Sheet

Feeder

2 Gear Train Remove all paper from the machine.

If the Auto Sheet Feeder is installed, remove it. Enter the Setup Menu and reset “ASF” to off. V erify th at the machine works co rrec tly with ou t the ASF installed.

If the printer fails only with the Auto Sheet Feeder installed, refer to the “Auto Sheet

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

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

For better visibility, remove the co vers and reconnect the operator panel to the sub logic board.

The upper and lowe r fee d rollers an d the upper and lower pinch rollers should all be clean and in good condition, and should all rotate during Form Feed.

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

Diagnostic Information 2-27

Page 52

FRU / Symptom Action

3 Paper Selector

Lever

4 Operator Panel If paper does not move at all, verify that the

5 Paper Feed Motor Disconnect the paper feed motor cable CN10

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

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

• The tractor gear engages correctly in the continuous f o rms posi tio n.

• The tractor belts are in good condition and rotate correctly.

• The pinc h roller shafts mo ve downw ard as the lever moves to the cut sheet position.

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

Form Feed button is working as follows: With the tractor in the pus h po si tio n, power off,

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

Check” on page 2-24.

from the main logic board. No pin should have continuity to ground. The resistances should be as follow s:

2-28

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

Page 53

FRU / Symptom Action

6 Paper Select

Sensor

7 Pull Tractor

Sensor

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

Press Form Feed and time how long the gear train rotates.

• With the paper select lever in the cut sheet position (sensor open) the gear train should rotate for less than 2 seconds;

• With the lever in the continuous forms position (sensor closed), the gear train should rotate for more than 3 seconds.

If the printer does not do this, inspect the sensor to make sure it is being opened and closed by the paper separator.

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

Replace the sensor if the resistance does not change from zero to infin ite as the pap er select lever is moved.

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

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

Tractor Sensor Service Check” on page 2-38.

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

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

Diagnostic Information 2-29

Page 54

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 Auto Sheet Feed (ASF) is set to OFF in the Setup Mode.

Press Form Feed and time how long the gear train rotates.

With the paper select lever in the cut sheet position (sensor open) the gear train should rotate for less than 2 se co nds ; with the lever in the continuous forms position (sensor closed), the gear train should rotate for more than 3 seconds. If the printer d oes not do this , inspec t the sensor to mak e s ure i t is being opene d and closed by the paper separator.

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

Replace the sensor if the resistance does not change from zero to infin ite as the pap er select lever is moved from cut sheet to continuous forms.

If the sensor is good b ut the ge ar train does no t run the right length of time , set the hea d gap t o position 1 and disconnect the short flexible cable from CN3 on the main logic board. Check the continuity between CP3-6 (paper select sensor) and GND while actuating the paper select lever.

Cut Sheet Continuous Forms

23XX-001 1K ± 0.5K ohms 0K ± 0.5K ohms 12K ± 0.5K ohms 3.5K ± 0.5K ohms

23XX-002

2-30

If the resistance is correct, replace the main logic board. If the resistance is incorrect, replace the sub logic board.

Page 55

FRU Action

2 Pull Tractor

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 times while alternately holding down and releasing the left pull tractor actuator. The paper should not park or load when the pull tracto r ac tua tor is held down. If i t does, go to the “Pull Tractor Sensor Service

Check” on page 2-38.

POST Service Check

FRU Action

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

Service Check” on page 2-32.

2 Cables A faulty interface cable can cause POST

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

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

Check the condition and continuity of the operator panel cable .

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

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

4 Main Logic Board Replace the main logic board if necessary.

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

Diagnostic Information 2-31

Page 56

Power Service Check

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

FRU Action

1 Power Supply If the carrier does not move to the left after

2 Sub Logic Board If the carrier moves to the left after turning the

turning the printer off and then on, do the following:

• Make sure the line cord voltage to the power supply is correct.

• Make sure the power supply outputs are +5 V dc at CN1-2 a nd +26 V dc a t C N1 -4. If the voltage is incorrect, check the internal fuses before replacing the power supply. Generally if F3 is blown it is due to a short in the printhead; replace the printhead and the fuse before powering on again.

• Check for +5 V 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 flexible cable is undamaged and correctly installed.

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 whenev er the printer is on. If the carrier moves to the left during after turning the printer off and then on, bu t the pow er LED is not on steady: Make sure the sub logic board is receiving voltage by checking for +5 V dc at sub logic board CN1-3.

• If no voltage or power cable problem is found, make sure there is +5 V on pins 3 and 9 of the sub logic board conne ctor f or the operator panel cable. If the voltage is incorrect replace the sub logic board.

2-32

Page 57

FRU Action

3 Op-Panel

Op-Panel Cable

4 Carrier Motor Disconnect the carrier motor from main logic

5 Paper Feed Motor Disconnect the paper feed motor from main

6 Printhead

Printhead Cables

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

If there is still a power LED problem, check the operator panel cab le con tinuity and repla ce the cable or the operator panel.

board CN9 and turn the printer off and then on . If the power LED lights correctly only with the carrier motor disconnected, replac e the ca rrier motor.

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

Disconnect the printhead cable from the sub logic board and turn the printer on. If the power LED lights correctly only with the printhead cables disconnected from the sub logic board, there is a short in the printhead or printhead cables.

Disconnect the printhead cable from the sub logic board and make sure none of the leads on the cable are shorted to ground.

but the printer still has a power problem, replace the main logic board.

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

Diagnostic Information 2-33

Page 58

Print Speed Service Check

Reduced speed while printing the top 2 inch (51 mm) of a job is normal; for Model 003 printers, the slow down can be eliminated by entering Setup Mode and disabling TOF Read. The speed of the 23XX printers varies 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, thermal slowdown may occur after 5 to 10 minutes of continuous operation on 239X-001 printers and after 10 to 20 minutes on 239X-002, 003 printers.

Print slowdown modes are as follows:

Thermal Slowdown

238X-001 No 26% speed reduction at Forms

239X-001 Yes No Forms Thickness speed

238X-002 238X-003

239X-002 239X-003

No Reduced print wire force at Forms

Yes Reduced print wire force at Forms

Forms Thickness Slowdown

Thickness 7. Head Gap Sensor contains one switch.

reduction. No Head Gap Sensor.

Thickness 1. 23% speed reduction at Forms Thickness 4 through 7. Head Gap Sensor Assemb ly contains two switches.

Thickness 1. 20% speed reductions at Forms Thickness 4 through 7. Head Gap Sensor Assemb ly contains two switches.

2-34

Page 59

FRU Action

1 Head Gap Sensor

23XX-001

2 Head Gap Sensor

23XX-002 23XX-003

Check the function of the head gap sensor by moving the forms thickness lever from 6 to 7 and back while printing the Demo Page Alt + Demo. Print speed is reset at the beginning of each line; listen for the printer to slow down in position 7.

Disconnect the head gap sensor from connector CN3 on the sub logic board. Check the resistance of the sensor while moving the forms thickness lever. Resistance should be 0 ohms at forms thickness position 7 and infinite at positions 1 through 6.

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

• With the forms thickness lever at 1, Macro LED 1 will light.

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

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

Disconnect the head gap sensor asm from connector CN3 on the sub logic board. Check the resistance of the sensor while moving the forms thickness lever. Resistance should be 0 ohms at position 1 and infinite at positions 2 through 7 .

Disconnect the head gap sensor asm from connector CN4 on the sub logic board. Check the resistance of the sensor while moving the forms thickness lever. Resistance should be 0 ohms at positions 1 through 3 and infinite at positions 4 through 7.

Diagnostic Information 2-35

Page 60

Printhead Service Check

FRU Action

1 Printhead Cables

Printhead

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

• Check the continuity and connection of the printhead cables and the short flex ibl e cable.

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

If dots are missing :

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

• Remove the printhead and check the printhead resistance according to the following table. Make sure no pins have continuity to the printhead housing.

2-36

Page 61

FRU Action

1 Printhead Continuity Table

The correct resistance is:

2.8 to 3.8 ohms (238X) or 7 to 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.

Diagnostic Information 2-37

Page 62

FRU Action

2 Carrier Shaft

Carrier Unit Platen Assembly Printhead Nose Ribbon Guide

Check and replace worn or damaged parts.

Pull Tractor Sensor Service Check

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

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

FRU Action

1 Pull Tractor

Sensor

With the tractor in the push position, press Alt+Park/Load several times while alternately holding down and releasing the left pull tractor actuator . The paper should park and load wh en the actuator is not held down, and should not park or load when the pull tractor actuator is held down.

If the paper does not move correctly:

2-38

• Disconnect CN4 from the main logic board.

• There should be 0 ohms from CP4-1 to CP4-2 when the left pull tractor actuator is pressed, and infini te resistance when the actuator is not pressed.

• Replace the sensor if necessary.

If the sensor is good b ut t he pa per still does n ot move correctly:

• Replace the main logic board.

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

4-5.

Page 63

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 Tr actor 2 gear drive and reengaging the printer tractors.

2-40

Page 65

10 Beeps and Blinking Ready, Paper, Font and Pitc h 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

2 Main Logic Board Remove Tractor 2 from the printer b ut le av e the

Remove 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.

cable connected. Make sure the slider (the black plastic piece just above the right cover) moves after tu rning the p rinte r off and the n 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 present replace the main logic board.

3Tractor 2 Motor

Board /Cable Asm

Check the resistances of the Tractor 2 motor windings: there 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, replace the board/cable assembly.

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

Diagnostic Information 2-41

Page 66

3 Beeps and Tractor 2 LED blinks 3 times

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

FRU Action

1Tractor 2

Board/Cable Asm.

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

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

The in-place sensor actuator extends through the Tractor 2 cover and rests on the printer cover when Tractor 2 is installed.

Remove the Tractor 2 co v er an d mak e s ure the in-place sensor opens when the Tractor 2 is installed. The voltage at Tractor 2 CN1-13 should be +5 V dc with the sensor open and 0 with it closed.

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

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

the printer. If possible, try the Tractor 2 with another p rinter

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

2-42

Page 67

Paper Feed Problems

FRU Action

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

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

Remove Tractor 2 from the printer and remove all paper. With the paper select lever in the continuous forms position, press Line Feed; the tractors should rotate.

Press the sub slider cam lever below the ASF/ T r actor 2 driv e gear an d press Line Feed again; the tractors should not rotate b ut the driv e gear should.

Check the condition of the pin feed belts. With the power off, make sure the slider does not bind.

Verify

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

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

Remove the Tractor 2 cover and reinstall T r actor 2 in t he printer (if nece ssary remov e the printer covers also). Note that the small idler gear just below t he sli der is he ld in pl ace b y the cover; with the cover removed it will tend to move off the stud. Also note that when operating the Tractor 2 with the printer cover removed, the Tractor 2 in-place se nsor must be held open.

Turn the printer on and look for mech ani ca l problems.

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

Diagnostic Information 2-43

Page 68

2-44

Page 69

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:

Line Feed Print test with sample fonts. Alt Sets printer in Hex Dump mode. Micro

↑ & Micro↓ Disables/Enables Operator Panel

Alt + Tear Off (with printhead at extreme left)

Alt + Setup (with printhead at extreme left)

Alt + Macro (23XX-002, 003)

Does This:

Lockout Mode. Resets to World Trade default paper

sizes. Resets to US default paper sizes.

Head Gap Sensor Test: Macro LEDs indicate sensor position.

Diagnostic Aids 3-1

Page 70

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 T est (Checks that this function works.)

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

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

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

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

• Feed Initialization (Form feed motor rotates forward, then

backward.)

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

3-2

Page 71

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.

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

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

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

to be sure the printer is operating correctly.

Diagnostic Aids 3-3

Page 72

Print Test Sample (9 wire)

Print Test Sample (24 wire)

3-4

Page 73

Hex Dump Mode

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

To activate hex dump mode:

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

2. After a few seco nds, 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

Diagnostic Aids 3-5

Page 74

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 printer off.

2. Turn on serial interface Switch 10.

3. Turn the printer on.

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

When the test is complete, turn off Switch 10.

3-6

Page 75

4. Repair Information

This chapter contains adjustments and removal procedures. Whenever parts are replaced, make sure that all adjustments are correct by running diagnostics procedures and checking adjustments as needed.

Handling ESD-Sensitive Parts

Many electronic products use parts that are known to be sensitive to electrostatic discharge (ESD). To prevent damage to ESD-sensitive parts, follow the instructions below in addition to all the usual precautions, such as turning off power before removing logic boards:

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

special “ESD bag”) until you are ready to 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 they make a discharge path from your body through the ESD-sensitive part. (Large metal objects can be discharge paths without being grounded.)

• Prevent ESD-sensitive parts from touching other personnel.

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

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

(case).

• Low humidity increases static electricity during cold-weather.

Repair Information 4-1

Page 76

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.

4-2

Page 77

1. Turn the printer off.

2. Remove the ribbon access cover.

3. Remove the ribbon cartridge and paper.

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.

Repair Information 4-3

Page 78

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 necessa ry.

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

12. Install the ribbon cartridge and paper.

13. Install the ribbon access cover.

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

4-4

Page 79

Bidirectional Print Adjustment

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

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

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

2. Turn the printer on.

3. Press Alt and then press Micro 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.

↑. The printer enters Setup

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7. Align the second and fourth lines to the first and third lines. Each time Micro toward the left. Each time Micro 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.

↑ is pressed, the second and fourth lines shift

↓ is pressed, the second and

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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.

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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. Remove the locker cam [6].

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

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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 rol ler [3] to both ends of the shaft, and then remove them.

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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 “Power Supply Removal” 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 bottom cover. Release the two latches [1] and then remove the Main Logic Board ground plate from the bottom cover by sliding it toward you.

8. Release the two latches [1] then remove the power supply ground plate [4] by sliding it toward you.

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Repair Information 4-11

Page 86

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.

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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 bracket 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 the 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 Adjustment see “Printhead-to-Platen Gap Adjustment” on page 4-2.

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This Page Intentionally Blank.

Repair Information 4-15

Page 90

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 carrie r mot o r p ul ley.

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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.

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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 Removal” 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 Frame 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].

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Repair Information 4-19

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

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

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

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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].

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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].

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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 lever to position 7.

5. Remove the screw [1] and remove the head gap sensor assembly [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.

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Home Position Sensor Remo val

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 suppor t plate on newer models.

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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.

4-26

Lexmark 2391 Plus Service Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Safety Notices

1. General Information

Description

Specifications

Recommended Machine Usage

Options

Tools

Abbreviations

Setup Mode

How To Change The Printer Functions

Serial Interface Adapters

Serial Interface Switches

Function Switch Setting

2. Diagnostic Inf ormation

Start

Voltage, Ground, And Continuity Readings

Error Indication Table

Symptom/Check Table

Irrecoverable Operator Errors

Service Checks

Abnormal Noise Service Check

Auto Sheet Feeder (ASF) Service Check

Carrier Drive, Home Position Sensor, Ribbon Feed Service Check

Intermittent Problem Service Check

No Print or Abnormal Print Service Check

Operator Panel Service Check

Paper Empty Sensor Service Check

Paper Feed Service Check

Paper Select Sensor Service Check

POST Service Check

Power Service Check

Print Speed Service Check

Printhead Service Check

Pull Tractor Sensor Service Check

Top of Forms Problem Service Check

Tractor 2 Service Check

3. Diagnostic Aids

Power-On Self Test (POST)

Print Test

Hex Dump Mode

Serial Interface Adapter Print Test

4. Repair Information

Handling ESD-Sensitive Parts

Adjustments

Printhead-to-Platen Gap Adjustment

Bidirectional Print Adjustment

Removal Procedures

Auto Sheet Feeder Gears Removal

Auto Sheet Feeder Pick-up Roller Removal

Bottom Cover Removal

Carrier Removal

Carrier Motor Assembly Removal

Carrier Plate Removal

Download or Print Buffer Module Removal

Form Thickness Lever Removal

Head Gap Sensor Removal (238X-001)

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

Home Position Sensor Remo val

Label Jam Removal