Lexmark 2391 Plus Service Manual
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.
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
All rights reserved.
UNITED STATES GOVERNMENT RESTRICTED RIGHTS
This software and documentation are provided with RESTRICTED RIGHTS.
Use, duplication or disclosure by the Government is subject to restrictions as
set forth in 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.
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
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
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
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
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
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.
x
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
Korean Saf e ty Information
xii
Preface
This manual is divided into the following chapters:
• “General Information” contains a general description of the
printer and the maintenance approach used to repair it. Special
tools and test equipment are listed in this chapter, as well as
general environmental and safety instructions.
• “Diagnostic Information” contains error code table, symptom
table, and service checks used to isolate failing field replaceable
units (FRUs).
• “Diagnostic Aids” contains tests and checks used to locate or
repeat symptoms of printer problems.
• “Repair Information” provides instructions for making printer
adjustments and removing and installing FRUs.
• “Connector Locations” uses illustrations to identify the major
components and test points on the printer.
• “Preventive Maintenance” contains lubrication specifications,
and maintenance information to prevent problems and maintain
optimum performance.
• “Parts Cat alog” contains illustrations and part numbers for
individual FRUs.
Preface xiii
xiv
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
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
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
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
Abbreviations
ASIC Application-Specific Integrated Circuit
CSU Customer Setup
DRAM Dynamic Random Access Memory
EPROM Erasable Programmable Read-Only Memory
ESD Electrostatic Discharge
FRU Field Replaceable Unit
HVPS High Voltage Power Supply
LAN Local Area Network
LCD Liquid Crystal Display
LED Light-Emitting Diode
LVPS Low Voltage Power Supply
NVRAM Nonvolatile Random Access Memory
OEM Original Equipment Manufacturer
POR Power-On Reset
POST Power-On Self Test
PQET Print Quality Enhancement Technology
ROS Read-Only Storage
SRAM Static Random Access Memory
UPR Used Parts Replacement
V ac Volts alternating current
V dc Volts direct current
General Information 1-5
Setup Mode
How To Change The Printer Functions
1. Make sure continuous forms are in the printer.
2. Press Alt and then press Setup to enter Setup Mode.The
printer prints out the Main Menu.
3. To select a function, press the buttons listed on the printout.
4. To save the setting and leave Setup Mode, press Start/Stop
until out of the menu.
1-6
Serial Interface Adapters
The 23XX printer product line uses three different serial adapters.
• 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
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)
Black Serial Adapter
Switch 1 Switch 2 Switch 3 Speed (bps)
N/A N/A N/A 150
On Off On 300
On Off Off 600
Off On On 1,200
Off On Off 2,400
Off Off On 4,800
Off Off Off 9,600
On On On 19,200
On On Off 38,400
(RS-422 Only)
Switch 5 - Data Bits:
Selects the number of data bits (7 or 8) in each data frame.
Switch 5 Data Bits
Off 8
On 7
General Information 1-9
Switches 6 and 7 - Parity:
Select the interface parity.
Switch 6 Switch 7 Parity
Off Off No
Off On Ignore
On Off Odd
On On Even
Note: When setting the “Ignore” for parity, the printer ignores the
received parity and transmits using even parity. For all other parity
settings, the transmitted parity matches the received parity.
Switch 8 - Stop Bits (Snap-On):.
Switch 8 Stop Bits
Off 1 Stop Bit
On 2 Stop Bits
Switch 8 - Buffer Size (Gray and Black):
Selects the buffer size.
Switch 8 Buffer Size
Off Normal (2048 bytes)
On Minimum (2 bytes)
1-10
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
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
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
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
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
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
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
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
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