Lexmark 2400 Series Service Manual

Lexmark Forms Printer 2400 Series

• Table of Contents

•Start Diagnostics

• Safety and Notices

• Trademarks

24XX-100

•Index

• Manuals Menu

Lexmark and Lexmark with diamond design are trade ma rks of Lexmark International, Inc., registered in the United States and/or ot her countries.

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Edition: March 24, 2006 The following paragraph does not apply to any country where such provisions are

inconsistent with local law: LEXMARK IN TERN ATIONAL, 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 all o w di sc la im er o f e x pres s o r i mpl i ed wa rr an tie s i n c ertai n t ra ns act ion s; t he refore, t hi s statement may not apply to you.

This publication could include technical inaccuracies or typographical errors. Changes are periodically made to the info rmation herein; these changes wil l be incorporated in later editions. Improvements or changes in the products or the programs described may be made at any time.

Comments may be addressed to Le xmark International, Inc., Department D22A /032-2 , 740 West New Circle Road, Lexington, Kentucky 40550, U.S.A or e-mail at ServiceInfoAndTraining@Lexmark.com. Lexmark may use or distribute any of the information you supply in any way it believes appropriat e without incurring any obligation to yo u.

Lexmark and Lexmark with diamond design are trademar ks of Lexmark International, Inc. , registered in the Unit ed States and/or other countries.

Other trademarks are the propert y of their respec tive owners.

UNITED STATES GOVERNMENT RESTRICTED RIGHTS

This software and documentation are provided with RESTRICTED RIGHTS. Use, duplication or disclosure by the Government is subject to restrictions as set forth in subparagraph (c)(1)(ii) of the Rights in Technical Data an d Computer Software clause at DFARS 252.227- 7013 and in appl icabl e FAR provisio ns: Le x mark Internatio nal, Inc., Lexington, KY 40550.

U.S.A. P/N: 12G3662

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Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .vii

Preface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .xii

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

Printer Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

Printer Speeds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

Setup Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

Entering Setup Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

Exiting Setup Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

Setup Menu Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

Interface Menu Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

Setting The Tear Off Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

Setting Top-Of-Form (Continuous - Pull Mode) . . . . . . . . . . . . . . 1-5

Setting Top-Of-Form (Cut Forms - Envelopes) . . . . . . . . . . . . . . 1-5

Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6

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

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

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

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

Symptom Check Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5

Irrecoverable Operator Errors . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 -12

Service Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 -13

Abnormal Noise Service Check . . . . . . . . . . . . . . . . . . . . . . . . . 2 -13

Auto Sheet Feeder (ASF) Service Check . . . . . . . . . . . . . . . . . 2 -14

Carrier Service Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16

Intermittent Problem Service Check . . . . . . . . . . . . . . . . . . . . . 2 -18

No Print or Abnormal Print Service Check. . . . . . . . . . . . . . . . . 2 -21

Operator Panel Service Check. . . . . . . . . . . . . . . . . . . . . . . . . . 2-21

Paper Present Sensor Service Check . . . . . . . . . . . . . . . . . . . . 2-22

Paper Feed Service Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-23

Paper Select Sensor Service Check . . . . . . . . . . . . . . . . . . . . . 2-25

POST Service Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-26

Power Service Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 -27

Print Speed Service Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 -28

Printhead Service Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 -29

Pull Tractor Sensor Service Check . . . . . . . . . . . . . . . . . . . . . . 2 -31

Top-Of-Forms Service Check . . . . . . . . . . . . . . . . . . . . . . . . . . 2-32

Tractor 2 Service Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 -33

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

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

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

Hex Trace Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-4

Printer Default Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-5

U.S. Defaults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-5

Wor ld Trade Defaults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-5

Clearing Paper Jams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-6

Cut Sheet Jams. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-6

Continuous Forms Jams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-6

Repa ir Inform atio n . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-1

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

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

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

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

Removal Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-5

Covers, Removals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-5

Covers, Front Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-6

Covers, Ribbon Access Removal . . . . . . . . . . . . . . . . . . . . . . . . .4-6

Covers, Option Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-7

Covers, Top Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-8

Covers, Operator Panel Assembly Removal. . . . . . . . . . . . . . . .4-11

Cove r s , Botto m Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-12

Electronics Removals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-13

EPROM Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-13

Logic Board Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-14

Power Supply Remo va l. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-15

Carrier Removals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-16

Carrier Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-16

Carrier, Motor Assembly Removal . . . . . . . . . . . . . . . . . . . . . . .4-21

Paper Handling Removals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-24

Paper Select Lever Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . .4-24

Paper Feed Motor Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-24

Form Thickness Lever Removal . . . . . . . . . . . . . . . . . . . . . . . . .4-25

Print Handling Removals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-26

Platen Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-26

Printhead Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-27

Printhead Cables Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-27

Print Unit Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-28

Ribbon Drive Rack Gear Removal . . . . . . . . . . . . . . . . . . . . . . .4-30

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Gears Removals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 -31

Left Side Gears Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-31

Right Side Gears, Sub Frame Removal. . . . . . . . . . . . . . . . . . . 4 -34

Rollers Removals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-36

Roller, Upper Feed Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-36

Roller, Lower Pinch Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . 4-38

Roller, Lower Feed Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-41

Sensors Removals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-43

Sensor, Pull Tractor Removal . . . . . . . . . . . . . . . . . . . . . . . . . . 4-44

Sensor, Head Gap Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-44

Sensor, Top-Of-Form Removal . . . . . . . . . . . . . . . . . . . . . . . . . 4-44

Sensor, Paper Select Removal . . . . . . . . . . . . . . . . . . . . . . . . . 4 -45

Sensor, Paper Present Removal . . . . . . . . . . . . . . . . . . . . . . . . 4 -45

Flags, Paper Present / Top-Of-Form Removal . . . . . . . . . . . . . 4-45

Sensor, Home Position Sensor Removal. . . . . . . . . . . . . . . . . . 4 -46

Options Removals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-47

Auto Sheet Feeder Gears Removal. . . . . . . . . . . . . . . . . . . . . . 4-47

Auto Sheet Feeder Pick-up Roller Removal . . . . . . . . . . . . . . . 4-48

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

Signal Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2

Power Supply (9w & 24w) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2

Logic Board - Parallel Interface Cable (9w & 24w) . . . . . . . . . . . 5-4

Logic Board - Serial Board (9w & 24w) . . . . . . . . . . . . . . . . . . . . 5-6

Logic Board - USB Cable (9w & 24w) . . . . . . . . . . . . . . . . . . . . . 5-8

Logic Board - DC Power (9w & 24w) . . . . . . . . . . . . . . . . . . . . . 5-8

Logic Bo ard - Pr i nthead (9w) . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10

Logic Board - Pri nthead (24w) . . . . . . . . . . . . . . . . . . . . . . . . . 5-12

Logic Board - Pri nthead (24w) . . . . . . . . . . . . . . . . . . . . . . . . . 5-14

Logic Board - Gap Set Sensor (9w & 24w) . . . . . . . . . . . . . . . . 5-16

Logic Board - Home Position Sensor (9w & 24w) . . . . . . . . . . . 5-16

Logic Board - Paper Present Sensor (9w & 24w) . . . . . . . . . . . 5-16

Logic Board - Paper Select Sensor (9w & 24w). . . . . . . . . . . . . 5 -18

Logic Board - Pull Tractor Sensor (9w & 24w). . . . . . . . . . . . . . 5-18

Logic Board - Top Of Form Sensor (9w & 24w). . . . . . . . . . . . . 5-18

Logic Board - Carrier Motor (9w & 24w). . . . . . . . . . . . . . . . . . . 5-20

Logic Board - Paper Feed Motor (9w & 24w). . . . . . . . . . . . . . . 5-20

Logic Board - Operator Panel (9w & 24w) . . . . . . . . . . . . . . . . . 5 -22

Logic Board - Dual Tractor Cable (9w & 24w) . . . . . . . . . . . . . . 5 -24

Serial Board - Serial Cable (9w & 24w) . . . . . . . . . . . . . . . . . . . 5-25

Tractor 2 Cable Connectors. . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-26

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

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

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

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

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

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

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

Assembly 1: Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-2

Assembly 2: Carrier / Paper Feed Right Side . . . . . . . . . . . . . . . . . .7-6

Assembly 3: Carrier / Paper Feed Left Side . . . . . . . . . . . . . . . . . .7-10

Assembly 4: Electronics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-14

Assembly 5: ASF - Roller / Support . . . . . . . . . . . . . . . . . . . . . . . . .7-16

Assembly 6: ASF - Side Frame / Covers . . . . . . . . . . . . . . . . . . . . .7-18

Assembly 7: Tractor 2 Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-20

Coax / Twinax Adapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-22

Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I-1

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Safety Information

• This product is designed, tested and approved to meet strict

global safety standards with the use of specific Lexmark components. The safety features of some parts may not always be obvious. Lexmark is not responsible for the use of other replacement par ts.

• The maintenance information for this product has been

prepared for use by a professional service person and is not intended to be used by others.

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

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

Consig n es de Séc urité

• Ce produit a été conçu, testé et approuvé pour respecter les

normes strictes de sécurité globale lors de l'utilisation de composants Lexmark spécifiques. Les caractéristiques de sécurité de certains éléments ne sont pas toujours évidentes. Lexmark ne peut être tenu responsable de l'utilisation d'autres pièces de rechange.

• 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.

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Norme di sicurezza

• Il prodotto è stato progettato, testato e approv ato in conf ormità a

severi standard di sicurezza e per l’utilizzo con componenti Lexmark specifici. Le caratteristiche di sicurezza di alcune parti non sempre sono di immediata comprensione. Lexmark non è responsabile per l’u tilizzo di parti di ricambi o di altri produttori.

• Le informazioni riguardanti la manutenzione di questo prodotto

sono indirizzate soltanto al personale di assistenza autorizzato.

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

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

Sicherheitshinweise

• Dieses Produkt und die zugehör igen Komponenten wurden

entworfen und getestet, um beim Einsatz die weltweit gültigen Sicherheitsanforderungen zu erfüllen. Di e si c herheitsr elevante n Funktionen der Bauteile und Optionen sind nicht immer offensichtlich. Sofern Teile eingesetzt werden, die nicht von Lexmark sind, wird von Lexmark keinerlei Verantwortung oder Haftung für dieses Produkt übernomm en.

• Die Wartungsinformationen für dieses Produkt sind

ausschließlich für die Verwendung durch einen Wartungsfachmann bestimmt.

• Während des Auseinanderne hme ns und der Wartung des

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

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Pautas de Seguridad

• Este producto se ha diseñado, verificado y aprobado para

cumplir lo s más estrictos estándares de seguridad global usando los componentes específicos de Lexmark. Puede que las características de seguridad de algunas piezas no sean siempre evidentes. Lexmark no se hace responsable del uso de otras piezas de recambio.

• 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.

Inform ações de Segurança

• Este produto foi concebido, testado e aprovado para satisfazer

os padrões globais de segurança na utilização de componentes específicos da Lexmark. As funções de segurança de alguns dos componentes podem não ser sempre óbvias. A Lexmark não é responsável pela utilização de outros componentes de substituição.

• 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.

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Informació de Seguretat

• Aquest producte està dissenyat, compr ovat i aprovat per tal

d'acomplir les estrictes nor me s de seguretat globals amb la utililització de components específics de Lexmark. Les característiques de seguretat d'algunes peces pot ser que no sempre siguin òbvies. Lexmark no es responsabilitza de l'us d'altres peces de recanvi.

• La in formaci ó pel manteniment d’aquest producte està

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

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

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

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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.

• “Rep a i r In fo rma tion” provides instructions for making printer

adjustments and removing and installing FRUs.

• “Connector Locations” uses illustrations to identify the major

components and test points on the printer.

• “Preventive Maintenance” contains lubrication specifications,

and maintenance information to prevent problems and maintain optimum performance.

• “Parts Catalog” contains illustrations and part numbers for

individual FRUs.

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1. General Informatio n

Printer Description

The Lexmark TM Forms Printer 248X-100 and 249X-100 are small versatile tabletop printers suitable for use in the home or small business. They are especially well-suited for applications that use continuous or multipart forms. The 2481 and 2491 are wide-carriage versions of the 2480 and 2490.

Printer Specif icat ions

• Printhead life: 300 million characters

• Standard ribbon life: 4 million characters

• High yield ribbon life: 8 million characters

• Printer life: 5 Years

• Power consumption: 47 watts-maximum/7 watts idle

Printer Speeds

9 Wire 24 Wire

10 cpi 12 cpi 10 cpi 12 cpi

Fast Draft 438 cps 510 cps 409 cps 465 cps Draft 309 cps 304 cps 274 cps 328 cps NLQ -

Near

Letter Quality

cpi = characters per inch cps = characters per second

77.5 cps 77.5 cps 91.7 cps 109 cps

General Information 1-1

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Setup Mode

Entering Setup Mode

1. Open the operator panel cover to access layer two.

2. Press Setup to put the printer in setup mode and print the Main Menu.

3. Press LineFeed to pr int a list of all the available options.

4. Select any option from the Main Menu by pressing the corresponding button. A new menu prints each time you press a button, displaying new selections.

5. After making your selection, the printer prints a page with the changes shown.

Exiting Setup Mode

1. Press Set TOF until the printer returns to the Main Menu, or press Pitch from any menu containing a Return to Main Menu selection.

2. Press Set TOF again to exit Setup mode. New settings are saved only when the printer exits Setup mode.

Note: If the printer runs out of paper while using Setup mode, load more paper into the tractor pins and press Setup to continue .

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Setup Menu Options

Menus Function

Forms Macro options Customize macros to pri nt a variety of f orms. Data options Defines how information is processed. Control options Defines how the printer performs basi c tasks. Emulation options Determines how the printer interacts with

software applications.

Interfa ce options Defines how information is transferred from

computer to the printer.

Interface Menu Options

Menus Function

Interface • Automatically s e lect th e p rinter in terface.

• Use the paralle l cable.

• Use th e US B cable.

• Use the serial cable (only appears if

optional serial adapter is install ed).

Honor Init • Enable honors the init signal on the

parallel port.

• Disable ig nores the init signal on the parallel port.

Data speed • 300 bps

• 600 bps

• 1200 bps

• 2400 bps

• 4800 bps

• 9600 bps

• 19200 bps

Data bits 7, 8 Parity No, Ignore, Odd, Even Stop bits 1, 2 Protocol • XON/XOFF

• MultiXON/XOFF

• DTR Pacing

General Information 1-3

24xx

Printer Setti ngs

Setting The Tear Off Position

When Auto Tear Off is on, or set to One Second, it moves the top perforation of a continuous form to the tear off position, when all of the following are true:

• The printer has finished printing.

• The paper has advanced to the Top-Of-Form on the next page.

• No data, printer control codes, or escape codes have been sent

to the printer after advancing to the Top-Of-Form.

• The print buffer has not received data for one second.

If you have already set Top-Of-Form and now want to change the tear off bar position, follow these steps:

1. Press Start/Stop to take the printer offline.

2. Press and hold Tear Off until the printer beeps.

3. Open the operator panel cover to access layer two.

4. Press Micro↑ or Micro ↓ to move the paper to the correct position on the tear off bar.

5. Close the operator panel cover. The printer beeps twice. The paper rolls backward, then goes to the new tear off position. The Ready light is on.

The paper remains at the current Tear Off position until you send another job to the printer. The paper moves from the tear off position to the Top-Of-Form and begins printing.

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Setting Top-Of-Form (Continuous - Pul l Mode)

1. Turn the printer on. The Paper Out light blinks if no paper is loaded.

2. Move the paper select lever down to the continuous forms position.

3. Load continuous form paper on the pull tractor feed pins.

4. Open the operator panel cover to access layer two.

5. Press any paper movement button (LineFeed, Micro↑ or Micro ↓) to move the paper to the Top- Of-Form position.

6. Use the second sheet of continuous forms to set Top-Of-Form.

7. Press Set TOF to set and save Top-Of-Form.

8. Close the operator panel cover. Top-Of-Form is not saved if the printer is turned off, or runs out of paper when the printer is in pull trac to r mode.

9. Press Start/Stop to set the p r i n ter on li ne.

Sett ing Top-Of-Form (Cut Forms - Envelopes)

Top-Of-Form can range from minus 1 to plus 22 inches from the top of cut sheet paper. To set and save Top-Of-Form:

1. Turn the printer on. The Paper Out light blinks if no paper is loaded. If the Paper Out light is off, tear off excess forms and press Load/Unload. If an individual form is loaded, press FormFeed to clear the paper path.

2. Move the paper select lever up to the cut forms position.

3. Load a cut sheet of paper or envelope through the manual feed door. The printer moves the paper or envelope to the current Top-Of-Form, if Auto Cut Sheet is set to on. If not, press FormFeed when the Paper Out light goes off.

4. Open the operator panel cover to access layer two.

5. Press any paper movement button (LineFeed, Micro↑, or Micro ↓) to align with the horizontal lines (located on the platen) with the Top-Of-F orm you want.

6. Press Set TOF to set and save Top-Of-Form.

7. Close the operator panel cover.

8. Press Start/Stop to set the p r i n ter on li ne.

General Information 1-5

24xx

Options

The 24xx printers support the following options:

• Auto Sheet Feeder (ASF)

• Internal serial interface (RS232)

• OKI emulation (9 wire only)

• Tractor 2 Sheet Feeder

Tools

The basic tools necessary to service the 24xx-100 pr inters are:

• Basic CE tool kit

• #1 Phillips screwdriver

• #2 Phillips screwdriver

• Feeler gauges 0.33 mm (0.013 in.) 0.37 mm (0.015 in.)

• Analog or digital volt-ohmmeter

Abbreviations

CSU Customer Setup EPROM Erasable Programmable Read-Only Memory ESD Electrostatic Discharge FRU Fi eld Replaceable Unit HV High Voltage LAN Loc al Area Networ k LED Light-Emitting Diode LV Low Voltage POR Power-On Reset POST Power-On Self Test V ac Volts alternating current V dc Volts direct current

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2. Diagnostic Information

Start

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

Voltage, Ground, And Continuity Readings

Voltage Readings

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

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

Ground Checks

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

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

Continuity Readings

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

Diagnostic Information 2-1

24xx

Error Indication Table

The following t able describes the service check entries for t he printer error indication codes.

When an error indication changes after you have entered a service check, you have an intermittent problem. If this occurs, leave the service check and go to “Symptom Check Table” on page 2- 5.

LED Status Alarm Action

Power Ready Tractor 2 Paper Out Panel Lock Font Lock

Power Ready Paper Out Panel Lock

Power Ready Paper Out Font Lock

ON ON ON ON ON ON

ON Blinking Blinking Blinking

None POST

RAM, ROM Controller Error Go to “POST Serv ice Check” on

page 2-26.

None Switch Scan Test Error

Go to “Operator Panel Service

Check” on page 2-21.

None NVRAM Read/Write Error

Turn the printer off and then back on. If you get the same error during power- up, r eplace t he logic board and readjust the bidirectional print adjustment. Go to “Bidir ectional Print

Adjustment” on page 4-4.

If the printer completes POST successfully and eventually gets the same error, go to

“Intermittent Problem Service Check” on page 2-18.

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LED Status Alarm Action

Power Ready Paper Ou t Panel Lock Font Lock

Power Ready Tractor 2 Paper Ou t Font Lock

ON Blinking Blinking Blinking Blinking

Beeps 10 times

None Home Position Error Without

None Timer Error

None Hardware Drive Error

Home Posi ti on Error Go to “Carrier Service Check”

on page 2-16.

Tractor 2 Home Position Error If Tractor 2 is installed, remove it

to determine whether th e problem is with the carrier home posit ion sensor or the Tractor 2 home position sen sor . See t he “Tractor

2 Service Check” on page 2-33.

Alarm Go to “Power Servi ce Ch eck”

on page 2-27.

Turn the printer off and then back on. If you get the same error during power -up, replace t he logi c board and readjust the bidirectional print adjustment.

Go to “Bidirect ional Pr in t

Adjustment” on page 4-4.

The printhead or the printhead cable(s) can cause this error. Go to “Printhead Service Check”

on page 2-29.

Turn the printer off and then back on. If you get the same error, replace the logic board and readjust the “Bidirectio nal Print

Adjustment” on page 4-4.

If the pr in te r co mpletes P OS T successfull y and eventually gets the same error, go to

“Intermittent Problem Service Check” on page 2-18.

Diagnostic Information 2-3

24xx

LED Status Alarm Action

All LEDs OFF None Power Failure

Check the continuity of the power cord and the voltage of the user’s outlet. If they are correct, go to

“Power Servi c e C heck” on page 2-27.

Power Tractor 2 Paper Out Panel Lock Font Lock

Any LED on and Power LED off

If the P ower LED blinks or changes intensity .

ON OFF OFF OFF OFF

None Operator Panel Failure

Go to “Operator Panel Service

Check” on page 2-21.

None G o to “Operator Panel Service

Check” on page 2-21.

None G o to “Power Servi c e Check ”

on page 2-27.

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Symptom Check Table

1. Select the symptom that best describe s the problem.

2. Perform 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 t he int erf ace cab le f rom the printe r and turn the printer off and then on. If POST now runs correctly, the problem is in the computer or interf ace cable.

Go to “POST Service Check” on page 2-26.

Abnormal Noise Problems

Symptom Action

During POST, abnormal noise comes from the carrier.

During idling, abnormal noise comes from the printer.

When f eeding paper, abnormal noise is created.

During printing or POST, abnormal noise is created.

Check the ribbon cartridge for binds or damage . Go to “Carrier Service Check” on page 2-16.

Go to “Abnormal Noise Service Check” on

page 2-13.

Diagnostic Information 2-5

24xx

Abnormal Print Operation Problems

Symptom Action

Printer will not print, or become ready.

Abnormal operation, incorrect cha ra cters , or incorrect line width.

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

Undefined or incorrect character(s).

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

Be sure the interface cable is connected properly.

Go to “No Print or Abnormal Print Service

Check” on page 2-21.

page 2-28.

Auto Sheet Feeder Problems

Symptom Action

Auto sheet feeder will not feed paper.

Auto sheet feeder double feeds.

Auto sheet feeder has intermittent feed problems.

Be sure Sheet Feed i s enabl ed in th e Setup Mode. Be sure the paper select lever is in the cut sheet

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

Check” on page 2-14.

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Error Indication s

Symptom Action Ready and Paper

Out lights blink.

Paper Out and Font

lights blink.

Turn the printer off and then on. Go to “Abnormal Indications” on page 2-5.

Turn the printer off and then on. Go to “Irrecoverable Operator Error s” on

page 2-12.

Operator Panel Problems

Symptom Action Start/Stop does not

function b ut no error is indicated.

Only the Power light turns on.

One or more buttons do not function.

One or more lights do not function.

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

page 2-21.

Paper Feed Problems

Symptom Action Paper Out is

blinki ng with paper in the printer.

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

Print operati on starts without paper.

Go to “Paper Present Sensor Service Check”

on page 2-22.

Be sure the paper present sensor is not blocked. Go to “Paper Present Sensor Service Check”

on page 2-22.

Diagnostic Information 2-7

24xx

Symptom Action

Load/Unload

does not function when the push tractor is install e d .

Form feed length is not correct.

Load/Unload functions with cut shee ts in us e.

Continuous forms feed, but cut sheets fail to load.

Load/Unload functions when the pull trac tor is installed.

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

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

Go to “Paper Select Sensor Service Check” on

page 2-25.

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

Verify that continuous forms have been parked using the Load/Unload b utton.

Be sure Auto Cut Sheet is enab led in the Setup Mode.

Go to “Paper Select Sensor Service Check” on

page 2-25.

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

Go to “Pull Tractor Sensor Service Check” on

page 2-31.

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Symptom Action

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

Pressing FormFeed does not feed paper.

Abnormal noise created while feeding.

Paper jams, skews or creases.

Incorrect or no li ne spacing: wider, narrower, or overlapping lines.

Push/Pull Tractor does not work.

Incorrect Top of Form positioning.

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

Go to “Paper Feed Service Check” on

page 2-23.

Go to “Top-Of-Forms Service Check” on

page 2-32.

Power Problems

Symptom Action

When the power switch is on, the Power light does no t turn on or t he printer does not start.

The Power light blinks or changes intensity.

Check conti nuit y of th e po wer cor d an d the v olt age of the user’s outlet.

Go to “Power Service Check” on page 2-27.

Diagnostic Information 2-9

24xx

Print Quality Problems

Symptom Action

No print, but carrier moves as if printing.

Print density is light . Turn the ribbon adv ance knob on the print

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. Check the ribbon cartridge f or binds or damage. Go to “Print Speed Service Check” on

page 2-28.

cartridge from 1 to 2 to increase the darkness of print.

If the ribbon has reached its end of life or is worn, replace the ribbon cartridge.

Go to “C arrier Service Check” on page 2-16. Turn the ribbon adv ance knob on the print

cartridge from 1 to 2 to increase the darkness of print.

Be sure the printhead cables are connected correctly to the prin thead.

Clean the printhead. Set the form thicknes s le v er t o position “1” and run

the print test. Go to “C arrier Service Check” on page 2-16.

Scattered ink smearing, blur red characters.

Fuzzy print.

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

2-10 Service Manual

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

replace the ribbon cartridge. Go to “C arrier Service Check” on page 2-16.

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

the carrier unit. Go to “C arrier Service Check” on page 2-16.

24xx

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 “Carrier Service Check” on page 2-16.

Diagnostic Information 2-11

24xx

Irrecoverable Operator Errors

Paper Out and Font lights blink. If this indication occurs, the

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

Paper Present Sensor

Action Check

Remove all paper from the printer.

Turn the power on.

Pape r O u t blinks when paper does not exist . Pape r O u t turns off when paper exists. Go to “Paper Present Sensor Service Check”

on page 2-22.

Paper Select Sensor

Action Check

Turn the power off. Insta ll the Pus h

Tractor. Set the paper select

lever to the trac to r position and load continuous forms.

Turn the power on. Remove the

continuous forms. Set the paper select

lever t o the cut s heet position and insert a cut sheet.

Load/Unload function correctly. Go to “Paper Select Sensor Service Check” on

page 2-25.

When Auto Ready Cut Sheet is enab led, paper feeds automatically.

When Auto Ready Cut Sheet is disabled, press FormFeed to load a cut sheet. Verify Load/Unload does not function.

Go to “Paper Select Sensor Service Check” on

page 2-25.

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