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Lexmark 24XX-100 Service Manual

Forms printer
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Lexmark Forms Printer 2400 Series
24XX-100
• Table of Contents
• Start Diagnostics
• Safety and Notices
• Trademarks
• Index
Lexmark and Lexmark with diamond
design are trademarks of Lexmark
International, Inc., registered in the
United States and/or other countries.

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Summary of Contents for Lexmark 24XX-100

  • Page 1 Lexmark Forms Printer 2400 Series 24XX-100 • Table of Contents • Start Diagnostics • Safety and Notices • Trademarks • Index Lexmark and Lexmark with diamond design are trademarks of Lexmark International, Inc., registered in the United States and/or other countries.
  • Page 2 You can purchase additional copies of publications related to this product by calling 1-800-553-9727. In other countries, contact your point of purchase. Lexmark and Lexmark with diamond design are trademarks of Lexmark International, Inc., registered in the United States and/or other countries.

  • Page 3: Table Of Contents

    Printer Speeds ........
  • Page 4 Hex Trace Mode ........3-4 Printer Default Settings ........3-5 U.S.
  • Page 5 24xx Gears Removals ........4-31 Left Side Gears Removal .
  • Page 6 24xx Preventive Maintenance ....... . .6-1 Lubrication ..........6-1 Lubrication Points .

  • Page 7: Safety Information

    This product is designed, tested and approved to meet strict global safety standards with the use of specific Lexmark components. The safety features of some parts may not always be obvious. Lexmark is not responsible for the use of other replacement parts. •...
  • Page 8 Il prodotto è stato progettato, testato e approvato in conformità 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’utilizzo di parti di ricambio di altri produttori.
  • Page 9 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. •...
  • Page 10 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 informació pel manteniment d’aquest producte està...
  • Page 11 24xx...

  • Page 12: 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.

  • Page 13: General Information

    24xx 1. General Information Printer Description The Lexmark Forms Printer 248X-100 and 249X-100 are small versatile tabletop printers suitable for use in the home or small business. They are especially well-suited for applications that use continuous or multipart forms. The 2481 and 2491 are wide-carriage versions of the 2480 and 2490.

  • Page 14: 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 print a list of all the available options.

  • Page 15: Setup Menu Options

    Protocol Function Customize macros to print a variety of forms. Defines how information is processed. Defines how the printer performs basic tasks. Determines how the printer interacts with software applications. Defines how information is transferred from computer to the printer.

  • Page 16: Setting The 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. Service Manual...

  • Page 17: Setting Top-Of-Form (Continuous - Pull Mode)

    24xx Setting Top-Of-Form (Continuous - Pull 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.

  • Page 18: Options

    • Internal serial interface (RS232) • OKI emulation (9 wire only) • Tractor 2 Sheet Feeder Tools The basic tools necessary to service the 24xx-100 printers are: • Basic CE tool kit • #1 Phillips screwdriver • #2 Phillips screwdriver •...

  • Page 19: Diagnostic Information

    24xx 2. Diagnostic Information Start Make a quick visual check for defects (loose or broken parts, unplugged connectors, paper jams, and so on). Voltage, Ground, And Continuity Readings Voltage Readings All DC voltages must be within +5% through -10% of the values to be considered correct.

  • Page 20: Error Indication Table

    24xx Error Indication Table The following table describes the service check entries for the printer error indication codes. When an error indication changes after you have entered a service check, you have an intermittent problem. If this occurs, leave the...
  • Page 21 Go to “Power Service Check” on page 2-27. None Timer Error Turn the printer off and then back on. If you get the same error during power-up, replace the logic board and readjust the bidirectional print adjustment. Go to “Bidirectional Print Adjustment”...
  • Page 22 24xx Status All LEDs Power Tractor 2 Paper Out Panel Lock Font Lock Any LED on and Power LED If the Power LED blinks or changes intensity. Service Manual Alarm Action None Power Failure Check the continuity of the power cord and the voltage of the user’s outlet.

  • Page 23: Symptom Check Table

    POST, abnormal noise is created. Action Disconnect the interface cable 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 “POST Service Check” on page 2-26.
  • Page 24 24xx Abnormal Print Operation Problems Symptom 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. Auto Sheet Feeder Problems...
  • Page 25 ASF is not installed. Print operation starts without paper. Action Turn the printer off and then on. Go to “Abnormal Indications” on page Turn the printer off and then on. Go to “Irrecoverable Operator Errors” on page 2-12.
  • Page 26 24xx Symptom Load/Unload does not function when the push tractor is installed. Form feed length is not correct. Load/Unload functions with cut sheets in use. Continuous forms feed, but cut sheets fail to load. Load/Unload functions when the pull tractor is installed.
  • Page 27 Form positioning. Power Problems Symptom 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. Action Be sure the paper select lever is in the correct position.
  • Page 28 24xx Print Quality Problems Symptom No print, but carrier moves as if printing. Print density is light. Uneven print density across the print line. Specific dots missing. Extra dots or lines printing. Scattered ink smearing, blurred characters. Fuzzy print. Wavy vertical lines, uneven left margin or character width is reduced.
  • Page 29 24xx Ribbon Feed Problems Symptom Ribbon comes off, becomes loose or folded, or jams. Ribbon feeds correctly but is noisy. Action Check the ribbon cartridge for binds or damage. Go to “Carrier Service Check” on page Diagnostic Information 2-16. 2-11...

  • Page 30: 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.

  • Page 31: Service Checks

    3-3. Replace the printhead, if the noise is gone. Disconnect the carrier motor connector CN2 from the logic board. Turn the printer off and then on. If the abnormal noise is gone, look for a problem with the carrier motor or ribbon drive mechanism.

  • Page 32: Auto Sheet Feeder (Asf) Service Check

    ASF and the lower feed rollers of the printer. Although the ASF picker rollers continue to turn as the paper is fed, their drive is disengaged and they are actually turned by the paper.
  • Page 33 If the paper does not feed, do the following: • Remove the ASF. • Be sure the base printer feeds paper correctly. • If the base printer does not feed paper correctly, go to “Paper Feed Service Check” on page 2-23.

  • Page 34: Carrier Service Check

    24xx Carrier Service Check Note: The Carrier Service Check includes the carrier drive, home position sensor and ribbon feed. Carrier Home Position Sensor 2-16 Service Manual Action Verify the carrier motor connector is connected to the logic board at CN2. If the carrier motor connector is connected properly, check the carrier belt and the ribbon cartridge for wear or damage.
  • Page 35 24xx Carrier Motor Logic Board Action If the home position sensor is okay, verify the the resistance of the carrier motor windings are approximately 2 ohms for all printers. Check the resistance at the following pin locations: CN2 - 1 and CN2 - 3 CN2 - 2 and CN2 -4 If all parts appear okay but the home position error still occurs, replace the logic board.

  • Page 36: Intermittent Problem Service Check

    2. Electrical noise or static discharge. Check the following: • Power supply ground. • Printer frame ground. • Printer interface cable is grounded and shielded. 3. Intermittently low voltages. Check for ac and all dc voltages and short circuits on the logic board.
  • Page 37 2. Check the continuity of the power cord. 3. Disconnect the power supply cable from connector CN12 on the logic board. Turn the printer power on and check all dc output voltages at CN12-1, CN12-2 and CN12-6. Verify the following output voltages: CN12 - 1 (+40 V dc ±10%)
  • Page 38 3-4. 1. Turn the printer off. 2. Press and hold Tractor and turn the printer 3. Have the user print the failing job. 4. To stop printing, turn the power off. If the failure still occurs, replace the logic board.

  • Page 39: No Print Or Abnormal Print Service Check

    Off and Load/UnLoad buttons are active. 24xx printers have a Padlock LED to indicate that the operator panel is locked. To lock or unlock the operator panel, turn the printer off and while holding the Load/Unload and Tractor buttons, turn the printer on.

  • Page 40: Paper Present Sensor Service Check

    CN5-3 (GND) on the 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. • Be sure the paper present sensor and its actuator are properly installed and not damaged.

  • Page 41: Paper Feed Service Check

    Enter the Setup Menu and reset ASF to off. Verify that the printer works correctly without the ASF installed. If the printer fails only with the Auto Sheet Feeder installed, go to “Auto Sheet Feeder (ASF) Service Check” on page Remove all paper from the printer.
  • Page 42 • With the lever in the continuous forms position (sensor closed), the gear train should rotate for more than 3 seconds. If the printer does not do either of the above: • Inspect the sensor to be sure it opens and closes by the paper separator.

  • Page 43: Paper Select Sensor Service Check

    Mode” on page 1-2. Paper Select Sensor Action Remove all paper from the printer and do the following: • Place the tractor in the push position and be sure the Auto Sheet Feed (ASF) is set to OFF in Setup Mode.

  • Page 44: Post Service Check

    Check the condition and continuity of the operator panel cable. Turn the printer off and then on. If you get the same error during power-up, verify the code module on the logic board is correctly installed. Replace the logic board if necessary and reset “Bidirectional Print Adjustment”...

  • Page 45: Power Service Check

    Disconnect the carrier motor from logic board CN2 and turn the printer off and then on. If the power LED lights correctly only with the carrier motor disconnected, replace the carrier motor.

  • Page 46: Print Speed Service Check

    4-4. Action Check the function of the head gap sensor by turning the printer on with the Macro button pressed. Open the operator panel to the second level and do the following: • With the forms thickness lever at 1, Macro LED 1 lights.

  • Page 47: Printhead Service Check

    24xx Printhead Service Check Printhead Cables Printhead Carrier Shaft Carrier Unit Platen Assembly Printhead Nose Ribbon Guide Action If the printout contains missing or extra dots or lines, do the following: • Check the continuity and connection of the printhead cables and the short flexible cable. •...
  • Page 48 24xx Printhead Impedance Tables 2480, 2490 - Approximately 5 ohms 2481, 2491 - Approximately 8 to 16 ohms Connector CN300-1 & CN301-9 CN300-1 & CN301-11 CN300-1 & CN301-7 CN300-1 & CN301-13 CN300-1 & CN301-5 CN300-1 & CN301-15 CN300-1 & CN301-3 CN300-1 &...

  • Page 49: Pull Tractor Sensor Service Check

    24xx Pull Tractor Sensor Service Check The pull tractor sensor detects the tractor in the pull position and disables load/unload and auto tear-off. A failed sensor may prevent load/unload from functioning, with the tractor in the push position. Pull Tractor Sensor Action With the tractor in the push position, press...

  • Page 50: Top-Of-Forms Service Check

    • When there is paper in the printer the voltage should be 0 V dc. • When there is no paper in the printer the voltage should be 5 V dc. Replace the top of form sensor if the voltage is incorrect.

  • Page 51: Tractor 2 Service Check

    10 Beeps and Blinking Ready, Paper, Font and Pitch LEDs Tractor 2 home sensor never made after turning the printer off and then on, or made at the wrong time. (The same error indication is used for carrier home failure.)
  • Page 52 Board /Cable Asm 2-34 Service Manual Action Remove Tractor 2 from the printer but leave the cable connected. Be sure the slider (the black plastic piece just above the right cover) moves after turning the printer off and then on.
  • Page 53 24xx 3 Beeps and Tractor 2 LED blinks 3 times Tractor 2 selected from operator panel but printer does not detect Tractor 2 or detects that the Tractor 2 mechanism is not installed. Tractor 2 Board/Cable Asm. Logic Board Action Check the Tractor 2 in-place sensor or the cable connection.
  • Page 54 Check the condition of the pin feed belts. With the printer off and be sure the slider does not bind. Verify: • When the slider is to the rear, the white gear drives the tractors.

  • Page 55: Diagnostic Aids

    24xx 3. Diagnostic Aids The printer contains self tests to help find and solve problems. You do not need to connect the printer to a computer or terminal to run these tests. Types of self tests are: • Power-On Self Test (POST) •...

  • Page 56: Power-On Self Test (Post)

    • LEDs Test - Checks operation of LEDs on the operator panel. The LEDs turn on and off after the printer is turned on, then all LEDs turn on for a few seconds. • RAM Test - Checks that the CPU can write/read the RAM.

  • Page 57: Print Test

    24xx Print Test The print test helps you test and troubleshoot the printer. To start the print test: 1. Paper must be at the print position; test does not print if paper is parked. 2. Press and hold Line Feed and turn the printer on.

  • Page 58: Hex Trace Mode

    3. Start your application program. Be sure the printout is similar to the hex trace 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.

  • Page 59: Printer Default Settings

    5. Close the ribbon access cover. 6. Press and hold Tear Off + Tractor while you turn the printer on. 7. Continue holding these buttons until the carrier moves. The operator panel lights blink several times. Once the carrier moves, your settings have been reset to factory defaults.

  • Page 60: Clearing Paper Jams

    2. Set the forms thickness lever to position 7. 3. Push the paper select lever down to the continuous forms position. 4. Gently pull out the sheet of paper from the front of the printer. 5. Remove the ribbon access cover to clear any torn pieces of paper.

  • Page 61: Repair Information

    • Do not place the ESD-sensitive part on the printer cover or on a metal table; if you need to put down the ESD-sensitive part for any reason, first put it into its special bag.

  • Page 62: Adjustments

    1. Turn the printer off and remove all covers, with the exception of the bottom cover. See 2. Remove the ribbon cartridge and paper.
  • Page 63 24xx 8. Using a feeler gauge [1], slowly adjust the left gap adjust bushing [2] counterclockwise, until a gap of (within 0.33 and 0.37 mm) exists between the printhead [3] and the platen. 9. Move the printhead to the right edge of the rubber on the platen and using a feeler gauge [1], slowly adjust the right gap adjust bushing [2] clockwise, until a gap of (within 0.33 and 0.37 mm) exists between the printhead [3] and the platen.

  • Page 64: Bidirectional Print Adjustment

    24xx Note: For maximum print quality, adjust the head gap on both the left and right sides of the printer to within +/- 0.01mm. If the gap value exceeds the specified range, return to step 4 and re-adjust both left and right gap adjust bushings.

  • Page 65: Removal Procedures

    24xx Removal Procedures CAUTION: Be sure to unplug the power cord whenever you are working on the printer with one of the covers removed. Covers, Removals Repair Information...

  • Page 66: Covers, Front Removal

    [A], on either side of the ribbon access cover, up toward the front of the printer. 2. Lift the ribbon access cover up and out of the printer. Note: When replacing the ribbon access cover, be sure to hook the front hinge points on either side of the ribbon access cover first and lower the cover into place.

  • Page 67: Covers, Option Removal

    24xx Covers, Option Removal 1. From the bottom, pull the option cover [A] outward and up, removing it from the printer. Repair Information...

  • Page 68: Covers, Top Removal

    24xx Covers, Top Removal 1. Turn the printer off and disconnect the power cord at the printer. 2. Remove the tractor assembly, if it is installed in the pull tractor position, by pressing the locking levers and pulling the tractor assembly out of the printer.
  • Page 69 24xx 8. Turn the printer upside down. 9. Insert a flat blade screwdriver into each of the four holes [A] in the bottom cover, releasing the top cover from the bottom cover. Repair Information...
  • Page 70 24xx 10. Turn the printer right side up and insert a flat blade screwdriver into each of the two holes [A] in the back of the top cover. 11. Lift the top cover up and over the print unit assembly.

  • Page 71: Covers, Operator Panel Assembly Removal

    24xx Covers, Operator Panel Assembly Removal 1. Remove the top cover. Go to page 4-8. 2. Disconnect the operator panel cable from the operator panel card, on the inside of the top cover. 3. Push down on the two latches [A] at the top of the operator panel on the inside of the top cover, as shown.

  • Page 72: Covers, Bottom Removal

    24xx Covers, Bottom Removal 1. Remove the top cover. Go to page 4-8. 2. Remove the logic board. Go to page 4-14. 3. Remove the power supply unit. Go to Removal” on page 4. Remove the print unit. Go to page 4-28.

  • Page 73: Electronics Removals

    1. Remove the options cover [A], by pulling it outward, up and out of the printer. 2. Remove the EPROM module. Note: When replacing the EPROM module, be sure the notch on the module is toward the front of the printer. 4-13 Repair Information...

  • Page 74: Logic Board Removal

    24xx Logic Board Removal 1. Remove the top cover. Go to page 4-8. 2. Disconnect all cables connected to the logic board. Go to “Logic Board (9w & 24w)” on page details. Note: Do not twist the flexible cable when disconnecting the printhead cable(s).

  • Page 75: Power Supply Removal

    24xx Power Supply Removal CAUTION: The power supply may be hot. 1. Turn off the printer and disconnect the power cord at both ends. 2. Remove the top cover. Go to page 4-8. 3. Remove the print unit. Go to page 4-28.

  • Page 76: Carrier Removals

    24xx Carrier Removals Carrier Removal 1. Remove the top cover. Go to page 4-8. 2. Remove the printhead from the carrier. Go to Removal” on page 3. Loosen the carrier belt: Loosen the tension screw [A]. Remove tension from the belt, by pulling up on the belt. Tighten the tension screw.
  • Page 77 24xx 4. Remove the retaining wire [A] from the left side of the carrier shaft. 4-17 Repair Information...
  • Page 78 24xx 5. Remove the screw [A] from the forms thickness lever and remove the lever. 4-18 Service Manual...
  • Page 79 24xx 6. Remove the lower carrier motor mount screw [A]. 7. Remove the two screws [B] from the carrier shaft bushing bracket on the left end of the carrier shaft and remove the bracket. 8. Remove the E-clip from the right side of the carrier shaft. 4-19 Repair Information...
  • Page 80 24xx 9. Push the carrier shaft [A] from the right side and out the left side of the printer. 10. Remove the carrier from the printer. Note: Following replacement, perform the Printhead-to-Platen Gap Adjustment. Go to “Printhead-to-Platen Gap Adjustment” on page 4-2.

  • Page 81: Carrier, Motor Assembly Removal

    24xx Carrier, Motor Assembly Removal 1. Remove the top cover. Go to page 4-8. 2. Loosen the carrier belt Loosen the tension screw [A]. Remove tension from the carrier belt, by pulling up on the belt. Tighten the tension screw. Loosening the screw tightens the belt.: 3.
  • Page 82 24xx 4. Remove the screw [A] from the forms thickness lever and remove the lever. 4-22 Service Manual...
  • Page 83 24xx 5. Remove the screw [A] securing the carrier motor bracket to the bottom cover. 6. Disconnect the printhead cable from the logic board and move it back and out of the way, as shown. 7. Remove the five screws [B] securing the carrier motor bracket to the print unit.

  • Page 84: Paper Handling Removals

    24xx Paper Handling Removals Paper Select Lever Removal 1. Remove the top cover. Go to page 4-8. 2. Release the latch and remove the paper select lever from the right side frame. Paper Feed Motor Removal 1. Remove the top cover. Go to page 4-8.

  • Page 85: Form Thickness Lever Removal

    24xx Form Thickness Lever Removal 1. Remove the top cover. Go to page 4-8. 2. Remove the screw [A] from the lever and remove the form thickness lever. “Covers, Top Removal” on Repair Information 4-25...

  • Page 86: Print Handling Removals

    24xx Print Handling Removals Platen Removal 1. Remove the top cover. Go to page 4-8. 2. Remove the two platen screws [A] from each end of the platen. 3. Remove the platen from the paper tray. 4. Perform the Printhead-to-Platen Gap adjustment. Go to “Printhead-to-Platen Gap Adjustment”...

  • Page 87: Printhead Removal

    24xx Printhead Removal 1. Turn the printer off. 2. Disconnect the power cord at the printer and allow the printhead to cool for 15 minutes, prior to handling. 3. Set the form thickness lever to position 7. 4. Remove the ribbon access cover. Go to Access Removal”...

  • Page 88: Print Unit Removal

    24xx Print Unit Removal 1. Remove the top cover. Go to page 4-8. 2. Disconnect all cables from the logic board, except the power supply cable. 3. Remove the screw from the form thickness lever and remove the lever. 4. Remove the two grommet anchored screws [A] from the left side of the print unit.
  • Page 89 24xx 5. Remove the two grommet anchored screws [A] from the right side of the print unit. 6. Remove the print unit from the bottom cover, by pulling up forcefully on both sides of the print unit. 4-29 Repair Information...

  • Page 90: Ribbon Drive Rack Gear Removal

    24xx Ribbon Drive Rack Gear Removal 1. Remove the top cover. Go to page 4-8. 2. Remove the carrier. Go to 3. Unsnap the white plastic end stop [A] from the top left side of the print unit. 4. Unlatch the left side of the rack from the top of the print unit. 5.

  • Page 91: Gears Removals

    24xx Gears Removals Left Side Gears Removal 1. Remove the top cover. Go to page 4-8. 2. Remove the three screws [A] from the serial interface card bracket. “Covers, Top Removal” on Repair Information 4-31...
  • Page 92 24xx 3. Remove the four screws [A] from the paper feed motor bracket assembly. 4-32 Service Manual...
  • Page 93 24xx 4. Remove the paper feed motor bracket assembly, exposing the gears, as shown. 4-33 Repair Information...

  • Page 94: Right Side Gears, Sub Frame Removal

    24xx Right Side Gears, Sub Frame Removal 1. Remove the top cover. Go to page 4-8. 2. Unhook the wire retainer [A] from the carrier shaft. 3. Remove the two screws and washers [B] from the sub frame. 4. Remove the paper select lever [C]. 4-34 Service Manual “Covers, Top Removal”...
  • Page 95 24xx 5. Remove the sub frame exposing the right side gears [A], as shown. 4-35 Repair Information...

  • Page 96: Rollers Removals

    24xx Rollers Removals Roller, Upper Feed Removal 1. Remove the top cover. Go to page 4-8. 2. Remove the screw from the print cable shield and remove the shield. 3. Remove the gear from the left end of the upper feed roller, as shown.
  • Page 97 4. Remove the two screws [A] from the right upper feed roller bracket. One screw also retains the upper feed roller ground clip. 5. Pull the upper feed roller from the left bracket and out of the printer. 6. Be sure to perform the Printhead-to-Platen Gap Adjustment procedure. Go to page 4-2.

  • Page 98: Roller, Lower Pinch Removal

    1. Remove the top cover. Go to page 4-8. 2. Slide the carrier to the far left of the printer. 3. Remove the four screws [A] from the paper feed motor bracket. 4. Remove the screw from the top of the serial interface card bracket.
  • Page 99 7. Unhook the spring clip [A] from the right end of the lower pinch roller shaft and push it off the gray slotted spring block [B] toward the back of the printer, as shown. 8. Slide the carrier to the right side of the printer. 4-39 Repair Information...
  • Page 100 13. While holding the lower pinch roller shaft by the gear [C], move the shaft to the left approximately one half inch. Lift the shaft up and to the back of the printer and carefully remove the lower pinch roller and shaft.

  • Page 101: Roller, Lower Feed Removal

    24xx Roller, Lower Feed Removal 1. Remove the top cover. Go to page 4-8. 2. Remove the print unit. Go to page 4-28. 3. Remove the carrier. Go to 4. Remove the two screws securing the black bracket to the inside of the right side frame.
  • Page 102 24xx 9. Remove the two screws [A] securing the platen to the side frames. 10. Remove the carrier motor bracket. Go to Assembly Removal” on page 11. Remove the five screws securing the left side frame and remove the frame. 12.

  • Page 103: Sensors Removals

    24xx Sensors Removals 4-43 Repair Information...

  • Page 104: Sensor, Pull Tractor Removal

    24xx Sensor, Pull Tractor Removal 1. Remove the top cover. Go to page 4-8. 2. Remove the small screw securing the pull tractor sensor to the inside of the left frame. Go to page 4-43. 3. Disconnect the pull tractor sensor from the logic board. Sensor, Head Gap Removal 1.

  • Page 105: Sensor, Paper Select Removal

    24xx Sensor, Paper Select Removal 1. Remove the top cover. Go to page 4-8. 2. Remove the print unit. Go to page 4-28. 3. Turn the print unit upside down. 4. Remove the 4 small screws securing the paper select sensor to the left side frame.

  • Page 106: Sensor, Home Position Sensor Removal

    24xx Sensor, Home Position Sensor Removal 1. Remove the top cover. Go to page 4-8. 2. Disconnect the home position sensor cable from the logic board. 3. Unsnap the home position sensor [A] from the frame. 4-46 Service Manual “Covers, Top Removal” on...

  • Page 107: Options Removals

    24xx Options Removals Auto Sheet Feeder Gears Removal 1. Remove the right cover. 2. Release the joint gear latch [A] and remove the joint gear. 3. Release the idler gear latch and remove the idler gear. 4. Release the pick-up gear latch and remove the gear. 5.

  • Page 108: Auto Sheet Feeder Pick-Up Roller Removal

    24xx Auto Sheet Feeder Pick-up Roller Removal 1. Remove the covers and the cut sheet support. 2. Release the joint gear latch [A] and remove the joint gear, idler gear, and pick-up gear. 3. Remove the left and right roller bushings. 4.

  • Page 109: Connector Locations

    24xx 5. Connector Locations This chapter identifies the locations of specific parts of the printer. Connector Locations...

  • Page 110: Signal Connections

    24xx Signal Connections Power Supply (9w & 24w) Connector Connector Service Manual Pin # Signal +40 V dc +40 V dc Power Gnd Power Gnd Signal Gnd +5 V dc Power Save Mode Signal Fuse...
  • Page 111 24xx Logic Board (9w & 24w) Connector Locations...

  • Page 112: Logic Board - Parallel Interface Cable (9W & 24W)

    24xx Logic Board - Parallel Interface Cable (9w & 24w) Connector CN11 Service Manual Pin # Signal -Strobe Data 0 Data 1 Data 2 Data 3 Data 4 Data 5 Data 6 Data 7 -Acknlg Busy Select -AUTFED Signal Gnd Chassis Gnd +5 V dc Pin #...
  • Page 113 24xx Logic Board (9w & 24w) Connector Locations...

  • Page 114: Logic Board - Serial Board (9W & 24W)

    24xx Logic Board - Serial Board (9w & 24w) Connector CN200 Connector Service Manual Pin # Signal +5 V dc +5 V dc -CTS Signal Gnd SBSET Pin # Signal +5 V dc +5 V dc -CTS Signal Gnd SBSET...
  • Page 115 24xx Logic Board (9w & 24w) Connector Locations...

  • Page 116: Logic Board - Usb Cable (9W & 24W)

    24xx Logic Board - USB Cable (9w & 24w) Connector CN201 Logic Board - DC Power (9w & 24w) Connector CN12 Service Manual Pin # Signal +5 V dc DMNS DPLS Signal Gnd Pin # Signal +40 V dc +40 V dc Power Gnd Power Gnd Signal Gnd...
  • Page 117 24xx Logic Board (9w & 24w) Connector Locations...

  • Page 118: Logic Board - Printhead (9W)

    24xx Logic Board - Printhead (9w) Connector CN400 5-10 Service Manual Pin # Signal HDTHERMO +5 V dc...
  • Page 119 24xx Logic Board (9w & 24w) 5-11 Connector Locations...

  • Page 120: Logic Board - Printhead (24W)

    24xx Logic Board - Printhead (24w) Connector CN300 5-12 Service Manual Pin # Signal +40 V dc +40 V dc +40 V dc +40 V dc +40 V dc +40 V dc +40 V dc...
  • Page 121 24xx Logic Board (9w & 24w) 5-13 Connector Locations...
  • Page 122 24xx Logic Board - Printhead (24w) Connector CN301 5-14 Service Manual Pin # Signal HDTHERMO +5 V dc +40 V dc +40 V dc...
  • Page 123 24xx Logic Board (9w & 24w) 5-15 Connector Locations...

  • Page 124: Logic Board - Gap Set Sensor (9W & 24W)

    24xx Logic Board - Gap Set Sensor (9w & 24w) Connector Logic Board - Home Position Sensor (9w & 24w) Connector Logic Board - Paper Present Sensor (9w & 24w) Connector 5-16 Service Manual Pin # Signal GAP1 Signal Gnd GAP2 Pin # Signal...
  • Page 125 24xx Logic Board (9w & 24w) 5-17 Connector Locations...

  • Page 126: Logic Board - Paper Select Sensor (9W & 24W)

    24xx Logic Board - Paper Select Sensor (9w & 24w) Connector Logic Board - Pull Tractor Sensor (9w & 24w) Connector Logic Board - Top Of Form Sensor (9w & 24w) Connector 5-18 Service Manual Pin # Signal TR/FR Signal Gnd Pin # Signal PLTR...
  • Page 127 24xx Logic Board (9w & 24w) 5-19 Connector Locations...

  • Page 128: Logic Board - Carrier Motor (9W & 24W)

    24xx Logic Board - Carrier Motor (9w & 24w) Connector Logic Board - Paper Feed Motor (9w & 24w) Connector 5-20 Service Manual Pin # Signal Pin # Signal...
  • Page 129 24xx Logic Board (9w & 24w) 5-21 Connector Locations...

  • Page 130: Logic Board - Operator Panel (9W & 24W)

    24xx Logic Board - Operator Panel (9w & 24w) Connector CN13 Logic Board Connector Operator Panel 5-22 Service Manual Pin # Signal +5 V dc SLATCH +5 V dc Signal Gnd Signal Gnd SCLK Pin # Signal +5 V dc SLATCH +5 V dc Signal Gnd...
  • Page 131 24xx Logic Board (9w & 24w) 5-23 Connector Locations...

  • Page 132: Logic Board - Dual Tractor Cable (9W & 24W)

    24xx Logic Board - Dual Tractor Cable (9w & 24w) Connector CN10 5-24 Service Manual Pin # Signal +40 V dc +40 V dc Power Gnd Power Gnd +5 V dc COCOM D-SET Signal Gnd D-H.P D-POS...

  • Page 133: Serial Board - Serial Cable (9W & 24W)

    24xx Serial Board - Serial Cable (9w & 24w) Connector Pin # Signal Chassis Gnd -CTS Signal Gnd Pin # Signal Connector Locations 5-25...

  • Page 134: Tractor 2 Cable Connectors

    24xx Tractor 2 Cable Connectors The Tractor 2 cable is soldered to the Tractor 2 board at CN1; there is no connector. Connector Mode CN1-1 +26 V dc. CN1-2 +26 V dc. CN1-3 Frame GND. CN1-4 Not used. CN1-5 +5 V dc. CN1-6 Motor common.

  • Page 135: Preventive Maintenance

    24xx 6. Preventive Maintenance This chapter describes procedures for printer preventive maintenance. Following these recommendations can help prevent problems and maintain optimum performance. Lubrication Warning: Petroleum-based lubricants can attack polycarbonate parts causing premature failure. Use only mineral oil-based lubricants. The following parts should be lubricated when replaced: •...

  • Page 136: Lubrication Points

    24xx Lubrication Points • Oil Felt (carrier block) • Tractor Shaft Grease • Side Frame (Left) and Gears • Side Frame (Right) and ASF Gears • Pinch Roller, Pinch Roller Springs and Paper Separator • ASF Side Frames, Gears and Combination Lock Mechanism •...

  • Page 137: Lubrication Points (Oil)

    24xx Lubrication Points (Oil) The oil felt [1] in the carrier block. The tractor shaft [1]. Preventive Maintenance...

  • Page 138: Lubrication Points (Grease)

    24xx Lubrication Points (Grease) Gear mounting studs on the right side frame [2]. The lower pinch roller [2]. Service Manual...
  • Page 139 24xx Lubrication Points (Grease) Continued Gear mounting studs on the left side frame [2]. Preventive Maintenance...
  • Page 140 24xx Lubrication Points (Grease) Continued Gear mounting studs on the left ASF side frame [2]. Gear mounting studs on the right ASF side frame [2]. Service Manual...

  • Page 141: Parts Catalog

    24xx 7. Parts Catalog How To Use This Parts Catalog SIMILAR ASSEMBLIES: If two assemblies contain a majority of identical parts, they are shown on the same list. Common parts are shown by one index number. Parts peculiar to one or the other of the assemblies are listed separately and identified by description.

  • Page 142: Assembly 1: Covers

    24xx Assembly 1: Covers Service Manual...
  • Page 143 24xx Asm- Part Index Number 1 - 1 12G3877 12G3873 12G3874 12G3878 12G3858 12G3859 12G3868 12G3869 12G3871 12G3872 12G3870 79F4757 1339519 1339520 1339525 1339524 1339521 1339523 1339522 1339518 1339517 Description Guide, Left Paper Cover Asm., Front Unit (2480, 2490) Cover Asm., Front Unit (2481, 2491) Guide, Right Paper Cover, Ribbon Access Unit (2480) Cover, Ribbon Access Unit (2481)
  • Page 144 24xx Assembly 1: Covers Service Manual...
  • Page 145 24xx Asm- Part Index Number 1 - 8 12G3856 12G3857 12G3854 12G3855 12G3850 12G3853 79F4830 12G3851 12G3852 12G3849 12G3810 12G3811 12G3883 12G3875 12G3876 12G3999 12G3881 12G3882 12G3939 Description Cover, Bottom (2480, 2490) Cover, Bottom (2481, 2491) Tractor Unit (2480, 2490) Tractor Unit (2481, 2491) Frame, Right Side Tractor Tractors, Left and Right...

  • Page 146: Assembly 2: Carrier / Paper Feed Right Side

    24xx Assembly 2: Carrier / Paper Feed Right Side Service Manual...
  • Page 147 24xx Asm- Part Description Index Number 2 - 1 12G3841 Carrier Roller Set 12G3894 Printhead Assembly (2480, 2481) 12G3895 Printhead Assembly (2490, 2491) 12G3838 Carrier Unit (2480) 12G3837 Carrier Unit (2481) 12G3840 Carrier Unit (2490) 12G3839 Carrier Unit (2491) 12G3889 Cable, Printhead (2480) 12G3888 Cable, Printhead (2481)
  • Page 148 24xx Assembly 2: Carrier / Paper Feed Right Side Service Manual...
  • Page 149 24xx Asm- Part Description Index Number 2 - 22 12G3832 Roller, Upper Feed (2480, 2490) 12G3833 Roller, Upper Feed (2481, 2491) Parts Catalog...

  • Page 150: Assembly 3: Carrier / Paper Feed Left Side

    24xx Assembly 3: Carrier / Paper Feed Left Side 7-10 Service Manual...
  • Page 151 24xx Asm- Part Description Index Number 3 - 1 12G3905 Gears and Bushings, Parts Packet (248X) 12G3906 Gears and Bushings, Parts Packet (249X) 12G3907 Screws, Washers and Clips, Parts Packet 12G3942 Kit, Pull Tractor Actuator 12G3817 Frame, Left Side (2480, 2481) 12G3818 Frame, Left Side (2490, 2491) 12G3940...
  • Page 152 24xx Assembly 3: Carrier / Paper Feed Left Side 7-12 Service Manual...
  • Page 153 24xx Asm- Part Description Index Number 3 - 24 12G3931 Kit, Head Gap Adjustment 12G3947 Lever, Form Thickness 56P1224 Motor, Paper Feed (with BKT) 11A3274 Gear, Idle (248X) 11A3275 Gear, Idle (249X) 7-13 Parts Catalog...

  • Page 154: Assembly 4: Electronics

    24xx Assembly 4: Electronics 7-14 Service Manual...
  • Page 155 24xx Asm- Part Index Number 4 - 1 12G3907 12G3836 12G3887 12G3801 12G3800 12G3812 12G3813 12G3848 12G3802 12G3806 12G3803 12G3807 12G3804 12G3808 12G3805 12G3809 56P1476 12G3885 12G3861 12G3860 12G3903 12G3904 12G3929 12G3936 Description Screws, Washers and Clips, Parts Packet Kit, ESD Ground (2490, 2491) Kit, ESD Ground (2480, 2481) Power Supply Unit, LV Power Supply Unit, HV...

  • Page 156: Assembly 5: Asf - Roller / Support

    24xx Assembly 5: ASF - Roller / Support 7-16 Service Manual...
  • Page 157 24xx Asm- Part Index Number 5 - 1 12G3814 12G3908 95F6886 95F6896 95F6887 95F6897 95F6885 1333275 12G3911 12G3893 12G3912 12G3914 12G3915 12G3916 12G3933 12G3934 12G3918 95F6892 95F6893 95F6894 12G3944 Description Support, ASF Cut Sheet W/ Guides (2480, 2490) Support, ASF Cut Sheet W/ Guides (2481, 2491) Roller, ASF Upper Feed (2480, 2490) Roller, ASF Upper Feed (2481, 2491) Roller, ASF Lower Feed (2480, 2490)

  • Page 158: Assembly 6: Asf - Side Frame / Covers

    24xx Assembly 6: ASF - Side Frame / Covers 7-18 Service Manual...
  • Page 159 24xx Asm- Part Index Number 6 -1 95F6893 95F6892 12G3920 95F6894 12G3921 12G3930 12G3945 12G3939 Description ASF Springs, Parts Packet ASF Gears and Bushings, Parts Packet Cover, ASF Right ASF Screws, Parts Packet Cover, ASF/TR2 Front (2480, 2490) Cover, ASF/TR2 Front (2481, 2491) Frame, ASF Side Right Stand, Paper 7-19...

  • Page 160: Assembly 7: Tractor 2 Option

    24xx Assembly 7: Tractor 2 Option 7-20 Service Manual...
  • Page 161 24xx Asm- Part Index Number 7 - 1 12G3923 12G3924 11A3338 12G3926 12G3927 12G3853 11A3335 11A3336 11A3337 11A3341 12G3928 12G3921 12G3930 11A3283 11A3284 Description Table, Tractor 2 Paper W/ Guides (2480, 2490) Table, Tractor 2 Paper W/ Guides (2481, 2491) Guide, Tractor 2 Paper Tractor and Frame Assembly, Tractor 2 (2480, 2490) Tractor and Frame Assembly, Tractor 2 (2481, 2491)

  • Page 162: Coax / Twinax Adapter

    24xx Coax / Twinax Adapter Asm- Part Index Number 12G3704 12G3705 12G3709 13A0297 13A0296 11A6109 7-22 Service Manual Description Adapter, Coax (Power Cable and Adapter) Adapter, Twinax (Power Cable and Adapter) Bracket, Adapter (Bracket Only) Cable, Coax (Cable Only) Cable, Twinax (Cable Only) Cable, Socket Power Coax, Twinax (Socket Power Cable Only)
  • Page 163 24xx Index Abbreviations Adjustments Bidirectional Print Printhead-to-Platen Gap Principles of Operation Connections Logic Board Carrier Motor 5-20 DC Power Dual Tractor Cable Gap Set Sensor 5-16 Home Position Sensor Operator Panel 5-22 Paper Feed Motor Paper Present Sensor Paper Select Sensor Parallel Interface Cable Printhead (24w) 5-12...
  • Page 164 How to use POST Preventive Maintenance Lubrication Lubrication Points Specified Lubricants Print Test Printer Description Options Settings Specifications Speeds Printer Default Settings Service Manual Removals Gears Pick-up Roller Carrier Carrier Motor Assembly 7-18 Covers 7-10 Bottom Front Operator Panel Option...

  • Page 165: Index

    Tear Off Position Top-Of-Form (Continuous) Top-Of-Form (Cut Forms) Top-Of-Form (Envelopes) Setup Menu Options Setup Mode Entering Exiting Signal Connections Specific Printer Parts Specifications Start Symptom Checks Abnormal Indications Abnormal Noise Problems Abnormal Print Problems ASF Problems Error Indications Operator Panel Problems...
  • Page 166 24xx 12G3827 7-11 12G3828 7-11 12G3831 7-11 12G3832 12G3833 12G3834 12G3835 12G3836 7-15 12G3837 12G3838 12G3839 12G3840 12G3841 12G3844 7-11 12G3845 7-11 12G3848 7-15 12G3849 12G3850 12G3851 12G3852 12G3853 7-21 12G3854 12G3855 12G3856 12G3857 12G3858 12G3859 12G3860 7-15 12G3861 7-15 12G3868 12G3869 12G3870...
  • Page 167 24xx 12G3943 12G3944 7-17 12G3945 7-19 12G3946 7-11 12G3947 7-13 12G3948 7-11 12G3999 13A0296 7-22 13A0297 7-22 1333275 7-17 1339517 1339518 1339519 1339520 1339521 1339522 1339523 1339524 1339525 56P1219 7-11 56P1224 7-13 56P1476 7-15 79F4757 79F4802 7-11 79F4830 79F4834 7-11 95F6885 7-17 95F6886...
  • Page 168 24xx Service Manual...

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