Page 1 Edition: July 2006 Lexmark Forms Printer 2400 Series 24XX-200 • Table of contents • Start diagnostics • Start diagnostics • Safety and notices • Trademarks • Index Lexmark and Lexmark with diamond design are trademarks of Lexmark International, Inc., registered in the...
Page 2 Lexmark and Lexmark with diamond design are trademarks of Lexmark International, Inc., registered in the United States and/or other countries. All other trademarks are the property of their respective owners.
Page 3: Table Of Contents
24XX-200 Table of contents Safety information ........1-vii Preface .
Page 4 24XX-200 Diagnostic aids ........3-1 Power-On Self Test (POST) .
Page 5 24XX-200 Gears removals ........4-29 Left side gears removal .
Page 6 24XX-200 Preventive maintenance ....... . .6-1 Lubrication ..........6-1 Lubrication points .
Page 7: Safety Information
24XX-200 Safety information • The safety of this product is based on testing and approvals of the original design and specific components. The manufacturer is not responsible for safety in the event of use of unauthorized replacement parts. • 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.
Page 8 24XX-200 Norme di sicurezza • La sicurezza del prodotto si basa sui test e sull'approvazione del progetto originale e dei componenti specifici. Il produttore non è responsabile per la sicurezza in caso di sostituzione non autorizzata delle parti. • Le informazioni riguardanti la manutenzione di questo prodotto sono indirizzate soltanto al personale di assistenza autorizzato.
Page 9 24XX-200 Pautas de Seguridad • La seguridad de este producto se basa en pruebas y aprobaciones del diseño original y componentes específicos. El fabricante no es responsable de la seguridad en caso de uso de piezas de repuesto no autorizadas. •...
Page 10 24XX-200 Informació de Seguretat • La seguretat d'aquest producte es basa en l'avaluació i aprovació del disseny original i els components específics. El fabricant no es fa responsable de les qüestions de seguretat si s'utilitzen peces de recanvi no autoritzades. •...
Page 11 24XX-200...
Page 12: Preface
24XX-200 Preface This manual contains maintenance procedures for service personnel. It is divided into the following chapters: 1. General information contains a general description of the MFP and the maintenance approach used to repair it. Special tools and test equipment are listed, as well as general environmental and safety instructions.
Page 13: General Information
24XX-200 1. General information Printer description The Lexmark™ Forms Printer 248X-200 and 249X-200 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 multi-part forms. The 2481 and 2491 are wide- carriage versions of the 2480 and 2490.
Page 14: Printer Speeds
24XX-200 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— 77.5 cps 77.5 cps 91.7 cps 109 cps Near Letter Quality...
Page 15: Setup Menu Options
24XX-200 Setup menu options Menu Function Forms Macro options Customize macros to print a variety of forms. Data options Define how information is processed. Control options Define how the printer performs basic tasks. Emulation options Determine how the printer interacts with software applications.
Page 16: Printer Settings
24XX-200 Printer settings 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: •...
Page 17: Setting Top-Of-Form (Continuous-Pull Mode)
24XX-200 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. 4.
Page 18: Options
24XX-200 Options The 24xx printers support the following options: • Automatic 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-200 printers are: •...
Page 19: Diagnostic Information
24XX-200 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-200 circuit will read infinity. A circuit with correct continuity will read zero ohms. 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.
Page 21 24XX-200 Status Alarm Action Power Beeps Home Position Error Ready Blinking Go to “Carrier service check” Paper Out Blinking times on page 2-16. Panel Lock Blinking Font Lock Blinking Tractor 2 Home Position Error If Tractor 2 is installed, remove it to determine whether the problem is with the Carrier Home Position sensor or the Tractor 2 Home...
Page 22 24XX-200 Status Alarm Action All LEDs 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 service check” on page 2-28. Power None Operator Panel Failure Tractor 2 Go to “Operator panel service...
Page 23: Symptom Check Table
24XX-200 Symptom check table 1. Select the symptom that best describes the problem. 2. Perform the appropriate action before you go to the indicated service check. Abnormal indications Symptom Action 7 or more lights turn Disconnect the interface cable from the printer and on but do not turn turn the printer off and then back on.
Page 24 24XX-200 Abnormal print operation problems Symptom Action Be sure the interface cable is connected properly. Printer will not print, or become ready. Abnormal operation, Go to “No print or abnormal print service incorrect characters, check” on page 2-21. or incorrect line width Printer is ready but will not print from the...
Page 25: Error Indications
24XX-200 Error indications Symptom Action Ready and Paper Turn the printer off and then back on. Out lights blink. Go to “Abnormal indications” on page 2-5. Paper Out and Font Turn the printer off and then on. lights blink. Go to “Irrecoverable operator errors”...
Page 26 24XX-200 Symptom Action The Load/Unload Be sure the Paper Select lever is in the correct button does not position. function when the Go to “Paper Select sensor service check” on push tractor is page 2-26. installed. Form feed length is not correct.
Page 27: Power Problems
24XX-200 Symptom Action Lower feed roll shaft Be sure the Paper Select lever is in the correct rotates, but paper position. does not feed. Go to “Paper feed service check” on page 2-23. Pressing FormFeed does not feed paper. Abnormal noise created while printer is feeding.
Page 28: Print Quality Problems
24XX-200 Print quality problems Symptom Action No print, but the Adjust the Forms Thickness lever to a lower carrier moves as if number. printing. Be sure the printhead cables are not loose or damaged. Be sure the interface cable is connected properly. Check the ribbon cartridge for binds or damage.
Page 29: Irrecoverable Operator Errors
24XX-200 Ribbon feed problems Symptom Action Check the ribbon cartridge for binds or damage. Ribbon comes off, becomes loose or Go to “Carrier service check” on page 2-16. folded, or jams. Ribbon feeds correctly but is noisy. Irrecoverable operator errors Paper Out and Font lights blink.
Page 30: Paper Select Sensor
24XX-200 Paper Select sensor Action Check The Load/Unload button functions correctly. Turn the power off. Install the Push Go to “Paper Select sensor service check” on Tractor. page 2-26. Set the Paper Select lever to the tractor position and load continuous forms.
Page 31: Service Checks
24XX-200 Service checks Abnormal noise service check Check the entire printer for loose parts. Action Ribbon cartridge Remove and reinstall the ribbon cartridge. Printhead Disconnect the printhead cable(s). Run the print test (do not fold or damage the cables during the test). Go to “Print test”...
Page 32: Auto Sheet Feeder (Asf) Service Check
24XX-200 Auto Sheet Feeder (ASF) service check Note: Be sure the sheet feeder is enabled in the Setup mode. Go to “Setup mode” on page 1-2. Auto Sheet Feeder principles of operation The Auto Sheet Feeder (ASF) feeds into the cut sheet paper entry throat.
Page 33 24XX-200 Action Paper Select With the Paper Select lever in the cut sheet sensor position, do the following: • Try to load a cut sheet with the Load/Unload button. (This button should not work.) • If paper loads, go to “Paper Select sensor service check”...
Page 34: Carrier Service Check
24XX-200 Carrier service check Note: The carrier service check includes the carrier drive, Home Position sensor, and ribbon feed. Action Carrier 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-200 Action Carrier motor If the Home Position sensor is okay, verify that 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 Logic board If all parts appear okay but the Home Position...
Page 36: Intermittent Problem Service Check
24XX-200 Intermittent problem service check FRU/Symptom Action The printer Check for the following: sometimes fails 1. Loose connectors. Reconnect all before POST is connectors to the logic board. complete. 2. Electrical noise or static discharge. Check the following: • Power supply ground •...
Page 37 24XX-200 FRU/Symptom Action Printer power The cause of this problem may be that the sometimes turns power circuit is failing, or the wiring is off. intermittently open. Check the following in sequence: 1. Check the user’s outlet voltage and be sure it is within tolerance.
Page 38 24XX-200 FRU/Symptom Action The previous The following may cause undefined or suggestions have intermittent failures: not corrected the • Loose connector pins that fail to contact. problem. Check the following: – Reconnect the connectors of all FRUs and printer interface cables. –...
Page 39: No Print Or Abnormal Print Service Check
24XX-200 No print or abnormal print service check FRU/Function Action Logic board If the print test does not complete correctly, replace the logic board and reset the bidirectional print adjustment. See “Bidirectional print adjustment” on page 4-4. Interface cable Check the connection and continuity of the interface cable.
Page 40: Paper Present Sensor Service Check
24XX-200 Paper Present sensor service check Action Paper Present With no paper in the printer, the tractor in the sensor push position, and the Paper Select lever set to continuous forms, press Load/Unload; the gear train should turn forward to load paper. Activate the Paper Present sensor with a screwdriver and press Load/Unload again;...
Page 41: Paper Feed Service Check
24XX-200 Paper feed service check Note: If paper creases or jams frequently, verify that the paper is neither too thick nor thin. If necessary, refer the user to the User’s Guide for specifications of acceptable papers. If the paper does not stop in the correct location, see “Paper Present sensor service check”...
Page 42 24XX-200 FRU/symptom Action Operator panel If paper does not move at all, verify that the Load/Unload button is working as follows: With the tractor in the push position, turn the power off and then back on, and then press Load/Unload. The carrier should move to the center of the platen.
Page 43 24XX-200 FRU/symptom Action Logic board If no other problem is found, replace the logic board and reset the “Bidirectional print adjustment” on page 4-4. 2-25 Diagnostic information...
Page 44: Paper Select Sensor Service Check
24XX-200 Paper Select sensor service check If the form feed length is off by about 1 inch (25 mm), enter Setup mode and verify that the form length setting is correct. Go to “Setup mode” on page 1-2. Action Paper Select Remove all paper from the printer and do the sensor following:...
Page 45: Post Service Check
24XX-200 Action Pull Tractor A failed Pull Tractor sensor can cause the sensor Load/Unload button to malfunction. With the tractor in the push position: • Press Load/Unload several times while alternately holding down and releasing the left pull tractor actuator. The paper should not park or load when the pull tractor actuator is held down.
Page 46: Power Service Check
24XX-200 Power service check Action Power supply If the carrier does not move to the left after turning the printer off and then back on, be sure the line cord voltage to the power supply is correct and the power supply outputs are +40 V dc at CN12-1, +40 V dc at CN12-2 and +5 V dc at CN12-6.
Page 47: Print Speed Service Check
24XX-200 Action Logic board If no problem is found with the other components, but the power problem still remains, replace the logic board and reset the bidirectional print adjustment. Go to “Bidirectional print adjustment” on page 4-4. Print speed service check The speed of the 24xx printers varies with the font, forms thickness setting, and printhead temperature.
Page 48: Printhead Service Check
24XX-200 Printhead service check Action Printhead cables If the printout contains missing or extra dots or Printhead lines, do the following: • Check the continuity and connection of the printhead cables and the short flexible cable. • Be sure the voltages to the logic board are correct.
Page 49 24XX-200 Printhead impedance tables 2480, 2490 - approximately 5 ohms Connector CN400-13 & CN400-4 CN400-9 & CN400-6 CN400-15 & CN400-18 CN400-1 & CN400-7 CN400-17 & CN400-20 CN400-5 & CN400-2 CN400-19 & CN400-16 CN400-8 & CN400-3 CN400-10 & CN400- 14 2481, 2491 - approximately 8 to 16 ohms Connector Connector CN300-1 &...
Page 50: Pull Tractor Sensor Service Check
24XX-200 Pull Tractor sensor service check The Pull Tractor sensor detects the tractor in the pull position and disables the load/unload and auto tear-off functions. A failed sensor may prevent load/unload from functioning, with the tractor in the push position. Action Pull Tractor With the tractor in the push position, press...
Page 51: Top-Of-Forms Service Check
24XX-200 Top-of-forms service check Action Top-of-form Check that the Top-of-form sensor and its flag sensor are properly installed and are not damaged. Logic board Remove the paper, and set the Paper Select lever to the cut sheet position, and turn the printer on.
Page 52: Tractor 2 Service Check
24XX-200 Tractor 2 service check The Tractor 2 in-place sensor opens during installation, when its actuator touches the printer cover. The Tractor 2 Home sensor detects the position of the slider: • When Tractor 2 is selected, the motor-driven Tractor 2 slider pushes the printer sub slider cam lever to engage the printer gear train, which drives the Tractor 2 tractors.
Page 53 24XX-200 Action Logic board 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 back on. If the slider does not move after turning the printer off and then back on: •...
Page 54 24XX-200 3 beeps and Tractor 2 LED blinks 3 times Tractor 2 is selected from the operator panel but the printer does not detect Tractor 2, or detects that the Tractor 2 mechanism is not installed. Action Tractor 2 Check the Tractor 2 in-place sensor or the board/cable cable connection.
Page 55 24XX-200 Tractor 2 paper feed problems Action Tractor 2 Be sure the gear on the printer that drives Tractor 2 turns freely when the lever is not pressed, but remains still when the lever is pressed. Remove the Tractor 2 unit from the printer and remove all paper.
Page 56 24XX-200 2-38 Service Manual...
Page 57: Diagnostic Aids
24XX-200 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 58: Power-On Self Test (Post)
24XX-200 Power-On Self Test (POST) The following tests are automatically performed when the printer is turned on. • LEDs Test—Checks operation of LEDs on the operator panel. The LEDs turn on and off after the printer is turned on, and then all LEDs turn on for a few seconds.
Page 59: Print Test
24XX-200 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; the test does not print if paper is parked. 2. Press and hold Line Feed and turn the printer on. 3.
Page 60: Hex Trace Mode
24XX-200 Hex Trace mode The Hex Trace mode helps the user test and troubleshoot programs. Use the Hex Trace procedure to get a hexadecimal printout of the data stream sent to the printer. All data, including both control and character data, print in hexadecimal instead of ASCII. To activate Hex Trace mode: 1.
Page 61: Printer Default Settings
24XX-200 Printer default settings U.S. defaults To initialize or reset the printer to the U.S. factory defaults: (Code page 437, Character Set 1, form length 11 inch) 1. Make sure paper and the ribbon cartridge are installed. 2. Turn the printer off. 3.
Page 62: Clearing Paper Jams
24XX-200 Clearing paper jams Cut sheet jams To clear cut form paper jams: 1. Turn the printer off. 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.
Page 63: Repair Information
24XX-200 4. Repair information This chapter contains adjustments and removal procedures. Whenever parts are replaced, make sure that all adjustments are correct by running diagnostics procedures and checking adjustments as needed. Handling ESD-sensitive parts Many electronic products use parts that are known to be sensitive to electrostatic discharge (ESD).
Page 64: Adjustments
24XX-200 • Prevent ESD-sensitive parts from being accidently touched by other personnel. Install printer covers when not working on the printer, and do not put unprotected ESD-sensitive parts on a table. • Keep all ESD-sensitive parts in a grounded metal cabinet (case).
Page 65 24XX-200 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 66: Bidirectional Print Adjustment
24XX-200 11. After confirming that the head gap is within the specified range for all printhead positions (left, right and center), apply Lock Tite on both bushings. Bidirectional print adjustment After replacing any mechanical part which affects the operation of the logic board or the carrier, perform the following procedure to adjust the bidirectional print.
Page 67: Covers, Removals
24XX-200 Covers, removals Repair information...
Page 68: Covers, Front Removal
24XX-200 Covers, front removal 1. Rotate the front cover out and up about three inches from the bottom of the printer. 2. Push the front cover up and out of the printer. Covers, ribbon access removal 1. Pull the gray spring-loaded ribbon access cover release latches (A), located on either side of the ribbon access cover, up toward the front of the printer.
Page 69: Covers, Option Removal
24XX-200 Covers, option removal 1. From the bottom, pull the option cover (A) outward and up, removing it from the printer. Repair information...
Page 70: Covers, Top Removal
24XX-200 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 71 24XX-200 8. Turn the printer upside down. 9. Insert a flat blade screwdriver into each of the four holes (B) in the bottom cover, releasing the top cover from the bottom cover. 10.Turn the printer right side up and insert a flat blade screwdriver into each of the two holes (C) in the back of the top cover.
Page 72: Covers, Operator Panel Assembly Removal
24XX-200 Covers, operator panel assembly removal 1. Remove the top cover. Go to “Covers, top removal” on 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 73: Covers, Bottom Removal
24XX-200 Covers, bottom removal 1. Remove the top cover. Go to “Covers, top removal” on page 4-8. 2. Remove the logic board. Go to “Logic board removal” on page 4-12. 3. Remove the power supply unit. Go to “Power supply removal” on page 4-13.
Page 74: Logic Board Removal
24XX-200 Logic board removal 1. Remove the top cover. Go to “Covers, top removal” on page 4-8. 2. Disconnect all cables connected to the logic board. Go to “Logic board (9w & 24w)” on page 5-3 for connector location details. Note: Do not twist the flexible cable when disconnecting the printhead cable(s).
Page 75: Power Supply Removal
24XX-200 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 “Covers, top removal” on page 4-8. 3. Remove the print unit. Go to “Print unit removal”...
Page 76: Carrier Removals
24XX-200 Carrier removals Carrier removal 1. Remove the top cover. Go to “Covers, top removal” on page 4-8. 2. Remove the printhead from the carrier. Go to “Printhead removal” on page 4-25. 3. Loosen the carrier belt: 1. Loosen the tension screw (A). 2.
Page 77 24XX-200 4. Remove the retaining wire (B) from the left side of the carrier shaft. 4-15 Repair information...
Page 78 24XX-200 5. Remove the screw (C) from the forms thickness lever, and then remove the lever. 4-16 Service Manual...
Page 79 24XX-200 6. Remove the lower carrier motor mount screw (D). 7. Remove the two screws (E) from the carrier shaft bushing bracket on the left end of the carrier shaft, and then remove the bracket. 8. Remove the E-clip from the right side of the carrier shaft. 4-17 Repair information...
Page 80 24XX-200 9. Push the carrier shaft (F) from the right side so it goes out of 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-200 Carrier, motor assembly removal 1. Remove the top cover. Go to “Covers, top removal” on page 4-8. 2. Loosen the carrier belt: 1. Loosen the tension screw (A). 2. Remove tension from the carrier belt by pulling up on the belt.
Page 82 24XX-200 4. Remove the screw (B) from the forms thickness lever, and then remove the lever. 4-20 Service Manual...
Page 83 24XX-200 5. Remove the screw (C) 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 (D) securing the carrier motor bracket to the print unit.
Page 84: Paper Handling Removals
24XX-200 Paper handling removals Paper Select lever removal 1. Remove the top cover. Go to “Covers, top removal” on page 4-8. 2. Release the latch and remove the Paper Select lever from the right side frame. Paper feed motor removal 1.
Page 85: Forms Thickness Lever Removal
24XX-200 Forms Thickness lever removal 1. Remove the top cover. Go to “Covers, top removal” on page 4-8. 2. Remove the screw (A) from the lever, and then remove the Forms Thickness lever. 4-23 Repair information...
Page 86: Print Handling Removals
24XX-200 Print handling removals Platen removal 1. Remove the top cover. Go to “Covers, top removal” on 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.
Page 87: Printhead Removal
24XX-200 Printhead removal 1. Turn the printer off. 2. Disconnect the power cord at the printer and allow the printhead to cool for 15 minutes, before you handle it. 3. Set the Forms Thickness lever to position 7. 4. Remove the ribbon access cover. Go to “Covers, ribbon access removal”...
Page 88: Print Unit Removal
24XX-200 Print unit removal 1. Remove the top cover. Go to “Covers, top removal” on page 4-8. 2. Disconnect all cables from the logic board, except the power supply cable. 3. Remove the screw from the Forms Thickness lever, and then remove the lever.
Page 89 24XX-200 5. Remove the two grommet-anchored screws (B) 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. 4-27 Repair information...
Page 90: Ribbon Drive Rack Gear Removal
24XX-200 Ribbon drive rack gear removal 1. Remove the top cover. Go to “Covers, top removal” on page 4-8. 2. Remove the carrier. Go to “Carrier removal” on page 4-14. 3. Unsnap the white plastic end stop (A) from the top left side of the print unit.
Page 91: Gears Removals
24XX-200 Gears removals Left side gears removal 1. Remove the top cover. Go to “Covers, top removal” on page 4-8. 2. Remove the three screws (A) from the serial interface card bracket. 4-29 Repair information...
Page 92 24XX-200 3. Remove the four screws (B) from the paper feed motor bracket assembly. 4-30 Service Manual...
Page 93 24XX-200 4. Remove the paper feed motor bracket assembly, exposing the gears as shown. 4-31 Repair information...
Page 94: Right Side Gears, Sub Frame Removal
24XX-200 Right side gears, sub frame removal 1. Remove the top cover. Go to “Covers, top removal” on 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.
Page 95 24XX-200 5. Remove the sub frame, exposing the right side gears (D) as shown. 4-33 Repair information...
Page 96: Rollers Removals
24XX-200 Rollers removals Roller, upper feed removal 1. Remove the top cover. Go to “Covers, top removal” on page 4-8. 2. Remove the screw from the print cable shield, and then remove the shield. 3. Remove the gear from the left end of the upper feed roller, as shown.
Page 97 24XX-200 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 then out of the printer. 6.
Page 98: Roller, Lower Pinch Removal
24XX-200 Roller, lower pinch removal 1. Remove the top cover. Go to “Covers, top removal” on 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.
Page 99 24XX-200 7. Unhook the spring clip (B) from the right end of the lower pinch roller shaft, and then push it off the gray slotted spring block (C) toward the back of the printer, as shown. 8. Slide the carrier to the right side of the printer. 4-37 Repair information...
Page 100 24XX-200 9. Unhook the spring clip (D) from the left end of the lower pinch roller shaft, and then push it off the gray slotted spring block (B) toward the back of the printer, as shown. 10. Slide the carrier to the center of the printer. 11.
Page 101: Roller, Lower Feed Removal
24XX-200 Roller, lower feed removal 1. Remove the top cover. Go to “Covers, top removal” on page 4-8. 2. Remove the print unit. Go to “Print unit removal” on page 4-26. 3. Remove the carrier. Go to “Carrier removal” on page 4-14.
Page 102 24XX-200 9. Remove the two screws (A) securing the platen to the side frames. 10. Remove the carrier motor bracket. Go to “Carrier, motor assembly removal” on page 4-19. 11. Remove the five screws securing the left side frame, and then remove the frame.
Page 103: Sensors Removals
24XX-200 Sensors removals 4-41 Repair information...
Page 104: Sensor, Pull Tractor Removal
24XX-200 Sensor, Pull Tractor removal 1. Remove the top cover. Go to “Covers, top removal” on page 4-8. 2. Remove the small screw securing the Pull Tractor sensor to the inside of the left frame. Go to “Sensors removals” on page 4-41.
Page 105: Sensor, Paper Select Removal
24XX-200 Sensor, Paper Select removal 1. Remove the top cover. Go to “Covers, top removal” on page 4-8. 2. Remove the print unit. Go to “Print unit removal” on page 4-26. 3. Turn the print unit upside down. 4. Remove the four small screws securing the Paper Select sensor to the left side frame.
Page 106: Sensor, Home Position Sensor Removal
24XX-200 Sensor, Home Position sensor removal 1. Remove the top cover. Go to “Covers, top removal” on page 4-8. 2. Disconnect the Home Position sensor cable from the logic board. 3. Unsnap the Home Position sensor (A) from the frame. 4-44 Service Manual...
Page 107: Options Removals
24XX-200 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 pick-up gear. 5.
Page 108: Auto Sheet Feeder Pick-Up Roller Removal
24XX-200 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: Locations And Connectors
24XX-200 5. Locations and connectors This chapter identifies the locations of specific parts of the printer. Tension Ribbon Forms Carrier Paper Ribbon pulley cartridge thickness motor select drive plate lever lever rack assembly Printhead Carrier Printhead On/Off cable(s) switch Code Parallel Paper feed Tractor 2...
Page 110: Signal Connections
24XX-200 Signal connections Power supply (9w & 24w) Connector Pin # Signal +40 V dc +40 V dc Power Gnd Power Gnd Signal Gnd +5 V dc Power Save Mode Connector Signal Fuse Service Manual...
Page 111 24XX-200 Logic board (9w & 24w) Locations and connectors...
Page 112 24XX-200 Connector Signal Fuse Connector Pin # Signal +40 V dc +40 V dc Power Gnd Power Gnd Signal Gnd +5 V dc Power Save Mode Connector Signal Fuse Service Manual...
Page 113: Logic Board-Parallel Interface Cable (9W & 24W)
24XX-200 Logic board—Parallel interface cable (9w & 24w) Connector Pin # Signal Pin # Signal -Strobe Signal Gnd Data 0 Signal Gnd Data 1 Signal Gnd Data 2 Signal Gnd Data 3 Signal Gnd Data 4 Signal Gnd Data 5 Signal Gnd Data 6 Signal Gnd...
Page 114 24XX-200 Logic board (9w & 24w) Service Manual...
Page 115: Logic Board-Serial Board (9W & 24W)
24XX-200 Logic board—Serial board (9w & 24w) Connector Pin # Signal +5 V dc +5 V dc -CTS CN200 Signal Gnd SBSET Connector Pin # Signal +5 V dc +5 V dc -CTS Signal Gnd SBSET Locations and connectors...
Page 116 24XX-200 Logic board (9w & 24w) Service Manual...
Page 117: Logic Board-Usb Cable (9W & 24W)
24XX-200 Logic board—USB cable (9w & 24w) Connector Pin # Signal +5 V dc DMNS CN201 DPLS Signal Gnd Logic board—DC power (9w & 24w) Connector Pin # Signal +40 V dc +40 V dc Power Gnd CN12 Power Gnd Signal Gnd +5 V dc Power Save Mode...
Page 118 24XX-200 Logic board (9w & 24w) 5-10 Service Manual...
Page 119: Logic Board-Printhead (9W)
24XX-200 Logic board—Printhead (9w) Connector Pin # Signal CN400 HDTHERMO +5 V dc 5-11 Locations and connectors...
Page 120 24XX-200 Logic board (9w & 24w) 5-12 Service Manual...
Page 121: Logic Board-Printhead (24W)
24XX-200 Logic board—Printhead (24w) Connector Pin # Signal +40 V dc +40 V dc +40 V dc +40 V dc CN300 +40 V dc +40 V dc +40 V dc 5-13 Locations and connectors...
Page 122 24XX-200 Logic board (9w & 24w) 5-14 Service Manual...
Page 123: Logic Board—Printhead (24W)
24XX-200 Logic board—Printhead (24w) Connector Pin # Signal HDTHERMO CN301 +5 V dc +40 V dc +40 V dc 5-15 Locations and connectors...
Page 124 24XX-200 Logic board (9w & 24w) 5-16 Service Manual...
Page 125: Logic Board-Gap Set Sensor (9W & 24W)
24XX-200 Logic board—Gap Set sensor (9w & 24w) Connector Pin # Signal GAP1 Signal Gnd GAP2 Logic board—Home Position sensor (9w & 24w) Connector Pin # Signal HPSW Signal Gnd Logic board—Paper Present sensor (9w & 24w) Connector Pin # Signal PE1P Signal Gnd...
Page 126 24XX-200 Logic board (9w & 24w) 5-18 Service Manual...
Page 127: Logic Board-Paper Select Sensor (9W & 24W)
24XX-200 Logic board—Paper Select sensor (9w & 24w) Connector Pin # Signal TR/FR Signal Gnd Logic board—Pull Tractor sensor (9w & 24w) Connector Pin # Signal PLTR Signal Gnd Logic board—Top-of-form sensor (9w & 24w) Connector Pin # Signal Signal Gnd PE2P 5-19 Locations and connectors...
Page 128 24XX-200 Logic board (9w & 24w) 5-20 Service Manual...
Page 129: Logic Board-Carrier Motor (9W & 24W)
24XX-200 Logic board—Carrier motor (9w & 24w) Connector Pin # Signal Logic board—Paper feed motor (9w & 24w) Connector Pin # Signal 5-21 Locations and connectors...
Page 130 24XX-200 Logic board (9w & 24w) 5-22 Service Manual...
Page 131: Logic Board-Operator Panel (9W & 24W)
24XX-200 Logic board—Operator panel (9w & 24w) Connector Pin # Signal +5 V dc SLATCH +5 V dc CN13 Logic board Signal Gnd Signal Gnd SCLK Connector Pin # Signal +5 V dc SLATCH +5 V dc Operator panel Signal Gnd Signal Gnd SCLK 5-23...
Page 132 24XX-200 Logic board (9w & 24w) 5-24 Service Manual...
Page 133: Logic Board-Dual Tractor Cable (9W & 24W)
24XX-200 Logic board—Dual tractor cable (9w & 24w) Connector Pin # Signal +40 V dc +40 V dc Power Gnd Power Gnd +5 V dc COCOM CN10 D-SET Signal Gnd D-H.P D-POS 5-25 Locations and connectors...
Page 134: Serial Board-Serial Cable (9W & 24W)
24XX-200 Serial board—Serial cable (9w & 24w) Connector Pin # Signal Pin # Signal Chassis Gnd -CTS Signal Gnd 5-26 Service Manual...
Page 135: Tractor 2 Cable Connectors
24XX-200 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 CN1-7...
Page 136 24XX-200 5-28 Service Manual...
Page 137: Preventive Maintenance
24XX-200 6. Preventive maintenance This chapter describes procedures for preventive maintenance for the printer. 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.
Page 138: Lubrication Points
24XX-200 Lubrication points Lubricate the following contact positions: • Oil felt (carrier block) • Tractor shaft Grease Lubricate the following contact positions: • Side frame (left) and gears • Side frame (right) and ASF gears • Pinch roller, pinch roller springs, and paper separator •...
Page 139: Lubrication Points (Oil)
24XX-200 Lubrication points (oil) The oil felt (1) in the carrier block. The tractor shaft (1). Preventive maintenance...
Page 140: Lubrication Points (Grease)
24XX-200 Lubrication points (grease) Gear mounting studs on the right side frame (2). The lower pinch roller (2). Service Manual...
Page 141 24XX-200 Lubrication points (grease) cont. Gear mounting studs on the left side frame (2) Preventive maintenance...
Page 142 24XX-200 Lubrication points (grease) cont. Gear mounting studs on the left ASF side frame (2) Gear mounting studs on the right ASF side frame (2) Service Manual...
Page 143: Parts Catalog
24XX-200 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 144: Assembly 1: Covers
24XX-200 Assembly 1: Covers Service Manual...
Page 145 24XX-200 Assembly 1: Covers Asm- Part Description Index number 40X2912 Guide, left paper 40X2992 Cover assembly, front unit (2480, 2490) 40X2993 Cover assembly, front unit (2481, 2491) 40X2913 Guide, right paper 40X3013 Ribbon access cover unit (2480) 40X3014 Ribbon access cover unit (2481) 40X3025 Ribbon access cover unit (2490) 40X3026...
Page 146 24XX-200 Assembly 1 (cont.): Covers Service Manual...
Page 147 24XX-200 Assembly 1 (cont.): Covers Asm- Part Description Index number 40X3005 Cover, bottom (2480, 2490) 40X3006 Cover, bottom (2481, 2491) 40X3002 Tractor unit (2480, 2490) 40X3003 Tractor unit (2481, 2491) 40X2917 Frame, right side tractor 40X2918 Tractors, left and right 40X2905 Support, tractor paper 40X3000...
Page 148: Assembly 2: Carrier/Paper Feed (Right Side)
24XX-200 Assembly 2: Carrier/paper feed (right side) Service Manual...
Page 149 24XX-200 Assembly 2: Carrier/paper feed (right side) Asm- Part Description Index number 40X2887 Carrier roller set 40X2998 Printhead assembly (2480, 2481) 40X2999 Printhead assembly (2490, 2491) 40X2948 Carrier unit (2480) 40X2949 Carrier unit (2481) 40X2950 Carrier unit (2490) 40X2951 Carrier unit (2491) 40X2952 Cable, printhead (2480) 40X2953...
Page 150 24XX-200 Assembly 2 (cont.): Carrier/paper feed (right side) Service Manual...
Page 151 24XX-200 Assembly 2 (cont.): Carrier/paper feed (right side) Asm- Part Description Index number 2-191 40X2988 Shaft, carrier (2480, 2490) 40X2989 Shaft, carrier (2481, 2491) 40X2978 Roller, upper feed (2480, 2490) 40X2979 Roller, upper feed (2481, 2491) Parts catalog...
Page 152: Assembly 3: Carrier/Paper Feed (Left Side)
24XX-200 Assembly 3: Carrier/paper feed (left side) 7-10 Service Manual...
Page 153 24XX-200 Assembly 3: Carrier/paper feed (left side) Asm- Part Description Index number 40X2910 Gears and bushings, parts packet (248X) 40X2926 Screws, washers and clips, parts packet 40X2931 Kit, pull tractor actuator 40X2966 Frame, left side (2480, 2481) 40X2967 Frame, left side (2490, 2491) 40X2938 Sensor, Pull Tractor 40X3007...
Page 154 24XX-200 Assembly 3 (cont.): Carrier/paper feed (left side) 7-12 Service Manual...
Page 155 24XX-200 Assembly 3 (cont.): Carrier/paper feed (left side) Asm- Part Description Index number 3-23 40X2922 Kit, Head Gap adjustment 40X2894 Lever, Forms Thickness 40X2902 Motor, paper feed (with BKT) 40X2956 Gear, idler (248X) 40X2957 Gear, idler (249X) 7-13 Parts catalog...
Page 156: Assembly 4: Electronics
24XX-200 Assembly 4: Electronics 7-14 Service Manual...
Page 157 24XX-200 Assembly 4: Electronics Asm- Part Description Index number 40X2926 Screws, washers and clips, parts packet 40X2983 Kit, ESD ground (2490, 2491) 40X2982 Kit, ESD ground (2480, 2481) 40X2886 Power supply unit, LV 40X2885 Power supply unit, HV 40X3030 Module, EPROM (248X) 40X2964 Module, EPROM (249X) 40X2940...
Page 158: Assembly 5: Asf-Roller/Support
24XX-200 Assembly 5: ASF—Roller/support 7-16 Service Manual...
Page 159 24XX-200 Assembly 5: ASF—Roller/support Asm- Part Description Index number 40X2965 Support, ASF cut sheet with guides (2480, 2490) 40X3017 Support, ASF cut sheet with guides (2481, 2491) 40X2888 Roller, ASF upper feed (2480, 2490) 40X3023 Roller, ASF upper feed (2481, 2491) 40X2889 Roller, ASF lower feed (2480, 2490) 40X3024...
Page 160: Assembly 6: Asf-Side Frame/Covers
24XX-200 Assembly 6: ASF—Side frame/covers 7-18 Service Manual...
Page 161 24XX-200 Assembly 6: ASF—Side frame/covers Asm- Part Description Index number 40X2891 ASF Springs, parts packet 40X2890 ASF gears and bushings, parts packet 40X2936 Cover, ASF right 40X2892 ASF screws, parts packet 40X3011 Frame, ASF side right 40X2937 Stand, paper 7-19 Parts catalog...
Page 162: Assembly 7: Tractor 2 Option
24XX-200 Assembly 7: Tractor 2 option 7-20 Service Manual...
Page 163: Index
24XX-200 Assembly 7: Tractor 2 option Asm- Part Description Index number 40X3018 Table, Tractor 2 paper with guides (2480, 2490) 40X2881 Guide, Tractor 2 paper 40X3009 Tractor and frame assembly, Tractor 2 (2480, 2490) 40X2918 Kit, tractors left and right 40X2960 Board assembly with cable and ferrite, Tractor 2 (2480, 2490)
Page 164 24XX-200 7-22 Service Manual...
Page 165 24XX-200 Index Abbreviations General information Adjustments Bidirectional print Printhead-to-platen gap Hex Trace mode Principles of operation 2-14 Interface Menu options Irrecoverable operator errors Connections Paper Empty sensor 2-12 Logic Board Paper Present sensor 2-11 Printhead (9w) 5-11 Paper Select sensor 2-12 Logic board Carrier motor...
Page 166 24XX-200 Parts catalog Ribbon drive rack gear 4-28 How to use Right side sub frame 4-32 POST Rollers Preventive maintenance Lower feed 4-39 Lubrication Upper feed 4-34 Lubrication points Upper pinch 4-36 Specified lubricants Sensors Print test Head Gap 4-42 Printer Home Position 4-44...
Page 167 24XX-200 Specific printer parts Specifications Start Symptom checks Abnormal indications Abnormal noise problems ASF problems Error indications Operator panel problems Paper feed problems power problems Print quality problems 2-10 Tools Voltage, ground, and continuity...
Page 168 24XX-200 Service Manual...
Page 169: Part Number Index
24XX-200 Part number index Description Page 40X0271 Power cord—Malaysia, Singapore, United Kingdom 40X0274 Power cord—Switzerland 40X0275 Power cord—Israel 40X0276 Power cord—South Africa 40X0287 Power cord—Chile, Italy 40X0294 Power cord—Denmark 40X0296 Power cord—Australia, New Zealand 40X0297 Power cord—U.S., AFE (LV), Canada, Central and South America, Mexico, Saudi Arabia (LV) 40X1766 Power cord—Peru...
Page 170 24XX-200 40X2917 Frame, right side tractor 40X2918 Kit, tractors left and right 7-21 40X2918 Tractors, left and right 40X2919 Sensor, Top-of-form 7-11 40X2920 Sensor, home position 7-11 40X2921 Holder, lower pinch roller shaft, left 7-11 40X2922 Kit, Head Gap adjustment 7-7, 7-13 40X2923...
Page 171 24XX-200 40X2962 Operator panel assembly (248X) 40X2963 Operator panel assembly (249X) 40X2964 Module, EPROM (249X) 7-15 40X2965 Support, ASF cut sheet with guides (2480, 2490) 7-17 40X2966 Frame, left side (2480, 2481) 7-11 40X2967 Frame, left side (2490, 2491) 7-11 40X2968 Frame, right side 40X2969...
Page 172 24XX-200 40X3009 Tractor and frame assembly, Tractor 2 (2480, 2490) 7-21 40X3010 Holder, lower pinch roller shaft, right 40X3011 Frame, ASF side right 7-19 40X3013 Ribbon access cover unit (2480) 40X3014 Ribbon access cover unit (2481) 40X3015 Cable, power supply (2480, 2490) 7-15 40X3016 Cable, power supply (2481, 2491)

This manual is also suitable for:

249x-200 series

Lexmark 248X-200 series Service Manual

Preface

General Information

Diagnostic Information

24 Xx-200

Diagnostic Aids

Repair Information

24 Xx-200

Locations and Connectors

24 Xx-200

Preventive Maintenance

Parts Catalog

Index

Part Number Index

Quick Links

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Summary of Contents for Lexmark 248X-200 series

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Table of Contents