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.
4xx Edition: November 2000 The following paragraph does not apply to any country where such provisions are inconsistent with local law: LEXMARK INTERNATIONAL, INC. PROVIDES THIS PUBLICATION “AS IS” WITHOUT WARRANTY OF ANY KIND, EITHER EXPRESS OR IMPLIED, INCLUDING, BUT NOT LIMITED TO, THE IMPLIED WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. Some states do not allow disclaimer of express or implied warranties in certain transactions; therefore, this statement may not apply to you.
24xx Table of Contents Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . vii Preface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xii General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 Printer Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Printer Speeds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
24xx 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 .
24xx Right Side Gears, Sub Frame Removal. . . . . . . . . . . . . . . . . . . Rollers Removals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Roller, Upper Feed Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . Roller, Lower Pinch Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . Roller, Lower Feed Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . Sensors Removals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
24xx Preventive Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-1 Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-1 Lubrication Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-2 Lubrication Points (Oil) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-3 Lubrication Points (Grease). . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-4 Parts Catalog . . . . . . . .
24xx 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. 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.
24xx Norme di sicurezza • 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. Le informazioni riguardanti la manutenzione di questo prodotto sono indirizzate soltanto al personale di assistenza autorizzato.
24xx Pautas de Seguridad • Este producto se ha diseñado, verificado y aprobado para • • cumplir los 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.
24xx Informació de Seguretat • Aquest producte està dissenyat, comprovat i aprovat per tal • • d'acomplir les estrictes normes 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 informació pel manteniment d’aquest producte està orientada exclusivament a professionals i no està destinada a ningú que no ho sigui.
24xx xi
24xx 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).
24xx 1. General Information 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.
24xx 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. 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.
24xx Setup Menu Options Menus Function Forms Macro options Customize macros to print a variety of forms. Data options Defines how information is processed. Control options Defines how the printer performs basic tasks. Emulation options Determines how the printer interacts with software applications. Interface options Defines how information is transferred from computer to the printer. Interface Menu Options Menus Function Interface • • • • Automatically select the printer interface.
24xx 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: • 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.
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. 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 TopOf-Form position. 6. Use the second sheet of continuous forms to set Top-Of-Form. 7.
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 printers 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.
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. Unless stated otherwise, all connectors should be connected normally when a voltage measurement is performed.
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 service check and go to “Symptom Check Table” on page 2-5.
24xx LED Status Alarm Action Power Ready Paper Out Panel Lock Font Lock ON Blinking Blinking Blinking Blinking Beeps 10 times Home Position 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 the problem is with the carrier home position sensor or the Tractor 2 home position sensor. See the “Tractor 2 Service Check” on page 2-33. None Home Position Error Without Alarm Go to “Power Service Check” on page 2-27.
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 Service Check” on page 2-27. Power Tractor 2 Paper Out Panel Lock Font Lock ON OFF OFF OFF OFF None Operator Panel Failure Go to “Operator Panel Service Check” on page 2-21. Any LED on and Power LED off None Go to “Operator Panel Service Check” on page 2-21. If the Power LED blinks or changes intensity.
24xx 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 on but do not turn off. 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. The Power light is on, but POST will not run. Go to “POST Service Check” on page 2-26.
xx Abnormal Print Operation Problems Symptom Action Printer will not print, or become ready. Be sure the interface cable is connected properly. Abnormal operation, incorrect characters, or incorrect line width. Go to “No Print or Abnormal Print Service Check” on page 2-21. 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 page 2-28.
24xx Error Indications Symptom Action Ready and Paper Out lights blink. Turn the printer off and then on. Paper Out and Font lights blink. Turn the printer off and then on. Go to “Abnormal Indications” on page 2-5. Go to “Irrecoverable Operator Errors” on page 2-12. Operator Panel Problems Symptom Action Start/Stop does not function but no error is indicated. Turn the printer off and then on. Go to “Operator Panel Service Check” on page 2-21. Only the Power light turns on.
24xx Symptom Action Load/Unload does not function when the push tractor is installed. Be sure the paper select lever is in the correct position. Go to “Paper Select Sensor Service Check” on page 2-25. Form feed length is not correct. Load/Unload functions with cut sheets in use. Continuous forms feed, but cut sheets fail to load. Be sure the paper select lever is in the cut sheet position. Verify that continuous forms have been parked using the Load/Unload button.
24xx Symptom Action Lower feed roll shaft rotates, but paper does not feed. Be sure the paper select lever is in the correct position. Pressing FormFeed does not feed paper. Go to “Paper Feed Service Check” on page 2-23. Abnormal noise created while feeding. Paper jams, skews or creases. Incorrect or no line spacing: wider, narrower, or overlapping lines. Push/Pull Tractor does not work. Incorrect Top of Form positioning. Go to “Top-Of-Forms Service Check” on page 2-32.
24xx Print Quality Problems Symptom Action No print, but carrier moves as if 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 for binds or damage. Go to “Print Speed Service Check” on page 2-28. Print density is light. Turn the ribbon advance knob on the print cartridge from 1 to 2 to increase the darkness of print.
24xx Ribbon Feed Problems Symptom Action Ribbon comes off, becomes loose or folded, or jams. Check the ribbon cartridge for binds or damage. Go to “Carrier Service Check” on page 2-16. Ribbon feeds correctly but is noisy.
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. Paper Out blinks when paper does not exist. Turn the power on. Paper Out turns off when paper exists.
24xx Service Checks Abnormal Noise Service Check Check the entire printer for loose parts. FRU Action 1 Ribbon Cartridge Remove and reinstall the ribbon cartridge. 2 Printhead Disconnect the printhead cable(s). Run the print test (do not fold or damage the cables during the test). Go to “Print Test” on page 3-3. Replace the printhead, if the noise is gone. 3 Carrier Motor Ribbon Drive Mechanism Disconnect the carrier motor connector CN2 from the logic board. Turn the printer off and then on.
24xx 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. To use the ASF: • The paper select lever must be set to cut sheet. • The Auto Sheet Feeder must be selected in the Setup menu.
24xx 1 FRU Action Paper Select Sensor With the paper select lever in the cut sheet position, do the following: • Try to load a cut sheet with Load/Unload. (This button should not work) • If paper loads, go to “Paper Select Sensor Service Check” on page 2-25. 2 Paper Feed 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.
24xx Carrier Service Check Note: The Carrier Service Check includes the carrier drive, home position sensor and ribbon feed. 1 FRU 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. Check the belt and pulley engagement.
24xx 3 FRU Action Carrier Motor 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 4 Logic Board If all parts appear okay but the home position error still occurs, replace the logic board. After replacing the logic board or any parts affecting the carrier, perform the bidirectional print adjustment.
24xx Intermittent Problem Service Check 1 FRU/Symptom Action The printer sometimes fails before POST is complete. Check for the following: 1. Loose connectors. Reconnect all connectors to the logic board. 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. a.
24xx 2 FRU/Symptom Action Printer power sometimes turns off. The cause of this problem may be that the power circuit is failing, or the wiring is intermittently open. Check the following in sequence: 1. Check the user’s outlet voltage and be sure it is within tolerance. 2. Check the continuity of the power cord. 3. Disconnect the power supply cable from 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.
24xx 4 FRU/Symptom Action If the prior suggestions have not corrected the problem. The following may cause undefined or intermittent failures: 1.Loose connector pins that fail to contact. Check the following: • Reconnect the connectors of all FRUs and printer interface cables. • Check the continuity of the line cord. 2.Electrical noise. Check the following: • Power supply ground. • Printer frame ground. • Printer interface cable is grounded or shielded. 3.Undefined data in user applications.
24xx No Print or Abnormal Print Service Check FRU/Function Action 1 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. 2 Interface Cable Check the connection and continuity of the interface cable. 3 Emulation Mode Enter the Setup Menu and be sure the printer is in the correct emulation mode for the computer, either IBM or Epson. Go to “Setup Mode” on page 1-2.
24xx Paper Present Sensor Service Check 1 FRU Action Paper Present Sensor With no paper in the printer, the tractor in the 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; the gear train should turn backward to park paper. Measure the voltage between CN5-2 (paper present signal) and CN5-3 (GND) on the logic board.
24xx Paper Feed Service Check Note: If paper creases or jams frequently, verify 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” on page 2-22 and the “Top-OfForms Service Check” on page 2-32. 1 FRU / Symptom Action Auto Sheet Feeder If the Auto Sheet Feeder is installed, remove it. Enter the Setup Menu and reset ASF to off.
24xx 4 FRU / Symptom Action Operator Panel If paper does not move at all, verify the Load/Unload button is working as follows: With the tractor in the push position, power off, power on and then press Load/Unload. The carrier should move to the center of the platen. If it does not, go to “Operator Panel Service Check” on page 2-21. 5 Paper Feed Motor Disconnect the paper feed motor cable CN1 from the logic board. No pin should have continuity to ground.
24xx Paper Select Sensor Service Check If form feed length is off by about 1 inch (25 mm), enter Setup Mode and verify that the form length setting is correct. Go to “Setup Mode” on page 1-2. 1 FRU Action Paper Select Sensor 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. • Press FormFeed and time how long the gear train rotates.
24xx 2 FRU Action Pull Tractor Sensor A failed pull tractor sensor can cause Load/Unload 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. • If the paper does park or load with the pull tractor actuator held down, go to “Pull Tractor Sensor Service Check” on page 2-31.
24xx Power Service Check 1 FRU Action Power Supply If the carrier does not move to the left after turning the printer off and then 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. If the voltages are incorrect: • Check the internal fuse before replacing the power supply.
24xx 6 FRU Action Logic Board If no problem is found with the other components, but the power problem still remains, replace the logic board and reset “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. Graphics output may print slowly due to data throughput limitations. Thermal sensing is built into the printhead on 249x printers and protects the printhead from overheating.
24xx Printhead Service Check 1 FRU Action Printhead Cables Printhead 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. • Be sure the voltages to the logic board are correct. If dots are missing: • Perform the print test to determine which wire is not firing. • Remove the printhead and verify that no pins on the printhead are broken or missing.
24xx Printhead Impedance Tables 2480, 2490 - Approximately 5 ohms Dot Connector 1 CN400-13 & CN400-4 2 CN400-9 & CN400-6 3 CN400-15 & CN400-18 4 CN400-1 & CN400-7 5 CN400-17 & CN400-20 6 CN400-5 & CN400-2 7 CN400-19 & CN400-16 8 CN400-8 & CN400-3 9 CN400-10 & CN400- 14 2481, 2491 - Approximately 8 to 16 ohms Dot Connector Dot Connector 1 CN300-1 & CN301-9 13 CN300-1 & CN300-9 2 CN300-1 & CN301-11 14 CN300-1 & CN300-11 3 CN300-1 & CN301-7 15 CN300-1 & CN300-2 4 CN300-1 &
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. 1 FRU Action Pull Tractor Sensor With the tractor in the push position, press Load/Unload several times while alternately holding down and releasing the left pull tractor actuator.
24xx Top-Of-Forms Service Check FRU Action 1 Top-Of-Form Sensor Check that the top-of-form sensor and its flag are properly installed and are not damaged. 2 Logic Board Remove the paper and set the paper select lever to the cut sheet position and turn the printer on. Measure the voltage between logic board connector CN6-2 (TOF signal) and CN6-1 (GND). You should receive the following voltage readings: • When there is paper in the printer the voltage should be 0 V dc.
24xx Tractor 2 Service Check The Tractor 2 in-place sensor opens during installation, when its actuator touches the printer cover. The home sensor detects the position of the slider: • When Tractor 2 is selected, the motor-driven Tractor 2 slider • pushes the printer sub slider cam lever to engage the printer gear train which drives the Tractor 2 tractors. When the Tractor 2 is deselected, the motor retracts the slider, disengages the Tractor 2 gear drive, and reengages the printer tractors.
24xx 2 FRU 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 on. If the slider does not move after turning the printer off and then on: • Be sure the slider and gear train are properly connected and move freely with the power off. • Be sure the Tractor 2 board is receiving: +40 V dc on CN1-1 and +5 V dc on CN1-5.
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. 1 FRU Action Tractor 2 Board/Cable Asm. Check the Tractor 2 in-place sensor or the cable connection. The in-place sensor actuator extends through the Tractor 2 cover and rests on the printer cover when Tractor 2 is installed. Remove the Tractor 2 cover and be sure the inplace sensor opens when the Tractor 2 is installed.
24xx Tractor 2 Paper Feed Problems 1 FRU 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. With the paper select lever in the continuous forms position, press FormFeed; the tractors should rotate.
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) • Print Test • Hex Trace Mode (a computer or terminal is necessary) The following are special machine modes that run when the printer is turned off and then back on: Turn Printer On While Pressing Results LineFeed Prints print test with sample fonts.
24xx 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, then all LEDs turn on for a few seconds. RAM Test - Checks that the CPU can write/read the RAM. Font ROM/Microcode Sum Test - Checks that the ROM data is correct. Timer/Interrupt Controller Test - Checks that this function works.
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. 3. Release Line Feed when the printing starts. 4. To interrupt the printer test: a. Press Start/Stop. The test stops after a complete line of characters prints. b. Press Start/Stop to continue the test sample. 5. To stop the printer test, turn the printer off.
24xx 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. Press and hold Tractor and then turn the printer on. 2. After a few seconds, release Tractor and the lights go out. 3. Start your application program.
24xx 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. Open the ribbon access cover. 4. Move the printhead toward the operator panel side of the printer until it stops. 5. Close the ribbon access cover. 6. Press and hold Tear Off + Load/Unload while you turn the printer on. 7.
24xx 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. Remove the ribbon access cover to clear any torn pieces of paper. 6. Set the paper select lever to the cut forms position. 7. Set the forms thickness lever to the proper setting for the type of paper you are using.
24xx 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).
24xx Adjustments CAUTION: Be sure to unplug the power cord whenever you are working on the printer with one of the covers removed. Printhead-to-Platen Gap Adjustment Perform the printhead-to-platen gap adjustment after replacing the carrier, platen, lower pinch roller, ribbon drive rack gear, left side frame, right side frame, paper separator, lower feed roller, or paper guide. 1. Turn the printer off and remove all covers, with the exception of the bottom cover. See “Covers, Removals” on page 4-5. 2.
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. 10.
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. 11. After confirming the head gap is within the specified range for all (left, right and center) printhead positions, apply Lock Tite on both bushings.
24xx Removal Procedures CAUTION: Be sure to unplug the power cord whenever you are working on the printer with one of the covers removed.
24xx 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 both gray spring loaded ribbon access cover release latches [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.
24xx Covers, Option Removal 1. From the bottom, pull the option cover [A] outward and up, removing it from the printer.
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. 3. Remove the ribbon access cover. Go to “Covers, Ribbon Access Removal” on page 4-6. 4. Remove the front cover. Go to “Covers, Front Removal” on page 4-6. 5. Remove the option cover. Go to “Covers, Option Removal” on page 4-7.
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.
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. Note: When replacing the top cover, be sure the operator panel cable is correctly aligned and inserted securely into the logic board. Damage to the operator panel cable may cause failure of other electrical components in the printer.
24xx 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. 4. While holding the latches down, push the operator panel out of the top cover, toward the bottom of the cover.
24xx 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 4-14. 3. Remove the power supply unit. Go to “Power Supply Removal” on page 4-15. 4. Remove the print unit. Go to “Print Unit Removal” on page 4-28.
24xx Electronics Removals EPROM Removal 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.
24xx 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). 3. Remove the top screw [A] from the serial interface card bracket. 4. Remove the three screws [B] securing the logic board to the bottom cover.
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 “Covers, Top Removal” on page 4-8. 3. Remove the print unit. Go to “Print Unit Removal” on page 4-28. 4. Disconnect the power supply cable [A]. 5. Remove the five screws [B] securing the power supply to the bottom cover. Take care not to lose the ground clips which must be replaced between the ground plate and the board. 6.
24xx 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 4-27. 3. Loosen the carrier belt: a. Loosen the tension screw [A]. b. Remove tension from the belt, by pulling up on the belt. c. Tighten the tension screw. Loosening the screw tightens the belt.
24xx 4. Remove the retaining wire [A] from the left side of the carrier shaft.
24xx 5. Remove the screw [A] from the forms thickness lever and remove the lever.
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.
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.
24xx Carrier, Motor Assembly Removal 1. Remove the top cover. Go to “Covers, Top Removal” on page 4-8. 2. Loosen the carrier belt a. Loosen the tension screw [A]. b. Remove tension from the carrier belt, by pulling up on the belt. c. Tighten the tension screw. Loosening the screw tightens the belt.: 3. Slip the belt off the carrier motor pulley.
24xx 4. Remove the screw [A] from the forms thickness lever and remove the lever.
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. 8. Remove the home position sensor [C] from the top of the carrier motor bracket by pinching the clips underneath the bracket. 9.
24xx 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. Remove the top cover. Go to “Covers, Top Removal” on page 4-8. 2. Remove the two screws [A] from the paper feed motor bracket. 3. Remove the motor. 4. Disconnect the paper feed motor cable from the logic board.
24xx Form 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 remove the form thickness lever.
24xx 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. Perform the Printhead-to-Platen Gap adjustment. Go to “Printhead-to-Platen Gap Adjustment” on page 4-2.
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 “Covers, Ribbon Access Removal” on page 4-6. 5. Remove the ribbon cartridge. 6. Squeeze the printhead latches together while pulling the printhead up and out of the printer. 7. Disconnect the printhead cable(s) from the printhead.
24xx 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 form thickness lever and remove the lever. 4. Remove the two grommet anchored screws [A] from the left side of the print unit.
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.
24xx 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 4-16. 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. Slide the rack to the right and out of the print unit.
24xx 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.
24xx 3. Remove the four screws [A] from the paper feed motor bracket assembly.
24xx 4. Remove the paper feed motor bracket assembly, exposing the gears, as shown.
24xx 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. Remove the paper select lever [C].
24xx 5. Remove the sub frame exposing the right side gears [A], as shown.
24xx 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 remove the shield. 3. Remove the gear from the left end of the upper feed roller, as shown.
24xx 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 “Printhead-to-Platen Gap Adjustment” on page 4-2.
24xx 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. Remove the screw from the top of the serial interface card bracket. 5. Disconnect the paper feed motor cable from the logic board and remove the paper feed motor and bracket from the printer. 6. Slide the carrier to the left side of the printer.
24xx 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.
24xx 9. Unhook the spring clip [A] from the left 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. 10. Slide the carrier to the center of the printer. 11. Slide the gray slotted spring blocks [B], on each end, toward the center of the roller shaft, taking care that the blocks remain with the shaft during removal. 12. Slide the carrier to the right side of the printer. 13.
24xx 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 4-28. 3. Remove the carrier. Go to “Carrier Removal” on page 4-16. 4. Remove the two screws securing the black bracket to the inside of the right side frame. 5. Remove the right side sub frame and the right side gears. Go to “Right Side Gears, Sub Frame Removal” on page 4-34. 6. Remove the left side gears.
24xx 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 4-21. 11. Remove the five screws securing the left side frame and remove the frame. 12. Remove the four screws from the right side frame and remove the bottom frame assembly. 13. Remove the five screws from the frame support plate and remove the lower feed roller. 14. Be sure to perform the Printhead-to-Platen Gap Adjustment procedure.
24xx Sensors Removals Repair Information 4-43
24xx 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 4-43. 3. Disconnect the pull tractor sensor from the logic board. Sensor, Head Gap Removal 1. Remove the top cover. Go to “Covers, Top Removal” on page 4-8. 2. Remove the screw from the forms thickness lever and remove the lever. 3.
24xx 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 4-28. 3. Turn the print unit upside down. 4. Remove the 4 small screws securing the paper select sensor to the left side frame. Go to “Sensors Removals” on page 4-43. Sensor, Paper Present 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 4-28. 3.
24xx 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.
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. Release the combination lock mechanism latch. 6. Remove the tension plate on the locker cam and remove the cam. 7. Release the lift gear latch and remove the gear.
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. Move the pick-up rollers to the ends of the shaft and remove them.
24xx 5. Connector Locations This chapter identifies the locations of specific parts of the printer.
24xx Signal Connections Power Supply (9w & 24w) Connector CN1 Connector F1 5-2 Service Manual Pin # Signal 1 +40 V dc 2 +40 V dc 3 Power Gnd 4 Power Gnd 5 Signal Gnd 6 +5 V dc 7 Power Save Mode Signal Fuse
24xx Logic Board (9w & 24w) Connector Locations 5-3
24xx Logic Board - Parallel Interface Cable (9w & 24w) Connector CN11 5-4 Service Manual Pin # Signal Pin # Signal 1 -Strobe 19 Signal Gnd 2 Data 0 20 Signal Gnd 3 Data 1 21 Signal Gnd 4 Data 2 22 Signal Gnd 5 Data 3 23 Signal Gnd 6 Data 4 24 Signal Gnd 7 Data 5 25 Signal Gnd 8 Data 6 26 Signal Gnd 9 Data 7 27 Signal Gnd 10 -Acknlg 28 Signal Gnd 11 Busy 29 Signal Gnd 12 PE 30 Signal Gnd 13 Select 31 -INIT 14 -AUTFED 32 -ERROR 15 NC 33 Signal
24xx Logic Board (9w & 24w) Connector Locations 5-5
24xx Logic Board - Serial Board (9w & 24w) Connector CN200 Connector CN1 5-6 Service Manual Pin # Signal 1 +5 V dc 2 +5 V dc 3 -CTS 4 DTS 5 RXD 6 RTS 7 DSR 8 TXD 9 Signal Gnd 10 SBSET Pin # Signal 10 +5 V dc 9 +5 V dc 8 -CTS 7 DTS 6 RXD 5 RTS 4 DSR 3 TXD 2 Signal Gnd 1 SBSET
24xx Logic Board (9w & 24w) Connector Locations 5-7
24xx Logic Board - USB Cable (9w & 24w) Connector CN201 Pin # Signal 1 +5 V dc 2 DMNS 3 DPLS 4 Signal Gnd Logic Board - DC Power (9w & 24w) Connector CN12 5-8 Service Manual Pin # Signal 1 +40 V dc 2 +40 V dc 3 Power Gnd 4 Power Gnd 5 Signal Gnd 6 +5 V dc 7 Power Save Mode
24xx Logic Board (9w & 24w) Connector Locations 5-9
24xx Logic Board - Printhead (9w) Connector CN400 5-10 Service Manual Pin # Signal 1 H4 2 H6C 3 H8C 4 H1C 5 H6 6 H2C 7 H4C 8 H8 9 H2 10 H9 11 HDTHERMO 12 +5 V dc 13 H1 14 H9C 15 H3 16 H7C 17 H5 18 H3C 19 H7 20 HSC
24xx Logic Board (9w & 24w) Connector Locations 5-11
24xx Logic Board - Printhead (24w) Connector CN300 5-12 Service Manual Pin # Signal 1 +40 V dc 2 R15 3 +40 V dc 4 R21 5 +40 V dc 6 R23 7 +40 V dc 8 L24 9 R13 10 L22 11 L14 12 L20 13 +40 V dc 14 L18 15 +40 V dc 16 L16 17 +40 V dc
24xx Logic Board (9w & 24w) Connector Locations 5-13
24xx Logic Board - Printhead (24w) Connector CN301 5-14 Service Manual Pin # Signal 1 R9 2 R11 3 R7 4 R17 5 R5 6 R19 7 R3 8 HDTHERMO 9 R1 10 +5 V dc 11 L2 12 +40 V dc 13 L4 14 +40 V dc 15 L6 16 L12 17 L8 18 L10
24xx Logic Board (9w & 24w) Connector Locations 5-15
24xx Logic Board - Gap Set Sensor (9w & 24w) Connector CN4 Pin # Signal 1 GAP1 2 Signal Gnd 3 GAP2 Logic Board - Home Position Sensor (9w & 24w) Connector CN9 Pin # Signal 1 HPSW 2 Signal Gnd Logic Board - Paper Present Sensor (9w & 24w) Connector CN5 5-16 Service Manual Pin # Signal 1 PE1P 2 PE1 3 Signal Gnd
24xx Logic Board (9w & 24w) Connector Locations 5-17
24xx Logic Board - Paper Select Sensor (9w & 24w) Connector CN8 Pin # Signal 1 TR/FR 2 Signal Gnd Logic Board - Pull Tractor Sensor (9w & 24w) Connector CN3 Pin # Signal 1 PLTR 2 Signal Gnd Logic Board - Top Of Form Sensor (9w & 24w) Connector CN6 5-18 Service Manual Pin # Signal 1 Signal Gnd 2 PE2P 3 PE2
24xx Logic Board (9w & 24w) Connector Locations 5-19
24xx Logic Board - Carrier Motor (9w & 24w) Connector CN2 Pin # Signal 1 CAD 2 CAC 3 CAB 4 CAA Logic Board - Paper Feed Motor (9w & 24w) Connector CN1 5-20 Service Manual Pin # Signal 1 LFD 2 LFC 3 LFB 4 LFA 5 NC
24xx Logic Board (9w & 24w) Connector Locations 5-21
24xx Logic Board - Operator Panel (9w & 24w) Connector CN13 Logic Board Connector CN1 Operator Panel 5-22 Service Manual Pin # Signal 1 +5 V dc 2 SLATCH 3 +5 V dc 4 TXD 5 Signal Gnd 6 RXD 7 Signal Gnd 8 SCLK 9 SG Pin # Signal 1 +5 V dc 2 SLATCH 3 +5 V dc 4 TXD 5 Signal Gnd 6 RXD 7 Signal Gnd 8 SCLK 9 SG
24xx Logic Board (9w & 24w) Connector Locations 5-23
24xx Logic Board - Dual Tractor Cable (9w & 24w) Connector CN10 5-24 Service Manual Pin # Signal 1 +40 V dc 2 +40 V dc 3 Power Gnd 4 Power Gnd 5 +5 V dc 6 COCOM 7 D-SET 8 Signal Gnd 9 COA 10 COB 11 JAM 12 D-H.
24xx Serial Board - Serial Cable (9w & 24w) Connector CN2 Pin # Signal Pin # Signal 1 Chassis Gnd 13 NC 2 TXD 14 NC 3 RXD 15 NC 4 RTS 16 NC 5 -CTS 17 NC 6 DSR 18 NC 7 Signal Gnd 19 NC 8 NC 20 DTR 9 NC 21 NC 10 NC 22 NC 11 NC 23 NC 12 NC 24 NC 25 NC Connector Locations 5-25
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. CN1-7 D-Set (signal for Tractor 2 plugged in). CN1-8 Signal GND. CN1-9 Motor phase A; 0 V dc except when Tractor 2 motor is on. CN1-10 Motor phase B; +5 V dc when Tractor 2 not in use; 0 V dc when Tractor 2 is in use. CN1-11 Not used.
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.
24xx Lubrication Points Oil • 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 ASF Side Frame (Left) and Upper Feed Roll Shaft ASF Pick-up Roller Shaft and Roller Bushings 6-2 Service Manual
24xx Lubrication Points (Oil) The oil felt [1] in the carrier block. The tractor shaft [1].
24xx Lubrication Points (Grease) Gear mounting studs on the right side frame [2]. The lower pinch roller [2].
24xx Lubrication Points (Grease) Continued Gear mounting studs on the left side frame [2].
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].
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. NS: (Not Shown) in the Asm-Index column indicates that the part is procurable but is not pictured in the illustration.
24xx Assembly 1: Covers 7-2 Service Manual
24xx AsmIndex Part Number Description 1-1 12G3877 Guide, Left Paper 2 12G3873 Cover, Front Unit (2480, 2490) 2 12G3874 Cover, Front Unit (2481, 2491) 3 12G3878 Guide, Right Paper 4 12G3858 Cover, Ribbon Access Unit (2480) 4 12G3859 Cover, Ribbon Access Unit (2481) 4 12G3868 Cover, Ribbon Access Unit (2490) 4 12G3869 Cover, Ribbon Access Cover (2491) 5 12G3871 Cover, Top (2480, 2490) 5 12G3872 Cover, Top (2481, 2491) 6 12G3870 Cover, Option 7 79F4757 Line Cord: U.S.
24xx Assembly 1: Covers 7-4 Service Manual
24xx AsmIndex Part Number Description 1-8 12G3856 Cover, Bottom (2480, 2490) 8 12G3857 Cover, Bottom (2481, 2491) 9 12G3854 Tractor Unit (2480, 2490) 9 12G3855 Tractor Unit (2481, 2491) 9A 12G3850 Frame, Right Side Tractor 9B 12G3853 Tractors, Left and Right 9C 79F4830 Support, Tractor Paper 9D 12G3851 Shaft Set, Tractor (2480, 2490) 9D 12G3852 Shaft Set, Tractor (2481, 2491) 9E 12G3849 Frame, Left Side Tractor 10 12G3810 Operator Panel Assembly (248X) 10 12G3811 Operat
24xx Assembly 2: Carrier / Paper Feed Right Side 7-6 Service Manual
24xx AsmIndex Part Number Description 2-1 12G3841 Carrier Roller Set 2 12G3894 Printhead Assembly (2480, 2481) 2 12G3895 Printhead Assembly (2490, 2491) 3 12G3838 Carrier Unit (2480) 3 12G3837 Carrier Unit (2481) 3 12G3840 Carrier Unit (2490) 3 12G3839 Carrier Unit (2491) 4 12G3889 Cable, Printhead (2480) 4 12G3888 Cable, Printhead (2481) 4 12G3891 Cable, Printhead (2490) 4 12G3890 Cable, Printhead (2491) 5 12G3942 Kit, Pull Tractor Actuator 6 12G3896 Springs, Parts
24xx Assembly 2: Carrier / Paper Feed Right Side 7-8 Service Manual
24xx AsmIndex Part Number Description 2 - 22 12G3832 Roller, Upper Feed (2480, 2490) 22 12G3833 Roller, Upper Feed (2481, 2491) Parts Catalog 7-9
24xx Assembly 3: Carrier / Paper Feed Left Side 7-10 Service Manual
24xx AsmIndex Part Number Description 3-1 12G3905 Gears and Bushings, Parts Packet (248X) 1 12G3906 Gears and Bushings, Parts Packet (249X) 2 12G3907 Screws, Washers and Clips, Parts Packet 3 12G3942 Kit, Pull Tractor Actuator 4 12G3817 Frame, Left Side (2480, 2481) 4 12G3818 Frame, Left Side (2490, 2491) 5 12G3940 Sensor, Pull Tractor 6 12G3922 Plate, Frame Support (2480, 2490) 6 12G3844 Plate, Frame Support (2481, 2491) 7 12G3935 Holder, Lower Pinch Roller Shaft, Left 8 1
24xx Assembly 3: Carrier / Paper Feed Left Side 7-12 Service Manual
24xx AsmIndex Part Number Description 3 - 25 12G3931 Kit, Head Gap Adjustment 26 12G3947 Lever, Form Thickness 27 12G3842 Motor, Paper Feed 28 12G3843 Bracket, Paper Feed Motor Assembly 29 11A3274 Gear, Idle (248X) 29 11A3275 Gear, Idle (249X) Parts Catalog 7-13
24xx Assembly 4: Electronics 7-14 Service Manual
24xx AsmIndex Part Number Description 4-1 12G3907 Screws, Washers and Clips, Parts Packet 2 12G3836 Kit, ESD Ground (2490, 2491) 2 12G3887 Kit, ESD Ground (2480, 2481) 3 12G3801 Power Supply Unit, LV 3 12G3800 Power Supply Unit, HV 4 12G3812 Module, EPROM (248X) 4 12G3813 Module, EPROM (249X) 4 12G3848 Module, EPROM (Okidata MICROLINE) 5 12G3802 Board, Logic W/O EPROM (2480 LV) 5 12G3806 Board, Logic W/O EPROM (2480 HV) 5 12G3803 Board, Logic W/O EPROM (2481 LV) 5 12G380
24xx Assembly 5: ASF - Roller / Support 7-16 Service Manual
24xx AsmIndex Part Number Description 5-1 12G3814 Support, ASF Cut Sheet W/ Guides (2480, 2490) 1 12G3908 Support, ASF Cut Sheet W/ Guides (2481, 2491) 2 95F6886 Roller, ASF Upper Feed (2480, 2490) 2 95F6896 Roller, ASF Upper Feed (2481, 2491) 3 95F6887 Roller, ASF Lower Feed (2480, 2490) 3 95F6897 Roller, ASF Lower Feed (2481, 2491) 4 95F6885 Roller, ASF Pick-up Left and Right (2480, 2490) 4 1333275 Roller, ASF Pick-up Left and Right (2481, 2491) 5 12G3911 Hopper, ASF Right (24
24xx Assembly 6: ASF - Side Frame / Covers 7-18 Service Manual
24xx AsmIndex Part Number Description 6 -1 95F6893 ASF Springs, Parts Packet 2 95F6892 ASF Gears and Bushings, Parts Packet 3 12G3920 Cover, ASF Right 4 95F6894 ASF Screws, Parts Packet 5 12G3921 Cover, ASF/TR2 Front (2480, 2490) 5 12G3930 Cover, ASF/TR2 Front (2481, 2491) 6 12G3945 Frame, ASF Side Right NS 12G3939 Stand, Paper Parts Catalog 7-19
24xx Assembly 7: Tractor 2 Option 7-20 Service Manual
24xx AsmIndex Part Number Description 7-1 12G3923 Table, Tractor 2 Paper W/ Guides (2480, 2490) 1 12G3924 Table, Tractor 2 Paper W/ Guides (2481, 2491) 2 11A3338 Guide, Tractor 2 Paper 3 12G3926 Tractor and Frame Assembly, Tractor 2 (2480, 2490) 3 12G3927 Tractor and Frame Assembly, Tractor 2 (2481, 2491) 4 12G3853 Kit, Tractors Left and Right 5 11A3335 Board Assembly W/Cable and Ferrite, Tractor 2 (2480, 2490) 5 11A3336 Board Assembly W/Cable and Ferrite, Tractor 2 (2481, 2491) 6
24xx Coax / Twinax Adapter AsmIndex Part Number Description NS 12G3704 Adapter, Coax (Power Cable and Adapter) NS 12G3705 Adapter, Twinax (Power Cable and Adapter) NS 12G3709 Bracket, Adapter (Bracket Only) NS 13A0297 Cable, Coax (Cable Only) NS 13A0296 Cable, Twinax (Cable Only) NS 11A6109 Cable, Socket Power Coax, Twinax (Socket Power Cable Only) 7-22 Service Manual
24xx Index A E Abbreviations 1-6 Adjustments 4-2 Bidirectional Print 4-4 Printhead-to-Platen Gap 4-2 ASF Principles of Operation 2-14 Entering Setup Mode 1-2 Error Codes 2-2 Error Indication Table 2-2 ESD-sensitive parts 4-1 Exiting Setup Mode 1-2 C Connections Logic Board Carrier Motor 5-20 DC Power 5-8 Dual Tractor Cable 5-24 Gap Set Sensor 5-16 Home Position Sensor 5-16 Operator Panel 5-22 Paper Feed Motor 5-20 Paper Present Sensor 5-16 Paper Select Sensor 5-18 Parallel Interface Cable 5-4 Printhead
24xx P Paper Jams Clearing Continuous Forms 3-6 Clearing Cut Sheet 3-6 Parts ASF Roller/Support 7-16 Side Frame/Covers 7-18 Carrier/Paper Feed Left Side 7-10, 7-12 Carrier/Paper Feed Right Side 7-6, 7-8 Coax/Twinax Adapter 7-22 Covers 7-2 Electronics 7-14 Tractor 2 Option 7-20 Parts Catalog How to use 7-1 POST 3-2 Preventive Maintenance Lubrication 6-1 Lubrication Points 6-2 Specified Lubricants 6-1 Print Test 3-3 Printer Description 1-1 Options 1-6 Settings 1-4 Specifications 1-1 Speeds 1-1 Printer Defaul
24xx S T Safety Information vii Service Checks 2-13 Abnormal Noise 2-13 Abnormal Print 2-21 Auto Sheet Feeder 2-14 Carrier 2-16 Intermittent Problem 2-18 No Print 2-21 Operator Panel 2-21 Paper Feed 2-23 Paper Present Sensor 2-22 Paper Select Sensor 2-25 POST 2-26 Power 2-27 Print Speed 2-28 Printhead 2-29 Printhead Continuity Tables 2-30 Pull Tractor Sensor 2-31 Top-Of-Forms 2-32 Tractor 2 2-33 Settings Tear Off Position 1-4 Top-Of-Form (Continuous) 1-5 Top-Of-Form (Cut Forms) 1-5 Top-Of-Form (Envelopes
24xx Part Numbers 11A3274 11A3275 11A3283 11A3284 11A3335 11A3336 11A3337 11A3338 11A3341 11A6109 12G3704 12G3705 12G3709 12G3800 12G3801 12G3802 12G3803 12G3804 12G3805 12G3806 12G3807 12G3808 12G3809 12G3810 12G3811 12G3812 12G3813 12G3814 12G3817 12G3818 12G3819 12G3820 12G3821 12G3822 12G3823 12G3824 12G3825 12G3826 12G3827 12G3828 12G3831 12G3832 12G3833 12G3834 12G3835 7-7, 7-13 7-7, 7-13 7-21 7-21 7-21 7-21 7-21 7-21 7-21 7-22 7-22 7-22 7-22 7-15 7-15 7-15 7-15 7-15 7-15 7-15 7-15 7-15 7-15 7-5 7-5
24xx 12G3892 12G3893 12G3894 12G3895 12G3896 12G3897 12G3898 12G3900 12G3901 12G3902 12G3903 12G3904 12G3905 12G3906 12G3907 12G3908 12G3909 12G3911 12G3912 12G3914 12G3915 12G3916 12G3918 12G3920 12G3921 12G3922 12G3923 12G3924 12G3926 12G3927 12G3928 12G3929 12G3930 12G3931 12G3932 12G3933 12G3934 12G3935 12G3936 12G3937 12G3938 12G3939 12G3940 12G3941 12G3942 12G3943 12G3944 7-11 7-17 7-7 7-7 7-7, 7-11 7-7 7-7 7-7 7-7 7-11 7-15 7-15 7-7, 7-11 7-7, 7-11 7-7, 7-11, 7-15 7-17 7-11 7-17 7-17 7-17 7-17 7-17
24xx I-6 Service Manual
