Lexmark 24XX-100 - Manual

viii Service Manual 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 r...

ix 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 re...

x Service Manual 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 òb...

xii Service Manual 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 ...

General Information 1-1 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. Th...

1-2 Service Manual 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 th...

General Information 1-3 24xx Setup Menu Options Interface 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 th...

1-4 Service Manual 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 ...

Diagnostic Information 2-1 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 co...

2-2 Service Manual 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 ...

Diagnostic Information 2-5 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 Abnormal Noise Problems Symptom Action 7 or more lights turn on but do not turn off. The Pow...

2-6 Service Manual 24xx Abnormal Print Operation Problems Auto Sheet Feeder Problems Symptom Action Printer will not print, or become ready. Abnormal operation, incorrect characters, or incorrect line width. Printer is ready but will not print from the computer correctly. Undefined or incorrect char...

Diagnostic Information 2-7 24xx Error Indications Operator Panel Problems Paper Feed Problems Symptom Action Ready and Paper Out lights blink. Turn the printer off and then on. Go to “Abnormal Indications” on page 2-5 . Paper Out and Fontlights blink. Turn the printer off and then on. Go to “Irrecov...

Diagnostic Information 2-9 24xx Power Problems Lower feed roll shaft rotates, but paper does not feed. Pressing FormFeed does not feed paper. Abnormal noise created while feeding. Paper jams, skews or creases. Incorrect or no line spacing: wider, narrower, or overlapping lines. Push/Pull Tractor doe...

2-10 Service Manual 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...

Diagnostic Information 2-11 24xx Ribbon Feed Problems Symptom Action Ribbon comes off, becomes loose or folded, or jams. Ribbon feeds correctly but is noisy. Check the ribbon cartridge for binds or damage. Go to “Carrier Service Check” on page 2-16 .

2-12 Service Manual 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 serv...

Diagnostic Information 2-13 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 t...

2-14 Service Manual 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 ...

2-16 Service Manual 24xx Carrier Service Check Note: The Carrier Service Check includes the carrier drive, home position sensor and ribbon feed. FRU Action 1 Carrier Verify the carrier motor connector is connected to the logic board at CN2. If the carrier motor connector is connected properly, check...

2-18 Service Manual 24xx Intermittent Problem Service Check FRU/Symptom Action 1 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 suppl...

Diagnostic Information 2-21 24xx No Print or Abnormal Print Service Check Operator Panel Service Check If the operator panel is locked, only the Start/Stop, FormFeed, Tear Off and Load/UnLoad buttons are active. 24xx printers have a Padlock LED to indicate that the operator panel is locked. To lock ...

2-22 Service Manual 24xx Paper Present Sensor Service Check FRU Action 1 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 pr...

Diagnostic Information 2-23 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 “Pape...

Diagnostic Information 2-25 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 . FRU Action 1 Paper Select Sensor Remove all paper from the printer and do the f...

2-26 Service Manual 24xx POST Service Check 2 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 ...

Diagnostic Information 2-27 24xx Power Service Check FRU Action 1 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 ...

2-28 Service Manual 24xx 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 th...

Diagnostic Information 2-29 24xx Printhead Service Check FRU Action 1 Printhead CablesPrinthead 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 b...

2-30 Service Manual 24xx Printhead Impedance Tables 2480, 2490 - Approximately 5 ohms 2481, 2491 - Approximately 8 to 16 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 ...

Diagnostic Information 2-31 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. FRU Action 1 Pull Tractor S...

Diagnostic Information 2-33 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 sl...

Diagnostic Information 2-35 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. FRU Action 1 Tractor 2Board/Cable Asm. Check the Tractor 2 in-place sensor or the cable con...

2-36 Service Manual 24xx Tractor 2 Paper Feed Problems FRU Action 1 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...

Diagnostic Aids 3-3 24xx Print Test The print test helps you test and troubleshoot the printer. To star t 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...

3-4 Service Manual 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 ac...

Diagnostic Aids 3-5 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...

3-6 Service Manual 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....

Repair Information 4-1 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 produ...

4-2 Service Manual 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 driv...

4-4 Service Manual 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 i...

Repair Information 4-5 24xx Removal Procedures CAUTION: Be sure to unplug the power cord whenever you are working on the printer with one of the covers removed. Covers, Removals

Repair Information 4-7 24xx Covers, Option Removal 1. From the bottom, pull the option cover [A] outward and up, removing it from the printer.

4-8 Service Manual 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 ...

Repair Information 4-9 24xx 8. Turn the printer upside down. 9. Insert a flat blade screwdriver into each of the four holes [A] in the bottom cover, releasing the top cover from the bottom cover.

Repair Information 4-11 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 ...

4-12 Service Manual 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...

Repair Information 4-13 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.

4-14 Service Manual 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 disconnec...

Repair Information 4-15 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. Discon...

4-16 Service Manual 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...

Repair Information 4-17 24xx 4. Remove the retaining wire [A] from the left side of the carrier shaft.

4-20 Service Manual 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 .

Repair Information 4-21 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 ...

4-24 Service Manual 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 Remova...

Repair Information 4-25 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.

4-26 Service Manual 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 “Prin...

Repair Information 4-27 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 Remova...

4-28 Service Manual 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 scre...

Repair Information 4-29 24xx 5. Remove the two grommet anchored screws [A] from the right side of the print unit. 6. Remove the print unit from the bottom cover, by pulling up forcefully on both sides of the print unit.

4-30 Service Manual 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 ...

Repair Information 4-31 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.

4-32 Service Manual 24xx 3. Remove the four screws [A] from the paper feed motor bracket assembly.

4-34 Service Manual 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].

4-36 Service Manual 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.

Repair Information 4-37 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 proce...

4-38 Service Manual 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 ...

Repair Information 4-39 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.

4-40 Service Manual 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 ea...

Repair Information 4-41 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 bra...

4-42 Service Manual 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...

Repair Information 4-45 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 le...

4-46 Service Manual 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.

Repair Information 4-47 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 com...

4-48 Service Manual 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 ...

Connector Locations 5-1 24xx 5. Connector Locations This chapter identifies the locations of specific parts of the printer.

5-2 Service Manual 24xx Signal Connections Power Supply (9w & 24w) Connector Pin # Signal CN1 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 Connector Signal F1 Fuse

5-26 Service Manual 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). ...

Preventive Maintenance 6-1 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 c...

6-2 Service Manual 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) a...

Parts Catalog 7-1 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 par ts are shown by one index number. Par ts peculiar to one or the other of the assemblies are listed separately...

7-6 Service Manual 24xx Assembly 2: Carrier / Paper Feed Right Side

7-10 Service Manual 24xx Assembly 3: Carrier / Paper Feed Left Side 3 11 7 13 18 5 16 9 15 2 10 17 4 12 8 14 19 1 20 23 21 26 24 22 25 1 1 2 2 2 2 2 2 2 2 2 2 2 10 11 6

7-20 Service Manual 24xx Assembly 7: Tractor 2 Option

7-22 Service Manual 24xx Coax / Twinax Adapter Asm-Index 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...

Index I-1 24xx Index A Abbreviations 1-6 Adjustments 4-2 Bidirectional Print 4-4 Printhead-to-Platen Gap 4-2 ASF Principles of Operation 2-14 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...

Index I-3 24xx S 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...