Lexmark Forms Printer 2400 Service Manual - Page 4

iv

Service Manual

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

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-5

World Trade Defaults

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-5

Clearing Paper Jams

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-6

Cut Sheet Jams

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-6

Continuous Forms Jams

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-6

Repair Information

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-1

Handling ESD-Sensitive Parts

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-1

Adjustments

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

Printhead-to-Platen Gap Adjustment

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

Bidirectional Print Adjustment

. . . . . . . . . . . . . . . . . . . . . . . . . . . .4-4

Removal Procedures

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-5

Covers, Removals

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-5

Covers, Front Removal

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-6

Covers, Ribbon Access Removal

. . . . . . . . . . . . . . . . . . . . . . . . .4-6

Covers, Option Removal

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-7

Covers, Top Removal

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-8

Covers, Operator Panel Assembly Removal

. . . . . . . . . . . . . . . .4-11

Covers, Bottom Removal

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-12

Electronics Removals

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-13

EPROM Removal

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-13

Logic Board Removal

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-14

Power Supply Removal

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-15

Carrier Removals

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-16

Carrier Removal

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-16

Carrier, Motor Assembly Removal

. . . . . . . . . . . . . . . . . . . . . . .4-21

Paper Handling Removals

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-24

Paper Select Lever Removal

. . . . . . . . . . . . . . . . . . . . . . . . . . . .4-24

Paper Feed Motor Removal

. . . . . . . . . . . . . . . . . . . . . . . . . . . .4-24

Form Thickness Lever Removal

. . . . . . . . . . . . . . . . . . . . . . . . .4-25

Print Handling Removals

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-26

Platen Removal

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-26

Printhead Removal

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-27

Printhead Cables Removal

. . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-27

Print Unit Removal

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-28

Ribbon Drive Rack Gear Removal

. . . . . . . . . . . . . . . . . . . . . . .4-30

Section	Page
Table of Contents	3
Safety Information	7
Preface	12
1. General Information	13
Printer Specifications	13
Printer Speeds	13
Setup Mode	14
Entering Setup Mode	14
Exiting Setup Mode	14
Setup Menu Options	15
Interface Menu Options	15
Setting The Tear Off Position	16
Setting Top-Of-Form (Continuous - Pull Mode)	17
Setting Top-Of-Form (Cut Forms - Envelopes)	17
Options	18
2. Diagnostic Information	19
Start	19
Voltage, Ground, And Continuity Readings	19
Error Indication Table	20
Symptom Check Table	23
Irrecoverable Operator Errors	30
Service Checks	31
Abnormal Noise Service Check	31
Auto Sheet Feeder (ASF) Service Check	32
Carrier Service Check	34
Intermittent Problem Service Check	36
No Print or Abnormal Print Service Check	39
Operator Panel Service Check	39
Paper Present Sensor Service Check	40
Paper Feed Service Check	41
Paper Select Sensor Service Check	43
POST Service Check	44
Power Service Check	45
Print Speed Service Check	46
Printhead Service Check	47
Pull Tractor Sensor Service Check	49
Top-Of-Forms Service Check	50
Tractor 2 Service Check	51
3. Diagnostic Aids	55
Power-On Self Test (POST)	56
Print Test	57
Hex Trace Mode	58
Printer Default Settings	59
U.S. Defaults	59
World Trade Defaults	59
Clearing Paper Jams	60
Cut Sheet Jams	60
Continuous Forms Jams	60
4. Repair Information	61
Handling ESD-Sensitive Parts	61
Adjustments	62
Printhead-to-Platen Gap Adjustment	62
Bidirectional Print Adjustment	64
Removal Procedures	65
Covers, Removals	65
Covers, Front Removal	66
Covers, Ribbon Access Removal	66
Covers, Option Removal	67
Covers, Top Removal	68
Covers, Operator Panel Assembly Removal	71
Covers, Bottom Removal	72
Electronics Removals	73
EPROM Removal	73
Logic Board Removal	74
Power Supply Removal	75
Carrier Removals	76
Carrier Removal	76
Carrier, Motor Assembly Removal	81
Paper Handling Removals	84
Paper Select Lever Removal	84
Paper Feed Motor Removal	84
Form Thickness Lever Removal	85
Print Handling Removals	86
Platen Removal	86
Printhead Removal	87
Printhead Cables Removal	87
Print Unit Removal	88
Ribbon Drive Rack Gear Removal	90
Gears Removals	91
Left Side Gears Removal	91
Right Side Gears, Sub Frame Removal	94
Rollers Removals	96
Roller, Upper Feed Removal	96
Roller, Lower Pinch Removal	98
Roller, Lower Feed Removal	101
Sensors Removals	103
Sensor, Pull Tractor Removal	104
Sensor, Head Gap Removal	104
Sensor, Top-Of-Form Removal	104
Sensor, Paper Select Removal	105
Sensor, Paper Present Removal	105
Flags, Paper Present / Top-Of-Form Removal	105
Sensor, Home Position Sensor Removal	106
Options Removals	107
Auto Sheet Feeder Gears Removal	107
Auto Sheet Feeder Pick-up Roller Removal	108
5. Connector Locations	109
Signal Connections	110
Power Supply (9w & 24w)	110
Logic Board - Parallel Interface Cable (9w & 24w)	113
Logic Board - Serial Board (9w & 24w)	115
Logic Board - USB Cable (9w & 24w)	117
Logic Board - DC Power (9w & 24w)	117
Logic Board - Printhead (9w)	119
Logic Board - Printhead (24w)	121
Logic Board - Printhead (24w)	123
Logic Board - Gap Set Sensor (9w & 24w)	125
Logic Board - Home Position Sensor (9w & 24w)	125
Logic Board - Paper Present Sensor (9w & 24w)	125
Logic Board - Paper Select Sensor (9w & 24w)	127
Logic Board - Pull Tractor Sensor (9w & 24w)	127
Logic Board - Top Of Form Sensor (9w & 24w)	127
Logic Board - Carrier Motor (9w & 24w)	129
Logic Board - Paper Feed Motor (9w & 24w)	129
Logic Board - Operator Panel (9w & 24w)	131
Logic Board - Dual Tractor Cable (9w & 24w)	133
Serial Board - Serial Cable (9w & 24w)	134
Tractor 2 Cable Connectors	135
6. Preventive Maintenance	137
Lubrication	137
Lubrication Points	138
Lubrication Points (Oil)	139
Lubrication Points (Grease)	140
7. Parts Catalog	143
How To Use This Parts Catalog	143
Assembly 1: Covers	144
Assembly 1: Covers	146
Assembly 2: Carrier / Paper Feed Right Side	148
Assembly 2: Carrier / Paper Feed Right Side	150
Assembly 3: Carrier / Paper Feed Left Side	152
Assembly 3: Carrier / Paper Feed Left Side	154
Assembly 4: Electronics	156
Assembly 5: ASF - Roller / Support	158
Assembly 6: ASF - Side Frame / Covers	160
Assembly 7: Tractor 2 Option	162
Coax / Twinax Adapter	164
Index	165

Lexmark Forms Printer 2400 Service Manual - Page 4

Service Manual, Diagnostic Aids, Repair Information

Page 4 highlights